An alloy composition is provided. The alloy composition includes from about 0.5 wt. % to about 1.5 wt. % silicon (Si), from about 0.5 wt. % to about 1.5 wt. % magnesium (Mg), from about 0.1 wt. % to about 0.2 wt. % zirconium (Zr), from about 0.2 wt. % to about 0.4 wt. % iron (Fe), from 0 wt. % to about 0.3 wt. % chromium (Cr), from 0 wt. % to about 0.3 wt. % manganese (Mn), from about 0 wt. % to about 1 wt. % copper (Cu), from about 0 wt. % to about 0.2 wt. % titanium (Ti), from about 0 wt. % to about 1 wt. % vanadium (V), and a balance of aluminum (Al). Greater than or equal to about 60% of the alloy composition is derived from Al scrap. Methods of forming the alloy composition and methods of forming an extruded article from the composition are also provided.

Production of a bulk Al-RE alloy body (product) using cast billets/ingots (cooling rates <100 C/s) or rapidly solidified Al-RE particulates (cooling rates 10.sup.2-10.sup.6° C./second) that have beneficial microstructural refinements that are further refined by subsequent consolidation to produce a consolidated bulk alloy product having excellent mechanical properties over a wide temperature range such as up to and above 230° C.

Production of a bulk Al-RE alloy body (product) using cast billets/ingots (cooling rates <100 C/s) or rapidly solidified Al-RE particulates (cooling rates 10.sup.2-10.sup.6° C./second) that have beneficial microstructural refinements that are further refined by subsequent consolidation to produce a consolidated bulk alloy product having excellent mechanical properties over a wide temperature range such as up to and above 230° C.

A structural component for a motor vehicle is configured to extend transversely to a direction of travel for the motor vehicle and is configured to separate a passenger compartment and a front compartment of the motor vehicle. The structural component includes: a dashboard; two A-pillars arranged in each case laterally with respect to the dashboard; and a transverse reinforcement running along an upper side of the dashboard. The structural component is one-part or a one-piece light-metal die casting.

An aluminum alloy material comprising a composition containing no less than 1.2 at % and no more than 6.5 at % of Fe, no less than 0.15 at % and no more than 5 at % of at least one first element selected from the group consisting of Nd, W, and Sc, and no less than 0.005 at % and no more than 2 at % of at least one second element selected from the group consisting of C and B, the balance being Al and inevitable impurities.

A value stream method of manufacturing a plurality of vehicle structural rails includes feeding a coil of aluminum alloy sheet into a roll forming machine and forming a tubular shape with a seam, bobbin tool-friction stir welding the seam of the tubular shape and forming a welded tubular shape with a welded seam, cutting the welded tubular shape into a plurality of tubular sections, tube bending each of the plurality of tubular sections and forming a plurality of bent tubular sections, and hydroforming each of the plurality of bent tubular sections and forming a plurality of structural rails. The coil of aluminum alloy sheet may or may not be pre-treated and/or lubricated.

A value stream method of manufacturing a plurality of vehicle structural rails includes feeding a coil of aluminum alloy sheet into a roll forming machine and forming a tubular shape with a seam, bobbin tool-friction stir welding the seam of the tubular shape and forming a welded tubular shape with a welded seam, cutting the welded tubular shape into a plurality of tubular sections, tube bending each of the plurality of tubular sections and forming a plurality of bent tubular sections, and hydroforming each of the plurality of bent tubular sections and forming a plurality of structural rails. The coil of aluminum alloy sheet may or may not be pre-treated and/or lubricated.

A sheet metal assembly includes a drawn metal sheet constructed of a metal material. The drawn metal sheet defines a surface and includes one or more stiffening features disposed along the drawn metal sheet. The one or more stiffening features represents a raised area disposed along the surface of the drawn metal sheet. Each of the one or more stiffening features include a predefined draw depth ranging from about twenty millimeters to about eighty millimeters.

A sheet metal assembly includes a drawn metal sheet constructed of a metal material. The drawn metal sheet defines a surface and includes one or more stiffening features disposed along the drawn metal sheet. The one or more stiffening features represents a raised area disposed along the surface of the drawn metal sheet. Each of the one or more stiffening features include a predefined draw depth ranging from about twenty millimeters to about eighty millimeters.

A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.