HIGH RECYCLE CONTENT ALUMINUM ALLOYS AND METHODS OF MAKING AND USING
20260071303 · 2026-03-12
Assignee
Inventors
- Zeqin Liang (Sierre, CH)
- Guillaume Hubert Florey (Veyras, CH)
- Jonathan Friedli (Bern, CH)
- Géraldine Barman (Sierre, CH)
- Tudor Piroteala (Woodstock, GA, US)
- MILAN FELBERBAUM (LAUSANNE, CH)
- Jean-Francois Despois (Grones, CH)
Cpc classification
C22F1/002
CHEMISTRY; METALLURGY
B22D21/007
PERFORMING OPERATIONS; TRANSPORTING
International classification
B22D21/00
PERFORMING OPERATIONS; TRANSPORTING
C22F1/00
CHEMISTRY; METALLURGY
Abstract
Aluminum alloys, metal products made using the aluminum alloys, and methods of processing the aluminum alloys are disclosed. The disclosed alloys can be prepared using large amounts of recycled aluminum alloy content, such as up to 100% recycled content, or more. The disclosed aluminum alloys include amounts of iron, manganese, chromium, and/or silicon in excess of comparable aluminum alloys commonly made by alloying prime aluminum. Further, the disclosed alloys include ratios of a total amount of manganese and chromium to iron of greater than or about 0.60 or 0.70, which may contribute, at least partly, to desirable bending, forming, and surface properties and characteristics of metal products made using the aluminum alloys. The disclosed alloys can be used to prepare automotive and structural panels such that these products are generated using large amounts of recycled aluminum alloy content.
Claims
1. An aluminum alloy, comprising Al and about 1 wt. % to 1.5 wt. % Si, up to about 0.35 wt. % Fe, up to about 0.25 wt. % Cu, about 0.05 wt. % to 0.25 wt. % Mn, about 0.2 wt. % to 0.60 wt. % Mg, up to about 0.10 wt. % Cr, up to about 0.10 wt. % Ni, up to about 0.20 wt. % Zn, up to about 0.15 wt. % Ti, and up to about 0.10 wt. % V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content.
2-9. (canceled)
10. A metal product comprising the aluminum alloy of claim 1, wherein the metal product is a rolled metal product.
11. The metal product of claim 10, wherein the metal product is dual-recrystallized metal product.
12. The metal product of claim 10, wherein the metal product exhibits isotropic strain characteristics.
13. The metal product of claim 10, wherein the metal product exhibits a Lankford ratio at about 10% strain along longitudinal, transverse, and diagonal directions of about 0.6 or greater.
14. The metal product of claim 10, wherein the metal product exhibits an f15% bending factor along a transverse direction of from about 0.3 to 1.0.
15. The metal product of claim 10, wherein the metal product exhibits an inner-bending angle after pre-straining of 10% of about 10 to 60.
16. The metal product of claim 10, wherein the metal product exhibits a surface arithmetical mean height (Sa) of at most 0.60 m.
17. The metal product of claim 10, wherein the metal product exhibits a yield strength of from 90 MPa to 130 MPa when in a T4 temper or from 200 MPa to 235 MPa when in a T6 temper.
18. The metal product of claim 10, wherein the metal product exhibits an ultimate tensile strength of from 195 MPa to 270 MPa when in a T4 temper or from 240 MPa to 300 MPa when in a T6 temper.
19. The metal product of claim 10, wherein the metal product exhibits a uniform elongation of from 20% to 30% when in a T4 temper or from 10% to 20% when in a T6 temper.
20. A method of producing a metal product, the method comprising: casting an aluminum alloy to generate a cast product, wherein the aluminum alloy comprises Al and about 1 wt. % to 1.5 wt. % Si, up to about 0.35 wt. % Fe, up to about 0.25 wt. % Cu, about 0.05 wt. % to 0.25 wt. % Mn, about 0.2 wt. % to 0.60 wt. % Mg, up to about 0.10 wt. % Cr, up to about 0.10 wt. % Ni, up to about 0.20 wt. % Zn, up to about 0.15 wt. % Ti, and up to about 0.10 wt. % V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.7, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content; homogenizing the cast product to generate a homogenized product; hot rolling the homogenized product to generate a rolled product; and subjecting the rolled product to a final cold rolling process product to produce the metal product.
21. The method of claim 20, further comprising: subsequent to the hot rolling, subjecting the rolled product to a recrystallization process to generate a recrystallized product, wherein the final cold rolling process comprises cold rolling the recrystallized product to produce the metal product.
22. The method of claim 21, wherein the recrystallization process occurs between the hot rolling and the final cold rolling process.
23. The method of claim 21, further comprising: subjecting the rolled product to a preliminary cold rolling process subsequent to the hot rolling and prior to the recrystallization process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.
24. The method of claim 21, wherein the recrystallization process comprises: annealing the rolled product at peak metal temperature of from 325 C. to 425 C. for up to 1 minute to generate a recrystallized product; and quenching the recrystallized product.
25. The method of claim 20, wherein an exit temperature of the hot rolling is no more than 400 C.
26. The method of claim 20, wherein the hot rolling achieves a thickness reduction between the homogenized product and the rolled product of 90% or more.
27. The method of claim 20, further comprising: subjecting the metal product to a solutionizing process to generate a solutionized metal product.
28. The method of claim 20, further comprising: subjecting the metal product to an aging or artificial aging process to generate an aged metal product.
29-42. (canceled)
Description
BRIEF DESCRIPTION OF THE FIGURES
[0025] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
[0034]
[0035]
DETAILED DESCRIPTION
[0036] Described herein are aluminum alloys, metal products made using the aluminum alloys, and methods of processing the aluminum alloys. The disclosed alloys can be prepared using large amounts of recycled aluminum alloy content, such as up to 100% recycled content. The disclosed aluminum alloys include amounts of iron, manganese, chromium, and/or silicon in excess of comparable aluminum alloys commonly made by alloying prime aluminum. Further, the disclosed alloys include ratios of a total amount of manganese and chromium to iron of greater than or about 0.70, which may contribute, at least partly, to desirable bending, forming, and surface properties and characteristics of metal products made using the aluminum alloys. The disclosed alloys can be used to prepare automotive and structural panels such that these products are generated using large amounts of recycled aluminum alloy content.
[0037] Aluminum alloys used for recycling can contain a mixture or unknown amounts of various aluminum alloys. In some cases, contaminants can also be present in aluminum alloys used for recycling. For example, aluminum alloys used for recycling may correspond to scrap source aluminum, such as end of life automotive aluminum or industrial scrap source, such as remelt scrap ingot (RSI), extrusion profile, aluminum plate, brazing scrap, as well as casting alloy scrap.
[0038] By increasing the amount of recycled aluminum content that can be included in the aluminum alloys described herein while still retaining favorable physical and mechanical properties so that the aluminum alloys can be useful as metal products for particular applications (e.g., as body or structural panels), the energy requirements and carbon footprint for preparing the metal products can be significantly reduced. As examples, the alloys and processing techniques described herein are useful for generating aluminum alloy sheet metal, or other metal products, with desirable bending characteristics, strength characteristics, forming characteristics (e.g., isotropic forming properties), and the like.
[0039] The alloy known as AA6016 is commonly used in automotive or structural applications. In general, however, AA6016 is not prepared using large amounts of recycled aluminum. For example, the elemental limits on AA6016 are typically lower for certain elements (e.g., Fe) than are commonly found in recycled aluminum alloy material. Stated another way, adding amounts of recycled aluminum content to an aluminum alloy that is destined to become AA6016 may necessitate use of large amounts of prime aluminum to ensure that certain elements (e.g., Fe) are not included in excess of those limits defined by the AA6016 designation. Thus, when large amounts of recycled aluminum content are included in an aluminum alloy, the designation can be different from AA6016. When such alloy is processed according to techniques commonly used to prepare products using AA6016, the resultant products can have mechanical and physical characteristics different from those made using AA6016.
[0040] The alloys described herein, however, overcome these challenges by including certain elements (e.g., iron, manganese, chromium, and/or silicon) in particular amounts and/or ratios to still retain beneficial properties. Furthermore, by carefully controlling the ratio of certain elements (e.g., ratio of a total amount of manganese and chromium to iron), desirable properties (e.g., mechanical properties or physical properties) in aluminum alloy products can be achieved. Additionally, particular processing schemes, such as those employing a rapid, low temperature annealing process prior to cold rolling or in between cold rolling steps, can be used to impart desirable properties (e.g., bending properties, forming properties, strength properties, and/or surface characteristics) to the resultant aluminum alloy products.
Definitions and Descriptions:
[0041] As used herein, the terms invention, the invention, this invention and the present invention are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.
[0042] In this description, reference is made to alloys identified by AA numbers and other related designations, such as series or 7xxx. For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys or Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot, both published by The Aluminum Association.
[0043] As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.
[0044] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.
[0045] As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).
[0046] Reference may be made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see American National Standards (ANSI) H35 on Alloy and Temper Designation Systems. An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked, and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.
[0047] As used herein, terms such as cast metal product, cast product, cast aluminum alloy product, and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.
[0048] As used herein, the meaning of room temperature can include a temperature of from about 15 C. to about 30 C., for example about 15 C., about 16 C., about 17 C., about 18 C., about 19 C., about 20 C., about 21 C., about 22 C., about 23 C., about 24 C., about 25 C., about 26 C., about 27 C., about 28 C., about 29 C., or about 30 C. As used herein, the meaning of ambient conditions can include temperatures of about room temperature, relative humidity of from about 20% to about 100%, and barometric pressure of from about 975 millibar (mbar) to about 1050 mbar. For example, relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anywhere in between. For example, barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between.
[0049] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of 1 to 10 should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Unless stated otherwise, the expression up to when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt. %).
[0050] As used herein, the meaning of a, an, and the includes singular and plural references unless the context clearly dictates otherwise.
[0051] In the present disclosure, aluminum alloy products and their components may be described in terms of their elemental composition in weight percent (wt. %). In each alloy, the remainder is aluminum, with a maximum wt. % of 0.15% or 0.25% for the sum of all impurities.
[0052] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the disclosed alloys and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.
[0053] Unavoidable impurities, including materials or elements may be present in an alloy in minor amounts due to inherent properties of aluminum or leaching from contact with processing equipment. Some alloys, as described, may contain no more than about 0.15 wt. % or 0.25 wt. % of any element besides the alloying elements, incidental elements, and unavoidable impurities.
Methods of Producing and Preparing the Alloys and Aluminum Alloy Products
[0054] The aluminum alloy products described herein can be prepare using suitable methods. For example, aluminum alloys may be cast, homogenized, hot-rolled using break-down mill following by tandem mill or using break-down mill only, cold-rolled, heat treated, formed, or the like to generate aluminum alloy products.
[0055]
[0056] The alloys described herein can be cast using any suitable casting method known to those of ordinary skill in the art. As a few non-limiting examples, the casting process can include a direct chill (DC) casting process, a fusion casting process, or a continuous casting (CC) process. For example,
[0057] A cast aluminum alloy product, such as a cast ingot, cast slab, or other cast product, can be processed by suitable techniques described herein. Optionally, the processing steps can be used to prepare rolled aluminum alloy products, such as aluminum alloy sheets. Example optional processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, annealing, solution heat treatment, and pre-aging.
[0058] In a homogenization step, the cast aluminum alloy product is homogenized to form a homogenized aluminum alloy product. During homogenization, a cast product may be heated to a temperature ranging from about 400 C. to about 565 C. For example, the cast product can be heated to a temperature of about 400 C., about 410 C., about 420 C., about 430 C., about 440 C., about 450 C., about 460 C., about 470 C., about 480 C., about 490 C., about 500 C., about 510 C., about 520 C., about 530 C., or about 540 C. up to 565 C. The product may then be allowed to soak (i.e., held at the indicated temperature) for a period of time to form a homogenized product. In some examples, the total time for the homogenization step, including the heating and soaking phases, can be up to 72 hours. For example, the product can be heated up to 500 C. to 565 C., and soaked, for a total time of up to 18 hours for the homogenization step. Optionally, the product can be heated to below 490 C. and soaked, for a total time of greater than 18 hours for the homogenization step. In some cases, the homogenization step comprises multiple processes. In some non-limiting examples, the homogenization step includes heating a cast product to a first temperature for a first period of time followed by heating to a second temperature for a second period of time. For example, a cast product can be heated to about 465 C. for about 3.5 hours and then heated to about 480 C. for about 6 hours. In some cases, the homogenization process and casting process are combined as casting with in-situ homogenization.
[0059] The homogenized aluminum alloy product is subjected to one or more roll bonding passes and/or one or more hot rolling passes to form a rolled aluminum alloy product, which may correspond to an aluminum alloy article, such as an aluminum alloy plate, an aluminum alloy shate, or an aluminum alloy sheet. A roll bonding process can be carried out in different manners. For example, a roll bonding process can include both hot rolling and cold rolling. Further, a roll bonding process can be a one-step process or a multi-step process in which the material is gauged down during successive rolling steps. Separate rolling steps can optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, heating steps, cooling steps, and the like.
[0060] Prior to the start of hot rolling, the homogenized product can be allowed to cool to a temperature between 380 C. to 450 C. For example, the homogenized product can be allowed to cool to a temperature of between 400 C. to 425 C. The homogenized product can then be hot rolled at a temperature between 250 C. to 450 C. to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 2 mm and 200 mm (e.g., 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between).
[0061] Optionally, the cast product can be a continuously cast product that can be allowed to cool to a temperature between 300 C. to 535 C. For example, the continuously cast product can be allowed to cool to a temperature of between 325 C. to 510 C., from 350 C. to 485 C., from 375 C. to 460 C., or from 400 C. to 435 C. The continuously cast products can then be hot rolled at a temperature between 300 C. to 450 C., for example, to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 3 mm and 25 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, or anywhere in between). During hot rolling, temperatures and other operating parameters can be controlled so that the temperature of the hot rolled intermediate product upon exit from the hot rolling mill is no more than 470 C., no more than 450 C., no more than 440 C., or no more than 430 C.
[0062] Cast, homogenized, or hot-rolled products can optionally be subjected to a break down process or a break down and tandem process. Optionally, a cold rolling process may be used after a hot rolling process, a break down process, and or a break down and tandem process. The cold rolling process can use cold rolling mills to cold roll the aluminum product into thinner products, such as a cold rolled sheet. The cold rolled product can have a gauge between about 0.1 to 7 mm, e.g., between about 0.7 to 6.5 mm. Optionally, the cold rolled product can have a gauge of 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm. The cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to 95% (e.g., up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 55%, up to 60%, up to 70%, up to 75%, up to 80%, or up to 85%, or up to 90%, up to 95%, or up to 99% reduction) as compared to a gauge prior to the start of cold rolling.
[0063] Following cold rolling process, an intermediate annealing process can be optionally used. In some cases, a product after a hot rolling process, a breakdown process, and/or a breakdown/tandem process is subjected to an intermediate annealing process. The intermediate annealing process can be any suitable treatment which results in at least partial recrystallization to generate a recrystallized aluminum product. The intermediate annealing process can comprise subjecting an unrecrystallized aluminum product (e.g., a hot-rolled product or a cold-rolled product) to a heat treatment at a predefined temperature of less than or equal to 495 C. for a length of time less than or equal to 25 minutes to generate a recrystallized aluminum product. For example, the cast, homogenized, hot rolled, or cold rolled product can be heated to a temperature of up to 495 C. for a length of time up to 25 minutes as part of an intermediate annealing process. In some examples, the temperature may be from about 300 C. to about 495 C., such as from 300 C. to 305 C., from 305 C. to 310 C., from 310 C. to 315 C., from 315 C. to 320 C., from 320 C. to 325 C., from 325 C. to 330 C., from 330 C. to 335 C., from 335 C. to 340 C., from 340 C. to 345 C., from 345 C. to 350 C., from 350 C. to 355 C., from 355 C. to 360 C., from 360 C. to 365 C., from 365 C. to 370 C., from 370 C. to 375 C., from 375 C. to 380 C., from 380 C. to 385 C., from 385 C. to 390 C., from 390 C. to 395 C., from 395 C. to 400 C., from 400 C. to 405 C., from 405 C. to 410 C., from 410 C. to 415 C., from 415 C. to 420 C., from 420 C. to 425 C., from 425 C. to 430 C., from 430 C. to 435 C., from 435 C. to 440 C., from 440 C. to 445 C., from 445 C. to 450 C., from 450 C. to 455 C., from 455 C. to 460 C., from 460 C. to 465 C., from 465 C. to 470 C., from 470 C. to 475 C., from 475 C. to 480 C., from 480 C. to 485 C., from 485 C. to 490 C., from 490 C. to 495 C., or from 490 C. to 495 C. In some examples, the temperature may be from 320 C. to 495 C., from 340 C. to 485 C., from 350 C. to 475 C., or from 370 C. to 475 C. Any suitable temperature ramp rates may be used to heat up to and or cool down from the specified temperature. In some examples, the product is heated to the temperature for a length of time from about 0.1 seconds to about 25 minutes, such as from 0.1 seconds to 0.5 seconds, from 0.5 seconds to 1 second, from 1 second to 2 seconds, from 2 seconds to 3 seconds, from 3 seconds to 4 seconds, from 4 seconds to 5 seconds, from 5 seconds to 10 seconds, from 10 seconds to 15 second, from 15 seconds to 30 seconds, from 30 seconds to 45 seconds, from 45 seconds to 60 seconds, from 60 seconds to 75 seconds, from 75 seconds to 90 seconds, from 90 seconds to 105 seconds, from 105 seconds to 2 minutes, from 2 minutes to 3 minutes, from 3 minutes to 4 minutes, from 4 minutes to 5 minutes, from 5 minutes to 10 minutes, from 10 minutes to 15 minutes, from 15 minutes to 20 minutes, or from 20 minutes to 25 minutes. In some cases, this may indicate that the temperature is held at or about a specified temperature or within 5 C. or within 10 C. of the specified temperature for the length of time. In some examples, the temperature or temperature range may be paired with a specific length of time or time range. For example, the temperature may be from 340 C. to 485 C. while the length of time is less than or equal to 10 minutes, the temperature may be from 350 C. to 475 C. while the length of time is less than 1 minute, or the temperature may be from 370 C. to 475 C. while the length of time is from 2 seconds to 35 seconds. Any variation or combination of the above-mentioned temperatures and lengths of time may be used, and certain alloys or end product configurations may benefit from a particular temperature and length of time combination or range of particular temperatures and lengths of time.
[0064] The intermediate annealing process can include passing a cast, homogenized, or rolled product through a furnace at a speed from about 10 m/min to about 150 m/min, such as from 10 m/min to 15 m/min, from 15 m/min to 20 m/min, from 20 m/min to 25 m/min, from 25 m/min to 30 m/min, from 30 m/min to 40 m/min, from 40 m/min to 45 m/min, from 45 m/min to 50 m/min, from 50 m/min to 60 m/min, from 60 m/min to 70 m/min, from 70 m/min to 80 m/min, from 80 m/min to 90 m/min, from 90 m/min to 100 m/min, from 100 m/min to 110 m/min, from 110 m/min to 120 m/min, from 120 m/min to 130 m/min, from 130 m/min to 140 m/min. or from 140 m/min to 150 m/min. In some instances, the intermediate annealing process can include heating the cast, homogenized, or rolled product by passing the product through a gas-fired furnace. In some instances, the intermediate annealing process can include or use a magnetic heating unit with a heating rate of from 10 C./s to 150 C./s. Optionally, the intermediate annealing process can include or use a quenching process (e.g., a water quench or an air quench) with a cooling rate of from 5 C./s to 150 C./s, or more, to return the product to ambient or room temperature. Cold rolling the product after the intermediate annealing process may result in an unrecrystallized aluminum product with deformed grains. Cold rolling can be performed to create a final gauge thickness that represents a gauge reduction from 25% to 99% (e.g., from 25% to 30%, from 30% to 35%, from 35% to 40%, from 40% to 45%, from 45% to 50%, from 50% to 55%, from 55% to 60%, from 60% to 65%, from 65% to 70%, from 70% to 75%, from 75% to 80%, from 80% to 85%, from 85% to 90%, from 90% to 95%, or from 95% to 99% reduction) as compared to the gauge prior to cold rolling. In some specific examples, a cold rolling process may achieve a cold reduction from 55% to 75%, from 25% to 90%, from 45% to 95%, or from 60% to 99%.
[0065] Subsequently, the product can optionally undergo one or more solution heat treatment steps. The solution heat treatment steps can be any suitable treatment for the metal product which results in solutionizing of the soluble particles. As examples, the product can be heated to a peak metal temperature (PMT) of up to 590 C. (e.g., from 400 C. to 590 C.) and soaked for a period of time at the PMT to form a hot product. For example, the product can be soaked at 480 C. for a soak time of up to 30 minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10 minutes, 20 minutes, 25 minutes, or 30 minutes). After heating and soaking, the hot product is rapidly cooled at rates greater than 90 C./s to a temperature between 500 C. and room temperature to form a heat-treated product.
[0066] After quenching, the heat-treated product can optionally undergo a pre-aging treatment by reheating before coiling. The pre-aging treatment can be performed at a temperature of from about 50 C. to about 125 C. for a period of time of up to 6 hours. For example, the pre-aging treatment can be performed at a temperature of about 50 C., about 55 C. about 60 C., about 65 C., about 70 C., about 75 C., about 80 C., about 85 C., about 90 C., about 95 C., about 100 C., about 105 C., about 110 C., about 115 C., about 120 C., or about 125 C. Optionally, the pre-aging treatment can be performed for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours. The pre-aging treatment can be carried out by passing the heat-treated product through a heating device, such as a device that emits radiant heat, convective heat, induction heat, infrared heat, or the like.
[0067]
[0068] Following the casting stage 205, the metal product may be subjected to a homogenization process 210, where the metal is heated to a temperature less than the melting or solidus temperature of the metal. Optionally, the metal product is heated to a temperature at which the base metal and any alloying elements form a solid solution.
[0069] Following the homogenization process 210, the metal product may be exposed to one or more processes that may, for example, form desirable microcrystalline structures within the metal product while elongating the metal product. Such processes may correspond to hot rolling 215 and/or cold rolling 220, for example, such as to form shates, plates, or sheets from a metal ingot or other cast article or metal product.
[0070] In some embodiments, exposing a metal product at an elevated temperature to a solution, such as water, an aqueous solution, or a gas, gas mixture, or gas-phase solution, in a quenching or cooling process may be used to reduce the temperature of the metal product to a temperature desirable or useful for a subsequent process. For example, exposing the metal product to water or an aqueous solution may be useful for cooling the metal product between hot rolling process 215 and subsequent processing. Tandem and/or breakdown processing is not shown in
[0071] Following the hot rolling process 215 and/or the cold rolling process 220 (cold rolling process 220 may be optional), the metal product may be subjected to an intermediate annealing heat treatment process 225, where the metal product is heated to and held at a predefined temperature for a length of time less than or equal to an hour to generate at least partial recrystallization of the metal product. The metal product may be optionally subjected to an additional cold rolling process 230 after the intermediate annealing heat treatment process 225. Various different peak temperatures may be used for the intermediate annealing heat treatment process 225, as shown in
[0072] The metal product may then be subjected to a solution heat treatment process 235, where the temperature of the metal product is increased to a temperature above a threshold temperature, such as a temperature at which precipitated components in the metal product dissolve into a solid solution or a temperature at which recrystallization processes occur, and held at or above the threshold temperature for a period of time. At the end of the solution heat treatment process 235, the metal product may be subjected to a quenching process 240, where dissolved components are fixed into place by rapidly reducing the temperature of the metal by a quenching process. Such a quenching process 240 may involve exposing the metal product to a solution, such as a quench solution including water, an aqueous solution, or a gas or gas mixture.
[0073] In embodiments, the processes overviewed in
Methods of Using the Disclosed Aluminum Alloy Products
[0074] The aluminum alloy products described herein can be used in automotive applications and other transportation applications, including aircraft and railway applications. For example, the disclosed aluminum alloy products can be used to prepare automotive structural parts, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The aluminum alloy products and methods described herein can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels.
[0075] The aluminum alloy products and methods described herein can also be used in electronics applications. For example, the aluminum alloy products and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the aluminum alloy products can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones), tablet bottom chassis, and other portable electronics.
Methods of Treating Metals and Metal Alloys
[0076] Described herein are methods of treating and using metals and metal alloys, including aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites, and steel, among others, and the resultant treated metals and metal alloys. In some examples, the metals for use in the methods described herein include aluminum alloys, for example, 1xxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys. In some examples, material comprising 1xxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys are useful as recycled source content material for the aluminum alloys and metal products described herein. In some examples, the materials for use in the methods described herein include non-ferrous materials, including aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composites, sheets used in composites, or any other suitable metal, non-metal or combination of materials. Monolithic as well as non-monolithic, such as roll-bonded materials, cladded alloys, clad layers, composite materials, such as but not limited to carbon fiber-containing materials, or various other materials are also useful with the methods described herein. In some examples, aluminum alloys containing iron are useful with the methods described herein.
[0077] By way of non-limiting example, exemplary 1xxx series aluminum alloys for use in the methods described herein can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.
[0078] Non-limiting exemplary 2xxx series aluminum alloys for use in the methods described herein can include AA2001, AA2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.
[0079] Non-limiting exemplary 3xxx series aluminum alloys for use in the methods described herein can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.
[0080] Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein can include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.
[0081] Non-limiting exemplary 5xxx series aluminum alloys for use in the methods described herein product can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.
[0082] Non-limiting exemplary 6xxx series aluminum alloys for use in the methods described herein can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, AA6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.
[0083] Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.
[0084] Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein can include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.
[0085] The examples disclosed herein will serve to further illustrate aspects of the invention without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications, and equivalents thereof, which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the invention. The examples and embodiments described herein may also make use of conventional procedures, unless otherwise stated. Some of the procedures are described herein for illustrative purposes.
Example 1
[0086] Samples of an aluminum alloy sheet metal were prepared by casting, homogenizing, hot rolling, cold rolling, solutionizing, and aging an aluminum alloy. Conventional DC casting techniques were used to prepare ingots comprising AA6016. The aluminum alloy contained about 55% recycled aluminum content. The aluminum alloy contained about 0.23-0.30 wt. % Fe, 0.15-0.20 wt. % Mn and 0.009-0.025 wt. % Cr, such that the ratio of Mn+Cr to Fe was about 0.67-0.73.
[0087] The ingots were homogenized at about 540 C. for about 14 hours. The homogenized products were subjected to hot rolling, followed by cold rolling, followed by solutionizing, according to conventional hot rolling, cold rolling, and solution heat treatment techniques. An exit temperature after hot rolling was 405 C. The thickness reduction achieved by hot rolling was about 98% and the thickness reduction achieved by cold rolling prior to inter-annealing at 355 C. was 63%. Additional cold rolling was then used to generate a final gauge of 1.02 mm for the cold rolled product. The cold rolled product was subjected to a short (<1 minute) solutionizing treatment at a peak metal temperature between 560 C. and 570 C. Samples of the solutionized product were subjected to natural aging to achieve a T4 temper and these samples were subjected to testing for evaluation of properties. Some aged samples were also subjected to artificial aging to achieve a T6 temper and these samples were also subjected to testing for evaluation of properties. Measured values are shown in Tables 1 and 2. Roping characteristics (Sa and VDA 239-400 RK 10%) were also evaluated, with measured values shown in Table 3.
TABLE-US-00001 TABLE 1 T4 temper values Ultimate Yield Tensile Uniform Total Strength Strength Elongation Elongation Direction Position (MPa) (MPa) (%) (%) n5% r10% L Edge 106-116 227-241 21.69-22.42 25-26 0.304- 0.565- 0.309 0.572 T Edge 104-113 226-238 22-23.02 26-27 0.305- 0.608- 0.308 0.627 D Edge 103-112 223-236 22.24-22.98 26-27 0.303- 0.606- 0.309 0.614 L Center 108-115 229-240 21.9-22.11 25-26 0.308- 0.584- 0.310 0.606 T Center 106-112 228-238 21.77-22.46 25-26 0.308- 0.634- 0.310 0.668 D Center 105-111 225-235 22.7-23.47 26-27 0.306- 0.606- 0.309 0.628 L Edge 109-115 229-240 21.8-22.31 25-26 0.307- 0.557- 0.308 0.571 T Edge 106-112 228-237 22.2-22.69 26 0.306- 0.605- 0.308 0.620 D Edge 105-111 225-235 22.61-22.91 26-27 0.306- 0.602- 0.307 0.616
TABLE-US-00002 TABLE 2 T6 temper values Ultimate Yield Tensile Uniform Total Strength Strength Elongation Elongation Aging Condition Direction Position (MPa) (MPa) (%) (%) 170 C., 20 minutes T Center 163-171 246-256 18.46- 22-23 18.67 185 C., 20 minutes T Center 188-197 260-271 15.57- 19-20 16.09 180 C., 10 hours T Center 226-229 286-291 10.59- 15 11.27
TABLE-US-00003 TABLE 3 Roping values VDA 239-400 Position Direction Sa (m) RK 10% (%) Edge T 0.485-0.514 4.321-4.393 25% T 0.513-0.570 4.183-4.714 Center T 0.472-0.683 3.937-4.336
Example 2
[0088] Samples of an aluminum alloy sheet metal were prepared by casting, homogenizing, hot rolling, cold rolling, and interannealing recrystallization an aluminum alloy. Conventional DC casting techniques were used to prepare ingots comprising AA6016. The aluminum alloy contained about 55% recycled aluminum content. The aluminum alloy contained about 0.23-0.30 wt. % Fe, 0.15-0.20 wt. % Mn and 0.009-0.025 wt. % Cr, such that the ratio of Mn+Cr to Fe was about 0.67-0.73.
[0089] The ingots were homogenized at about 540 C. for about 13-14 hours. The homogenized products were subjected to hot rolling, followed by cold rolling to a gauge of about 3.5 mm, followed by an interannealing recrystallization, followed by cold rolling to a final gauge of about 1.0 mm. Conventional hot rolling and cold rolling techniques were used. An exit temperature after hot rolling was about 350 C., which generated fine precipitates in the samples. Several different interannealing recrystallization techniques were applied to samples of the product after hot rolling and cold rolling. Some of the samples were subjected to a solutionizing heat treatment and natural aging process following the final cold rolling to a T4 temper condition and properties were evaluated (e.g., grain characteristics, mechanical properties, crystal texture, surface character, etc.). Comparative samples of a different alloy (AA6016) including no recycled content (C1) and of the same alloy (C2) were also evaluated for comparison where the same hot and cold rolling processes were used but no interannealing recrystallization treatment was used.
[0090] The first and second interannealing recrystallization techniques (R1 and R2) included heating the samples to 350 C. for 5 seconds, followed by air quenching. The third interannealing recrystallization technique (RX3) included heating the samples to 365 C. for 5 seconds using a magnetic induction heating system, followed by water quenching. The fourth interannealing recrystallization technique (RX3) included heating the samples to 415 C. for 5 seconds using a magnetic induction heating system, followed by water quenching.
[0091] Full recrystallization of the samples was observed for all the tested interannealing recrystallization techniques. The grain growth observed in the first and second interannealing recrystallization techniques was different from that in the third and fourth interannealing recrystallization techniques, but no significant particle coarsening was observed in any of the interannealing recrystallization techniques.
[0092]
[0093] The fine grain size and high degree of random textures resulted in good bending and roping character, and improved formability character, as compared to processing without use of an interannealing recrystallization process. Further, the clean microstructure having a low fraction of undissolved precipitates and microvoids contributed to the good bending character.
Illustrative Aspects
[0094] As used below, any reference to a series of aspects (e.g., Aspects 1-4) or non-enumerated group of aspects (e.g., any previous or subsequent aspect) is to be understood as a reference to each of those aspects disjunctively (e.g., Aspects 1-4 is to be understood as Aspects 1, 2, 3, or 4). [0095] Aspect 1 is an aluminum alloy, comprising Al and about 1 wt. % to 1.5 wt. % Si, up to about 0.35 wt. % Fe, up to about 0.25 wt. % Cu, about 0.05 wt. % to 0.25 wt. % Mn, about 0.2 wt. % to 0.60 wt. % Mg, up to about 0.10 wt. % Cr, up to about 0.10 wt. % Ni, up to about 0.20 wt. % Zn, up to about 0.15 wt. % Ti, and up to about 0.10 wt. % V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content. [0096] Aspect 2 is the aluminum alloy of any previous or subsequent aspect, comprising up to 100% recycled aluminum alloy content or comprising more than 20% recycled aluminum alloy content. [0097] Aspect 3 is the aluminum alloy of any previous or subsequent aspect, comprising a 6xxx series aluminum alloy. [0098] Aspect 4 is the aluminum alloy of any previous or subsequent aspect, comprising about 1.2 wt. % to 1.5 wt. % Si, about 0.10 wt. % to 0.35 wt. % Fe, about 0.05 wt. % to 0.25 wt. % Cu, about 0.10 wt. % to 0.25 wt. % Mn, about 0.25 wt. % to 0.60 wt. % Mg, about 0.005 wt. % to 0.10 wt. % Cr, about 0.03 wt. % to 0.10 wt. % Ni, about 0.02 wt. % to 0.20 wt. % Zn, about 0.01 wt. % to 0.15 wt. % Ti, and about 0.01 wt. % to 0.10 wt. % V. [0099] Aspect 5 is the aluminum alloy of any previous or subsequent aspect, comprising about 1.35 wt. % to 1.5 wt. % Si, about 0.20 wt. % to 0.35 wt. % Fe, about 0.10 wt. % to 0.25 wt. % Cu, about 0.10 wt. % to 0.20 wt. % Mn, about 0.25 wt. % to 0.60 wt. % Mg, about 0.009 wt. % to 0.10 wt. % Cr, about 0.05 wt. % to 0.10 wt. % Ni, about 0.02 wt. % to 0.15 wt. % Zn, about 0.01 wt. % to 0.15 wt. % Ti, and about 0.02 wt. % to 0.10 wt. % V. [0100] Aspect 6 is the aluminum alloy of any previous or subsequent aspect, comprising up to 0.05 wt. % each of any individual impurity and up to 0.25 wt. % of all impurities. [0101] Aspect 7 is the aluminum alloy of any previous or subsequent aspect, comprising more alpha phase Fe-containing intermetallic particles than beta phase Fe-containing intermetallic particles. [0102] Aspect 8 is a metal product comprising an aluminum alloy, wherein the aluminum alloy comprises Al and about 1 wt. % to 1.5 wt. % Si, up to about 0.35 wt. % Fe, up to about 0.25 wt. % Cu, about 0.05 wt. % to 0.25 wt. % Mn, about 0.2 wt. % to 0.60 wt. % Mg, up to about 0.10 wt. % Cr, up to about 0.10 wt. % Ni, up to about 0.20 wt. % Zn, up to about 0.15 wt. % Ti, and up to about 0.10 wt. % V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content. [0103] Aspect 9 is the metal product of any previous or subsequent aspect, wherein the aluminum alloy is the aluminum alloy of any of any previous or subsequent aspect. [0104] Aspect 10 is the metal product of any previous or subsequent aspect, wherein the metal product is a rolled metal product. [0105] Aspect 11 is the metal product of any previous or subsequent aspect, wherein the metal product is dual-recrystallized metal product. [0106] Aspect 12 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits isotropic strain characteristics. [0107] Aspect 13 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a Lankford ratio at about 10% strain along longitudinal, transverse, and diagonal directions of about 0.6 or greater. [0108] Aspect 14 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits an f15% bending factor along a transverse direction of from about 0.3 to 1.0. [0109] Aspect 15 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits an inner-bending angle after pre-straining of 10% of about 10 to 60. [0110] Aspect 16 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a surface arithmetical mean height (Sa) of at most 0.60 m. [0111] Aspect 17 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a yield strength of from 90 MPa to 130 MPa when in a T4 temper or from 200 MPa to 235 MPa when in a T6 temper. [0112] Aspect 18 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits an ultimate tensile strength of from 195 MPa to 270 MPa when in a T4 temper or from 240 MPa to 300 MPa when in a T6 temper. [0113] Aspect 19 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a uniform elongation of from 20% to 30% when in a T4 temper or from 10% to 20% when in a T6 temper. [0114] Aspect 19A is the metal product of any previous or subsequent aspect prepared using the method of any subsequent aspect. [0115] Aspect 19B is the metal product of any previous aspect prepared using the aluminum alloy of any previous aspect. [0116] Aspect 20 is a method of producing a metal product, the method comprising casting an aluminum alloy to generate a cast product, wherein the aluminum alloy comprises Al and about 1 wt. % to 1.5 wt. % Si, up to about 0.35 wt. % Fe, up to about 0.25 wt. % Cu, about 0.05 wt. % to 0.25 wt. % Mn, about 0.2 wt. % to 0.60 wt. % Mg, up to about 0.10 wt. % Cr, up to about 0.10 wt. % Ni, up to about 0.20 wt. % Zn, up to about 0.15 wt. % Ti, and up to about 0.10 wt. % V, wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.7, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content; homogenizing the cast product to generate a homogenized product; hot rolling the homogenized product to generate a rolled product; and subjecting the rolled product to a final cold rolling process product to produce the metal product. [0117] Aspect 21 is the method of any previous or subsequent aspect, further comprising subsequent to the hot rolling, subjecting the rolled product to a recrystallization process to generate a recrystallized product, wherein the final cold rolling process comprises cold rolling the recrystallized product to produce the metal product. [0118] Aspect 22 is the method of any previous or subsequent aspect, wherein the recrystallization process occurs between the hot rolling and the final cold rolling process. [0119] Aspect 23 is the method of any previous or subsequent aspect, further comprising subjecting the rolled product to a preliminary cold rolling process subsequent to the hot rolling and prior to the recrystallization process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process. [0120] Aspect 24 is the method of any previous or subsequent aspect, wherein the recrystallization process comprises annealing the rolled product at peak metal temperature of from 325 C. to 425 C. for up to 1 minute to generate a recrystallized product; and quenching the recrystallized product. [0121] Aspect 25 is the method of any previous or subsequent aspect, wherein an exit temperature of the hot rolling is no more than 400 C. [0122] Aspect 26 is the method of any previous or subsequent aspect, wherein the hot rolling achieves a thickness reduction between the homogenized product and the rolled product of 90% or more. [0123] Aspect 27 is the method of any previous or subsequent aspect, further comprising subjecting the metal product to a solutionizing process to generate a solutionized metal product. [0124] Aspect 28 is the method of any previous or subsequent aspect, further comprising subjecting the metal product to an aging or artificial aging process to generate an aged metal product. [0125] Aspect 29 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises up to 100% recycled aluminum alloy content or more than 20% recycled aluminum alloy content. [0126] Aspect 30 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises a 6xxx series aluminum alloy. [0127] Aspect 31 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises about 1.2 wt. % to 1.5 wt. % Si, about 0.10 wt. % to 0.35 wt. % Fe, about 0.05 wt. % to 0.25 wt. % Cu, about 0.10 wt. % to 0.25 wt. % Mn, about 0.25 wt. % to 0.60 wt. % Mg, about 0.005 wt. % to 0.10 wt. % Cr, about 0.03 wt. % to 0.10 wt. % Ni, about 0.02 wt. % to 0.20 wt. % Zn, about 0.01 wt. % to 0.15 wt. % Ti, and about 0.01 wt. % to 0.10 wt. % V. [0128] Aspect 32 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises about 1.35 wt. % to 1.5 wt. % Si, about 0.20 wt. % to 0.35 wt. % Fe, about 0.10 wt. % to 0.25 wt. % Cu, about 0.10 wt. % to 0.20 wt. % Mn, about 0.25 wt. % to 0.60 wt. % Mg, about 0.009 wt. % to 0.10 wt. % Cr, about 0.05 wt. % to 0.10 wt. % Ni, about 0.02 wt. % to 0.15 wt. % Zn, about 0.01 wt. % to 0.15 wt. % Ti, and about 0.02 wt. % to 0.10 wt. % V. [0129] Aspect 33 is the method of any previous or subsequent aspect, wherein the aluminum alloy comprises up to 0.05 wt. % each of any individual impurity and up to 0.25 wt. % of all impurities. [0130] Aspect 34 is the method of any previous or subsequent aspect, wherein the metal product exhibits isotropic strain characteristics. [0131] Aspect 35 is the method of any previous or subsequent aspect, wherein the metal product exhibits a Lankford ratio at about 10% strain along longitudinal, transverse, and diagonal directions of about 0.6 or greater. [0132] Aspect 36 is the method of any previous or subsequent aspect, wherein the metal product exhibits an f15% bending factor along a transverse direction of from about 0.3 to 1.0. [0133] Aspect 37 is the method of any previous or subsequent aspect, wherein the metal product exhibits an inner-bending angle after pre-straining of 10% of about 10 to 60. [0134] Aspect 38 is the method of any previous or subsequent aspect, wherein the metal product exhibits a surface arithmetical mean height (Sa) of at most 0.60 m. [0135] Aspect 39 is the method of any previous or subsequent aspect, wherein the metal product exhibits a yield strength of from 90 MPa to 130 MPa when in a T4 temper or from 200 MPa to 235 MPa when in a T6 temper. [0136] Aspect 40 is the method of any previous or subsequent aspect, wherein the metal product exhibits an ultimate tensile strength of from 195 MPa to 270 MPa when in a T4 temper or from 240 MPa to 300 MPa when in a T6 temper. [0137] Aspect 41 is the method of any previous or subsequent aspect, wherein the metal product exhibits a uniform elongation of from 20% to 30% when in a T4 temper or from 10% to 20% when in a T6 temper. [0138] Aspect 42 is the method of any previous aspect, wherein the aluminum alloy is the aluminum alloy of any previous aspect.
[0139] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of the embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.