Feedstock for metal foil product and method of making thereof

Abstract

The present invention discloses a product comprising a 1xxx, 3xxx and 8xxx series aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product. The product has an O-temper tensile strength, O-temper elongation, and O-temper Mullen pressure that are at least 10% greater compared to the average values of the same alloy in O-temper cast using a slab or roll-casting process. The product is substantially free of pinholes caused by centerline segregation of intermetallic particles. In another embodiment, the present invention discloses a 8111 or 8921 aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product. The product has an O-temper tensile strength, O-temper elongation, and O-temper Mullen pressure that are at least 10% greater than the average values of the same alloy in O-temper made from feedstock prepared by slab or roll casting processes. The product is substantially free of pinholes caused by centerline segregation of intermetallic particles.

1 . A product comprising:
 a 1xxx, 3xxx and 8xxx series aluminum alloy made by a non-ingot casting process,   wherein the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product,   wherein the product has an O-temper tensile strength that is at least 10% greater compared to the average values of the same alloy in O-temper cast using a slab or roll-casting process,   wherein the product has an O-temper elongation that is at least 10% greater compared to the average values of the same alloy in O-temper cast using a slab or roll-casting process,   wherein the product has an O-temper Mullen pressure that is at least 10% greater compared to the average values of the same alloy in O-temper cast using a slab or roll-casting process,   wherein the product is substantially free of pinholes caused by centerline segregation of intermetallic particles.   
   
   
       2 . A product comprising:
 an 8111 aluminum alloy made by a non-ingot casting process,   wherein the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product,   wherein the product has a tensile strength in O-temper that is at least 10% greater than the average values of standard 8111 alloy in O-temper,   wherein the product has an elongation in O-temper that is at least 10% greater than the average values of standard 8111 alloy in O-temper,   wherein the product has a Mullen pressure in O-temper that is at least 10% greater than the average values of standard 8111 alloy in O-temper,   wherein the product is substantially free of pinholes caused by centerline segregation of intermetallic particles.   
   
   
       3 . A product comprising:
 an 8921 aluminum alloy made by a non-ingot casting process,   wherein the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product,   wherein the product has a tensile strength in O-temper that is at least 10% greater than the average values of standard 8921 alloy in O-temper,   wherein the product has an elongation in O-temper that is at least 10% greater than the average values of standard 8921 alloy in O-temper,   wherein the product has a Mullen pressure in O-temper that is at least 10% greater than the average values of standard 8921 alloy in O-temper,   wherein the product is substantially free of pinholes caused by centerline segregation of intermetallic particles.