Aluminum alloys, aluminum alloy products and methods for making the same

Abstract

Decorative shape cast products and methods, systems, compositions and apparatus for producing the same are described. In one embodiment, the decorative shape cast products are produced from an Al—Ni or Al—Ni—Mn alloy, with a tailored microstructure to facilitate production of anodized decorative shape cast product having the appropriate finish and mechanical properties.

What is claimed is: 
     
         1 . A method comprising:
 (a) selecting a product application for a shape cast aluminum alloy product;   (b) selecting a finishing style for the shape cast aluminum alloy product;   (c) selecting, based on at least one of steps (a) and (b):
 (i) a predetermined microstructure of the shape cast aluminum alloy product; and 
 (ii) an alloy for use in producing the shape cast aluminum alloy product, wherein the alloy consists essentially of from 0.5 wt. % to 8.0 wt. % Ni, up to 3.5 wt. % Mn, the balance being aluminum and incidental elements and impurities; and 
   (d) producing the shape cast aluminum alloy product in response to the selection step (c), wherein the producing comprises:
 (i) die casting the shape cast aluminum alloy product from the alloy; and 
 (ii) anodizing the shape cast aluminum alloy product, wherein the anodizing comprises forming a uniform oxide layer from a portion of the shape cast aluminum alloy product; 
   
       wherein after the anodizing step (ii), the shape cast aluminum alloy product realizes both (A) a CIELAB L-value of at least about 55 and (B) an ISO brightness of at least about 20. 
     
     
         2 . The method of  claim 1 , wherein the alloy includes at least 0.5 wt. % Mn. 
     
     
         3 . The method of  claim 2 , wherein the alloy includes at least 6.6 wt. % Ni. 
     
     
         4 . The method of  claim 3 , wherein the alloy includes at least 1.0 wt. % Mn. 
     
     
         5 . The method of  claim 2 , wherein the alloy includes from 2 wt. % to 6 wt. % Ni. 
     
     
         6 . The method of  claim 5 , wherein the alloy includes at least 3.1 wt. % Mn. 
     
     
         7 . The method of  claim 5 , wherein the alloy includes not greater than 3.0 wt. % Mn. 
     
     
         8 . The method of  claim 1 , wherein the alloy includes from 5.7 wt. % to 7.1 wt. % Ni and from 1.8 wt. % to 3.1 wt. % Mn. 
     
     
         9 . The method of  claim 1 , wherein the alloy includes from 5.6 wt. % to 6.8 wt. % Ni and from 2.0 wt. % to 3.2 wt. % Mn. 
     
     
         10 . The method of  claim 1 , wherein the alloy includes from 1.8 wt. % to 3.2 wt. % Ni and from 0.8 wt. % to 3.2 wt. % Mn. 
     
     
         11 . The method of  claim 1 , wherein the incidental elements comprise a grain refiner, wherein the grain refiner comprises titanium in an amount of from 0.005 wt. % to 0.10 wt. %. 
     
     
         12 . The method of  claim 1 , wherein each one of the incidental elements and impurities does not exceed 0.25 wt. % in the alloy.