Corrosion resistant aluminum alloys having high amounts of magnesium and methods of making the same

Abstract

Systems and methods for continuously casting Al—Mg alloy sheet or plate product having a high amount of magnesium are disclosed. The Al—Mg products have 4 or 6 to 8 or 10 wt, % Mg and are resistant to both stress corrosion cracking and intergranular corrosion.

What is claimed is: 
     
         1 . A method comprising:
 (a) continuously casting an Al—Mg alloy comprising from about 6 wt. % to about 10 wt. % Mg;   (b) hot rolling the Al—Mg alloy to a thickness of less than 6.35 mm;   (c) annealing the Al—Mg alloy via a furnace, wherein the annealing step comprises:
 (i) heating the Al—Mg alloy at elevated temperature and for a time sufficient to achieve an O temper; and 
 (ii) cooling the Al—Mg alloy, wherein, after the cooling step, the Al—Mg alloy comprises a plurality of grains, and wherein the Al—Mg alloy is substantially free of a continuous film of β-phase at the grain boundaries after the Al—Mg alloy has been age sensitized. 
   
     
     
         2 . The method of  claim 1 , wherein after the cooling step (c)(ii), the Al—Mg alloy is free of a continuous film of β-phase. 
     
     
         3 . The method of  claim 1 , wherein the heating step (c)(i) comprises:
 heating the Al—Mg alloy to a temperature T 1 , wherein T 1  is from about 365° C. to about 500° C., for a period of at least about 2 hours.   
     
     
         4 . The method of  claim 3 , wherein the cooling step (c)(ii) comprises:
 first cooling the Al—Mg alloy from the temperature T 1  to a temperature T 2 , wherein the temperature T 2  is at least about 25° C. less than the temperature T 1 , and wherein the rate of cooling from temperature T 1  to temperature T 2  is not greater than about 100° C. per hour; and   second cooling the Al—Mg alloy from the temperature T 2  to a temperature T 3 , wherein T 3  is at least about 100° C. less than temperature T 2 .   
     
     
         5 . The method of  claim 4 , wherein the cooling rate of the first cooling step is in the range of from about 30° C./hour to about 60° C./hour. 
     
     
         6 . The method of  claim 1 , wherein the continuously casting comprises strip casting. 
     
     
         7 . The method of  claim 6 , wherein the cooling rate of the second cooling step is at least about 100° C./hour.