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.

What is claimed is: 
     
         1 . A product comprising:
 a 1xxx, 3xxx or 8xxx series aluminum alloy,   wherein the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product,   wherein the aluminum alloy is substantially free of beta intermetallic phase particles;   wherein the aluminum alloy is substantially free of alpha prime intermetallic phase particles; and   wherein a yield strength of the product is 45 MPa to 120 MPa.   
     
     
         2 . A product comprising:
 an 8111 aluminum alloy,   wherein the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product,   wherein the aluminum alloy is substantially free of beta intermetallic phase particles;   wherein the aluminum alloy is substantially free of alpha prime intermetallic phase particles; and   wherein a yield strength of the product is 45 MPa to 120 MPa.   
     
     
         3 . A product comprising:
 an 8921 aluminum alloy made by a non-ingot casting process without homogenization and without intermediate anneal,   wherein the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product, and wherein the aluminum alloy is free of beta intermetallic phase particles.   
     
     
         4 . The product of  claim 1 , wherein the aluminum alloy consists essentially of a 1xxx series aluminum alloy. 
     
     
         5 . The product of  claim 1 , wherein the aluminum alloy consists essentially of a 3xxx series aluminum alloy. 
     
     
         6 . The product of  claim 1 , wherein the aluminum alloy consists essentially of an 8xxx series aluminum alloy.