Aluminum alloys and methods of manufacture

Abstract

Provided herein are novel aluminum alloy compositions and methods of making and processing the same. The alloys described herein can be used in bottle making applications and exhibit enhanced runnability, formability, and appearance. The methods of producing an aluminum alloy sheet described herein can include casting an aluminum alloy to form an ingot, homogenizing the ingot, hot rolling the ingot to produce a hot band, and cold rolling the hot band to an aluminum alloy sheet of final gauge.

What is claimed is: 
     
         1 . An aluminum alloy comprising 0.2-0.8 wt. % Fe, 0.05-0.50 wt. % Si, 0.40-1.65 wt. % Mg, 0.40-1.50 wt. % Mn, 0.03-0.35 wt. % Cu, up to 0.07 wt. % Cr, up to 0.05 wt. % Ni, up to 0.07 wt. % Ti, up to 0.35 wt. % of Zn, up to 0.04 wt. % Zr, up to 0.15 wt. % impurities, with the remainder as Al, and wherein the alloy comprises an Effective Mg Index up to about 0.9. 
     
     
         2 . The aluminum alloy of  claim 1 , comprising 0.3-0.6 wt. % Fe, 0.12-0.36 wt. % Si, 0.65-1.22 wt. % Mg, 0.65-1.1 wt. % Mn, 0.05-0.25 wt. % Cu, up to 0.05 wt. % Cr, up to 0.03 wt. % Ni, up to 0.05 wt. % Ti, up to 0.25 wt. % of Zn, up to 0.03 wt. % Zr, and up 0.15 wt. % impurities, with the remainder as Al. 
     
     
         3 . The aluminum alloy of  claim 1 , comprising 0.36-0.44 wt. % Fe, 0.21-0.27 wt. % Si, 0.75-0.85 wt. % Mg, 0.75-0.85 wt. % Mn, 0.11-0.15 wt. % Cu, up to 0.05 wt. % Cr, up to 0.03 wt. % Ni, up to 0.05 wt. % Ti, up to 0.25 wt. % of Zn, up to 0.03 wt. % Zr, and up 0.15 wt. % impurities, with the remainder as Al. 
     
     
         4 . The aluminum alloy of  claim 1 , comprising 0.36-0.44 wt. % Fe, 0.21-0.27 wt. % Si, 0.75-0.85 wt. % Mg, 0.75-0.85 wt. % Mn, 0.06-0.1 wt. % Cu, up to 0.05 wt. % Cr, up to 0.03 wt. % Ni, up to 0.05 wt. % Ti, up to 0.25 wt. % of Zn, up to 0.03 wt. % Zr, and up 0.15 wt. % impurities, with the remainder as Al. 
     
     
         5 . The aluminum alloy of  claim 1 , comprising 0.36-0.44 wt. % Fe, 0.15-0.21 wt. % Si, 0.75-0.85 wt. % Mg, 0.75-0.85 wt. % Mn, 0.11-0.15 wt. % Cu, up to 0.05 wt. % Cr, up to 0.03 wt. % Ni, up to 0.05 wt. % Ti, up to 0.25 wt. % of Zn, up to 0.03 wt. % Zr, and up 0.15 wt. % impurities, with the remainder as Al. 
     
     
         6 . The aluminum alloy of  claim 1 , comprising 0.36-0.44 wt. % Fe, 0.21-0.27 wt. % Si, 0.75-0.85 wt. % Mg, 0.75-0.85 wt. % Mn, 0.18-0.22 wt. % Cu, up to 0.05 wt. % Cr, up to 0.03 wt. % Ni, up to 0.05 wt. % Ti, up to 0.25 wt. % of Zn, up to 0.03 wt. % Zr, and up 0.15 wt. % impurities, with the remainder as Al. 
     
     
         7 . The aluminum alloy of  claim 1 , comprising 0.46-0.54 wt. % Fe, 0.27-0.33 wt. % Si, 0.93-1.07 wt. % Mg, 0.8-0.94 wt. % Mn, 0.11-0.15 wt. % Cu, up to 0.05 wt. % Cr, up to 0.03 wt. % Ni, up to 0.05 wt. % Ti, up to 0.25 wt. % of Zn, up to 0.03 wt. % Zr, and up 0.15 wt. % impurities, with the remainder as Al. 
     
     
         8 . The aluminum alloy of  claim 1 , further comprising a Fe to Si ratio of 0.5 to 6.7, 0.8 to 5, 1.3 to 2.1, 1.7 to 2.9, or 1.4 to 2.0. 
     
     
         9 . A bottle or can comprising the aluminum alloy of  claim 1 . 
     
     
         10 . An aluminum sheet comprising the aluminum alloy of  claim 1 . 
     
     
         11 . A method of producing an aluminum alloy product from the aluminum alloy of  claim 1 , comprising:
 casting an aluminum alloy to form an ingot or a slab;   homogenizing the ingot or the slab;   hot rolling the ingot or the slab to produce an aluminum alloy body; and   cold rolling the aluminum alloy body to an aluminum alloy product with a final gauge.   
     
     
         12 . The method of  claim 11 , wherein the homogenizing step includes subjecting the ingot or slab to a temperature of from 550° C. to 625° C. for between 2 hours to 30 hours. 
     
     
         13 . The method of  claim 11 , wherein the hot rolling step includes an entry temperature of from 380° C. to 500° C. 
     
     
         14 . The method of  claim 11 , wherein the hot rolling step includes an exit temperature of from 280° C. to 400° C. 
     
     
         15 . The method of  claim 11 , wherein a hot rolling exit temperature is greater than a recrystallization temperature of the aluminum alloy. 
     
     
         16 . The method of  claim 11 , wherein the hot rolling step includes a first hot rolling operation that reduces a thickness of the ingot or slab in a range between 94% to 96% to provide an intermediate thickness and a second hot rolling operation that reduces a thickness of the ingot or slab having the intermediate thickness in a range between 80% to 93%. 
     
     
         17 . The method of  claim 11 , wherein the cold rolling step includes reducing the aluminum alloy body by about 70% to 98% thickness reduction. 
     
     
         18 . The method of  claim 11 , wherein the cold rolling step comprises a first cold rolling operation, a second cold rolling operation, a third cold rolling operation, and a fourth cold rolling operation. 
     
     
         19 . The method of  claim 18 , wherein the cold rolling step comprises reducing a thickness of the aluminum alloy body between about 89% to 91%. 
     
     
         20 . The method of  claim 18 , wherein each of the first cold rolling operation, the second cold rolling operation, the third cold rolling operation, and the fourth cold rolling operation provides a reduction in thickness in a range of about 40% to 60%.