High-strength 6xxx aluminum alloys and methods of making the same

Abstract

Disclosed are high-strength aluminum alloys and methods of making and processing such alloys. More particularly, disclosed is a 6XXX series aluminum alloy exhibiting improved mechanical strength, formability, corrosion resistance, and anodized qualities. An exemplary method includes homogenizing, hot rolling, solutionizing, and quenching. In some cases, the processing steps can further include annealing and/or cold rolling.

1 . A method of producing an aluminum alloy metal product, the method comprising:
 casting an aluminum alloy to form an ingot, wherein the aluminum alloy comprises about 0.6-0.9 wt. % Cu, about 0.8-1.3 wt. % Si, about 1.0-1.3 wt. % Mg, about 0.03-0.25 wt. % Cr, about 0.05-0.2 wt. % Mn, about 0.15-0.3 wt. % Fe, up to about 0.2 wt. % Zr, up to about 0.2 wt. % Sc, up to about 0.25 wt. % Sn, up to about 0.9 wt. % Zn, up to about 0.1 wt. % Ti, up to about 0.07 wt. % Ni, up to about 0.15 wt. % of impurities, and Al;   homogenizing the ingot;   hot rolling the ingot to produce a plate or shate; and   solutionizing the plate or shate at a temperature between about 520° C. and about 590° C.   
     
     
         2 . The method of  claim 1 , wherein the homogenizing step comprises heating the ingot to a temperature of about 520° C. to about 580° C. 
     
     
         3 . The method of  claim 1 , wherein the hot rolling step is conducted at an entry temperature of about 500° C. to about 540° C. and an exit temperature of about 250° C. to about 380° C. 
     
     
         4 . The method of  claim 1 , further comprising annealing the plate or shate. 
     
     
         5 . The method of  claim 4 , wherein the annealing step is performed at a temperature that is between about 400° C. and about 500° C. for a soaking time of about 30 to about 120 minutes. 
     
     
         6 . The method of  claim 1 , further comprising cold rolling the plate or shate. 
     
     
         7 . The method of  claim 1 , further comprising quenching the plate or shate after the solutionizing step. 
     
     
         8 . The method of  claim 1 , further comprising aging the plate or shate. 
     
     
         9 . The method of  claim 8 , wherein the aging comprises heating the plate or shate between about 180° C. to about 225° C. 
     
     
         10 . A method of producing an aluminum alloy product, the method comprising:
 casting an aluminum alloy to form an ingot, wherein the aluminum alloy comprises about 0.5-2.0 wt. % Cu, about 0.5-1.5 wt. % Si, about 0.5-1.5 wt. % Mg, about 0.001-0.25 wt. % Cr, about 0.005-0.4 wt. % Mn, about 0.1-0.3 wt. % Fe, up to about 0.2 wt. % Zr, up to about 0.2 wt. % Sc, up to about 0.25 wt. % Sn, up to about 4.0 wt. % Zn, up to about 0.15 wt. % Ti, up to about 0.1 wt. % Ni, up to about 0.15 wt. % of impurities, and Al;   homogenizing the ingot;   hot rolling and cold rolling the ingot to produce a rolled aluminum alloy product; and   solutionizing the rolled aluminum alloy product, wherein a solutionizing temperature is between about 540° C. and about 590° C.   
     
     
         11 . The method of  claim 10 , wherein the aluminum alloy product comprises about 0.5-1.8 wt. % Cu, about 0.5-1.0 wt. % Si, about 0.6-1.2 wt. % Mg, about 0.05-0.2 wt. % Cr, about 0.05-0.25 wt. % Mn, about 0.1-0.3 wt. % Fe, up to about 0.15 wt. % Zr, up to about 0.15 wt. % Sc, up to about 0.15 wt. % Sn, up to about 0.4 wt. % Zn, up to about 0.15 wt. % Ti, less than 0.05 wt. % Ni, up to about 0.15 wt. % of impurities, and Al. 
     
     
         12 . The method of  claim 10 , wherein the aluminum alloy product comprises about 0.6-1.7 wt. % Cu, about 0.5-0.9 wt. % Si, about 0.7-1.1 wt. % Mg, about 0.05-0.15 wt. % Cr, about 0.1-0.2 wt. % Mn, about 0.1-0.3 wt. % Fe, up to about 0.1 wt. % Zr, up to about 0.1 wt. % Sc, up to about 0.1 wt. % Sn, up to about 0.25 wt. % Zn, up to about 0.15 wt. % Ti, less than 0.05 wt. % Ni, up to about 0.15 wt. % of impurities, and Al. 
     
     
         13 . The method of  claim 10 , wherein the aluminum alloy product has a Si to Mg ratio of from about 0.55:1 to about 1.30:1 by weight. 
     
     
         14 . The method of  claim 10 , wherein the aluminum alloy product has an excess Si content of from −0.5 to 0.1. 
     
     
         15 . The method of  claim 10 , wherein the homogenizing step is a one-step homogenization comprising heating the ingot to a temperature of about 520° C. to about 580° C. 
     
     
         16 . The method of  claim 10 , wherein the homogenizing step is a two-step homogenization comprising heating the ingot to a temperature of about 480° C. to about 520° C., and further heating the ingot to a temperature of about 520° C. to about 580° C. 
     
     
         17 . The method of  claim 10 , wherein the hot rolling is conducted at an entry temperature of about 500° C. to about 540° C. 
     
     
         18 . The method of  claim 10 , further comprising quenching the aluminum alloy product after the solutionizing step. 
     
     
         19 . The method of  claim 10 , wherein the aluminum alloy product is a plate, shate, or sheet. 
     
     
         20 . A method of producing an aluminum alloy product, the method comprising:
 casting an aluminum alloy to form an ingot, wherein the aluminum alloy comprises about 0.9-1.5 wt. % Cu, about 0.7-1.1 wt. % Si, about 0.7-1.2 wt. % Mg, about 0.06-0.15 wt. % Cr, about 0.05-0.3 wt. % Mn, about 0.1-0.3 wt. % Fe, up to about 0.2 wt. % Zr, up to about 0.2 wt. % Sc, up to about 0.25 wt. % Sn, up to about 0.2 wt. % Zn, up to about 0.15 wt. % Ti, up to about 0.07 wt. % Ni, up to about 0.15 wt. % of impurities, and Al;   homogenizing the ingot;   hot rolling the ingot to produce a plate, shate or sheet; and   solutionizing the plate, shate or sheet at a temperature between about 520° C. and about 590° C.