Extrusion feedstock and product thereof including extrudable aluminum scrap

Abstract

A feedstock may include at least 1 wt % of aluminum scrap composition comprising: an extrudable floated fragmentizer aluminum scrap composition, an extrudable fragmentizer aluminum scrap composition, an extrudable secondary aluminum scrap composition; or a mixture of at least two thereof. A feedstock may include at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising: silicon, copper, iron, magnesium, chromium, manganese, zinc, oxygen; a rare earth element, or a mixture of at least two thereof.

What is claimed is: 
     
         1 . An extrusion feedstock comprising:
 at least 1 wt % of aluminum scrap composition comprising:
 an extrudable floated fragmentizer aluminum scrap composition; 
 an extrudable fragmentizer aluminum scrap composition; 
 an extrudable secondary aluminum scrap composition; or 
 a mixture of at least two thereof; and 
   at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising:
 silicon in a range of from about 0.01 to about 15 wt % of the alloying element composition; 
 copper in a range of from about 0.01 to about 7 wt % of the alloying element composition; 
 iron in a range of from about 0.01 to about 6 wt % of the alloying element composition 
 magnesium in a range of from about 0.01 to about 10 wt % of the alloying element composition; 
 chromium in a range of from about 0.01 to about 5 wt % of the alloying element composition; 
 manganese in a range of from about 0.01 to about 5 wt % of the alloying element composition; 
 zinc in a range of from about 0.01 to about 8 wt % of the alloying element composition; 
 oxygen in a range of from about 0.01 to about 15 wt % of the alloying element composition; 
 a rare earth element in a range of from about 0.01 to about 15 wt % of the alloying element composition; or 
 a mixture of at least two thereof. 
   
     
     
         2 . The extrusion feedstock of  claim 1 , wherein aluminum is at least 80 wt % of the aluminum scrap composition. 
     
     
         3 . The extrusion feedstock of  claim 1 , wherein the extrudable secondary aluminum scrap composition comprises a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or a mixture of at least two thereof. 
     
     
         4 . The extrusion feedstock of  claim 3 , wherein the extrudable secondary aluminum scrap composition comprises an AA6063 alloy. 
     
     
         5 . The extrusion feedstock of  claim 1 , wherein the alloying element composition is in a range of from about 5 to about 60 wt % of the feedstock. 
     
     
         6 . The extrusion feedstock of  claim 1 , further comprising at least one of:
 a pre-consumer scrap composition;   a post-consumer scrap composition differing in chemical composition to the extrudable floated fragmentizer aluminum scrap composition;   a primary aluminum; or   a mixture of at least two thereof.   
     
     
         7 . A method of forming a high-performance alloy, the method comprising:
 using a shear assisted extrusion device, providing relative rotation between an extrusion die face and a feedstock;   applying a relative axial translating force between the extrusion die face and the feedstock sufficient to heat and plasticize, and mix the feedstock at an interface between the feedstock and the extrusion die face to form an alloy that is extruded through an aperture of the die;   wherein, the feedstock comprises:
 at least 1 wt % of aluminum scrap composition comprising:
 an extrudable floated fragmentizer aluminum scrap composition; 
 an extrudable fragmentizer aluminum scrap composition; 
 an extrudable secondary aluminum scrap composition; or 
 a mixture of at least two thereof; and 
 
 at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising: 
 silicon in a range of from about 0.01 to about 15 wt % of the alloying element composition; 
 copper in a range of from about 0.01 to about 7 wt % of the alloying element composition; 
 iron in a range of from about 0.01 to about 6 wt % of the alloying element composition 
 magnesium in a range of from about 0.01 to about 10 wt % of the alloying element composition; 
 chromium in a range of from about 0.01 to about 5 wt % of the alloying element composition; 
 manganese in a range of from about 0.01 to about 5 wt % of the alloying element composition; 
 zinc in a range of from about 0.01 to about 8 wt % of the alloying element composition; 
 oxygen in a range of from about 0.01 to about 15 wt % of the alloying element composition; 
 a rare earth element in a range of from about 0.01 to about 15 wt % of the alloying element composition; or 
   
       a mixture of at least two thereof. 
     
     
         8 . The method of  claim 7 , wherein the extrudable secondary aluminum scrap composition comprises a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or a mixture of at least two thereof. 
     
     
         9 . A high-performance alloy, comprising an extruded product of feedstock comprising:
 at least 1 wt % of aluminum scrap composition comprising:
 an extrudable floated fragmentizer aluminum scrap composition; 
 an extrudable fragmentizer aluminum scrap composition; 
 an extrudable secondary aluminum scrap composition; or 
 a mixture of at least two thereof; and 
   at least 0.01 wt % of an alloying element composition at least partially intermixed relative to the aluminum scrap composition, the alloying element composition comprising:
 silicon in a range of from about 0.01 to about 15 wt % of the alloying element composition; 
 copper in a range of from about 0.01 to about 7 wt % of the alloying element composition; 
 iron in a range of from about 0.01 to about 6 wt % of the alloying element composition 
 magnesium in a range of from about 0.01 to about 10 wt % of the alloying element composition; 
 chromium in a range of from about 0.01 to about 5 wt % of the alloying element composition; 
 manganese in a range of from about 0.01 to about 5 wt % of the alloying element composition; 
 zinc in a range of from about 0.01 to about 8 wt % of the alloying element composition; 
 oxygen in a range of from about 0.01 to about 15 wt % of the alloying element composition; 
 a rare earth element in a range of from about 0.01 to about 15 wt % of the alloying element composition; or 
   
       a mixture of at least two thereof. 
     
     
         10 . The high-performance alloy of  claim 9 , wherein the shear assisted extrusion device forms a high-performance alloy having a refined microstructure relative to a corresponding high-performance alloy that is not extruded by a shear assisted extrusion device. 
     
     
         11 . The high-performance alloy of  claim 10 , wherein the refined microstructure comprises an average grain size that is smaller in at least one dimension relative to a corresponding non-extruded product. 
     
     
         12 . The high-performance alloy of  claim 10 , wherein the refined microstructure comprises an average grain length that is smaller than an average grain length of a corresponding non-extruded product. 
     
     
         13 . The high-performance alloy of  claim 10 , wherein the impurities present in the refined microstructure are broken down to smaller pieces relative to the impurities in a corresponding non-extruded product. 
     
     
         14 . The high-performance alloy of  claim 10 , wherein an average grain length of the extruded product of the extrusion feedstock is less than about 10 μm. 
     
     
         15 . The high-performance alloy of  claim 9 , wherein the high-performance alloy is produced by the shear assisted extrusion device and has increased mechanical properties compared to the aluminum scrap composition. 
     
     
         16 . The high-performance alloy of  claim 9 , wherein the alloying elements include silicon (Si) and magnesium (Mg) to form Mg 2 Si precipitates that enhance the strength of the high-performance alloy. 
     
     
         17 . The high-performance alloy of  claim 9 , wherein the alloying elements include copper (Cu) to promote precipitation hardening and increase the yield strength of the high-performance alloy. 
     
     
         18 . The high-performance alloy of  claim 9 , wherein the alloying elements include zinc (Zn) and magnesium (Mg) in proportions that facilitate the formation of Mg(Zn,Cu) 2  phases within the high-performance alloy. 
     
     
         19 . The high-performance alloy of  claim 9 , wherein the alloying elements are added in stoichiometric amounts to achieve a specific alloy designation according to the Aluminum Association (AA) standards. 
     
     
         20 . The high-performance alloy of  claim 9 , wherein the alloying elements include a combination of manganese (Mn) and chromium (Cr) to improve the alloy's resistance to corrosion.