New scrap-based aluminum alloy products

Abstract

New aluminum alloys are disclosed. The new aluminum alloys may include from 1.05 to 1.55 wt. % Si, from 0.85 to 2.10 wt. % Mg, from 0.15 to 0.75 wt. % Cu, from 0.20 to 0.90 wt. % Fe, from 0.5 to 1.5 wt. % Mn, from 0.01 to 0.15 wt. % Ti, up to 0.4 wt. % Zn, up to 0.25 wt. % of any of Cr, Zr and V, and up to 0.05 wt. % Ni, the balance being aluminum, incidental elements and impurities. The new aluminum alloys may be at least partially derived from scrap materials, such as UBC or brazing scrap. The new aluminum alloy may be processed into an H-temper sheet product. The new aluminum alloys may realize and improved combination of at least two of strength, elongation and corrosion resistance.

What is claimed is: 
     
         1 . An aluminum alloy sheet product comprising:
 from 1.05 to 1.55 wt. % Si;   from 0.85 to 2.10 wt. % Mg;   from 0.15 to 0.75 wt. % Cu;   from 0.20 to 0.90 wt. % Fe;   from 0.5 to 1.5 wt. % Mn;   from 0.01 to 0.15 wt. % Ti;   up to 0.4 wt. % Zn;   up to 0.25 wt. % of any of Cr, Zr and V; and   up to 0.05 wt. % Ni;   the balance being aluminum, incidental elements and impurities;   
       wherein the aluminum alloy sheet product has a thickness of from 0.4 to 4 mm; 
       wherein the aluminum alloy sheet product realizes at least one of the following:
 (i) not greater than 50 vol. % recrystallized grains; 
 (ii) an Mg 2 Si area percent of at least 0.5%; 
 (iii) an average Mg 2 Si particle area of at least 0.5 particles per square micrometer; 
 (iv) a constituent area percent of at least 0.5%; and 
 (v) an average constituent particle area of at least 0.5 particles per square micrometer. 
 
     
     
         2 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product includes at from 1.15 to 1.40 wt. % Si. 
     
     
         3 . The aluminum alloy sheet product  claim 2 , wherein the aluminum alloy sheet product includes from 0.90 to 1.90 wt. % Mg. 
     
     
         4 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product includes from 0.25 to 0.60 wt. % Cu. 
     
     
         5 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product includes from 0.30 to 0.75 wt. % Fe. 
     
     
         6 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product includes from 0.65 to 1.35 wt. % Mn. 
     
     
         7 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product realizes not greater than 25 vol. % recrystallized grains. 
     
     
         8 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product realizes an Mg 2 Si area percent of at least 0.7%. 
     
     
         9 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product realizes an average Mg 2 Si particle area of at least 1.0 particles per square micrometer. 
     
     
         10 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product realizes a constituent area percent of at least 1.0%. 
     
     
         11 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product realizes an average constituent particle area of at least 1.0 particles per square micrometer. 
     
     
         12 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product realizes a longitudinal (L) tensile yield strength of at least 35 ksi. 
     
     
         13 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product realizes a longitudinal (L) elongation of at least 3.0%. 
     
     
         14 . The aluminum alloy sheet product of  claim 1 , wherein the aluminum alloy sheet product realizes at least equivalent ASTM G85 corrosion resistance as compared to a conventional AA3004 sheet product of equivalent gauge. 
     
     
         15 . A method of making an aluminum alloy sheet product comprising:
 (a) creating an aluminum alloy ingot from aluminum-based scrap, wherein the creating comprises:
 (i) mixing a first aluminum scrap material with another aluminum material to achieve a target ingot composition, wherein the another aluminum material is at least one of (A) a second aluminum scrap material and (B) primary aluminum; 
 (ii) prior to or after the mixing step, heating the first aluminum scrap material and the another aluminum material to create a molten aluminum alloy; and 
 (iii) casting the molten aluminum alloy into the aluminum alloy ingot, wherein the aluminum alloy ingot achieves the target ingot composition, wherein the target ingot composition is: 
 from 1.05 to 1.55 wt. % Si; 
 from 0.85 to 2.10 wt. % Mg; 
 from 0.15 to 0.75 wt. % Cu; 
 from 0.20 to 0.90 wt. % Fe; 
 from 0.5 to 1.5 wt. % Mn; 
 from 0.01 to 0.15 wt. % Ti; 
 up to 0.4 wt. % Zn; 
 up to 0.25 wt. % of any of Cr, Zr and V; and 
 up to 0.05 wt. % Ni; 
 the balance being aluminum, incidental elements and impurities; and 
   (b) processing the aluminum alloy ingot into an H-temper sheet product having a thickness of from 0.4 to 4.0 mm.   
     
     
         16 . The method of  claim 15 , wherein the processing the aluminum alloy ingot into an H-temper sheet product comprises cold rolling to a final gauge and then partially annealing to achieve an H2 temper. 
     
     
         17 . The method of  claim 15 , wherein the first aluminum scrap material is selected from the group consisting of brazing scrap, used beverage can (UBC) scrap, and mixtures thereof. 
     
     
         18 . The method of  claim 15 , wherein at least 30% of the ingot comprises the first aluminum scrap material.