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WO2019241070A1 - Alliages d'aluminium et procédés de fabrication - Google Patents

Alliages d'aluminium et procédés de fabrication Download PDF

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Publication number
WO2019241070A1
WO2019241070A1 PCT/US2019/036091 US2019036091W WO2019241070A1 WO 2019241070 A1 WO2019241070 A1 WO 2019241070A1 US 2019036091 W US2019036091 W US 2019036091W WO 2019241070 A1 WO2019241070 A1 WO 2019241070A1
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WIPO (PCT)
Prior art keywords
aluminum alloy
examples
alloy
cold rolling
alloys
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2019/036091
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English (en)
Inventor
Wei Wen
Yi Wang
Richard Hamerton
Adriano Manuel Povoa FERREIRA
Babak Raeisinia
Zhuoru Wu
Sebastijan JURENDIC
Vishwanath Hegadekatte
Carlos Nobrega
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Novelis Inc Canada
Novelis Inc
Original Assignee
Novelis Inc Canada
Novelis Inc
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Publication of WO2019241070A1 publication Critical patent/WO2019241070A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/047—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with magnesium as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
    • B21B2001/221—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length by cold-rolling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
    • B21B2001/225—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length by hot-rolling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • B21B2003/001—Aluminium or its alloys

Definitions

  • novel aluminum alloy compositions and methods of making and processing the same are provided herein.
  • the alloys described herein can be used in bottle making applications and exhibit enhanced runnability, formability, and appearance.
  • the manufacturing process typically involves first producing a cylinder using a drawing and wall ironing (DWI) process.
  • DWI drawing and wall ironing
  • the resulting cylinder is then formed into a bottle shape using, for example, a sequence of necking steps, blow molding, or other mechanical shaping, or a combination of these processes.
  • the demands on any alloy used in such a process or combination of processes are complex.
  • novel aluminum alloy chemical compositions which in some examples can offer good defect rate, good earing, and/or minimum denting defect.
  • the alloys can be used in aluminum bottle making with good runnability, formability, and appearance.
  • the aluminum alloys described herein comprise about 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 0.2 wt. % Cr, up to 0.2 wt. % Ni, up to 0.2 wt. % Ti, up to 1.0 wt. % of Zn, up to 0.2 wt. % Zr, up to 0.15 wt. % impurities, with the remainder as Al.
  • the aluminum alloys can have a ratio of Fe to Si of about 0.5 to 7.0. In some examples, the aluminum alloys can include an Effective Mg Index up to and including 0.9. Throughout this application, all elements are described in weight percentage (wt. %) based on the total weight of the alloy.
  • the aluminum alloys described herein comprise about 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 0.1 wt. % Cr, up to 0.1 wt. % Ni, up to 0.1 wt. % Ti, up to 0.5 wt. % of Zn, up to 0.15 wt. % Zr, up to 0.15 wt. % impurities, with the remainder as Al.
  • the aluminum alloys can include a ratio of Fe to Si of 0.8 to 5.
  • the aluminum alloys can include an Effective Mg Index up to and including 0.9, for example, up to and including 0.87.
  • the aluminum alloy comprises about 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, up to 0.15 wt. % impurities, with the remainder as Al.
  • the aluminum alloys can include a ratio of Fe to Si of 1.3 to 2.1.
  • the aluminum alloys can include an Effective Mg Index up to and including 0.9 or 0.75.
  • the aluminum alloy comprises about 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, up to 0.15 wt. % impurities, with the remainder as Al.
  • the aluminum alloys can include a ratio of Fe to Si of 1.3 to 2.1.
  • the aluminum alloys can include an Effective Mg Index up to and including 0.9 or 0.77. In some cases, the aluminum alloy comprises about 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, up 0.15 wt. % impurities, with the remainder as Al. In some examples, the aluminum alloys can include a ratio of Fe to Si of 1.7 to 2.9. In some examples, the aluminum alloys can include an Effective Mg Index up to and including 0.9 or 0.8.
  • the aluminum alloy comprises about 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, up 0.15 wt. % impurities, with the remainder as Al.
  • the aluminum alloys can include a ratio of Fe to Si of 1.3 to 2.1.
  • the aluminum alloys can include an Effective Mg Index up to and including 0.9 or 0.73.
  • the aluminum alloy comprises about 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, up to 0.15 wt. % impurities, with the remainder as Al.
  • the aluminum alloys can include a ratio of Fe to Si of 1.4 to 2.0.
  • the aluminum alloys can include an Effective Mg Index up to and including 0.9, 0.88, or 0.75.
  • the products can include a sheet, a plate, an extrusion, a casting, or a forging.
  • the product is a bottle or can.
  • the product can have an average dislocation cell size below 500 nm, for example, in some cases, below 300 nm.
  • the product can have a geometrically necessary boundary spacing distance of less than 1.6 pm.
  • the methods of producing the metal product include, but are not limited to, the steps of casting an aluminum alloy as described herein to form an ingot or a slab, homogenizing the ingot or the slab, hot rolling the ingot or the slab to form an aluminum alloy body (e.g., a coil, plate, shate, sheet, foil, slab or other product after being hot rolled), and cold rolling the aluminum alloy body to a metal product of final gauge.
  • the homogenizing step includes subjecting the ingot or slab to a temperature of from about 550 °C to about 625 °C for between 2 to 30 hours.
  • the homogenizing step refers to a period in which the ingot or slab is at a peak metal temperature (“PMT”).
  • PMT peak metal temperature
  • a two-step homogenization is performed where a prepared ingot is heated to attain a first temperature and allowed to soak for a period of time.
  • the ingot can be cooled to a temperature lower than the temperature used in the first stage and allowed to soak for a period of time during the second stage.
  • a prepared ingot may be heated from about 300 °C over a 5 hour ramp period to a PMT temperature of approximately 580 °C to approximately 610 °C and allowed to soak for approximately 4 hours at the PMT temperature.
  • the ingot may be cooled to a second temperature of about 540 °C to about 560 °C and allowed to soak for approximately 3 hours during the second stage.
  • the hot rolling comprises a two-stage process that includes processing an ingot on a single stand breakdown mill and then processing a slab on a hot finishing mill to produce the aluminum body or coil.
  • the entry temperature for the breakdown mill also known as the ingot laydown temperature
  • the slab can be at a second temperature (also referred to as the slab transfer temperature) of about 400 °C to about 470 °C, and then fed to a hot finishing mill.
  • the exit temperature for the hot rolling step (after the hot finishing mill) is from about 280 °C to about 400 °C. In some cases, the hot rolling exit temperature is greater than the recrystallization temperature of the alloy.
  • the cold rolling step includes reducing the aluminum alloy body by about 60 % to about 99 % thickness reduction.
  • the cold rolling step can include a plurality of cold rolling operations, for example, one, two, three, four, or more cold rolling operations.
  • the methods described herein can optionally include an annealing step after the hot rolling step (and before the cold rolling step).
  • the optional annealing step includes self-annealing.
  • the annealing step can include subjecting the aluminum alloy body (e.g., a hot rolled coil) to a PMT from about 280 °C to about 480 °C for between about 0.5 hours to about 10 hours.
  • the methods described herein can optionally include a partial annealing step after the cold rolling step.
  • the partial annealing step can include subjecting the metal product (e.g., a cold rolled coil) to a PMT from about 100 °C to about 300 °C for between about 0.5 hours to about 4 hours.
  • the methods described herein can produce an aluminum sheet. In some examples, the methods can be used to make bottles or cans from the sheet.
  • FIG. 1 A shows locations where an average R-value can be calculated for a given location on a cup.
  • FIG. 1B is a graph showing a representative curve of the calculated Ravg for a
  • FIG. 2 is a graph showing the general relationship of volume fraction of cube texture in the hot band for alloys as compared to hot rolling coiling temperatures.
  • FIG. 3 is a graph showing the volume fraction of cube texture of exemplary alloys described herein at final gauge after hot rolling at similar temperatures.
  • FIG. 4A is a graph showing mean earing and earing balance of exemplary alloys described herein at final gauge after hot rolling at similar temperatures.
  • FIG. 4B is a graph showing mean earing and earing balance of alloy V5 under low, medium, and high levels of cold reduction (CR).
  • FIG. 5 is a graph showing the cup height by angle to rolling direction (RD) of exemplary alloys described herein.
  • FIG. 6 is a micrograph showing the relative cell size of an exemplary aluminum alloy described herein.
  • FIG. 7 is a graph showing the cell size distribution of an exemplary alloy described herein under low, medium, and high levels of cold reduction (CR).
  • the left histogram bar in each group corresponds to a sample having a high level of cold roll reduction.
  • the center histogram bar in each group corresponds to a sample having a medium level of cold roll reduction.
  • the right histogram in each group corresponds to a sample having a low level of cold roll reduction.
  • FIG. 8 shows the geometrically necessary boundaries of the microstructures of an exemplary alloy described herein under medium level cold reduction.
  • FIG. 9 is chart showing the spacing for geometrically necessary boundaries with misorientation greater than 20-degrees and cold roll strain for an exemplary alloy described herein.
  • FIG. 10 is a drawing showing the rolling direction (RD) and traverse direction (TD) for a sheet, cup, and preform.
  • FIG. 11 is a graph showing mean earing and hot band gauge thickness of exemplary alloys as described herein.
  • alloys identified by AA numbers and other related designations such as“series.”
  • Aluminum alloys are described herein in terms of their elemental composition in weight percent (wt. %). In each alloy, the remainder is aluminum, with a maximum wt. % of 0.15 % for the sum of all impurities.
  • room temperature can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C.
  • a plate generally has a thickness of greater than about 15 mm.
  • a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.
  • a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm.
  • a shate may have a thickness of 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or 15 mm.
  • a sheet generally refers to an aluminum product having a thickness of less than about 4 mm.
  • a sheet may have a thickness of less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm.
  • “cast product,”“cast aluminum alloy,”“cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.
  • novel aluminum alloy chemical compositions which when made according to the processes described herein can in some cases offer aluminum bottle making with minimum defect rate (e.g., due to fracture or denting during forming) and good earing.
  • the alloys can offer aluminum bottle making with good runnability, formability, and appearance.
  • Table 1 shows exemplary alloys made according to the processes described herein that may offer good defect rates due to fracture, good earing, and minimum denting defects.
  • the alloy can have the following elemental composition as provided in
  • the alloy can have the following elemental composition as provided in
  • the alloy can have the following elemental composition as provided in
  • the alloy can have the following elemental composition as provided in
  • the alloy can have the following elemental composition as provided in
  • the alloys described herein include iron (Fe) in an amount of from 0.2 % to 0.8 % (e.g., from 0.3 % to 0.6 %, from 0.36 % to 0.44 %, or from 0.46 % to 0.54 %) based on the total weight of the alloy.
  • the alloy can include 0.2 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.3 %, 0.31 %, 0.32 %, 0.33 %, 0.34 %,
  • the alloys described include silicon (Si) in an amount of from 0.05 % to 0.50 % (e.g., from 0.12 % to 0.36 %, from 0.21 % to 0.27 %, from 0.15 % to 0.21 %, or from 0.27 % to 0.33 %) based on the total weight of the alloy.
  • the alloy can include 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.1 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %,
  • the alloys described herein include magnesium (Mg) in an amount of from 0.40 % to 1.65 % (e.g., from 0.65 % to 1.22 %, from 0.75 % to 0.85 %, or from 0.93 % to 1.07 %).
  • the alloy can include 0.4 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.5 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.6 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %,
  • Mg can be reduced to relatively low levels to reduce work hardening and defect rate during bottle necking process.
  • lower Mg levels can promote more cube texture formation in the hot band and thus more cube texture is retained in final gauge to offer a more balanced earing profile with high cold rolling reduction.
  • the lower Mg level can also lead to less shear-type texture, such as cube rotated around the rolling direction (Cube RD), during hot rolling, which reduces the propensity of denting formation.
  • Texture components such as Cube RD lying in the beta fiber for the sheet can be transformed during the drawing and wall ironing (DWI) process into Goss texture in the top thin wall of the preform at the south-east location.
  • transformation may then result in metal flow incompatibility during die-necking at the south-east locations where the dents are usually formed, as shown in FIG. 1 A and FIG. 10.
  • the alloys described herein include manganese (Mn) in an amount of from 0.40 % to 1.50 % (e.g., from 0.65 % to 1.1 %, from 0.75 % to 0.85 %, or from 0.8 % to 0.94 %).
  • the alloy can include 0.4 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.5 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.6 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.69 %, 0.7 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.8 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89
  • Mn can be included at a relatively low level to reduce work hardening of the material for better defect performance, e.g., from splitting during curling.
  • the alloys described herein include copper (Cu) in an amount of from 0.03 % to 0.35 % (e.g., from 0.03 % to 0.33 %, from 0.1 1 % to 0.15 %, from 0.06 % to 0.1 %, or from 0.18 % to 0.22 %).
  • the alloy can include 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.1 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18
  • the concentration of Cu can be reduced to a relatively low level within the ranges described herein to reduce work hardening and the defect rate during the bottle necking process as well as to reduce shear texture formation during the hot rolling process.
  • the reduced localized shearing during hot rolling can promote more cube texture formation in the hot band and allow more cube texture to be retained at final gauge to offer improved earing.
  • the lower Cu level can lead to less shear-type texture, including beta-fiber formation, during hot rolling, which reduces the propensity for dent formation.
  • the Cu level can be increased to a relatively high level within the ranges described herein to form over-aged S phase precipitates through the final annealing process. These incoherent S phase precipitates reduce the localized strain during cold forming, which can improve the strain accommodation.
  • the ratio of Fe to Si may range from 0.5 to 7.0 (e.g., from 0.8 to 5, from 1.3 to 2.1, from 1.7 to 2.9, or from 1.4 to 2).
  • the ratio of Fe to Si can be 0.5,
  • the concentration of Fe and Si can be designed to a relatively low level to maximize the formation of cube texture component in hot band by minimizing particle stimulated nucleation (PSN) effects.
  • the Fe to Si ratio can be designed to be relatively high to reduce PSN and promote cube texture in the hot band.
  • the composition and ratio can maximize the cube texture component in final gauge and thus reduce mean earing to reach a more balanced earing profile when cold rolling reduction is high.
  • the alloys described herein include chromium (Cr) in an amount of up to 0.2 % based on the total weight of the alloy.
  • the alloy can include 0.01 %, 0.011 %, 0.012 %, 0.013 %, 0.014 %, 0.015 %, 0.016 %, 0.017 %, 0.018 %, 0.019 %, 0.02 %, 0.021 %,
  • the alloys described herein include nickel (Ni) in an amount of up to 0.2 % based on the total weight of the alloy.
  • the alloy can include 0.010 %, 0.011
  • Ni is not present in the alloy (i.e., 0 %). All are expressed in wt. %.
  • the alloys described herein include titanium (Ti) in an amount of up to 0.2 % based on the total weight of the alloy.
  • the alloy can include 0.01 %, 0.011 %, 0.012 %, 0.013 %, 0.014 %, 0.015 %, 0.016 %, 0.017 %, 0.018 %, 0.019 %, 0.02 %, 0.021 %,
  • Ti is not present in the alloy (i.e., 0 %). All are expressed in wt. %.
  • the alloys described herein include zinc (Zn) in an amount of up to 1 % based on the total weight of the alloy.
  • the alloy can include 0.01 %, 0.02 %,
  • the alloys described herein include zirconium (Zr) in an amount of up to 0.2 % based on the total weight of the alloy.
  • the alloy can include 0.01 %, 0.011 %, 0.012 %, 0.013 %, 0.014 %, 0.015 %, 0.016 %, 0.017 %, 0.018 %, 0.019 %, 0.02 %, 0.021 %, 0.022 %, 0.023 %, 0.024 %, 0.025 %, 0.026 %, 0.027 %, 0.028 %, 0.029 %, 0.03 %, 0.031 %, 0.032 %, 0.033 %, 0.034 %, 0.035 %, 0.036 %, 0.037 %, 0.038 %, 0.039 %, 0.04 %, 0.041 %, 0.042 %, 0.043 %, 0.044 %, 0.045
  • the alloys can include Zr is not present in the alloy (i.e., 0 %). All are expressed in wt. %.
  • the alloy compositions described herein can further include other minor elements, sometimes referred to as impurities, in amounts of about 0.05% or below, about 0.04% or below, about 0.03% or below, about 0.02% or below, or about 0.01% or below each.
  • the sum of all impurities does not exceed 0.15 % (e.g., 0.10 %). All expressed in wt. %. The remaining percentage of the alloy is aluminum.
  • Mg may exist in three major forms in an alloy: (1) in solid solution; (2) bonded with Si in magnesium silicide phase (Mg 2 Si); and (3) bonded with Cu and Al in S phase (AhCuMg).
  • the Eff Mg Index may be used as an indicator of the amount of Mg in the solid solution of the alloy.
  • the amount of Mg in the solid solution can contribute to the work hardening levels as reflected by the tensile spread (also referred to as the spread) of an alloy, which is the difference between the yield strength and ultimate tensile strength.
  • the Eff. Mg Index is proportional to work hardening, i.e., the higher the Eff. Mg Index, the higher the work hardening.
  • an aluminum alloy with 0.85 wt. % Mg, 0.15 wt. % Cu, 0.27 wt. % Si, 0.44 wt. % Fe, 0.85 wt. % Mn, and 0.05 wt. % Cr would have an Eff. Mg Index of 0.75 as shown by the following equation: 0.44 + 0.85 + 0.05 ⁇
  • the alloys described herein include an Eff. Mg Index in an amount of up to and including 0.9.
  • the alloy can include an Eff. Mg Index of up to 0.01, 0.02, 0.03,
  • the alloys described herein and those made according to methods described herein can provide high recyclability.
  • the alloys can have moderate combinations of defect rate, earing, and denting performance.
  • the alloys made according to methods described herein can provide additional improved properties and performance by modifying the
  • composition as compared to a conventional alloy.
  • levels of magnesium (Mg), copper (Cu), silicon (Si), and manganese (Mn) can be modified to achieve certain properties and characteristics, such as a targeted ratio of Fe to Si or Effective Mg Index.
  • the processing conditions further described herein can provide additional improved properties and performance by modifying the temperature and timing of certain steps as compared to a conventional alloy.
  • the level of cold roll reduction as compared to a conventional alloy can be adjusted to achieve certain properties and characteristics, such as earing balance, mean earing, and geometrically necessary boundaries (GNB) spacing.
  • modifying both the composition and processing conditions as compared to a conventional alloy as described herein can provide additional improved properties and performance.
  • the alloys described herein can be cast into ingots using a direct chill (DC) process.
  • the casting process can include a continuous casting (CC) process.
  • the continuous casting may include, but is not limited to, twin roll casters, twin belt casters, and block casters.
  • the alloys are not processed using continuous casting methods.
  • the cast product (e.g., cast coil or metal coil) can be subjected to further processing steps to form a metal sheet.
  • the further processing steps include subjecting a metal coil to a homogenization cycle, a hot rolling step, and a cold rolling step.
  • the further processing steps include subjecting a metal coil to a homogenization cycle, a hot rolling step, an optional annealing step, and a cold rolling step.
  • the further processing steps include subjecting a metal coil to a homogenization cycle, a hot rolling step, a cold rolling step, an optional annealing step, a second cold rolling step, and an optional partial annealing step.
  • the methods described herein can subject an alloy to thermo- mechanical processing that can provide certain microstructure properties and characteristics that provide an aluminum product that can be used in different applications, for example, used to make bottles.
  • the homogenization step can involve a one-step homogenization or a two-step homogenization.
  • the homogenization step comprises heating a cast product (e.g., an ingot or a slab) prepared from the alloy compositions described herein is to a peak metal temperature (PMT). The cast product is then allowed to soak (i.e., held at the PMT temperature) for a period of time.
  • a cast product e.g., an ingot or a slab
  • PMT peak metal temperature
  • the homogenizing is performed at a temperature of 550 °C to 625 °C for up to 30 hours (e.g., 525 °C to 625 °C for a period of 2 hours to 30 hours or 535 °C to 615 °C, 545 °C to 605 °C, 555 °C to 595 °C, 565 °C to 585 °C, or 575 °C to 600 °C each for a period of 2 hours to 30 hours, or in some cases, each for a period of 2 hours to 15 hours).
  • the homogenization step comprises a two-step homogenization.
  • the homogenization process can include the above-described heating and soaking steps, which can be referred to as the first stage, and can further include a second stage.
  • the cast product temperature can be decreased to a temperature lower than the temperature used for the first stage of the homogenization process.
  • the cast product temperature can be decreased, for example, to a temperature at least five degrees Celsius lower than the PMT during the first stage of the homogenization process.
  • the cast product temperature can be decreased to a temperature of at least 540 °C (e.g., at least 550 °C, at least 560 °C, or at least 570 °C).
  • the heating rate to the second stage homogenization temperature can be 5 °C /hour or less, 3 °C /hour or less, or 2.5 °C /hour or less.
  • the cast product is then allowed to soak for a period of time at the second temperature during the second stage. In some cases, the ingot is allowed to soak for up to 10 hours (e.g., from 30 minutes to 10 hours, inclusively). For example, the cast product can be soaked at the
  • the cast product can be allowed to cool to room temperature in the air.
  • the time required to ramp the ingot or slab to the homogenizing temperature may vary.
  • a hot rolling process can be performed.
  • the hot rolling speed, reduction, and temperature can be controlled such that full recrystallization of the hot rolled materials is achieved following coiling at the exit of the hot finishing mill.
  • the hot rolling temperature is greater than the recrystallization temperature of the alloy.
  • the hot rolling comprises a two-stage process that includes processing an ingot on a single stand breakdown mill and then processing a slab on a hot finishing mill to produce the aluminum alloy body or coil.
  • the entry temperature for the breakdown mill also known as the ingot laydown temperature
  • the ingot laydown temperature is from about 480 °C to about 600 °C (e.g., 480 °C to 600 °C, 490 °C to 590 °C, 500 °C to 580 °C, 510 °C to 570 °C, 520 °C to 560 °C, or 520 °C to 540 °C).
  • the ingot laydown temperature for the hot rolling operation is from about 500 °C to about 560 °C.
  • the slab Upon exiting the breakdown mill, the slab can be at a second temperature (also referred to as the slab transfer temperature) of about 400 °C to about 470 °C and then fed to a hot finishing mill.
  • the exit temperature for the hot rolling operation can be from about 280 °C to about 400 °C (e.g., 280 °C to 400 °C, 290 °C to 390 °C, 300 °C to 380 °C, 310 °C to 370 °C, 320 °C to 360 °C, 330 °C to 350 °C, or 340 °C to 360 °C).
  • the exit temperature for the hot rolling operation is from about 315 °C to about 360 °C.
  • the ingots or slabs can be hot rolled to a final gauge of a 10 mm thick gauge or less.
  • the ingots or slabs can be hot rolled to a 6.3 mm thick gauge or less, 5.2 mm thick gauge or less, 4.3 mm thick gauge or less, or 4 mm thick gauge or less.
  • the ingots or slabs can be hot rolled to a final gauge between about 4 mm to 6 mm thick gauge.
  • hot rolling produces a total reduction in thickness of from about 60 % to 99 % (e.g., about 65 % to 95 %, about 70 % to 95 %, about 75 % to 95 %, 80 % to 95 %, 85 % to 95 %, or 90 % to 99 %).
  • the hot rolling step produces a reduction in thickness of about 60 %, 61 %, 62 %, 63 %, 64 %, 65 %, 66 %, 67 %, 68 %, 69 %, 70 %, 71 %, 72 %, 73 %, 74 %, 75 %, 76 %, 77 %, 78 %, 79 %, 80 %, 81 %, 82 %, 83 %, 84 %, 85 %, 86 %, 87 %, 88 %,
  • the percent hot rolling, or % HR is referred to in this context as the change in thickness due to hot rolling divided by the initial strip thickness prior to hot rolling.
  • the hot rolling can be conducted in several individual hot rolling steps, for example, using a breakdown mill, a hot finishing mill, and/or a reversing mill.
  • the hot rolled products can be rolled to an intermediate gauge thickness.
  • the intermediate gauge thickness can correspond to a reduction in thickness of about 60 %, 61 %, 62 %, 63 %, 64 %, 65 %, 66 %, 67
  • the first stage of the hot rolling process can provide a reduction in the range of 94.0 % to 96.0 %.
  • the second stage of the hot rolling process can further reduce the thickness of the aluminum alloy body to the final gauge.
  • the second stage can provide a reduction in thickness of about 60 %, 61 %, 62 %, 63 %, 64 %, 65 %, 66 %, 67 %, 68
  • the second stage of the hot rolling process can provide a reduction in the range of 80 % to 93 %, for a total reduction in thickness of over 95 %, for example about 99 %.
  • the hot rolling step according to methods described herein can provide an appropriate balance of texture in the final materials in order to aid in superior properties of the alloy.
  • the hot rolled products can be cold rolled to a final gauge thickness.
  • cold rolling produces a total reduction in thickness of from about 60 % to 99 % (e.g., about 60 % to 70 %, about 60 % to 80 %, about 60 % to 90 %, about 70 % to 98 %, about 85 % to 95 %, or about 88 % to 92 %).
  • the cold rolling can be conducted in several individual cold rolling operations using a single stand reversing mill and/or a multi-stand tandem mill.
  • the cold rolling step can produces a total reduction in thickness of about 60 %, 61 %,
  • the percent cold rolling, or % CR is referred to in this context as the change in thickness due to cold rolling divided by the initial strip thickness prior to cold rolling.
  • multiple cold rolling steps are performed, each with a reduction in thickness in the range of about 40 % to about 60 % to achieve a total cold rolling reduction from a hot band to final gauge (e.g., from about 50 % to about 55 %, about 45 % to about 55 %, about 45 % to about 60 %, about 40 % to about 50 %, or about 55 % to about 60 %).
  • a first cold rolling operation produces a reduction in thickness of about 40 %, 45 %, 50 %, 55 %, or 60 %
  • a second cold rolling operation produces a further reduction in thickness of about 40 %, 45 %, 50 %, 55 %, or 60 % of the aluminum alloy body after the first cold rolling operation
  • a third cold rolling operation produces a further reduction in thickness of about 40 %, 45 %, 50 %, 55 %, or 60 % of the aluminum alloy body after the second cold rolling operation.
  • additional cold rolling steps can be employed, for example, a fourth cold rolling operation or a fifth cold rolling operation, or more. In some cases, between each of the multiple cold rolling steps, the aluminum alloy body can be cooled.
  • an optional annealing step is performed between the hot rolling and the cold rolling steps.
  • the annealing step can include subjecting the aluminum alloy body (e.g., a hot rolled coil) to a PMT from about 280 °C to about 480 °C for between about 0.5 hours to about 10 hours.
  • the annealing step can include heating the aluminum alloy body or hot band from room temperature to a temperature from about 280 °C to about 480 °C (e.g., from about 300 °C to about 450 °C, from about 325 °C to about 425 °C, from about 300 °C to about 400 °C, from about 400 °C to about 480 °C, from about 330 °C to about 470 °C, from about 375 °C to about 450 °C, or from about 450 °C to about 480 °C).
  • a temperature from about 280 °C to about 480 °C e.g., from about 300 °C to about 450 °C, from about 325 °C to about 425 °C, from about 300 °C to about 400 °C, from about 400 °C to about 480 °C, from about 330 °C to about 470 °C, from about 375 °C to about 450 °
  • an additional annealing step can be included after the cold rolling step. In some cases, this annealing step can be referred to as partial annealing.
  • the partial annealing is at a metal temperature from about 100 °C to about 300 °C for about 0.5 to about 10 hours. In some cases, the partial annealing can be conducted at a metal temperature from about 120 °C to about 280 °C and holding at that temperature for about 0.5 hours to about 4 hours. In another example, the partial annealing can be conducted at a PMT of about 150 °C to about 250 °C for about 1 hour to about 3 hours. In some cases, the partial annealing is at a PMT of about 240 °C for about 1 hour. In some cases, the partial annealing is at a PMT from about 210 °C to about 240 °C.
  • the partial annealing step can include heating the alloy body or metal product from room temperature to a temperature from about 100 °C to about 300 °C (e.g., from about 120 °C to about 250 °C, from about 125 °C to about 200 °C, from about 200 °C to about 300 °C, from about 150 °C to about 275 °C, from about 225 °C to about 300 °C, from about 210 °C to about 240 °C from about 220 °C to about 230 °C, or from about 100 °C to about 175 °C).
  • a temperature from about 100 °C to about 300 °C (e.g., from about 120 °C to about 250 °C, from about 125 °C to about 200 °C, from about 200 °C to about 300 °C, from about 150 °C to about 275 °C, from about 225 °C to about 300 °C, from about 210 °C to about
  • the first and second annealing processes can be performed in a batch process.
  • the first annealing process can be performed as a self-annealing step, for example, following hot rolling.
  • the alloys and methods described herein can be used to prepare highly shaped metal objects, such as aluminum cans or bottles.
  • the cold rolled sheets described above can be subjected to a series of conventional can and bottle making drawing and wall ironing (DWI) processes to produce preforms according to other shaping processes as known to those of ordinary skill in the art.
  • DWI drawing and wall ironing
  • the shaped aluminum bottles may be used for beverages including but not limited to soft drinks, water, beer, energy drinks, and other beverages.
  • Conventional aluminum bottles manufactured by multi-stage die necking of a drawn and wall-ironed preform have in some cases exhibited various types of defects at different stages of the manufacturing process, including excessive earing, out-of-roundness, shoulder dents formed during necking and splitting during curling.
  • the severity of the dent can be determined upon visual inspection of the defects. In some cases, the number of visible shoulder dents on the products can be used as a measure of the severity of denting. In some cases, a minor amount of denting includes up to 2 shoulder dents (e.g., 0, 1, or 2 shoulder dents). In some cases, severe denting includes 4 shoulder dents on one product, including at 45°, 135°, 225°, and 315° angles.
  • FIG. 1A shows the various locations around the circumference of the aluminum preform discussed herein. These locations have been designated the South (S), South- East (SE), and East (E) locations.
  • the line connecting South to North is parallel to the rolling direction (RD) of the starting sheet from which the preform is made.
  • the line between East and West which is shown in FIG. 10, is parallel to the transverse direction (TD) of the starting sheet.
  • TD transverse direction
  • angles are used to describe orientations relative to the axis of the cup, preform or bottle in the plane of the sheet or cup, preform or bottle wall (FIGS. 1 A and 1B), whereas points of the compass are used to describe locations around the circumference of the cup, preform or bottle with north and south defined as the locations where the original rolling direction of the sheet aligns with the axis of the preform or bottle, and east and west defined as locations where the original transverse direction of the sheet aligns with the axis of the cup, preform or bottle (FIGS. 1 A and 10).
  • an incompatibility may develop in the average value of the anisotropy ratio, or average R-value, at the denting location as the bottle is formed.
  • the average R-value, or R avg at a specific location on the bottle is determined from the individual R-values measured or calculated for the 0°, 45° and 90° orientations measured relative to the vertical axis of the bottle at that location according to the equation:
  • FIG. 1B A representative curve of the calculated Ravg for a representative alloy at a given location on a bottle is shown in FIG. 1B.
  • the R-value from 0° orientation to about 30° orientation and near 90° orientation is relatively low, at approximately 1. As the orientation approaches 45°, the R-value increases to a value of about 3.5.
  • the average R-value increases at all locations.
  • the average R-value at the SE location increases more during the later stages of necking than at other locations.
  • the alloys and the methods described herein can yield a product which simultaneously meets the mechanical properties and earing requirements, as well as requirements for low levels of defects such as splitting during curling and shoulder dents, for different applications, for example bottle making. Temperature is one variable that impacts texture in the hot band.
  • the alloys and methods described herein can provide a desirable crystallographic texture in the hot band by adjusting the temperature during the final stages of hot rolling and subsequent coiling.
  • the methods described herein employ a hot roll exit temperature that is sufficiently high to achieve full recrystallization in the hot band. Additionally though, these methods also employ a hot rolling exit temperature which is higher than a range just above that required for
  • the alloys and methods described herein can employ a temperature to ensure low denting susceptibility on the one hand, and good earing behavior on the other.
  • a danger zone for denting in the bottle neck exists near the recrystallization temperature.
  • FIG. 2 is a representative curve showing the relationship of volume fraction of cube texture as compared to hot rolling coiling temperature.
  • the hot rolling exit temperature is greater than the left boundary of the“danger zone” to ensure the hot band is fully recrystallized.
  • the exit temperature is also greater than the right boundary of the“danger zone” to minimize the formation of texture that contributes to dent formation during the necking process.
  • Dual aims of full recrystallization and increased fractions of ideal -oriented cube texture must be balanced against the risk of forming the undesirable Cube RD texture.
  • the hot rolling exit temperature must be greater than the right boundary of the“danger zone” for denting, but also as low as possible to maximize the amount of ideal-oriented cube texture in the hot band.
  • the alloys and methods described herein can meet the combined aims of full crystallization, increased ideal-oriented cube texture and low Cube RD texture. For some examples of the present alloy, it has been found that final hot rolling above about 300 °C but below about 380 °C can be employed to meet these combined aims.
  • a final hot rolling above about 310 °C but below about 370 °C can be employed to meet these combined aims.
  • the alloys described herein can have a sufficiently high level of ideal -oriented cube texture for good earing, but avoid significant amounts of the rotated cube texture which promotes denting.
  • the alloys and methods described herein can provide low susceptibility to dent formation. In some examples, the alloys and methods described herein can provide low earing. In some examples, the alloys and methods described herein can provide low tensile spread. In some examples, the alloys and methods described herein can provide the improved combination of attributes in the sheet to give low susceptibility to dent formation, low earing, and low tensile spread. This combination of attributes ensures good runnability and low levels of defects during the bottle making process and produces bottles with good appearance.
  • the disclosed aluminum alloys have improved earing, which is determined by mean earing and earing balance.
  • Earing is the formation of a wavy edge having peaks and valleys at the top edge of a drawn aluminum preform during processing. Earing is calculated by measuring the cup sidewall height around the circumference of the cup (from 0 to 360 degrees).
  • Mean earing is calculated by the equation: average peak height— average valley height
  • Earing balance is calculated by the equation: mean of two 0° or 180° heights— mean of four 45° heights
  • the aluminum alloys can have an earing balance between -3.5 % and 2.0 %, such as between -3.0 % and 2.0 %, between -3.0 % and 1.0 %, or between -2.5 % and 1.5 %.
  • the aluminum alloys have a mean earing of less than or equal to 5.5 %, such as less than 5 % or less than 4.5 %. Earing is determined in accordance with European Standard EN 1669: 1996, as further described in Example 5.
  • the methods disclosed herein can include cold rolling reduction sufficiently large enough to minimize the cell size in the deformation substructure of the final gauge sheet.
  • the methods disclosed herein can include cold rolling reduction sufficiently large enough to minimize the spacing of geometrically necessary boundaries (GNBs) in the substructure of the final gauge sheet.
  • the methods disclosed herein can include cold rolling reduction sufficiently large enough to minimize the cell size and GNB spacing in the substructure of the final gauge.
  • the products and materials made according to the alloys and methods described herein can include an average cell diameter size below 500 nm, for example, in some cases, below 400 nm, below 300 nm, or below 200 nm.
  • the products and materials made according to the alloys and methods described herein can include an average cell area of less than about 0.8 pm 2 , for example, in some cases, less than about 0.5 pm 2 , less than about 0.3 pm 2 , or less than about 0.15 pm 2 .
  • the substantial majority of cells has an area below 0.5 pm 2 .
  • the majority of cell area can be at or below 0.2 pm 2 .
  • the products and materials made according to the alloys and methods described herein can have a geometrically necessary boundary spacing distance of less than about 2 pm, for example, in some cases, below 1.8 pm, below 1.6 pm, or below 1.4 pm.
  • Alloys VI, V3, V4, and V5 were prepared for cube texture measurement and earing testing. Alloys VI, V3, V4, and V5 were prepared according to the methods described herein with the hot rolling exit temperature range of 335 °C to 345 °C, hot finishing mill reduction of 88.7 % to 89.9 %, and cold roll reduction range of 89 % to 90 %.
  • the compositions of the alloys, including the iron to silicon ratio (Fe/Si Ratio) and weight percent ranges of Mg, Mn, and Cu, are shown in Table 7. Each of the alloys also includes Cr, Ni, Ti, Zn, and Zr in the amounts described herein and in equal amounts. Table 7
  • the volume fraction of cube texture for the alloys is shown in FIG. 3.
  • Alloy V4 has the highest amount of cube texture while the cube texture of alloy V5 is lower than the other alloys.
  • FIG. 3 shows the impact that the amount of Mg, Cu, Fe, and Si have on the resulting cube texture.
  • FIG. 4A shows the mean earing and earing balance of the Alloys VI, V3, V4, and V5.
  • FIG. 4A shows that the higher volume fraction of cube texture gives improved earing balance (i.e., closer to zero).
  • Alloys VI, V3, and V4 have a mean earing below 3.8 % and an earing balance from about -1.0 to about 0.75.
  • FIG. 4B shows the impact that the amount of cold roll reduction has on the resulting cube texture.
  • FIG. 4B shows the mean earing and earing balance of the Alloy V5 at three levels of cold roll reduction.
  • Each of the coils had the same hot rolling exit temperature of about 360 °C, but with different hot band gauges.
  • the white square, triangle, and diamond data points represent aluminum alloy coils that include a high level of cold roll reduction (e.g., 92 %) from a hot band gauge of 0.235 in.
  • the solid, black square, triangle, and diamond data points represent aluminum alloy coils that include a medium level of cold roll reduction (e.g., 90 %) from a hot band gauge of 0.185 in.
  • the gray square, triangle, and diamond data points represent aluminum alloy coils that include a low level of cold roll reduction (e.g., 86 %) from a hot band gauge of 0.130 in.
  • the coils were measured at different points, including at the drive (“Dr”), center (“Cen”), and operator (“Op”) positions as known to those of ordinary skill in the art.
  • the alloys described herein can adjust the level of mean earing and earing balance to achieve the desired earing performance.
  • FIG. 4B shows that moderate level reduction in the cold rolling process (0.185 inches or 90 % cold roll reduction) provided improved earing balance (i.e., close to zero without becoming positive).
  • the lower level of cold reduction (0.130 inches or 86 % cold roll reduction) showed the lowest overall earing balance (i.e., closest to zero); however, the shift in earing balance resulted in the earing balance tending to be positive (greater than zero).
  • the highest level of cold reduction (0.235 inches or 92 % cold roll reduction) resulted in an earing balance ranging from -4 % to -6 %.
  • FIG. 4B shows that the mean earing increases with the increase in cold rolling reduction.
  • FIGS. 6 and 7 show Alloy V5 prepared according to the methods described herein with the hot rolling exit temperature set at 340 °C.
  • the micrograph shows that the average cell size diameter is below 500 nm. In an example alloy, the average cell size diameter is more preferable at less than about 300 nm.
  • FIG. 7 shows the cell size distribution of Alloy V5 under low, medium, and high cold rolling levels (85.7 %, 90.7 %, and 92.1 %). The substantial majority of cells have an area below 0.8 pm 2 .
  • Front end runnability refers to a qualitative analysis of whether the aluminum alloy bodies included defects or jammed during the process of forming the aluminum alloy bodies.
  • Back end spoilage indicates whether the percentage of bottles rejected due to defects after forming the bottles was within an acceptable range (relatively low percentage of rejected bottles) or an unacceptable range (relatively high percentage of rejected bottles).
  • the geometrically necessary boundaries (GNBs) in the microstructure and the effect of cold rolling reduction on the boundary spacing in Alloy V5 is shown in FIG. 8.
  • the image shows that the GNB spacing distance is less than 1.45 pm.
  • the level of cold rolling reduction must be relatively high.
  • the GNB spacing as described herein is the average distance of two adjacent GNBs. As shown in FIG. 9, the spacing of the high angle GNB impacts the amount of CR strain.
  • the spacing of high angle GNB will be too high; however, if the cold roll reduction is too high, the alloy will have a smaller spacing of high angle GNB and exhibit low tensile spread.
  • the alloys described herein can balance the level of CR strain to achieve the desired level of GNB spacing as shown as the preferred range in FIG. 9. For example, CR reduction in the range of 88 % to 92 % can provide GNB spacing to achieve better formability.
  • FIG. 11 shows an alloy prepared according to the methods described herein.
  • the graph shows the mean earing (%) decreases when the hot band gauge is increased and the hot rolling exit temperature is decreased.
  • the overall mean earing (%) is lowered as well as the rate of change in mean earing as hot band thickness increases.
  • the temperature and time profile of the alloy during cold rolling can also impact performance.
  • a cold rolling practice that offers a warm exit temperature (70 °C to 200 °C) at each pass with a holding period to allow the coil to cool down before entering the next cold rolling pass can be utilized. Not to be bound by theory, this practice may allow the following microstructural evolution: (1) recovery of the microstructure after each pass; (2) promotion of dislocation alignment and annihilation and the development of GNBs; (3) promotion of precipitation of clusters/beta’Vbeta’ phase and clusters/S”/S’ phase which consume a part of the Mg in solid solution.
  • each pass as Pl (first pass or first cold roll operation), P2 (second pass or second cold roll operation), P3 (third pass or third cold roll operation), and P4 (fourth pass or fourth cold roll operation) “red.” means reduction.
  • comparative alloys Cl and C2 and aluminum alloy V5’ were analyzed.
  • the compositions are listed in Table 11 below (all amounts in wt. %):
  • V5’ and Cl were made according to the methods described herein with the hot rolling exit temperature range of 340 °C to 370 °C and cold roll reduction range of 86 %.
  • C2 was made according to the methods described herein with the hot rolling exit temperature range of 320 °C to 335 °C and cold roll reduction range of 91 %.
  • the alloys described herein demonstrate improved runnability as compared to conventional alloys.
  • any reference to a series of illustrative alloys, products, or methods is to be understood as a reference to each of those alloys, products, or methods disjunctively (e.g., “Illustrative embodiment 1-4” is to be understood as“Illustrative embodiment 1, 2, 3, or 4”).
  • Illustrative embodiment 1 is an aluminum alloy comprising about 0.2 - 0.8 wt. % Fe,
  • Illustrative embodiment 2 is the aluminum alloy of any preceding or subsequent embodiment, comprising about 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.
  • Illustrative embodiment 3 is the aluminum alloy of any preceding or subsequent embodiment, comprising about 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.
  • Illustrative embodiment 4 is the aluminum alloy of any preceding or subsequent embodiment, comprising about 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.
  • Illustrative embodiment 5 is the aluminum alloy of any preceding or subsequent embodiment, comprising about 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.
  • Illustrative embodiment 6 is the aluminum alloy of any preceding or subsequent embodiment, comprising about 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.
  • Illustrative embodiment 7 is the aluminum alloy of any preceding or subsequent embodiment, comprising about 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.
  • Illustrative embodiment 8 is the aluminum alloy of any preceding or subsequent embodiment, 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.
  • Illustrative embodiment 9 is a bottle or can comprising the aluminum alloy of any preceding or subsequent embodiment.
  • Illustrative embodiment 10 is an aluminum sheet comprising the aluminum alloy of any preceding or subsequent embodiment.
  • Illustrative embodiment 11 is a method of producing a metal product from the aluminum alloy of any preceding or subsequent illustration, 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 a metal product with a final gauge.
  • Illustrative embodiment 12 is the method of any preceding or subsequent embodiment, wherein the homogenizing step includes subjecting the ingot or slab to a temperature of from about 550 °C to about 625 °C for between 2 hours to 30 hours.
  • Illustrative embodiment 13 is the method of any preceding or subsequent embodiment, wherein the hot rolling step includes an entry temperature of from about 380 °C to about 500 °C.
  • Illustrative embodiment 14 is the method of any preceding or subsequent embodiment, wherein the hot rolling step includes an exit temperature of from about 280 °C to about 400 °C.
  • Illustrative embodiment 15 is the method of any preceding or subsequent embodiment, wherein a hot rolling exit temperature is greater than a recrystallization temperature of the aluminum alloy.
  • Illustrative embodiment 16 is the method of any preceding or subsequent embodiment, wherein the hot rolling step includes a first hot rolling operation that reduces the 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 the thickness of the ingot or slab having the intermediate thickness in a range between 80 % to 93 %.
  • the hot rolling step includes a first hot rolling operation that reduces the 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 the thickness of the ingot or slab having the intermediate thickness in a range between 80 % to 93 %.
  • Illustrative embodiment 17 is the method of any preceding or subsequent embodiment, wherein the cold rolling step includes reducing the aluminum alloy body by about 70 % to 98 % thickness reduction.
  • Illustrative embodiment 18 is the method of any preceding or subsequent embodiment, 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.
  • Illustrative embodiment 19 is the method of any preceding or subsequent embodiment, wherein the cold rolling step comprises reducing the thickness of the aluminum alloy body between about 89 % to 91 %.
  • Illustrative embodiment 20 is the method of any preceding or subsequent embodiment, 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 the range of about 40 % to 60 %.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Continuous Casting (AREA)

Abstract

La présente invention concerne des compositions d'alliages d'aluminium et des procédés de fabrication et de traitement de ces dernières. Les alliages de l'invention peuvent être utilisés dans des applications de fabrication de bouteilles et présentent une coulabilité, une formabilité et un aspect améliorés. L'invention concerne en outre des procédés de production d'une feuille d'alliage d'aluminium telle que celle de l'invention, qui peuvent comprendre le coulage d'un alliage d'aluminium pour former un lingot, l'homogénéisation du lingot, le laminage à chaud du lingot pour produire une bande chaude, et le laminage à froid de la bande chaude pour obtenir une feuille d'alliage d'aluminium d'une épaisseur finale.
PCT/US2019/036091 2018-06-12 2019-06-07 Alliages d'aluminium et procédés de fabrication Ceased WO2019241070A1 (fr)

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US10689041B2 (en) 2015-10-15 2020-06-23 Novelis Inc. High-forming multi-layer aluminum alloy package
WO2019191400A1 (fr) 2018-03-29 2019-10-03 Oerlikon Metco (Us) Inc. Alliages ferreux à teneur réduite en carbures
US11788178B2 (en) * 2018-07-23 2023-10-17 Novelis Inc. Methods of making highly-formable aluminum alloys and aluminum alloy products thereof
CA3117043A1 (fr) 2018-10-26 2020-04-30 Oerlikon Metco (Us) Inc. Alliages a base de nickel resistants a la corrosion et a l'usure
CN113039303A (zh) 2018-11-07 2021-06-25 奥科宁克技术有限责任公司 2xxx铝锂合金
WO2020172046A1 (fr) 2019-02-20 2020-08-27 Howmet Aerospace Inc. Alliages d'aluminium-magnésium-zinc améliorés
EP3947571B1 (fr) 2019-03-28 2024-05-22 Oerlikon Metco (US) Inc. Alliages à base de fer pour projection à chaud destinés au revêtement d'alésages de moteur
EP3962693A1 (fr) 2019-05-03 2022-03-09 Oerlikon Metco (US) Inc. Charge d'alimentation pulvérulente destinée au soudage en vrac résistant à l'usure, conçue pour optimiser la facilité de production
CA3255995A1 (fr) * 2022-05-23 2023-11-30 Arconic Technologies Llc Nouveaux produits en alliage d'aluminium à base de déchets

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