Corrosion resistant aluminum electrode alloy

Abstract

New aluminum alloy compositions are provided. The new aluminum alloy compositions may include, for instance, from 20 to 600 ppm Fe and from 10 to 800 ppm Mn. A ratio of Fe (ppm)-to-Mn (ppm) in the aluminum alloy may be from 0.25:1 to 7:1. The new aluminum alloys may be useful, for instance, as an electrode alloy product.

What is claimed is: 
     
         1 . An aluminum alloy comprising:
 a) 20-600 ppm Fe;   b) 10-800 ppm Mn; and   c) at least 0.005 vol. % of Fe—Mn-bearing intermetallic particles, wherein:
 (i) a ratio of Fe (ppm)-to-Mn (ppm) in the aluminum composition alloy is from 0.25:1 to 7:1. 
   
     
     
         2 . The aluminum alloy of  claim 1 , wherein the ratio of Fe (ppm)-to-Mn (ppm) in the aluminum alloy is at least 0.5. 
     
     
         3 . The aluminum alloy of  claim 3 , wherein the ratio of Fe (ppm)-to-Mn (ppm) in the aluminum alloy is at least 0.9. 
     
     
         4 . The aluminum alloys of  claim 1 , wherein the ratio of Fe (ppm)-to-Mn (ppm) in the aluminum alloy is not greater than 5.0. 
     
     
         5 . The aluminum alloy of  claim 5 , wherein the ratio of Fe (ppm)-to-Mn (ppm) in the aluminum alloy is not greater than 3.0. 
     
     
         6 . The aluminum alloy of  claim 6 , wherein the ratio of Fe (ppm)-to-Mn (ppm) in the aluminum alloy is not greater than 1.5. 
     
     
         7 . The aluminum alloy of  claim 1  comprising not greater than 0.04 vol. % of the Fe—Mn-bearing intermetallic particles. 
     
     
         8 . The aluminum alloy of  claim 1 , wherein the aluminum alloy composition comprises one of (a) 20-500 ppm Zn, (b) 20-500 ppm Ga, or (c) 20-500 ppm Zn and 20-500 ppm Ga. 
     
     
         9 . A method comprising:
 a) forming an aluminum alloy melt, wherein the forming comprises:
 (i) using 20-600 ppm Fe in the melt; and 
 (ii) using 10-800 ppm Mn in the melt, wherein:
 (A) a ratio of Fe (ppm)-to-Mn (ppm) in the melt is from 0.25:1 to 7:1; and 
 
   b) depositing the melt to form an aluminum electrode alloy product, wherein the depositing comprises:
 (i) casting the melt into the aluminum electrode alloy product; and 
 (ii) producing at least 0.005 vol. % of Fe—Mn-bearing intermetallic particles, 
   wherein the aluminum electrode alloy product includes the at least 0.005 vol. % of the Fe—Mn-bearing intermetallic particles.   
     
     
         10 . The method of  claim 9 , wherein the ratio of Fe (ppm)-to-Mn (ppm) in the melt is at least 0.9. 
     
     
         11 . The method of  claim 10 , wherein the ratio of Fe (ppm)-to-Mn (ppm) in the melt is not greater than 1.5. 
     
     
         12 . The method of  claim 11 , wherein the aluminum electrode alloy product includes not greater than 0.04 vol. % of the Fe—Mn-bearing intermetallic particles. 
     
     
         13 . A 5xxx aluminum alloy comprising:
 a) 0.2-5.0 wt. % Mg;   b) 20-600 ppm Fe; and   c) 10-800 ppm Mn, wherein a ratio of Fe (ppm)-to-Mn (ppm) in the aluminum composition alloy is from 0.25:1 to 7:1.   
     
     
         14 . The 5xxx aluminum alloy composition of  claim 13 , wherein the aluminum alloy composition includes:
 70-110 ppm Fe;   30-50 ppm Mn;
 wherein a ratio of Fe (ppm)-to-Mn (ppm) in the aluminum alloy composition is from 1.4:1 to 3.6:1; 
   90-110 ppm Zn; and   90-110 ppm Ga.   
     
     
         15 . The 5xxx aluminum alloy of  claim 14 , wherein the 5xxx aluminum alloy comprises from 0.005 to 0.04 vol. % of Fe—Mn-bearing intermetallic particles.