Aluminum flat rolled products with high recycled content for light gauge packaging solutions and related methods

Abstract

Described herein are aluminum alloy products for packaging and/or producing a beverage. The aluminum alloy products include beverage capsules. The aluminum alloy products can include a 3xxx series aluminum alloy. The aluminum alloy products can include at least 50 wt. % recycled aluminum. Also described herein are methods for processing the aluminum alloys to produce beverage capsules and other packaging products.

1 . An aluminum alloy capsule comprising:
 a dome-shaped body comprising a lip that extends outwardly from the body; and   a cover secured with the lip,   wherein the body defines a cavity configured to contain a substance for preparation of a beverage and the cover forms a seal around the lip of the body to seal the substance within the body until the capsule is ready for use, and   wherein at least one of the body and the cover comprises a 3xxx series aluminum alloy.   
     
     
         2 . The aluminum alloy capsule of  claim 1 , wherein the 3xxx series aluminum alloy comprises AA3104 or AA3105. 
     
     
         3 . (canceled) 
     
     
         4 . The aluminum alloy capsule of  claim 1 , wherein the 3xxx series aluminum alloy comprises at least 50 weight percent recycled aluminum. 
     
     
         5 . (canceled) 
     
     
         6 . The aluminum alloy capsule of  claim 4 , wherein the recycled aluminum comprises at least one of process run-around scrap, post-manufacturing scrap, or post-consumer scrap aluminum. 
     
     
         7 . The aluminum alloy capsule of  claim 1 , wherein the 3xxx series aluminum alloy comprises at least one of manganese or magnesium. 
     
     
         8 . The aluminum alloy capsule of  claim 1 , wherein the 3xxx series aluminum alloy is processed to produce an O temper alloy. 
     
     
         9 . The aluminum alloy capsule of  claim 8 , wherein the 3xxx series aluminum alloy exhibits less than 2.0 percent earing in O temper. 
     
     
         10 . The aluminum alloy capsule of  claim 9 , wherein the 3xxx series aluminum alloy exhibits a ratio of texture components (Cube+Goss)/(Brass+S+Cu) between 0.5 and 1.5. 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . The aluminum alloy capsule of  claim 1 , wherein the aluminum alloy capsule comprises a thickness of from 30 μm to 170 μm. 
     
     
         14 . (canceled) 
     
     
         15 . The aluminum alloy capsule of  claim 1 , wherein the aluminum alloy has an ultimate tensile strength of from 110 MPa to 195 MPa when the aluminum alloy is in O temper. 
     
     
         16 . The aluminum alloy capsule of  claim 1 , wherein the aluminum alloy has a yield strength at 0.2 percent strain of from 45 MPa to 85 MPa when the aluminum alloy is in O temper. 
     
     
         17 . The aluminum alloy capsule of  claim 1 , wherein the aluminum alloy has a total elongation of at least 13 percent when the aluminum alloy is in O temper. 
     
     
         18 . A method of producing an aluminum alloy product, comprising:
 melting recycled aluminum into liquid metal;   adding an alloying element to the liquid metal to form a modified liquid metal, the alloying element comprising at least one of manganese or magnesium;   casting the modified liquid metal to form a cast aluminum alloy, wherein the modified liquid metal includes at least 50 weight percent recycled aluminum;   heating the cast aluminum alloy;   hot rolling the cast aluminum alloy to produce a rolled product comprising a thickness of 1.5 mm to 10 mm;   cold rolling the rolled product to produce an aluminum alloy product comprising a thickness of from 30 μm to 170 μm; and   annealing the aluminum alloy product to produce an O temper product.   
     
     
         19 . (canceled) 
     
     
         20 . The method of  claim 18 , further comprising, performing a plurality of passes during the cold rolling step and interannealing the aluminum alloy product between the plurality of passes of the cold rolling step. 
     
     
         21 . The method of  claim 20 , wherein the product is processed to a H18 or H19 temper before the annealing step. 
     
     
         22 . The method of  claim 18 , further comprising cleaning the aluminum alloy product with a mild alkaline or acidic agent after cold rolling the rolled product. 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . An aluminum alloy product prepared according to the method of  claim 18 . 
     
     
         26 . The aluminum alloy product of  claim 25 , wherein the aluminum alloy product comprises a 3xxx series aluminum alloy. 
     
     
         27 - 33 . (canceled) 
     
     
         34 . The aluminum alloy product of  claim 25 , wherein the aluminum alloy product is a package for preparing a beverage. 
     
     
         35 . The aluminum alloy product of  claim 25 , wherein the aluminum alloy product is a beverage capsule.