Extrusion feedstock and product thereof including extrudable aluminum scrap

Abstract

A feedstock may include at least 1 wt % of an extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof comprising an impurity, the impurity comprising at least one of: silicon, copper, iron magnesium, manganese, zinc or an extrudable mixture thereof; or a mixture of at least two thereof.

What is claimed is: 
     
         1 . An extrusion feedstock comprising:
 at least 1 wt % of an extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof comprising an impurity, the impurity comprising at least one of:
 silicon in a range of from about 2 wt % to about 15 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 copper in a range of from about 0.3 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 iron in a range of from about 0.2 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 magnesium in a range of from about 0.3 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 manganese in a range of from about 0.1 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 zinc in a range of from about 0.1 wt % to about 1 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; or 
 a mixture of at least two thereof. 
   
     
     
         2 . The extrusion feedstock of  claim 1 , wherein aluminum is at least 80 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof. 
     
     
         3 . The extrusion feedstock of  claim 1 , wherein the impurity comprises at least one of:
 silicon in a range of from about 4 wt % to about 15 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   copper in a range of from about 0.6 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   iron in a range of from about 0.3 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   magnesium in a range of from about 0.7 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   manganese in a range of from about 0.2 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   zinc in a range of from about 0.4 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; or   a mixture of at least two thereof.   
     
     
         4 . The extrusion feedstock of  claim 1 , wherein the impurity comprises silicon in a range of from about 2 wt % to about 15 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof. 
     
     
         5 . 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, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   a primary aluminum; or   a mixture of at least two thereof.   
     
     
         6 . The extrusion feedstock of  claim 5 , wherein the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof, the post-consumer scrap, and the pre-consumer scrap composition independently range from about 20 wt % to about 80 wt % of the extrusion feedstock. 
     
     
         7 . The extrusion feedstock of  claim 1 , wherein the feedstock is not homogenized. 
     
     
         8 . The extrusion feedstock of  claim 1 , wherein the feedstock is a billet. 
     
     
         9 . A method of making an extrusion feedstock, the method comprising:
 disposing a molten post-consumer aluminum composition in a mold, the composition comprising:
 at least 1 wt % of an extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof comprising an impurity, the impurity comprising at least one of:
 silicon in a range of from about 2 wt % to about 15 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 copper in a range of from about 0.3 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 iron in a range of from about 0.2 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 magnesium in a range of from about 0.3 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 manganese in a range of from about 0.1 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; 
 zinc in a range of from about 0.1 wt % to about 1 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; or 
 
 a mixture of at least two thereof; and 
   allowing the molten post-consumer aluminum composition to solidify.   
     
     
         10 . The method of  claim 9 , further comprising:
 disposing a molten pre-consumer scrap composition in the mold; and   allowing the molten pre-consumer scrap composition to solidify.   
     
     
         11 . The method of  claim 9 , further comprising disposing a molten post-consumer scrap in the mold. 
     
     
         12 . An extruded product comprising:
 at least 1 wt % of an extruded floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof comprising an impurity, the impurity comprising at least one of:
 silicon in a range of from about 2 wt % to about 15 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 copper in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 iron in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 magnesium in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 manganese in a range of from about 0.1 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 zinc in a range of from about 0.1 wt % to about 1 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; or 
 a mixture of at least two thereof, 
   wherein the extruded product has a refined microstructure relative to a corresponding non-extruded product having a substantially identical chemical composition.   
     
     
         13 . The extruded product of  claim 12 , wherein the refined microstructure comprises an average grain size that is smaller in at least one dimension relative to the corresponding non-extruded product. 
     
     
         14 . The extruded product of  claim 12 , wherein the refined microstructure comprises an average grain length that is smaller than an average grain length of the corresponding non-extruded product. 
     
     
         15 . The extruded product of  claim 12 , wherein the impurities are broken down to smaller pieces relative to the impurities in the corresponding non-extruded product. 
     
     
         16 . The extruded product of  claim 12 , wherein a feedstock used to form the product is not homogenized. 
     
     
         17 . The extruded product of  claim 12 , wherein a yield strength of the product is at least about 200 MPa. 
     
     
         18 . The extruded product of  claim 12 , wherein an ultimate tensile strength of the product is at least about 300 MPa. 
     
     
         19 . The extruded product of  claim 12 , wherein the impurity comprises at least one of:
 silicon in a range of from about 4 wt % to about 15 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   copper in a range of from about 0.6 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   iron in a range of from about 0.3 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   magnesium in a range of from about 0.7 wt % to about 3 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   manganese in a range of from about 0.2 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof;   zinc in a range of from about 0.4 wt % to about 2 wt % of the extrudable floated fragmentizer aluminum scrap composition, extrudable fragmentizer aluminum scrap composition, or an extrudable mixture thereof; or   a mixture of at least two thereof.   
     
     
         20 . An extruded product comprising:
 at least 1 wt % aluminum and at least one of:
 silicon in a range of from about 2 wt % to about 15 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 copper in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 iron in a range of from about 0.2 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 magnesium in a range of from about 0.3 wt % to about 3 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 manganese in a range of from about 0.1 wt % to about 2 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; 
 zinc in a range of from about 0.1 wt % to about 1 wt % of the floated fragmentizer aluminum scrap composition, fragmentizer aluminum scrap composition, or a mixture thereof, fragmentizer aluminum scrap composition, or a mixture thereof; or 
 a mixture of at least two thereof, wherein
 a microstructure of the extruded product comprises an average grain length of less than about 10 μm; 
 a yield strength of the product is at least about 200 MPa; 
 an ultimate tensile strength of the product is at least about 300 MPa; and 
 an elongation percentage of the product is at least about 5%.