High recycle content aluminum alloys and methods of making and using

Abstract

Aluminum alloys, metal products made using the aluminum alloys, and methods of processing the aluminum alloys are disclosed. The disclosed alloys can be prepared using large amounts of recycled aluminum alloy content, such as up to 100% recycled content, or more. The disclosed aluminum alloys include amounts of iron, manganese, chromium, and/or silicon in excess of comparable aluminum alloys commonly made by alloying prime aluminum. Further, the disclosed alloys include ratios of a total amount of manganese and chromium to iron of greater than or about 0.60 or 0.70, which may contribute, at least partly, to desirable bending, forming, and surface properties and characteristics of metal products made using the aluminum alloys. The disclosed alloys can be used to prepare automotive and structural panels such that these products are generated using large amounts of recycled aluminum alloy content.

1 . An aluminum alloy, comprising Al and about 1 wt. % to 1.5 wt. % Si,
 up to about 0.35 wt. % Fe,   up to about 0.25 wt. % Cu,   about 0.05 wt. % to 0.25 wt. % Mn,   about 0.2 wt. % to 0.60 wt. % Mg,   up to about 0.10 wt. % Cr,   up to about 0.10 wt. % Ni,   up to about 0.20 wt. % Zn,   up to about 0.15 wt. % Ti, and   up to about 0.10 wt. % V,   wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content.   
     
     
         2 - 9 . (canceled) 
     
     
         10 . A metal product comprising the aluminum alloy of  claim 1 , wherein the metal product is a rolled metal product. 
     
     
         11 . The metal product of  claim 10 , wherein the metal product is dual-recrystallized metal product. 
     
     
         12 . The metal product of  claim 10 , wherein the metal product exhibits isotropic strain characteristics. 
     
     
         13 . The metal product of  claim 10 , wherein the metal product exhibits a Lankford ratio at about 10% strain along longitudinal, transverse, and diagonal directions of about 0.6 or greater. 
     
     
         14 . The metal product of  claim 10 , wherein the metal product exhibits an f15% bending factor along a transverse direction of from about 0.3 to 1.0. 
     
     
         15 . The metal product of  claim 10 , wherein the metal product exhibits an inner-bending angle after pre-straining of 10% of about 10° to 60°. 
     
     
         16 . The metal product of  claim 10 , wherein the metal product exhibits a surface arithmetical mean height (Sa) of at most 0.60 μm. 
     
     
         17 . The metal product of  claim 10 , wherein the metal product exhibits a yield strength of from 90 MPa to 130 MPa when in a T4 temper or from 200 MPa to 235 MPa when in a T6 temper. 
     
     
         18 . The metal product of  claim 10 , wherein the metal product exhibits an ultimate tensile strength of from 195 MPa to 270 MPa when in a T4 temper or from 240 MPa to 300 MPa when in a T6 temper. 
     
     
         19 . The metal product of  claim 10 , wherein the metal product exhibits a uniform elongation of from 20% to 30% when in a T4 temper or from 10% to 20% when in a T6 temper. 
     
     
         20 . A method of producing a metal product, the method comprising:
 casting an aluminum alloy to generate a cast product, wherein the aluminum alloy comprises Al and   about 1 wt. % to 1.5 wt. % Si,   up to about 0.35 wt. % Fe,   up to about 0.25 wt. % Cu,   about 0.05 wt. % to 0.25 wt. % Mn,   about 0.2 wt. % to 0.60 wt. % Mg,   up to about 0.10 wt. % Cr,   up to about 0.10 wt. % Ni,   up to about 0.20 wt. % Zn,   up to about 0.15 wt. % Ti, and   up to about 0.10 wt. % V,   wherein a ratio of a total amount of Mn and Cr to an amount of Fe is greater than 0.7, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content;   homogenizing the cast product to generate a homogenized product;   hot rolling the homogenized product to generate a rolled product; and   subjecting the rolled product to a final cold rolling process product to produce the metal product.   
     
     
         21 . The method of  claim 20 , further comprising:
 subsequent to the hot rolling, subjecting the rolled product to a recrystallization process to generate a recrystallized product, wherein the final cold rolling process comprises cold rolling the recrystallized product to produce the metal product.   
     
     
         22 . The method of  claim 21 , wherein the recrystallization process occurs between the hot rolling and the final cold rolling process. 
     
     
         23 . The method of  claim 21 , further comprising:
 subjecting the rolled product to a preliminary cold rolling process subsequent to the hot rolling and prior to the recrystallization process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.   
     
     
         24 . The method of  claim 21 , wherein the recrystallization process comprises:
 annealing the rolled product at peak metal temperature of from 325° C. to 425° C. for up to 1 minute to generate a recrystallized product; and   quenching the recrystallized product.   
     
     
         25 . The method of  claim 20 , wherein an exit temperature of the hot rolling is no more than 400° C. 
     
     
         26 . The method of  claim 20 , wherein the hot rolling achieves a thickness reduction between the homogenized product and the rolled product of 90% or more. 
     
     
         27 . The method of  claim 20 , further comprising:
 subjecting the metal product to a solutionizing process to generate a solutionized metal product.   
     
     
         28 . The method of  claim 20 , further comprising:
 subjecting the metal product to an aging or artificial aging process to generate an aged metal product.   
     
     
         29 - 42 . (canceled)