U.S. patent application number 13/284505 was filed with the patent office on 2012-05-03 for 5xxx aluminum alloys, and methods for producing the same.
This patent application is currently assigned to Alcoa Inc.. Invention is credited to Francine S. Bovard, John M. Newman, Ralph R. Sawtell.
Application Number | 20120103476 13/284505 |
Document ID | / |
Family ID | 45994798 |
Filed Date | 2012-05-03 |
United States Patent
Application |
20120103476 |
Kind Code |
A1 |
Newman; John M. ; et
al. |
May 3, 2012 |
5XXX ALUMINUM ALLOYS, AND METHODS FOR PRODUCING THE SAME
Abstract
Improved 5xxx aluminum alloys having an improved combination of
properties are disclosed. The new 5xxx aluminum alloys generally
contain 0.50 to 3.25 wt. % Mg, 0.05 to 0.20 wt. % Sc, 0.05 to 0.20
wt. % Zr, up to 0.50 wt. % in total of Cu and Ag, less than 0.10
wt. % Mn, up to 0.30 wt. % in total of Cr, V and Ti, up to 0.50 wt.
% in total of Ni and Co, up to 0.25 wt. % Fe, up to 0.25 wt. % Si,
up to 0.50 wt. % Zn, and up to 0.10 wt. % of any other element,
with the total of these other elements not exceeding 0.35 wt. %,
the balance being aluminum. The new 5xxx aluminum alloys may be
used in high strength electrical conductor products, among
others.
Inventors: |
Newman; John M.; (Export,
PA) ; Bovard; Francine S.; (Monroeville, PA) ;
Sawtell; Ralph R.; (Gibsonia, PA) |
Assignee: |
Alcoa Inc.
Pittsburgh
PA
|
Family ID: |
45994798 |
Appl. No.: |
13/284505 |
Filed: |
October 28, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61408269 |
Oct 29, 2010 |
|
|
|
61435543 |
Jan 24, 2011 |
|
|
|
Current U.S.
Class: |
148/439 ;
148/440; 420/533; 420/541; 420/543; 420/544; 420/545 |
Current CPC
Class: |
C22C 21/06 20130101;
C22F 1/04 20130101; C22F 1/047 20130101; C22C 21/00 20130101; C22C
21/08 20130101 |
Class at
Publication: |
148/439 ;
420/543; 420/533; 420/541; 420/544; 420/545; 148/440 |
International
Class: |
C22C 21/06 20060101
C22C021/06; C22C 21/00 20060101 C22C021/00; C22C 21/08 20060101
C22C021/08 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 28, 2011 |
US |
PCT/US2011/058293 |
Claims
1. An aluminum alloy comprising: 0.50 to 3.25 wt. % Mg; 0.05 to
0.20 wt. % Sc; 0.05 to 0.20 wt. % Zr; up to 0.50 wt. % in total of
Cu and Ag; less than 0.10 wt. % Mn; up to 0.30 wt. % in total of
Cr, V and Ti; up to 0.50 wt. % in total of Ni and Co; up to 0.25
wt. % Fe; up to 0.25 wt. % Si; up to 0.50 wt. % Zn; up to 0.10 wt.
% of any other element, with the total of these other elements not
exceeding 0.35 wt. %; and the balance being aluminum.
2. The aluminum alloy of claim 1, comprising 0.07 to 0.18 wt. % Sc
and 0.07 to 0.18 wt. % Zr.
3. The aluminum alloy of claim 1, comprising 0.05 to 0.50 wt. % in
total of Cu and Ag.
4. The aluminum alloy of claim 3, comprising 0.20 to 0.40 wt. % in
total of Cu and Ag.
5. The aluminum alloy of claim 4, wherein the alloy excludes Ag,
except as an other element.
6. The aluminum alloy of claim 4, wherein the alloy excludes Cu,
except as an other element.
7. The aluminum alloy of claim 1, wherein the alloy includes not
greater than 0.03 wt. % Mn.
8. The aluminum alloy of claim 7, wherein the alloy includes not
greater than 0.01 wt. % Mn.
9. The aluminum alloy of claim 1, wherein the alloy includes not
greater than 0.03 wt. % in total of Cr, V and Ti.
10. The aluminum alloy of claim 9, wherein the alloy includes at
least 0.005 wt. % Ti.
11. The aluminum alloy of claim 1, wherein the alloy includes not
greater than 0.10 wt. % Fe and 0.05 wt. % Si.
12. The aluminum alloy of claim 11, wherein the alloy includes not
greater than 0.25 wt. % Zn.
13. The aluminum alloy of claim 1, wherein the alloy includes up to
0.05 wt. % each of the other element, with the total of these other
elements not exceeding 0.15 wt. %.
14. The aluminum alloy of claim 1, wherein the aluminum alloy
realizes an electrical conductivity (EC) of at least 35% IACS and a
longitudinal tensile yield strength (TYS-L) of at least 270 MPa,
and wherein the combination of EC to TYS-L satisfies the following
expression: % IACS.gtoreq.-0.195*(TYS-L)+96, wherein the EC and
TYS-L properties are tested after the electrical conductor has been
annealed at 250.degree. F. for 6 hours.
15. The aluminum alloy of claim 14, wherein the combination of EC
to TYS-L satisfies the following expression: %
IACS.gtoreq.-0.195*(TYS-L)+102.
16. The aluminum alloy of claim 15, wherein the aluminum alloy
realizes a longitudinal tensile yield strength (TYS-L) of at least
290 MPa.
17. The aluminum alloy of claim 16, wherein the aluminum alloy
achieves an electrical conductivity (EC) of at least 40.0%
IACS.
18. The aluminum alloy of claim 1, wherein a thermally exposed
version of the aluminum alloy retains at least 80% of its
longitudinal tensile yield strength relative to the longitudinal
tensile yield strength of a non-thermally exposed version of the
aluminum alloy.
19. The aluminum alloy of claim 18, wherein the aluminum alloy
realizes a mass loss of not greater than 10 mg/cm.sup.2 when tested
in accordance with ASTM G67.
20. An electrical conductor made the aluminum alloy of claim 1.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority to U.S. Provisional
Patent Application No. 61/408,269, entitled "IMPROVED 5XXX ALUMINUM
ALLOYS, AND METHODS FOR PRODUCING THE SAME", filed Oct. 31, 2010,
and U.S. Provisional Patent Application No. 61/435,543, entitled
"IMPROVED 5XXX ALUMINUM ALLOYS, AND METHODS FOR PRODUCING THE
SAME", filed Jan. 24, 2011. This patent application also claims
priority to PCT Patent Application No. PCT/US11/58293, entitled
"IMPROVED 5XXX ALUMINUM ALLOYS, AND METHODS FOR PRODUCING THE
SAME", filed Oct. 28, 2011. Each of the above-identified patent
applications is incorporated herein by reference in its
entirety.
BACKGROUND
[0002] Aluminum alloys are useful in a variety of applications.
However, improving one property of an aluminum alloy without
degrading another property often proves elusive.
SUMMARY OF THE DISCLOSURE
[0003] Broadly, the present patent application relates to new 5xxx
aluminum alloy products having an improved combination of
properties. 5xxx aluminum alloys are aluminum alloys having
magnesium as the predominate alloying ingredient, other than
aluminum, and containing silicon as an impurity. The new 5xxx
aluminum alloy products are made from aluminum alloys containing
0.50 to 3.25 wt. % Mg, 0.05 to 0.20 wt. % Sc and/or 0.05 to 0.20
wt. % Zr, up to 0.50 wt. % in total of Cu and Ag, less than 0.10
wt. % Mn, up to 0.30 wt. % in total of Cr, V and Ti, up to 0.50 wt.
% in total of Ni and Co, up to 0.25 wt. % Fe, up to 0.25 wt. % Si,
up to 0.50 wt. % Zn, and up to 0.10 wt. % of any other element,
with the total of these other elements not exceeding 0.35 wt. %,
the balance being aluminum. The new 5xxx aluminum alloys may
comprise, consist essentially of, or consist of the stated
ingredients. The new 5xxx aluminum alloys may realize an improved
combination of properties, such as an improved combination of two
or more of electrical conductivity, strength, strength retention,
and intragranular corrosion resistance, among others, as shown by
the below examples. The new 5xxx aluminum alloys may be used in
high strength electrical conductor products, among others.
[0004] The new 5xxx aluminum alloy products may realize high
electrical conductivity. In one embodiment, a new 5xxx aluminum
alloy product realizes an electrical conductivity of at least 35%
IACS. In other embodiments, a new 5xxx aluminum alloy product
realizes an electrical conductivity of at least 36%, or at least
37%, or at least 37.5%, or at least 38%, or at least 39%, or at
least 40%, or at least 41%, or at least 42%, or at least 42.5%, or
at least 43%, or at least 44%, or at least 45%, or at least 46%, or
at least 47%, or at least 47.5%, or at least 48%, or at least 49%,
or at least 50%, or at least 51%, or at least 52%, or at least 53%,
or at least 54%, or at least 55% IACS, or higher. These properties
are measured after the new 5xxx aluminum alloy product has been
stabilized, i.e., annealed at 250.degree. F. for 6 hours.
[0005] The new 5xxx aluminum alloy products may realize high
strength. In one embodiment, a new 5xxx aluminum alloy product
realizes a longitudinal (L) tensile yield strength (TYS) of at
least 270 MPa. In other embodiments, a new 5xxx aluminum alloy
product realizes a longitudinal tensile yield strength of at least
280 MPa, or at least 290 MPa, or at least 300 MPa, or at least 310
MPa, or at least 320 MPa, or at least 330 MPa, or at least 340 MPa,
or at least 350 MPa, or at least 360 MPa, or at least 370 MPa, or
at least 380 MPa, or at least 390 MPa, or at least 400 MPa, or
higher. These properties are measured after the new 5xxx aluminum
alloy has been stabilized, i.e., annealed at 250.degree. F. for 6
hours.
[0006] The new 5xxx aluminum alloy products may realize high
retained strength. For example, a thermally exposed version of the
new 5xxx aluminum alloy product (e.g., exposed to temperatures of
250.degree. F.-500.degree. F., or higher, for 100 hours+/-0.5 hour)
may retain at least 70% of its longitudinal tensile yield strength
relative to the longitudinal tensile yield strength of a
non-thermally exposed version of the same 5xxx aluminum alloy
product. A non-thermally exposed version of the same 5xxx aluminum
alloy product is the product as annealed at 250.degree. F. for 6
hours (i.e., the stabilized baseline product). A piece of the
non-thermally exposed version of the 5xxx aluminum alloy product is
then exposed to elevated temperature for an additional 100
hours+/-0.5 hour to obtain the thermally exposed version of the new
5xxx aluminum alloy product. To determine strength retention,
strength properties of both the non-thermally exposed and the
thermally exposed products are measured at room temperature, and in
accordance with ASTM E8 and B557. See, Example 4, below.
[0007] Strength retention may be measured relative to the
longitudinal tensile yield strength, the long-transverse tensile
yield strength and/or the short-transverse yield strength of the
aluminum alloy. In one embodiment, strength retention is measured
relative to longitudinal tensile yield strength. Those skilled in
the art recognize that different combinations of temperatures
and/or exposure periods may yield varying results.
[0008] In one approach, the thermally exposed version is exposed to
a temperature of 260.degree. F. for 100 hours+/-0.5 hour. In this
approach, the thermally exposed version may realize a retained
longitudinal tensile yield strength of at least 95% relative to the
longitudinal tensile yield strength of a non-thermally exposed
version of the same 5xxx aluminum alloy product. In one embodiment,
the thermally exposed version may realize a retained strength of at
least 96% relative to the non-thermally exposed version of the same
5xxx aluminum alloy product. In other embodiments, the thermally
exposed version may realize a retained strength of at least 97%,
such as at least 98%, or at least 99%, or at least 100% relative to
the non-thermally exposed version of the same 5xxx aluminum alloy
product. In some embodiments, the thermally exposed version of the
new 5xxx aluminum alloy product has a higher strength than the
non-thermally exposed version of the same 5xxx aluminum alloy
product, such as at least about 1% or 2% higher strength, i.e., a
retained strength of at least 101%, or at least 102%. See, Example
4, below.
[0009] In another approach, the thermally exposed version is
exposed to a temperature of 300.degree. F. for 100 hours+/-0.5
hour. In this approach, the thermally exposed version may realize a
retained longitudinal tensile yield strength of at least 93%
relative to the longitudinal tensile yield strength of a
non-thermally exposed version of the same 5xxx aluminum alloy
product. In one embodiment, the thermally exposed version may
realize a retained strength of at least 94% relative to the
non-thermally exposed version of the same 5xxx aluminum alloy
product. In other embodiments, the thermally exposed version may
realize a retained strength of at least 95%, such as at least 96%,
or at least 97%, or at least 98% relative to the non-thermally
exposed version of the same 5xxx aluminum alloy product.
[0010] In yet another approach, the thermally exposed version is
exposed to a temperature of 350.degree. F. for 100 hours+/-0.5
hour. In this approach, the thermally exposed version may realize a
retained longitudinal tensile yield strength of at least 84%
relative to the longitudinal tensile yield strength of a
non-thermally exposed version of the same 5xxx aluminum alloy
product. In one embodiment, the thermally exposed version may
realize a retained strength of at least 85% relative to the
non-thermally exposed version of the same 5xxx aluminum alloy
product. In other embodiments, the thermally exposed version may
realize a retained strength of at least 86%, such as at least 87%,
or at least 88%, or at least 89%, or at least 90%, or at least 91%
relative to the non-thermally exposed version of the same 5xxx
aluminum alloy product.
[0011] In yet another approach, the thermally exposed version is
exposed to a temperature of 400.degree. F. for 100 hours+/-0.5
hour. In this approach, the thermally exposed version may realize a
retained longitudinal tensile yield strength of at least 75%
relative to the longitudinal tensile yield strength of a
non-thermally exposed version of the same 5xxx aluminum alloy
product. In one embodiment, the thermally exposed version may
realize a retained strength of at least 80% relative to the
non-thermally exposed version of the same 5xxx aluminum alloy
product. In other embodiments, the thermally exposed version may
realize a retained strength of at least 82%, such as at least 84%,
or at least 86%, or at least 88% relative to the non-thermally
exposed version of the same 5xxx aluminum alloy product.
[0012] In yet another approach, the thermally exposed version is
exposed to a temperature of 450.degree. F. for 100 hours+/-0.5
hour. In this approach, the thermally exposed version may realize a
retained longitudinal tensile yield strength of at least 70%
relative to the longitudinal tensile yield strength of a
non-thermally exposed version of the same 5xxx aluminum alloy
product. In one embodiment, the thermally exposed version may
realize a retained strength of at least 75% relative to the
non-thermally exposed version of the same 5xxx aluminum alloy
product. In other embodiments, the thermally exposed version may
realize a retained strength of at least 80%, such as at least 82%,
or at least 84%, or at least 86% relative to the non-thermally
exposed version of the same 5xxx aluminum alloy product.
[0013] In yet another approach, the thermally exposed version is
exposed to a temperature of 500.degree. F. for 100 hours+/-0.5
hour. In this approach, the thermally exposed version may realize a
retained longitudinal tensile yield strength of at least 70%
relative to the longitudinal tensile yield strength of a
non-thermally exposed version of the same 5xxx aluminum alloy
product. In one embodiment, the thermally exposed version may
realize a retained strength of at least 75% relative to the
non-thermally exposed version of the same 5xxx aluminum alloy
product. In other embodiments, the thermally exposed version may
realize a retained strength of at least 80%, such as at least 82%,
or at least 84%, or at least 85% relative to the non-thermally
exposed version of the same 5xxx aluminum alloy product.
[0014] The new 5xxx aluminum alloy products may realize low
intragranular corrosion. In one embodiment, a new 5xxx aluminum
alloy product realizes a mass loss of not greater than 15
mg/cm.sup.2 when tested in accordance with ASTM G67. To test
corrosion resistance, the new 5xxx aluminum alloy product is
annealed at 250.degree. F. for 6 hours, and is then sensitized by
exposing to a temperature of 100.degree. C. (212.degree. F.) for 1
week. See, Example 1, below. In other embodiments, a new 5xxx
aluminum alloy product realizes a mass loss of not greater than 14
mg/cm.sup.2, or not greater than 13 mg/cm.sup.2, or not greater
than 12 mg/cm.sup.2, or not greater than 11 mg/cm.sup.2, or not
greater than 10 mg/cm.sup.2, or not greater than 9 mg/cm.sup.2, or
not greater than 8 mg/cm.sup.2, or not greater than 7 mg/cm.sup.2,
or not greater than 6 mg/cm.sup.2, or not greater than 5
mg/cm.sup.2, or less mass loss.
[0015] The new 5xxx aluminum alloys generally include from 0.5 wt.
% to 3.25 wt. % Mg. In one embodiment, the new 5xxx aluminum alloys
include at least 0.80 wt. % Mg. In one embodiment, the new 5xxx
aluminum alloys include not greater than 2.90 wt. % Mg. The amount
of magnesium used in the alloy may be related to the strength,
electrical conductivity, and/or corrosion resistance properties of
the alloy. High electrical conductivity and better corrosion
resistance occurs with lower levels of magnesium. Higher strength
occurs with higher levels of magnesium. See Tables I-A to I-C,
below, for various magnesium ranges relative to various electrical
conductivity properties.
[0016] The new 5xxx aluminum alloys may include both scandium (Sc)
and zirconium (Zr), and generally from 0.05 to 0.20 wt. % each of
Sc and Zr. The combination of scandium and zirconium may contribute
to increased strength. In one embodiment, the new 5xxx aluminum
alloys include from 0.07 to 0.18 wt. % each of Sc and Zr. However,
in other embodiments, only one of scandium or zirconium may be
used, and in the above amounts, such as in lower strength
applications.
[0017] The new 5xxx aluminum alloys may optionally include copper
(Cu) and/or silver (Ag). Copper and/or silver may improve strength.
However, too much copper may decrease corrosion resistance. In one
approach, the new 5xxx aluminum alloys include up to 0.50 wt. % Cu,
and silver is absent from the alloy (i.e., the alloy contains
silver as an "other element", defined below). In one embodiment of
this approach, the new 5xxx aluminum alloys include 0.05 to 0.50
wt. % Cu. In another embodiment of this approach, the new 5xxx
aluminum alloys include 0.10 to 0.45 wt. % Cu. In yet another
embodiment of this approach, the new 5xxx aluminum alloys include
0.20 to 0.40 wt. % Cu. In yet another embodiment of this approach,
the new 5xxx aluminum alloys include 0.25 to 0.35 wt. % Cu.
[0018] In another approach, the new 5xxx aluminum alloys include up
to 0.50 wt. % Ag, and copper is absent from the alloy (i.e., the
alloy contains copper as an "other element", defined below). In one
embodiment of this approach, the new 5xxx aluminum alloys include
0.05 to 0.50 wt. % Ag. In another embodiment of this approach, the
new 5xxx aluminum alloys include 0.10 to 0.45 wt. % Ag. In yet
another embodiment of this approach, the new 5xxx aluminum alloys
include 0.20 to 0.40 wt. % Ag. In yet another embodiment of this
approach, the new 5xxx aluminum alloys include 0.25 to 0.35 wt. %
Ag.
[0019] In yet another approach, the new 5xxx aluminum alloys
include both Cu+Ag and up to 0.50 wt. % Ag. In one embodiment of
this approach, the new 5xxx aluminum alloys include 0.05 to 0.50
wt. % total of Cu+Ag. In another embodiment of this approach, the
new 5xxx aluminum alloys include 0.10 to 0.45 wt. % total of Cu+Ag.
In yet another embodiment of this approach, the new 5xxx aluminum
alloys include 0.20 to 0.40 wt. % total of Cu+Ag. In yet another
embodiment of this approach, the new 5xxx aluminum alloys include
0.25 to 0.35 wt. % total of Cu+Ag.
[0020] The new 5xxx aluminum alloys should include low amounts of
manganese (Mn). Manganese detrimentally impacts electrical
conductivity. In one embodiment, the new 5xxx aluminum alloys
include less than 0.10 wt. % Mn. In another embodiment, the new
5xxx aluminum alloys include not greater than 0.07 wt. % Mn. In yet
another embodiment, the new 5xxx aluminum alloys include not
greater than 0.05 wt. % Mn. In yet another embodiment, the new 5xxx
aluminum alloys include not greater than 0.03 wt. % Mn. In yet
another embodiment, the new 5xxx aluminum alloys include not
greater than 0.01 wt. % Mn.
[0021] The new 5xxx aluminum alloys should restrict the amount of
chromium (Cr), vanadium (V), and titanium (Ti). These elements may
detrimentally impact electrical conductivity. In one embodiment,
the new 5xxx aluminum alloys include not greater than 0.30 wt. %
total of Cr, V and Ti (i.e., the total combined amounts of Cr, V,
and Ti does not exceed 0.30 wt. %). In one embodiment, the new 5xxx
aluminum alloys include not greater than 0.25 wt. % total of Cr, V
and Ti. In yet another embodiment, the new 5xxx aluminum alloys
include not greater than 0.20 wt. % total of Cr, V and Ti. In yet
another embodiment, the new 5xxx aluminum alloys include not
greater than 0.15 wt. % total of Cr, V and Ti. In yet another
embodiment, the new 5xxx aluminum alloys include not greater than
0.10 wt. % total of Cr, V and Ti. In yet another embodiment, the
new 5xxx aluminum alloys include not greater than 0.05 wt. % total
of Cr, V and Ti. In yet another embodiment, the new 5xxx aluminum
alloys include not greater than 0.03 wt. % total of Cr, V and Ti.
In any of these embodiments, the new 5xxx aluminum alloy may
include at least 0.005 wt. % Ti (e.g., for grain refining
purposes).
[0022] The new 5xxx aluminum alloys should restrict the amount of
nickel (Ni) and cobalt (Co). These elements may detrimentally
impact electrical conductivity. In one embodiment, the new 5xxx
aluminum alloys include not greater than 0.50 wt. % total of Ni and
Co (i.e., the total combined amounts of Ni and Co does not exceed
0.50 wt. %). In one embodiment, the new 5xxx aluminum alloys
include not greater than 0.35 wt. % total of Ni and Co. In another
embodiment, the new 5xxx aluminum alloys include not greater than
0.20 wt. % total of Ni and Co. In yet another embodiment, the new
5xxx aluminum alloys include not greater than 0.15 wt. % total of
Ni and Co. In yet another embodiment, the new 5xxx aluminum alloys
include not greater than 0.10 wt. % total of Ni and Co. In yet
another embodiment, the new 5xxx aluminum alloys include not
greater than 0.05 wt. % total of Ni and Co. In yet another
embodiment, the new 5xxx aluminum alloys include not greater than
0.03 wt. % total of Ni and Co. In yet another embodiment, the new
5xxx aluminum alloys include not greater than 0.01 wt. % total of
Ni and Co.
[0023] The new 5xxx aluminum alloys should restrict the amount of
iron (Fe), silicon (Si) and zinc (Zn) impurities. Iron and silicon
impurities may detrimentally impact strength. In one embodiment,
the new 5xxx aluminum alloys include not greater than 0.25 wt. %
each of Fe and Si. In another embodiment, the new 5xxx aluminum
alloys include not greater than 0.20 wt. % Fe and not greater than
0.15 wt. % Si. In yet another embodiment, the new 5xxx aluminum
alloys include not greater than 0.15 wt. % Fe and not greater than
0.10 wt. % Si. In yet another embodiment, the new 5xxx aluminum
alloys include not greater than 0.10 wt. % Fe and not greater than
0.05 wt. % Si. Zinc impurities may detrimentally affect corrosion
resistance. In one embodiment, the new 5xxx aluminum alloys include
not greater than 0.50 wt. % Zn. In another embodiment, the new 5xxx
aluminum alloys include not greater than 0.35 wt. % Zn. In yet
another embodiment, the new 5xxx aluminum alloys include not
greater than 0.25 wt. % Zn.
[0024] The new 5xxx aluminum alloys may be substantially free of
other elements (e.g., casting aids and other impurities, i.e.,
other than the iron, silicon and zinc impurities described above).
As used herein, "other elements" means any other elements of the
periodic table other than the above-listed magnesium, scandium,
zirconium, copper and/or silver (as applicable--see above),
manganese, chromium, vanadium, titanium, nickel, cobalt, iron,
silicon, and zinc, described above. In the context of this
paragraph the phrase "substantially free" means that the new 5xxx
aluminum alloys contain not more than 0.10 wt. % each of any other
element, with the total combined amount of these other elements not
exceeding 0.35 wt. % in the new 5xxx aluminum alloy. In another
embodiment, each one of these other elements, individually, does
not exceed 0.05 wt. % in the 5xxx aluminum alloy, and the total
combined amount of these other elements does not exceed 0.15 wt. %
in the 5xxx aluminum alloy. In another embodiment, each one of
these other elements, individually, does not exceed 0.03 wt. % in
the 5xxx aluminum alloy, and the total combined amount of these
other elements does not exceed 0.10 wt. % in the 5xxx aluminum
alloy.
[0025] Examples of various types of new 5xxx aluminum alloy
compositions are provided in Tables I-A to I-C, below. Embodiments
of properties that may be achieved by the new 5xxx aluminum alloys
when rolled to a thickness of about 1.0-1.1 mm, and annealed at a
temperature of 250.degree. F. for a period of 6 hours are provided
in Table I-D, below.
TABLE-US-00001 TABLE I-A Non-Limiting examples of compositions of
new 5xxx aluminum alloys for achieving an electrical conductivity
of 35.0 to 39.9% IACS Elect. Cond. Preferred More Preferred (%
IACS) Broad Composition Composition Composition 35.0-39.9 2.70-3.25
wt. % Mg; 2.70-3.25 wt. % Mg; 2.70-3.25 wt. % Mg; 0.05-0.20 wt. %
Sc; 0.07-0.18 wt. % Sc; 0.07-0.18 wt. % Sc; and/or and and
0.05-0.20 wt. % Zr; 0.07-0.18 wt. % Zr; 0.07-0.18 wt. % Zr;
.ltoreq.0.50 wt. % Cu + Ag; 0.05-0.50 wt. % 0.10-0.45 wt. %
<0.10 wt. % Mn; Cu + Ag; Cu + Ag; .ltoreq.0.50 wt. % Ni + Co;
.ltoreq.0.05 wt. % Mn; .ltoreq.0.03 wt. % Mn; .ltoreq.0.30 wt. % Cr
+ V + .ltoreq.0.25 wt. % Ni + Co; .ltoreq.0.05 wt. % Ni + Co; Ti;
.ltoreq.0.15 wt. % Cr + V + .ltoreq.0.05 wt. % Cr + V +
.ltoreq.0.50 wt. % Zn; Ti; Ti; .ltoreq.0.25 wt. % Fe; .ltoreq.0.35
wt. % Zn; .ltoreq.0.25 wt. % Zn; .ltoreq.0.25 wt. % Si;
.ltoreq.0.15 wt. % Fe; .ltoreq.0.10 wt. % Fe; .ltoreq.0.10 wt. %
other .ltoreq.0.10 wt. % Si; .ltoreq.0.05 wt. % Si; elements;
.ltoreq.0.05 wt. % other .ltoreq.0.03 wt. % other .ltoreq.0.35 wt.
% of the elements; elements; other elements; .ltoreq.0.15 wt. % of
the .ltoreq.0.10 wt. % of the other balance aluminum other
elements; elements; balance aluminum balance aluminum
TABLE-US-00002 TABLE I-B Non-Limiting examples of compositions of
new 5xxx aluminum alloys for achieving an electrical conductivity
of 40.0 to 44.9% IACS Elect. Cond. Preferred More Preferred (%
IACS) Broad Composition Composition Composition 40.0-44.9 1.85-2.70
wt. % Mg; 1.85-2.70 wt. % Mg; 1.85-2.70 wt. % Mg; 0.05-0.20 wt. %
Sc; 0.07-0.18 wt. % Sc; 0.07-0.18 wt. % Sc; and/or and and
0.05-0.20 wt. % Zr; 0.07-0.18 wt. % Zr; 0.07-0.18 wt. % Zr;
.ltoreq.0.50 wt. % Cu + Ag; 0.05-0.50 wt. % 0.10-0.45 wt. %
.ltoreq.0.07 wt. % Mn; Cu + Ag; Cu + Ag; .ltoreq.0.20 wt. % Ni +
Co; .ltoreq.0.05 wt. % Mn; .ltoreq.0.03 wt. % Mn; .ltoreq.0.10 wt.
% Cr + V + .ltoreq.0.10 wt. % Ni + Co; .ltoreq.0.05 wt. % Ni + Co;
Ti; .ltoreq.0.07 wt. % Cr + V + .ltoreq.0.05 wt. % Cr + V +
.ltoreq.0.50 wt. % Zn; Ti; Ti; .ltoreq.0.25 wt. % Fe; .ltoreq.0.35
wt. % Zn; .ltoreq.0.25 wt. % Zn; .ltoreq.0.25 wt. % Si;
.ltoreq.0.15 wt. % Fe; .ltoreq.0.10 wt. % Fe; .ltoreq.0.10 wt. %
other .ltoreq.0.10 wt. % Si; .ltoreq.0.05 wt. % Si; elements;
.ltoreq.0.05 wt. % other .ltoreq.0.03 wt. % other .ltoreq.0.35 wt.
% of the elements; elements; other elements; .ltoreq.0.15 wt. % of
the .ltoreq.0.10 wt. % of the other balance aluminum other
elements; elements; balance aluminum balance aluminum
TABLE-US-00003 TABLE I-C Non-Limiting examples of compositions of
new 5xxx aluminum alloys for achieving an electrical conductivity
of at least 45.0% IACS Elect. Cond. Preferred More Preferred (%
IACS) Broad Composition Composition Composition .gtoreq.45.0
0.50-1.85 wt. % Mg; 0.50-1.85 wt. % Mg; 0.50-1.85 wt. % Mg;
0.05-0.20 wt. % Sc; 0.07-0.18 wt. % Sc; 0.07-0.18 wt. % Sc; and/or
and and 0.05-0.20 wt. % Zr; 0.07-0.18 wt. % Zr; 0.07-0.18 wt. % Zr;
.ltoreq.0.50 wt. % Cu + Ag; 0.05-0.50 wt. % 0.10-0.45 wt. %
.ltoreq.0.05 wt. % Mn; Cu + Ag; Cu + Ag; .ltoreq.0.05 wt. % Ni +
Co; .ltoreq.0.03 wt. % Mn; .ltoreq.0.01 wt. % Mn; .ltoreq.0.07 wt.
% Cr + V + .ltoreq.0.03 wt. % Ni + Co; .ltoreq.0.01 wt. % Ni + Co;
Ti; .ltoreq.0.05 wt. % Cr + V + .ltoreq.0.03 wt. % Cr + V +
.ltoreq.0.50 wt. % Zn; Ti; Ti; .ltoreq.0.25 wt. % Fe; .ltoreq.0.35
wt. % Zn; .ltoreq.0.25 wt. % Zn; .ltoreq.0.25 wt. % Si;
.ltoreq.0.15 wt. % Fe; .ltoreq.0.10 wt. % Fe; .ltoreq.0.10 wt. %
other .ltoreq.0.10 wt. % Si; .ltoreq.0.05 wt. % Si; elements;
.ltoreq.0.10 wt. % other .ltoreq.0.05 wt. % other .ltoreq.0.35 wt.
% of the elements; elements; other elements; .ltoreq.0.35 wt. % of
the .ltoreq.0.15 wt. % of the other balance aluminum other
elements; elements; balance aluminum balance aluminum
TABLE-US-00004 TABLE I-D Non-Limiting Embodiments of property
boundaries of new 5xxx aluminum alloys (see, FIG. 15c) Elec. TYS
Embod- Conduct. (L) Intercept iment (% IACS) (MPa) Bounding line
(Int.) 1 .gtoreq.35% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int.
96 2 .gtoreq.35% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 100 3
.gtoreq.35% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 102 4
.gtoreq.35% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 104 5
.gtoreq.35% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 106 6
.gtoreq.35% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 108 7
.gtoreq.35% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 110 9
.gtoreq.35% .gtoreq.290 IACS .gtoreq. -0.195(TYS) + Int. 96 10
.gtoreq.35% .gtoreq.290 IACS .gtoreq. -0.195(TYS) + Int. 100 11
.gtoreq.35% .gtoreq.290 IACS .gtoreq. -0.195(TYS) + Int. 102 12
.gtoreq.35% .gtoreq.290 IACS .gtoreq. -0.195(TYS) + Int. 104 13
.gtoreq.35% .gtoreq.290 IACS .gtoreq. -0.195(TYS) + Int. 106 14
.gtoreq.35% .gtoreq.290 IACS .gtoreq. -0.195(TYS) + Int. 108 15
.gtoreq.35% .gtoreq.290 IACS .gtoreq. -0.195(TYS) + Int. 110 16
.gtoreq.35% .gtoreq.310 IACS .gtoreq. -0.195(TYS) + Int. 96 17
.gtoreq.35% .gtoreq.310 IACS .gtoreq. -0.195(TYS) + Int. 100 18
.gtoreq.35% .gtoreq.310 IACS .gtoreq. -0.195(TYS) + Int. 102 19
.gtoreq.35% .gtoreq.310 IACS .gtoreq. -0.195(TYS) + Int. 104 20
.gtoreq.35% .gtoreq.310 IACS .gtoreq. -0.195(TYS) + Int. 106 21
.gtoreq.35% .gtoreq.310 IACS .gtoreq. -0.195(TYS) + Int. 108 22
.gtoreq.35% .gtoreq.310 IACS .gtoreq. -0.195(TYS) + Int. 110 23
.gtoreq.35% .gtoreq.330 IACS .gtoreq. -0.195(TYS) + Int. 100 24
.gtoreq.35% .gtoreq.330 IACS .gtoreq. -0.195(TYS) + Int. 102 25
.gtoreq.35% .gtoreq.330 IACS .gtoreq. -0.195(TYS) + Int. 104 26
.gtoreq.35% .gtoreq.330 IACS .gtoreq. -0.195(TYS) + Int. 106 27
.gtoreq.35% .gtoreq.330 IACS .gtoreq. -0.195(TYS) + Int. 108 28
.gtoreq.35% .gtoreq.330 IACS .gtoreq. -0.195(TYS) + Int. 110 29
.gtoreq.35% .gtoreq.350 IACS .gtoreq. -0.195(TYS) + Int. 104 30
.gtoreq.35% .gtoreq.350 IACS .gtoreq. -0.195(TYS) + Int. 106 31
.gtoreq.35% .gtoreq.350 IACS .gtoreq. -0.195(TYS) + Int. 108 32
.gtoreq.35% .gtoreq.350 IACS .gtoreq. -0.195(TYS) + Int. 110 33
.gtoreq.37.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 96 34
.gtoreq.37.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 100 35
.gtoreq.37.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 102 36
.gtoreq.37.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 104 37
.gtoreq.37.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 106 38
.gtoreq.37.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 108 39
.gtoreq.37.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 110 40
.gtoreq.40.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 96 41
.gtoreq.40.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 100 42
.gtoreq.40.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 102 43
.gtoreq.40.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 104 44
.gtoreq.40.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 106 45
.gtoreq.40.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 108 46
.gtoreq.40.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 110 47
.gtoreq.42.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 96 48
.gtoreq.42.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 100 49
.gtoreq.42.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 102 50
.gtoreq.42.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 104 51
.gtoreq.42.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 106 52
.gtoreq.42.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 108 53
.gtoreq.42.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 110 54
.gtoreq.45.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 100 55
.gtoreq.45.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 102 56
.gtoreq.45.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 104 57
.gtoreq.45.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 106 58
.gtoreq.45.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 108 59
.gtoreq.45.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 110 60
.gtoreq.47.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 102 61
.gtoreq.47.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 104 62
.gtoreq.47.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 106 63
.gtoreq.47.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 108 64
.gtoreq.47.5% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 110 65
.gtoreq.50.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 103 66
.gtoreq.50.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 104 67
.gtoreq.50.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 106 68
.gtoreq.50.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 108 69
.gtoreq.50.0% .gtoreq.270 IACS .gtoreq. -0.195(TYS) + Int. 110
Any of the above-described examples and embodiments are within the
scope of the claimed invention, and may be utilized in any claim to
define the invention.
[0026] Generally, the new 5xxx aluminum alloys are in the form of a
wrought product. For purposes of the present patent application,
wrought products include products made from semi-continuous casting
processes, such as ingot or billet casting processes, as well as
those products made from continuous casting processes, such as belt
casting, rod casting, twin roll casting, twin belt casting (e.g.,
Hazelett casting), drag casting, and block casting, among others.
The wrought products may be, for example, a sheet, extrusion,
forging, rod or wire, and pipe or tube, among others. A sheet is a
rolled product having a thickness of 0.006 to 0.249 inch (0.1524 to
6.3246 mm). An extrusion is product formed by pushing material
through a die. A forging is metal part worked to a predetermined
shape by one or more processes such as hammering, pressing or
rolling. In one embodiment, the forging is a die forging. A die
forging is a forging formed to the required shape and size by
working impression dies. A rod is a solid product that is long in
relation to cross section, and which is 0.375 inch (9.525 mm) or
greater in diameter. A wire is a solid wrought product that is long
in relation to its cross section, which is square or rectangular
with sharp or rounded corners or edges, or is round, a regular
hexagon or regular octagon, and whose diameter or greatest
perpendicular distance between parallel faces (except for flattened
wire) is less than 0.375 inch (9.525 mm). A tube is a hollow
wrought product that is long in relation to its cross section,
which is round, a regular hexagon, a regular octagon, elliptical,
or square or rectangular, with sharp or rounded corners, and that
has a uniform wall thickness except as affected by corner radii. A
pipe is a tube in standardized combinations of outside diameter and
wall thickness, commonly designated by "Nominal Pipe Sizes" and
"ANSI Schedule Numbers." In one embodiment, the new 5xxx aluminum
alloy product is in the form of sheet. In another embodiment, the
new 5xxx aluminum alloy product is in the form of an extrusion. In
another embodiment, the new 5xxx aluminum alloy product is in the
form of a forging. In another embodiment, the new 5xxx aluminum
alloy product is in the form of a die forging. In another
embodiment, the new 5xxx aluminum alloy product is in the form of a
wire. In another embodiment, the new 5xxx aluminum alloy product is
in the form of a rod. In another embodiment, the new 5xxx aluminum
alloy product is in the form of a tube. In yet another embodiment,
the new 5xxx aluminum alloy product is in the form of a pipe.
[0027] To produce a new 5xxx aluminum alloy wrought product using a
semi-continuous casting process, the new 5xxx aluminum alloy may be
cast in the form of an ingot or billet, after which the ingot or
billet is homogenized and hot worked to an intermediate gauge
product. The intermediate gauge product may then be optionally
thermally treated (e.g., annealed) and then cold worked to final
gauge or form. After cold working, the product may be annealed for
a time and temperature sufficient to stabilize properties (e.g., 6
hours at 250.degree. F., or similar type of anneal). Similar steps
may be employed with a continuous casting process, although hot
working may not be required. In one embodiment, the new 5xxx
aluminum alloy products are cold worked at least 10%. In other
embodiments, the new 5xxx aluminum alloy products are cold worked
at least worked at least 25%, or at least 50%, or at least 60%, or
at least 70%, or at least 80%, or at least 90%, or more. In this
regard, the new 5xxx aluminum alloy products may be processed to an
H temper, such as any of an H1, H2 or H3 temper.
[0028] An H1 temper means that the alloy is strain hardened. An H2
temper means that the alloy is strain-hardened and partially
annealed. An H3 temper means that the alloy is strain hardened and
stabilized (e.g., via low temperature heating). In some
embodiments, the new 5xxx aluminum alloy products may achieve an
improved combination of properties in one or more of an H1X, H2X or
an H3X temper, where X is a whole number from 1-9. This second
digit following the designations H1, H2, H3 indicate the final
degree of strain hardening. The number 8 is assigned to tempers
having a final degree of strain-hardening equivalent to that
resulting from approximately 75% reduction in area. Tempers between
that of the 0 Temper (annealed) and 8 (full hard) are designated by
the numbers 1 through 7. A number 4 designation is considered
half-hard; number 2 is considered quarter-hard; and the number 6 is
three-quarter hard. When the number is odd, the limits of ultimate
strength are about halfway between those of the even numbered
tempers. An H9 temper has a minimum ultimate tensile strength that
exceeds the ultimate tensile strength of the H8 temper by at least
2 ksi.
[0029] Given the strength, electrical conductivity, corrosion
resistance and/or strength retention properties of the new 5xxx
aluminum alloy products, such products are well-suited as
electrical conductors. An electrical conductor is a material whose
primary application is to conduct electricity and that has an
electrical conductivity of at least 35% IACS, such as any of the
IACS values described above. Examples of electrical conductors
include electrical connectors and electrical conveyors, among
others. For the present patent application, the term "electrical
conductors" does not include memory disk stock and the like, whose
primary application is as a substrate for memory storage.
[0030] A high strength electrical conductor is an electrical
conductor having a tensile yield strength of at least 270 MPa, such
as any of the strength values described above.
[0031] A corrosion-resistant electrical conductor is an electrical
conductor that realizes a mass loss of not greater than 15
mg/cm.sup.2 when tested in accordance with ASTM G67, such as any of
the mass loss values described above.
[0032] A high strength retention electrical conductor is an
electrical conductor that retains at least 70% of its longitudinal
tensile yield strength after prolonged exposure to elevated
temperature, relative to the longitudinal tensile yield strength of
a non-thermally exposed version of the same 5xxx aluminum alloy
product, as described above, and such as any of the strength
retention values described above. In these embodiments, the
mechanical properties may be measured at about room temperature
(e.g., about 25.degree. C.), such as after the thermal exposure has
been completed.
[0033] An electrical connector is a device configured to reliably
connect one thing to and another thing such that the two things are
in sound electrical communication upon and during application of an
electrical current. Non-limiting examples of electrical connectors
include terminal blocks, pins, crimp-on connectors, plug and socket
connectors, blade connectors, and ring and spade terminals, to name
a few. In one embodiment, a first electrical connector is a male
connector and a second electrical connector is a female connector,
adapted to receive the male connector. In some of these embodiment,
the male and female electrical connectors may be in a keyed
arrangement, where the male connector may connect with the female
connector only when the male connector is in a predetermined
configuration and/or orientation relative to the female connector.
In one embodiment, the male and female connectors may be reliably
and/or repeatably connected to and disconnected from one another
(i.e., mated and unmated), and over many connect and disconnect
cycles. Examples of some useful electrical connectors using the
aluminum alloy of the present application include automotive
electrical connectors.
[0034] An automotive electrical connector is an electrical
connector that is used in an automotive vehicle. One non-limiting
example of an automotive electrical connector is an electrical
distribution system. The automotive electrical connectors may
include the aluminum alloys described herein, and those aluminum
alloys may be corrosion resistant and/or have high strength
retention, to name a few. Automotive electrical conductors may also
and/or alternatively be in the form of an electrical conveyor,
described below.
[0035] For purpose of the present application, an automotive
vehicle means a vehicle designed to transport one or more
passengers via locomotion using one or more motors and/or one or
more engines. Non-limiting examples of automotive vehicles include
hydrocarbon powered vehicles (e.g., gasoline, diesel, alcohol
(e.g., ethanol), and mixtures thereof (e.g., E85), to name a few),
electrically powered vehicles, and hybrid powered
(hydrocarbon+electric) vehicles, among others. For example, buses,
trains, cars, trucks, motorcycles, off-road vehicles, and
airplanes, among others, are all automotive vehicles. Automotive
vehicles may travel via rail, road, water, snow, earth, air and/or
otherwise.
[0036] An electrical conveyor is a device whose primary application
is to convey electricity from one point to another point. Examples
of electrical conveyers include wires, cables and bus bars, among
others. An electrical wire is an elongated piece, resembling a
string, and which is designed to carry electrical current from a
first location to a second location. A cable is a device including
a plurality of electrical wires, generally in a twisted
configuration. A bus bar is a device, usually in the form of a bar,
which is designed to carry electrical current from a first location
to a second location. A bus bar may be comprised of a plurality of
long and/or thin sheets.
[0037] The electrical conductors may be in a plated or unplated
form. When in plated form, the electrical conductors may include
the new 5xxx aluminum alloy products with a plated portion included
on one or more surfaces of the new 5xxx aluminum alloy products.
The plated portion may include another metal, such as tin, zinc or
copper, to name a few. The plated portion may be coupled to the new
5xxx aluminum alloy products via any suitable technique, such via
electroplating and/or other known deposition techniques.
[0038] These and other aspects, advantages, and novel features of
this new technology are set forth in part in the description that
follows, and will become apparent to those skilled in the art upon
examination of the description and figures, or may be learned by
practicing one or more embodiments of the technology provided for
by the patent application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a graph illustrating electrical conductivity
versus Mg content for the Example 1 alloys.
[0040] FIG. 2 is a graph illustrating Mn content versus electrical
conductivity for some Example 1 alloys.
[0041] FIG. 3 is a graph illustrating tensile strength versus Mg
content for Example 1 alloys annealed at 250.degree. F. for 6
hours.
[0042] FIG. 4 is a graph illustrating tensile strength versus Mg
content for Example 1 alloys annealed at 400.degree. F. for 6
hours.
[0043] FIG. 5 is a graph illustrating tensile strength versus Mg
content for Example 1 alloys annealed at 450.degree. F. for 6
hours.
[0044] FIG. 6 is a graph illustrating electrical conductivity
versus Mg content for the Example 2 alloys.
[0045] FIG. 7 is a graph illustrating tensile strength versus Mg
content for Example 2 alloys annealed at 250.degree. F. for 6 hours
for alloys without copper.
[0046] FIG. 8 is a graph illustrating tensile strength versus Mg
content for Example 2 alloys annealed at 450.degree. F. for 6 hours
for alloys without copper.
[0047] FIG. 9 is a graph illustrating tensile strength versus Mg
content for Example 2 alloys annealed at 250.degree. F. for 6 hours
for some alloys without copper and some alloys with copper.
[0048] FIG. 10 is a graph illustrating tensile strength versus Mg
content for Example 2 alloys annealed at 450.degree. F. for 6 hours
for some alloys without copper and some alloys with copper.
[0049] FIG. 11 is a graph illustrating tensile strength versus Cu
content for Example 2 alloys annealed at 320.degree. F. for 6
hours.
[0050] FIG. 12 is a graph illustrating mass loss versus Mg content
for Example 2 alloys annealed at 250.degree. F. for 6 hours for
alloys without copper.
[0051] FIG. 13 is a graph illustrating electrical conductivity
versus Mg content for the Example 3 alloys.
[0052] FIG. 14 is a graph illustrating yield strength versus Mg
content for Example 3 alloys annealed at 250.degree. F. for 6
hours.
[0053] FIG. 15a is a graph illustrating electrical conductivity
versus yield strength for various Example 3 alloys.
[0054] FIG. 15b is a graph illustrating electrical conductivity
versus yield strength for various Example 3 alloys.
[0055] FIG. 15c is a graph illustrating electrical conductivity
versus yield strength for various Example 3 alloys, with
embodiments of performance trend lines illustrated for various
alloys.
[0056] FIG. 16 is a graph illustrating mass loss versus Mg content
for Example 3 alloys annealed at 250.degree. F. for 6 hours.
[0057] FIG. 17a is a graph illustrating thermal treatment
temperature versus yield strength for various Example 2 and Example
3 alloys.
[0058] FIG. 17b is a graph illustrating electrical conductivity
versus yield strength for various Example 2 and Example 3
alloys.
[0059] FIG. 18a is a graph illustrating yield strength versus cold
work amount for various Example 5 alloys.
[0060] FIG. 18b is a graph illustrating electrical conductivity
versus cold work amount for various Example 5 alloys.
[0061] FIG. 19a is a graph illustrating thermal treatment
temperature versus yield strength for various Example 5 alloys.
[0062] FIG. 19b is a graph illustrating thermal treatment
temperature versus yield strength for various Example 5 alloys.
[0063] FIG. 20a is a graph illustrating electrical conductivity
versus yield strength for various Example 6 alloys.
[0064] FIG. 20b is a graph illustrating electrical conductivity
versus yield strength for various Example 6 alloys.
[0065] FIG. 20c is a graph illustrating mass loss versus yield
strength for various Example 6 alloys.
[0066] FIG. 20d is a graph illustrating electrical conductivity
versus yield strength for various Example 6 alloys.
DETAILED DESCRIPTION
Example 1
[0067] Various 5xxx aluminum alloys are cast as book molds. The
experimental alloys have the composition provided in Table 1,
below.
TABLE-US-00005 TABLE 1 Example 1 Alloy Compositions (all values in
weight percent) Alloy Mg Mn Sc Zr 1 4.05 0.53 0.19 0.072 2 4.04
0.27 0.23 0.065 3 4.09 0.29 0.17 0.078 4 3.00 0.28 0.27 0.068 5
2.98 0.26 0.17 0.083 6 1.97 0.2 0.19 0.064 7 4.04 -- 0.16 0.066 8
2.96 -- 0.19 0.064 9 1.96 -- 0.21 0.064 10 1.88 -- 0.21 0.08 11
5.06 -- 0.18 0.06 12 5.02 -- 0.13 0.074 13 4.09 -- 0.15 0.072 14
4.02 -- 0.078 0.078
Unless otherwise indicated, other than the above-listed
ingredients, all of the experimental alloys 1-14 contained about
0.01-0.02 wt. % Ti, not greater than 0.01 wt. % Cu, not greater
than 0.04 wt. % Si as an impurity, not greater than 0.10 wt. % Fe
as an impurity, not greater than 0.02 wt. % Zn as an impurity, not
greater than 0.05 wt. % each of any other elements, and with the
other elements not exceeding 0.15 wt. % in total, the balance being
aluminum. Alloy 13 contained 0.94 wt. % Zn. Alloy 1 is similar to
Alloy B of U.S. Pat. No. 5,624,632, to Baumann et al.
[0068] After casting, all of the samples are homogenized
(preheated) using the following practice:
[0069] Linear ramp to 260.degree. C. (500.degree. F.) in 4 hrs
[0070] Soak at 260.degree. C. (500.degree. F.)+/-2.degree. C.
(5.degree. F.) for 5 hrs
[0071] Linear ramp to 290.degree. C. (550.degree. F.) in 2 hrs
[0072] Soak at 290.degree. C. (550.degree. F.)+/-2.degree. C.
(5.degree. F.) for 5 hrs
[0073] Linear ramp to 455.degree. C. (850.degree. F.) in 5 hrs
[0074] Soak at 455.degree. C. (850.degree. F.)+/-2.degree. C.
(5.degree. F.) for 4 hrs
[0075] Air cool
[0076] After homogenization, the book molds are processed to an H3y
type temper (e.g., an H38 temper). Specifically, the book molds are
scalped to remove about 3 mm (about 0.125'') from both rolling
faces; the sides of the book molds are also surface machined. Prior
to hot rolling, all the book molds are given a heat-to-roll
practice of from about 425 to about 455.degree. C. (about 800 to
850.degree. F.) for from about 30 to about 60 minutes, after which
they are hot rolled. The book molds are hot rolled using a six pass
schedule to a final gauge of about 7.1 mm (about 0.28 inch). A
final hot roll exit temperature of about 260.degree. C. (about
500.degree. F.) is targeted. The pieces are air cooled, and then
machined on the edges to minimize edge cracking. The material is
then cold rolled about 80 to 85% to a nominal thickness of about 1
to 1.1 mm.
[0077] Each of the experimental alloys is divided into various
pieces. Some of the pieces are subjected to a thermal treatment in
the form of an anneal. Other pieces are not annealed. Table 2
correlates the thermal treatments (or lack thereof) to the various
alloys pieces.
TABLE-US-00006 TABLE 2 Anneal Treatments for Example 1 Alloys
Piece(s) Piece(s) Piece(s) Piece(s) receiving Piece(s) receiving
receiving receiving anneal at receiving anneal at anneal at anneal
at 475.degree. F. no 450.degree. F. 400.degree. F. for 6
250.degree. F. for 6 for 6 Alloy anneal for 6 hours hours hours
hours 1 1a 1b 1c -- -- 2 2a 2b 2c -- -- 3 3a 3b 3c -- -- 4 4a 4b --
4c -- 5 5a 5b -- 5c -- 6 6a 6b 6d 6c -- 7 7a 7b 7c -- -- 8 8a 8b --
8c -- 9 9a 9b 9d 9c -- 10 10a -- -- 10b -- 11 11a 11b -- -- 11c 12
12a 12b -- -- 12c 13 13a 13b 13c -- -- 14 14a 14b 14c -- --
[0078] Each of the pieces is further split, and some of those
splits are treated (sensitized), while others are not. The specific
practice key is provided below, for correlating the mechanical
properties of Table 3, below, to the sensitization category.
[0079] A=No thermal treatment (F temper)
[0080] B=1 week at 100.degree. C. (212.degree. F.)--Typical
sensitization practice
[0081] C=1000 hrs at 85.degree. C. (185.degree. F.)--Alternative 1
sensitization practice
[0082] D=100 hrs at 125.degree. C. (258.degree. F.)--Alternative 2
sensitization practice
[0083] Material properties, including strength, ductility and
corrosion resistance are measured for each piece, the results of
which are provided in Table 3, below. Tensile properties are
measured in the longitudinal direction in accordance with ASTM E8
and B557 using a sub-size specimen (about 100 mm). Duplicate
tensile specimens are used for each condition. Corrosion properties
are measured using the NAMLT (Nitric Acid Mass Loss Test) or "mass
loss" test (ASTM G67-04) to assess intergranular corrosion
resistance. Duplicate mass loss tests are run for each condition
and the results are averaged. The material is tested in both the
as-received (thermal treatment A) and thermally treated conditions
(B, C and D). Thermal treatment can affect corrosion performance by
accelerating the precipitation of the .beta. phase
(Mg.sub.5Al.sub.8), which can give an indication of potential
long-term service behavior.
TABLE-US-00007 TABLE 3 Mechanical and Corrosion Properties of
Example 1 Alloys Elect. TYS Sensitization Cond. (L) UTS (L) NAMLT
Piece Category (% IACS) (MPa) (MPa) El. % (mg/cm.sup.2) 1a A 27.0
425.5 444.8 4.0 1.17 B 27.9 370.3 429.8 8.0 22.13 C 28.2 373.0
433.5 8.0 31.51 D 28.1 356.8 420.5 8.5 25.12 1b A 27.7 326.8 396.0
9.0 1.18 B 28.2 323.8 396.8 11.0 7.32 C 28.2 328.5 404.8 10.0 18.26
D 28.2 327.5 398.5 9.5 17.11 1c A 27.8 337.5 399.5 9.0 6.04 B 28.2
338.5 407.0 8.5 16.21 C 28.1 344.3 412.3 8.5 19.44 D 28.4 339.3
409.3 9.0 21.88 2a A 29.0 415.8 439.8 3.5 1.26 B 30.1 357.8 416.0
9.0 20.82 C 30.3 365.8 424.8 7.5 29.14 D 30.4 346.3 412.3 8.5 23.80
2b A 29.7 319.3 387.0 10.0 1.27 B 30.3 317.3 387.8 10.0 7.10 C 30.0
321.0 390.0 9.0 17.12 D 30.3 315.0 388.0 10.5 15.23 2c A 30.1 322.5
388.0 9.5 4.46 B 30.4 322.3 389.5 9.5 10.49 C 30.1 333.8 403.5 9.5
18.78 D 30.5 329.3 398.8 10.0 21.31 3a A 28.2 419.3 436.3 3.0 1.04
B 29.1 362.0 413.5 6.0 18.01 C 29.2 354.8 411.5 8.5 27.84 D 29.3
350.0 409.0 6.0 22.64 3b A 28.7 317.3 384.8 6.0 1.03 B 29.2 320.5
391.0 10.0 3.60 C 29.4 313.8 382.0 10.0 13.46 D 29.3 313.0 385.8
10.0 11.36 3c A 29.0 326.5 389.3 8.0 3.34 B 29.0 322.0 390.8 8.0
10.99 C 29.4 324.8 391.0 8.5 17.62 D 29.5 322.8 392.8 8.0 16.77 4a
A 31.8 368.5 382.8 3.0 1.18 B 32.4 331.0 375.8 8.5 4.43 C 32.5
341.5 386.0 7.0 8.83 D 32.5 324.0 366.5 8.0 4.67 4b A 32.4 294.0
347.8 10.0 1.16 B 32.7 290.0 342.3 8.0 1.47 C 32.5 304.3 359.3 9.5
2.05 D 32.9 294.5 350.3 9.0 1.56 4c A 32.4 337.0 376.0 9.0 1.40 B
32.7 333.5 375.5 9.0 3.22 C 32.5 345.0 388.3 8.0 5.68 D 32.6 333.8
377.0 8.0 5.25 5a A 31.5 383.5 393.8 5 1.22 B 32.1 339.5 377.3 6
3.78 C 32.4 335.8 366.8 5.5 7.88 D 32.2 328 371.5 6 3.60 5b A 32.2
298.5 350.3 7 1.41 B 32.3 299.3 351 8 1.60 C 32.6 294.5 345 7 2.28
D 32.4 300.8 354.8 8 1.80 5c A 32.1 340.3 377.3 6 1.45 B 32.1 336.8
376 6 3.37 C 32.2 337.5 378 7.5 5.86 D 32.4 329.8 372 6 5.16 6a A
36 329.5 337.5 5 1.11 B 37.1 301.25 330.75 7 1.09 C 36.7 306.5
335.8 6 1.25 D 36.9 296.5 326.75 8 1.14 6b A 36.8 268.25 309.5 8
1.04 B 37.4 268.5 312.75 9 1.05 C 37.1 268.3 309.5 7.5 1.09 D 37.1
267.25 308.25 8 1.04 6c A 36.3 303.5 328.25 5.5 1.14 D 36.7 296.5
325.75 7 1.09 6d A 37.1 273.25 312.75 7 1.09 B 37.3 278.25 317.75
8.5 1.07 C 37 275.3 316 7.5 1.03 D 36.9 277 314.25 8 1.09 7a A 33.2
380.25 398.75 4.5 1.18 B 34.9 322.75 374 7.5 20.38 C 35.1 334 393.5
8 26.29 D 35.1 312.75 375 8 20.78 7b A 34.2 272.25 353.25 11 1.14 B
34.2 275 351.5 11.5 9.25 C 34.2 282 355.5 10.5 15.31 D 34.6 270.75
343 10.5 12.56 7c A 34 279 344.5 10.5 1.37 B 34.5 295.5 364.75 10
6.46 C 34.4 293 366.8 11 12.10 D 34.6 291.75 365.5 10.5 10.55 8a A
37 352.25 367.5 3.5 1.07 B 38.4 306.25 349 7.5 6.49 C 38.4 307.5
353.8 7 11.36 D 38.6 293.5 343 7 5.37 8b A 38.5 261 323.75 10 1.04
B 38.7 262.75 324.75 10 1.59 C 38.3 267.5 327.8 8.5 3.28 D 38.3
264.75 326.25 10 2.02 8c A 37.9 310 348.75 7.5 1.62 B 38.2 305.25
349.25 8 6.20 C 38.2 306.5 353.8 7.5 9.18 D 38.2 300.25 345.75 9.5
6.58 9a A 42.4 315.25 323 5 1.00 B 43 280.25 313.5 7.5 1.07 C 43
286 316 7 1.38 D 43.3 275.75 308.25 7 0.98 9b A 43.2 247 291 8 0.98
B 43.6 248.5 292.5 8 0.96 C 43.5 250.5 298 7.5 0.99 D 43.5 248.5
295 9 0.95 9c A 43 283 312.25 7 1.01 D 43.3 276.5 304.75 6 1.07 9d
A 43.5 256.5 295.5 9 1.00 B 43.5 260.25 299.5 7 0.99 C 43.2 260
300.5 8.5 1.03 D 43.4 257.5 297.25 7.5 0.99 10a A 42.1 322 329.5 4
1.04 B 42.3 293.3 321.3 6 1.06 10b A 42.3 292 319 6 1.03 B 42.3
289.5 318.9 6 1.07 C 42.7 290.5 319.3 7 1.12 D 42.9 282.3 313 6
1.09 11a A 30.2 429.25 456.5 5 1.48 B 31.7 344.25 421 8.5 31.86 C
32.1 353.5 432.8 8 39.09 D 32.7 330.25 414.75 8 35.09 11b A 31.6
291.75 381.5 11 2.21 B 32 292 382.5 12 5.89 C 32.2 294 387.3 11
10.76 D 32.5 290.25 377.5 11 10.11 11c A 31.2 288.5 373 11.5 1.47 B
31.8 282.5 376.25 11.5 9.69 C 31.8 296.5 389.5 11.5 14.86 D 32.1
289.75 386.25 11 15.70 12a A 30.2 430.75 463 4 1.72 B 32.7 390.25
458.5 7 42.13 C 33.2 399 459 6 49.58 D 34.1 365.75 442.75 7 44.51
12b A 32.7 290.25 369.5 8.5 3.30 B 33.6 288.5 383 10.5 4.07 C 33.6
288.8 362 6 5.80 D 34.4 291 379 10.5 6.36 12c A 32.7 285 373.25 11
3.26 B 33.4 284.75 371.25 10.5 4.61 C 33.6 289 378.8 10.5 6.93 D
34.1 282.75 372 10 6.83 13a A 33 395.75 414.5 5 1.14 B 34.2 331.25
386.75 7 21.21 C 34.3 333.3 394 8 26.75 D 34.3 318 380.5 8.5 22.19
13b A 34.3 279.25 350.5 10.5 1.10 B 34.5 265.25 340.25 9.5 9.91 C
34.3 283.8 357.8 11 14.84 D 34.9 279.25 350.5 10.5 12.61 13c A 34.6
280.25 348.5 11.5 1.67 B 34.7 292 357 8.5 6.35 C 34.7 294.5 363 8.5
11.23 D 35 291 355.25 7.5 9.50 14a A 33 383.5 399.25 4 1.22 B 34.5
310.25 363.75 6 14.77 C 34.6 321.5 380 7 24.68 D 35.1 300.25 361.5
7.5 21.16 14b A 34 253.75 327.25 11 1.13 B 34.4 243 317.5 12 7.59 C
34.4 262 335.8 11.5 12.73 D 34.6 247.25 320.5 10.5 10.28 14c A 34.4
262.25 327.75 11 1.69 B 34.7 275.25 345.5 10 4.59 C 34.5 276.3
349.3 10 8.26 D 34.7 274 344.5 10 7.90
[0084] As shown in Table 3 and FIG. 1, irrespective of anneal or
sensitization category, electrical conductivity generally changes
linearly as a function of magnesium content. Alloys having more
than 4 wt. % Mg realize poor electrical conductivity (e.g.,
<35.0% IACS). The alloys having less than about 3% Mg generally
realize good electrical conductivity, especially when Mn is absent,
as shown in FIG. 2. However, alloys containing low Mg and no Mn
have low strength as illustrated in FIGS. 3-5. However, alloys
having Sc and Zr tend to have increased strength. For example,
alloys 8-10 have low Mg and no Mn, but with Sc and Zr realize
strengths near or above 300 MPa when annealed at 250.degree. F. for
6 hours.
Example 2
Affect of Sc and Zr
[0085] Based on the Example 1 data, additional book mold testing is
conducted on low Mg, no Mn 5xxx aluminum alloys. Nineteen
additional experimental book molds are produced using generally the
same practice described in Example 1. Two additional alloys (B-1
and B-2) having a composition similar to Alloy B of U.S. Pat. No.
5,624,623 to Baumann et al. are also produced in book mold form.
The experimental materials and the Baumann materials are cold
rolled about 80 to 85% to a nominal thickness of about 1 to 1.1 mm.
Aluminum Association alloys 5454, 5086, 5052 are produced in book
mold form, and processed to a final gauge of about 1 to 1.1 mm with
80 to 85% cold work using conventional 5xxx production
practices.
[0086] The Example 2 alloy compositions are provided in Table 4,
below. The thermal treatment chart is provided as Table 5, below.
The mechanical and corrosion data are provided in Table 6, below.
Only some of the alloys are tested for corrosion resistance.
TABLE-US-00008 TABLE 4 Example 2 Alloy Compositions (all values in
weight percent) Alloy Mg Mn Sc Zr Cu 15 0.93 -- -- -- -- 16 1.00 --
0.066 0.092 -- 17 0.95 -- 0.14 0.13 -- 18 3.57 -- -- -- -- 19 3.49
-- 0.065 0.091 -- 20 3.64 -- 0.14 0.14 -- 21 3.98 -- 0.063 0.092 --
22 0.48 -- 0.14 0.16 -- 23 1.97 -- -- -- -- 24 1.87 -- -- 0.078 --
25 1.99 -- 0.066 -- -- 26 1.96 -- 0.064 0.074 -- 27 1.92 -- -- 0.14
-- 28 1.91 -- 0.14 -- -- 29 1.96 -- 0.13 0.14 -- 30 1.89 -- -- --
0.15 31 3.58 -- 0.062 0.075 0.16 32 3.44 -- 0.064 0.068 0.24 33
3.53 -- 0.066 0.075 0.50 AA5454 2.80 0.63 -- -- 0.07 AA5086 3.95
0.44 -- -- 0.07 AA5052 2.31 -- -- -- 0.06 B-1 4.04 0.53 0.17 0.079
B-2 3.89 0.53 0.12 0.063
Unless otherwise indicated below, other than the above-listed
ingredients, all of the experimental alloys 15-33 and alloys
AA5454, AA5086, AA5052, B-1 and B-2 contained about 0.01-0.02 wt. %
Ti, not greater than 0.01 wt. % Cu, not greater than 0.06 wt. % Si
as an impurity, not greater than 0.10 wt. % Fe as an impurity, not
greater than 0.02 wt. % Zn as an impurity, not greater than 0.05
wt. % each of other elements, and with the other elements not
exceeding 0.15 wt. % in total, the balance being aluminum. The
prior art Aluminum Association alloys 5454, 5086, and 5052 contain
not more than 0.13 wt. % Si and not more than 0.25 wt. % Fe. Alloy
5454 also contains 0.089 wt. % Cr and 0.11 wt. % Zn. Alloy 5086
contains 0.083 wt. % Cr. Alloy 5052 contains 0.2 wt. % Cr.
TABLE-US-00009 TABLE 5 Anneal Treatments for Example 2 Alloys
Piece(s) Piece(s) Piece(s) Piece(s) receiving receiving receiving
receiving Piece(s) anneal at anneal at anneal at anneal at
receiving 450.degree. F. 400.degree. F. 250.degree. F. 320.degree.
F. no for 6 for 6 for 6 for 6 Alloy anneal hours hours hours hours
15 15a 15b -- 15c -- 16 16a 16b -- 16c -- 17 17a 17b -- 17c -- 18
18a 18b 18c -- -- 19 19a 19b 19c 19d 19e 20 20a 20b 20c -- -- 21
21a 21b 21c -- -- 22 22a 22b -- 22c -- 23 23a 23b -- 23c -- 24 24a
24b -- 24c -- 25 25a 25b -- 25c -- 26 26a 26b -- 26c -- 27 27a 27b
-- 27c -- 28 28a 28b -- 28c -- 29 29a 29b -- 29c -- 30 30a 30b --
30c -- 31 31a 31b 31c 31d 31e 32 32a 32b 32c 32d 32e 33 33a 33b 33c
33d 33e AA5454 5454a 5454b -- 5454c -- AA5086 5086a 5086b 5086c --
-- AA5052 5052a 5052b -- 5052c -- B-1 B-1-a B-1-b B-1-c -- -- B-2
B-2-a B-2-b B-2-c -- --
TABLE-US-00010 TABLE 6 Mechanical and Corrosion Properties of
Example 2 Alloys Elect. TYS UTS Sensitization Cond. (L) (L) NAMLT
Piece Category (% IACS) (MPa) (MPa) El. % (mg/cm.sup.2) 15a A 52.6
221.5 226.0 4.0 15b A 53.2 145.5 174.8 11.0 15c A 53.2 204.5 219.3
7.0 16a A 51.7 247.5 252.0 4.0 16b A 51.8 197.5 224.5 10.0 16c A
51.3 233.5 247.8 7.0 17a A 50.4 269.3 274.5 6.0 17b A 50.8 229.8
255.8 7.0 17c A 51.2 255.8 271.8 7.0 18a A 37.6 351.8 363.8 5.0 18b
A 38.5 174.5 264.3 20.0 18c A 38.6 205.8 274.8 15.0 19a A 36.4
372.0 384.3 4.0 19b A 36.8 250.0 313.0 11.5 19c A 37.5 258.3 316.7
11.0 19c A 36.5 258.0 316.3 11.0 1.11 19c B 37.2 264.0 324.8 11.0
6.06 19c D 36.7 262.0 321.3 11.0 8.65 19d A 36.2 321.3 362.0 7.5
5.05 19d B 37.1 314.5 360.3 8.0 17.47 19d D 37.2 301.8 353.0 9.5
18.98 19e A 36.1 297.5 343.3 9.0 5.73 19e B 37.3 295.3 346.3 7.5
12.13 19e D 36.9 291.5 343.5 8.5 15.27 20a A 35.3 393.3 409.5 4.0
20b A 36.2 286.0 348.3 12.0 20c A 36.3 297.5 351.5 10.0 21a A 34.2
391.5 400.8 4.0 21b A 35.0 255.8 326.0 13.0 21c A 35.3 267.8 332.5
11.0 22a A 54.7 245.5 252.0 5.0 22b A 55.1 213.0 237.5 9.0 22c A
54.3 241.3 255.3 9.0 23a A 45.4 277.0 283.5 4.5 23b A 46.0 158.0
208.5 14.0 23c A 46.1 239.5 262.0 7.0 23c A 44.5 239.5 262.0 7.0
0.98 23c B 45.6 235.8 263.3 7.0 1.05 23c D 46.1 228.8 258.5 8.5
1.04 24a A 43.8 279.5 284.8 5.0 24b A 44.5 164.8 214.5 16.0 24c A
44.8 242.8 263.8 7.0 25a A 44.6 281.3 287.8 5.0 25b A 45.1 166.8
219.3 15.0 25c A 45.2 242.5 265.0 7.0 26a A 43.5 300.8 305.8 5.0
26b A 44.6 214.0 253.3 10.0 26c A 44.3 263.3 284.0 7.0 26c A 43.7
263.3 284.0 7.0 1.02 26c B 44.0 268.0 293.3 7.0 1.02 26c D 44.5
277.3 281.8 7.0 1.04 27a A 42.7 280.5 285.5 4.0 27b A 43.3 171.3
219.3 17.0 27c A 43.3 246.0 267.3 7.0 28a A 44.6 290.0 298.3 5.0
28b A 45.0 182.8 232.5 13.0 28c A 45.1 251.3 276.5 7.0 29a A 43.8
322.5 328.3 6.0 29b A 44.3 260.8 293.8 9.0 29c A 44.2 289.3 312.8
7.0 29c A 43.4 289.3 312.8 7.0 1.01 29c B 43.9 295.0 320.0 7.0 1.00
29c D 44.1 289.5 316.3 7.5 1.02 30a A 44.5 295.8 298.8 4.0 30b A
45.6 181.3 227.0 10.0 30c A 45.0 269.8 292.3 7.0 30c A 43.6 269.8
292.3 7.0 0.89 30c B 44.7 278.3 307.0 7.0 0.91 30c D 44.5 281.8
315.5 8.5 0.93 31a A 35.9 390.5 401.8 4.0 31b A 37.0 259.5 326.5
12.0 31c A 37.0 274.8 330.3 10.0 31c A 36.3 274.8 330.3 10.0 1.17
31c B 37.3 282.3 338.5 11.0 6.13 31c D 36.5 281.0 338.8 10.5 9.52
31d A 35.7 352.3 391.3 7.0 3.14 31d B 36.3 350.3 396.8 8.5 14.67
31d D 36.3 344.0 392.5 8.5 18.38 31e A 35.6 340.0 384.0 8.5 5.20
31e B 36.4 340.8 387.3 8.5 12.27 31e D 36.4 338.8 385.0 9.0 15.74
32a A 35.9 402.0 414.8 4.0 32b A 37.2 263.0 327.3 11.5 32c A 37.3
284.3 338.8 10.5 32c A 36.3 284.3 338.8 10.5 1.18 32c B 37.4 291.0
345.8 10.0 8.37 32c D 36.9 288.0 346.5 10.5 10.42 32d A 35.5 362.5
399.5 8.0 3.44 32d B 36.2 363.5 407.0 8.5 13.73 32d D 36.3 359.3
405.3 8.5 18.76 32e A 35.9 349.8 395.5 7.0 5.12 32e B 36.5 348.8
394.0 9.0 12.68 32e D 36.5 348.0 394.5 9.0 16.02 33a A 35.6 419.5
430.8 4.5 33b A 37.0 278.0 336.8 12.0 33c A 37.2 298.5 349.5 10.0
33c A 36.4 298.5 349.5 10.0 1.62 33c B 37.3 301.0 353.8 9.0 8.06
33c D 36.8 302.0 357.3 9.5 8.81 33d A 36.3 376.0 414.8 7.0 3.30 33d
B 36.9 379.3 423.0 8.5 12.27 33d D 36.3 370.8 417.3 9.0 16.40 33e A
36.3 356.8 400.0 9.0 4.31 33e B 37.2 355.0 401.3 8.0 12.03 33e D
36.6 351.0 396.8 9.0 13.87 5052a A 35.5 320.5 324.5 4.0 5052b A
36.0 220.0 259.0 10.0 5052c A 36.0 283.0 307.5 7.0 5086a A 28.9
426.8 438.0 5.0 5086b A 30.1 271.8 337.5 13.0 5086c A 30.0 302.5
358.8 10.0 5454a A 32.1 373.5 379.5 4.0 5454b A 33.1 237.3 271.8
13.0 5454c A 32.7 328.5 361.0 7.0 B-1-a A 28.5 439.3 454.8 5.0 1.26
B-1-a B 29.8 374.5 429.8 8.0 27.86 B-1-a C 29.4 370.3 429.5 8.5
34.36 B-1-a D 30.5 355.5 416.5 8.0 29.68 B-1-b A 29.4 324.3 388.3
10.0 1.22 B-1-b B 29.8 324.8 391.5 10.5 14.85 B-1-b C 29.5 327.3
391.8 8.5 31.91 B-1-b D 30.2 324.5 389.3 10.5 23.74 B-1-c A 29.5
338.3 394.8 8.0 3.35 B-1-c B 29.8 334.8 405.0 9.5 16.58 B-1-c C
29.9 339.5 404.0 9.0 25.79 B-1-c D 30.5 334.0 402.5 9.0 25.11 B-2-a
A 28.8 436.0 450.3 5.0 1.20 B-2-a B 30.0 369.8 421.3 7.0 27.39
B-2-a C 30.1 369.5 427.3 8.0 37.12 B-2-a D 30.5 354.0 409.0 5.0
31.90 B-2-b A 29.9 320.5 384.8 10.5 1.15 B-2-b B 30.1 321.8 385.8
10.0 14.20 B-2-b C 30.1 322.0 385.3 9.0 30.83 B-2-b D 30.5 319.0
384.8 10.5 23.43 B-2-c A 29.8 334.8 392.5 9.0 3.04 B-2-c B 30.1
331.5 397.3 10.0 15.23 B-2-c C 30.1 333.5 395.8 9.0 27.44 B-2-c D
30.6 331.8 392.8 7.5 25.62
[0087] As shown in FIG. 6, alloys having more than about 3.5 wt. %
Mg do not have good electrical conductivity. Indeed, of the prior
art alloys, only alloy 5052 has a conductivity above 35% IACS even
though it has low Mg (about 2.3 wt. %).
[0088] FIGS. 7 and 8 illustrate the synergistic effect of combining
Sc and Zr. Alloys that contain no Sc or Zr, or alloys that contain
only one of Sc or Zr generally realize much lower strengths than
alloys containing even moderate amounts of Sc+Zr. Alloys containing
higher amounts of Sc+Zr generally realize much higher strengths
than alloys without Sc and/or Zr. Indeed, as illustrated by Example
alloys 23 and 29, about a 40 MPa strength difference is realized at
the 250.degree. F. anneal (FIG. 7), and about a 100 MPa strength
difference is realized at the 450.degree. F. anneal (FIG. 8) for
alloys that contain Sc+Zr as opposed to alloys that contain no Sc
or Zr.
[0089] FIGS. 9-11 illustrate the benefit of using Cu additions to
improve strength. As illustrated in FIGS. 9 and 10, alloys with Cu
additions realize improved strength, with or without Sc+Zr. As
shown in FIG. 9, alloy 30, which contains no Sc or Zr, but contains
0.15 wt. % Cu, realizes about the same strength as alloys
containing lower levels of Sc+Zr for the 250.degree. F. anneal.
Alloys that contain all of Cu, Sc, and Zr realize significant
strength improvements, as shown by the alloys having about 3.5 wt.
% Mg. Similar results are realized with the 450.degree. F. anneal
(FIG. 10). As shown in FIG. 11, the influence of Cu appears to be
non-linear. Cu additions of 0.15 wt. % and 0.24 wt. % are shown to
significantly benefit strength over alloys containing no Cu. The
increase to 0.50 wt. % Cu did not dramatically increase strength
beyond that achieved by the 0.24 wt. % Cu alloy.
[0090] FIG. 12 illustrates the benefit of using lower amounts of Mg
so as to achieve an acceptable level of intragranular corrosion
resistance. Alloys having about 3.5 wt. % Mg realize poor
intergranular corrosion resistance. Alloys having 2 wt. % Mg
realize good intragranular corrosion resistance, all realizing a
mass loss of not greater than 5 mg/cm.sup.2. As shown in FIG. 12,
Cu additions tend to decrease the nitric acid mass loss values.
Alloys 31-33, which all contain some Cu, have lower intragranular
corrosion than their counterpart alloys without Cu. Thus, Cu
additions of up to 0.50 wt. % should not detrimentally affect, and
may even benefit, the intragranular corrosion resistance of the
alloys.
[0091] With respect to pitting and exfoliation resistance, several
2 wt. % Mg alloys, with and without Cu, are subjected to corrosion
resistance testing in accordance with a modified version of ASTM
B117. The alloys are tested in the annealed condition and after
sensitization treatments B or C are applied. The samples are
alternatively immersed (AI) in a 3.5% NaCl solution (without
stress), with 8 hours spray and 16 hours soak. The AI test is run
for exposure intervals of 6, 10, 20 and 40 days. All alloys
performed well, with no evidence of any corrosion attack.
Example 3
Affect of Copper
[0092] Based on the Example 2 data, additional book mold testing is
conducted on low Mg, no Mn 5xxx aluminum alloys, with Sc+Zr, and
sometimes with Cu. Fifteen additional experimental book molds are
produced using generally the same practice described in Example 1.
The compositions of the additional book molds are provided in Table
7, below. Pieces of the Example 3 alloys received no thermal
treatment (piece "a") or were annealed at 250.degree. F. for 6
hours (piece "b"). The mechanical and corrosion data are provided
in Table 8, below.
TABLE-US-00011 TABLE 7 Example 3 Alloy Compositions (all values in
weight percent) Alloy Mg Mn Sc Zr Cu 34 1.92 -- 0.13 0.16 -- 35
1.90 -- 0.084 0.12 0.21 36 1.91 -- 0.084 0.17 0.21 37 1.96 -- 0.13
0.12 0.21 38 1.95 -- 0.14 0.17 0.21 39 1.94 -- 0.086 0.11 0.36 40
1.93 -- 0.13 0.16 0.36 41 2.93 -- 0.079 0.12 0.21 42 2.94 -- 0.14
0.16 0.20 43 0.49 -- 0.14 0.16 0.20 44 0.97 -- 0.14 0.16 0.20 45
1.46 -- 0.14 0.16 0.20 46 2.45 -- 0.13 0.16 0.21 47 2.71 -- 0.13
0.16 0.21 48 3.23 -- 0.13 0.16 0.20
Unless otherwise indicated below, other than the above-listed
ingredients, all of the experimental alloys 34-48 contained about
0.01 wt. % Ti, not greater than 0.05 wt. % Si as an impurity, not
greater than 0.17 wt. % Fe as an impurity, not greater than 0.01
wt. % Zn as an impurity, not greater than 0.05 wt. % each of other
elements, and with the other elements not exceeding 0.15 wt. % in
total, the balance being aluminum.
TABLE-US-00012 TABLE 8 Mechanical and Corrosion Properties of
Example 3 Alloys Elect. TYS Sensitization Cond. (L) UTS (L) NAMLT
Piece Category (% IACS) (MPa) (MPa) El % (mg/cm.sup.2) 34a A 43.1
316.5 326.8 5.0 -- 34b A 43.1 286.5 311.3 7.0 0.98 34b B 42.4 287.5
315.3 7.0 1.01 34b D 42.3 281.3 311.0 8.0 1.02 35a A 41.9 337.0
343.3 4.0 -- 35b A 42.0 314.3 340.8 6.0 1.04 35b B 41.5 313.8 346.5
8.0 1.03 35b D 41.9 317.0 354.0 8.0 1.03 36a A 41.7 343.8 349.3 4.0
-- 36b A 41.7 324.0 349.8 6.0 1.04 36b B 41.6 326.8 357.5 7.0 1.01
36b D 41.8 326.3 358.5 8.0 1.02 37a A 42.2 344.0 348.5 4.0 -- 37b A
42.5 317.8 346.5 6.0 1.07 37b B 41.4 314.3 354.3 8.0 1.04 37b D
42.0 323.3 364.8 9.0 1.02 38a A 41.8 342.8 353.0 4.0 -- 38b A 41.7
323.0 352.5 8.0 1.06 38b B 41.2 326.3 358.0 8.0 1.03 38b D 41.8
324.8 360.3 8.0 1.04 39a A 41.5 361.3 369.3 4.0 -- 39b A 41.4 340.3
370.0 7.5 1.10 39b B 41.2 340.0 373.5 8.0 1.11 39b D 41.6 343.5
378.0 8.0 1.10 40a A 40.9 370.8 375.5 4.0 -- 40b A 40.9 349.8 379.0
7.0 1.16 40b B 40.9 352.3 386.0 8.0 1.16 40b D 41.4 354.0 390.3
10.0 1.14 41a A 36.8 383.5 392.8 4.0 -- 41b A 37.2 349.0 381.3 7.0
1.28 41b B 37.1 344.3 385.5 8.0 3.73 41b D 37.7 346.8 385.5 9.5
5.46 42a A 37.4 384.0 398.5 4.0 -- 42b A 37.6 355.8 392.8 8.0 1.36
42b B 36.9 354.0 395.0 10.0 3.39 42b D 37.7 351.0 395.8 10.0 4.61
43a A 52.7 269.8 275.5 4.0 -- 43b A 52.4 269.8 287.0 6.0 0.84 43b B
51.9 273.5 297.8 8.0 0.80 43b D 52.7 275.8 303.0 10.0 0.82 44a A
48.4 301.0 305.3 4.0 -- 44b A 48.4 294.3 313.0 6.0 0.88 44b B 48.3
297.0 323.8 8.0 0.84 44b D 49.0 300.3 329.3 8.0 0.84 45a A 44.9
324.0 327.5 4.0 -- 45b A 44.9 310.3 333.0 8.0 1.02 45b B 44.6 317.5
350.0 8.0 0.92 45b D 45.5 308.3 343.8 8.0 0.92 46a A 38.9 366.8
379.0 5.0 -- 46b A 39.1 341.0 369.8 7.5 1.07 46b B 38.7 336.0 376.3
8.0 1.27 46b D 39.4 337.5 377.5 8.0 1.27 47a A 38.2 377.8 390.0 5.0
47b A 38.4 341.5 379.3 8.0 1.15 47b B 38.3 344.5 385.3 7.0 1.93 47b
D 38.6 343.8 387.5 8.0 2.29 48a A 35.0 401.5 414.3 4.5 -- 48b A
35.6 362.0 403.8 8.0 1.86 48b B 35.6 363.8 406.8 8.0 8.63 48b D
36.3 356.8 406.5 8.0 11.81
[0093] As shown in FIG. 13, electrical conductivity increases with
decreasing Mg content, as shown in the previous examples. As shown
in FIG. 14, the use of Sc and Zr in combination with the Cu
additions of 0.20 to 0.36 wt. % can significantly increase
strength. Indeed, the alloys containing only about 2 wt. % Mg
realize a yield strength of at least about 310 MPa.
[0094] FIGS. 15a-15c illustrate the electrical conductivity versus
yield strength performance of various Example 3 alloys. As shown in
FIG. 15a, the Type B and D sensitized alloys having about 0.2 wt. %
Cu realize a generally linear EC-TYS relationship. The Type B
alloys have a trend line of EC=-0.1854(TYS)+101.87 with an R.sup.2
value of 0.9276. The Type D alloys have a trend line of
EC=-0.2055(TYS)+109.01 with an R.sup.2 value of 0.9672. FIG. 15b
shows that the same general linear trend exists for the
non-sensitized alloys.
[0095] FIG. 15c illustrates one manner of characterizing the new
5xxx aluminum alloy products. The new 5xxx aluminum alloy products
are bounded by a minimum yield strength (L) of 270 MPa and a
minimum electrical conductivity of 35% IACS, as shown by the solid
lines. These properties are measured after the aluminum alloy is
annealed at 250.degree. F. for 6 hours. In this graph, a trend line
of having an equation of EC=-0.195 (TYS)+Intercept is shown, where
the intercept shifts based on the amount of Sc, Zr and/or Cu in the
alloy. A minimum performance line is shown, having an equation of
EC=-0.195 (TYS)+96. This minimum performance line correlates to the
performance of the low Sc+Zr and no Cu alloys. As the amount of
Sc+Zr and/or copper present in the new 5xxx aluminum alloys
increases, the performance line shifts to the right by changing the
intercept, but keeping the same slope (-0.195). For all Sc+Zr
alloys with 0.2 wt. % Cu, the intercept is about 102-108 (an
intercept of 105.4 is illustrated). For the 0.36 wt. % Cu alloys
having lower levels of Sc+Zr, the intercept is about 107-109. For
the 0.36 wt. % Cu alloys having higher levels of Sc+Zr, the
intercept is about 109-111.
[0096] The performance trend correlates to the alloy performance of
the Example 2 alloys that were also annealed at 250.degree. F. for
6 hours. For instance, Alloys 19 and 26, which are no copper, low
Sc+Zr alloys (0.156 and 0.138 wt. % Sc+Zr, respectively), generally
meet the requirements set forth above for the Type B and D alloys.
Of these alloys, one of the 0.138 wt. % Sc+Zr alloys barely misses
the criteria of FIG. 15c, having a yield strength of 268 MPa. This
indicates that the minimum Sc+Zr level may be at least 0.14 wt. %,
such as when lower amounts of Mg are utilized in the alloy.
[0097] Alloy 29, which contains no copper and higher levels of
Sc+Zr alloy (0.27 wt. % Sc+Zr), falls within the bounds of the
performance requirements of FIG. 15c, having an intercept of in the
range of from about 100.5 to about 101.5, depending on
sensitization type (B or D).
[0098] Alloy 30, with no Sc+Zr, but 0.15 wt. % Cu, falls within the
performance bounds of FIG. 15c, but will likely have low retained
strength due to the absence of Sc+Zr, as shown by Alloy 23 of
Example 4, below.
[0099] Alloy 31, with lower levels of Sc+Zr (0.137), and 0.16 wt. %
Cu, falls within the performance bounds of FIG. 15c, having an
intercept in the range of from about 103 to about 104.5, depending
on sensitization type (B or D).
[0100] Alloy 32, with lower levels of Sc+Zr (0.132), and 0.24 wt. %
Cu, falls within the performance bounds of FIG. 15c, having an
intercept in the range of from about 106 to about 107.5, depending
on sensitization type (B or D).
[0101] Alloy 33, with lower levels of Sc+Zr (0.137), and 0.50 wt. %
Cu, falls within the performance bounds of FIG. 15c, having an
intercept in the range of from about 108.5 to about 111, depending
on sensitization type (B or D).
[0102] Table 9, below, correlates the Cu and Sc+Zr levels to the
intercept of the performance line in accordance with the data
(sorted by increasing Cu level, which appears to have the most
prominent affect on the shift of the intercept).
TABLE-US-00013 TABLE 9 Performance line intercepts for various new
5xxx aluminum alloys Cu Line Alloys (wt. %) Sc + Zr (wt. %)
Intercept 19, 26, 34 0 0.138 to 0.29 96-101.5 31 0.16 0.137
103-104.5 35-37, 41 0.2 0.20-0.25 102-105 38, 42-48 0.2 0.29-0.31
104-108 33 0.24 0.132 106-107.5 39 0.36 0.196 107-109 40 0.36 0.29
109-111 34 0.50 0.141 108.5-111
Based on these trends, it is expected that the new 5xxx aluminum
alloys having high amounts of Cu and Sc+Zr could have a performance
line intercept of 113, or higher.
[0103] The new 5xxx aluminum alloys generally have good corrosion
resistance when Mg levels are kept below 3.25 wt. %, such as below
3.0 wt. %. As shown in FIG. 16, intragranular corrosion is high
when the alloys contain more than 3.25 wt. % Mg. Indeed, once the
alloys exceed about 3 wt. % Mg, the intragranular corrosion
increases dramatically.
[0104] Salt spray tests similar to those described in Example 2 are
conducted on a selection of the Example 3 alloys containing from
about 2 wt. % to about 3 wt. % Mg, all of which also contain
copper. The test samples are visually observed after 6, 10, 20, 40,
and 80 days (20 days is the specification requirement). After 20
days of exposure, the samples do not show any evidence of attack
for any of the thermal treatment conditions, although the higher
copper alloys appear slightly darker in color. Even after 40 and 80
days exposure there is little or no attack.
Example 4
Retained Strength
[0105] Several Example 2 and Example 3 alloys are exposed to
varying elevated temperatures for 100 hours, after which their
electrical conductivity and mechanical properties are tested. The
results of these tests are provided in Table 10, below. All tested
alloys were those alloys that had been previously annealed at
250.degree. F. for 6 hours.
TABLE-US-00014 TABLE 10 Strength Retention Properties Elect.
Percent Drop Treatment Treatment Cond. in TYS Time Temp (% TYS (L)
(relative to Alloy (hrs) (.degree. F.) IACS) (MPa) no TT) El % 23 0
None 44.5 239.5 -- 7.0 23 100 260 46.1 228.8 4% 8.5 23 100 300 45.8
205.0 14% 8.0 23 100 350 45.7 179.5 25% 11.0 23 100 400 45.7 153.8
36% 13.0 23 100 450 45.5 100.3 58% 20.0 23 100 500 45.9 74.5 69%
25.0 29 0 None 43.4 289.3 -- 7.0 29 100 260 44.1 289.5 0% 7.5 29
100 300 43.3 271.8 6% 6.0 29 100 350 43.4 264.3 9% 6.0 29 100 400
43.3 255.8 12% 7.5 29 100 450 43.4 250.8 13% 8.0 29 100 500 43.4
245.5 15% 8.0 35 0 None 42.0 314.3 -- 6.0 35 100 260 41.9 317.0 -1%
8.0 35 100 300 42.4 302.5 4% 8.0 35 100 350 42.9 268.5 15% 8.0 35
100 400 43.2 252.8 20% 9.0 35 100 450 43.7 242.0 23% 9.0 35 100 500
43.5 233.0 26% 8.5 38 0 None 41.7 323.0 -- 8.0 38 100 260 41.8
324.8 -1% 8.0 38 100 300 42.1 312.5 3% 8.0 38 100 350 42.9 282.5
13% 7.5 38 100 400 43.2 268.0 17% 8.0 38 100 450 43.2 261.8 19% 9.0
38 100 500 42.6 254.0 21% 8.0 40 0 None 40.9 349.8 -- 7.0 40 100
260 41.4 354.0 -1% 10.0 40 100 300 42.5 329.0 6% 8.0 40 100 350
43.5 295.8 15% 8.0 40 100 400 43.7 274.8 21% 10.5 40 100 450 44.0
264.8 24% 9.0 40 100 500 44.1 255.5 27% 8.5 42 0 None 37.6 355.8 --
8.0 42 100 260 37.7 351.0 1% 10.0 42 100 300 37.6 335.3 6% 8.0 42
100 350 37.9 303.5 15% 8.0 42 100 400 38.1 290.3 18% 10.0 42 100
450 38.3 280.3 21% 11.0 42 100 500 38.4 273.3 23% 10.5 43 0 None
52.4 269.8 -- 4.0 43 100 260 52.7 275.8 -2% 10.0 43 100 300 53.1
264.5 2% 8.0 43 100 350 54.3 237.0 12% 8.0 43 100 400 54.7 220.0
18% 8.0 43 100 450 54.9 215.3 20% 8.5 43 100 500 54.8 213.5 21% 9.0
44 0 None 48.4 294.3 -- 6.0 44 100 260 49.0 300.3 -2% 8.0 44 100
300 49.1 286.0 3% 8.5 44 100 350 50.0 254.8 13% 8.0 44 100 400 50.4
239.0 19% 8.0 44 100 450 50.4 233.5 21% 8.0 44 100 500 50.6 227.3
23% 8.0 5454 0 None 32.7 328.5 -- 7.0 5454 100 300 32.9 301.0 8%
8.0 5454 100 350 33.0 276.0 16% 8.5 5454 100 400 33.1 250.0 24%
12.0 5454 100 450 33.4 123.3 62% 21.0 5454 100 500 33.2 125.5 62%
20.0 5052 0 None 36.0 283.0 -- 7.0 5052 100 300 35.3 269.0 5% 8.0
5052 100 350 35.3 239.5 15% 9.0 5052 100 400 35.5 226.0 20% 10.5
5052 100 450 35.7 131.8 53% 17.5 5052 100 500 35.7 100.8 64%
22.5
[0106] As illustrated in FIGS. 17a-17b, the new 5xxx aluminum
alloys containing both Sc and Zr realize improved strength
retention capabilities. The new 5xxx aluminum alloys realize a drop
in yield strength of only about 15-27% when processed at
500.degree. F. for 100 hours relative to their counterpart alloys
having no thermal treatment. As a comparison, alloy 23, which
contained no Sc or Zr, realizes a yield strength decrease of 69%,
and alloys 5052 and 5454 realize, yield strength decreases of 64%
and 62%, respectively. Electrical conductivity generally remains
unchanged irrespective of thermal treatment. This indicates that
the new 5xxx aluminum alloys are well-suited for high temperature
applications in which strength retention is important, such as
automotive electrical conductor applications.
Example 5
Cold Work Amount
[0107] Hot rolled, but non-cold rolled portions of alloys 38, 43,
and 48, from above, are cold rolled 30%, 50%, 65% and 83%. The
alloys received no thermal treatment (piece "a") or were annealed
at 250.degree. F. for 6 hours (piece "b"). The mechanical data are
provided in Table 11, below.
TABLE-US-00015 TABLE 11 Mechanical Properties of Example 5 Alloys
Cold Elect. TYS UTS Work Sensitization Cond. (L) (L) Alloy Piece
(%) Category (% IACS) (MPa) (MPa) El % 38 38a 83 A 40.8 337.0 346.0
5.5 38 38b 83 A 41.5 319.5 349.3 9.0 38 38b 83 B 41.8 318.5 354.8
9.0 38 38b 83 D 42.0 317.5 356.5 10.5 38 38a 65 A 41.0 326.5 336.3
6.0 38 38b 65 A 41.5 301.5 332.3 8.0 38 38b 65 B 42.1 301.0 338.5
9.5 38 38b 65 D 42.1 302.8 345.5 10.0 38 38a 50 A 41.1 326.0 334.8
6.0 38 38b 50 A 41.6 298.3 331.0 8.0 38 38b 50 B 42.2 297.8 338.0
9.0 38 38b 50 D 42.1 300.3 343.8 10.0 38 38a 30 A 41.2 312.8 325.5
6.5 38 38b 30 A 41.5 285.0 317.8 8.0 38 38b 30 B 42.0 289.3 330.3
10.0 38 38b 30 D 42.2 291.3 331.3 10.0 43 43a 83 A 51.9 259.5 263.0
5.5 43 43b 83 A 52.1 253.8 271.5 6.0 43 43b 83 B 52.9 254.0 282.5
7.0 43 43b 83 D 52.9 259.8 289.5 8.0 43 43a 65 A 52.0 260.8 263.8
6.0 43 43b 65 A 52.1 251.5 269.0 8.0 43 43b 65 B 52.9 255.3 280.3
8.0 43 43b 65 D 52.8 259.5 288.0 10.0 43 43a 50 A 51.7 254.5 258.0
6.0 43 43b 50 A 52.0 243.8 263.0 9.0 43 43b 50 B 52.8 247.8 274.8
9.0 43 43b 50 D 52.8 253.5 283.7 9.0 43 43a 30 A 51.8 241.8 245.5
6.0 43 43b 30 A 52.2 237.0 256.5 8.0 43 43b 30 B 52.8 236.8 263.8
10.0 43 43b 30 D 52.9 240.8 270.3 10.0 48 48a 83 A 34.7 391.8 406.0
6.0 48 48b 83 A 35.3 354.8 393.3 9.5 48 48b 83 B 36.0 352.0 400.5
9.5 48 48b 83 D 36.1 352.0 398.0 10.0 48 48a 65 A 34.8 384.0 399.3
5.5 48 48b 65 A 35.6 341.3 384.5 10.0 48 48b 65 B 36.0 335.5 390.5
10.0 48 48b 65 D 36.1 343.5 396.8 10.0 48 48a 50 A 34.7 366.0 383.5
6.5 48 48b 50 A 35.3 327.3 373.5 10.0 48 48b 50 B 36.0 326.5 380.3
10.0 48 48b 50 D 35.9 325.5 375.8 10.0 48 48a 30 A 35.0 352.3 369.5
6.0 48 48b 30 A 35.3 312.0 368.5 9.0 48 48b 30 B 35.9 318.8 373.0
10.0 48 48b 30 D 36.0 316.3 371.8 11.5
As shown in FIGS. 18a-18b, depending on Mg level, the alloys
containing about 2 wt. % and about 3.25 wt. % Mg achieve an
electrical conductivity of at least about 35% and a longitudinal
tensile yield strength of at least about 270 MPa, even with low
amounts of cold work. This suggests that some alloys may be useful
in high strength electrical applications even with low amounts of
cold work (e.g., .gtoreq.10% CW). The 0.5 wt. % Mg alloy (Alloy 43)
did not quite achieve a tensile yield strength of 270 MPa, but
could potentially reach 270 MPa as shown in Example 3, above. This
suggests that at least 0.75 wt. % or 1.0 wt. % Mg and/or from 0.35
to 0.45 wt. % Cu may be required in some instance to achieve a
tensile yield strength of at least 270 MPa. In these embodiments,
at least 50% cold work may be required.
[0108] The alloys are also tested for strength retention by
prolonged exposure to elevated temperature as shown in Table 12
below. As shown in FIGS. 19a-19b, the alloys all realize good
strength retention, irrespective of cold work amount.
TABLE-US-00016 TABLE 12 Strength Retention Properties Percent Cold
Treatment Treatment Drop in TYS Work Time Temp TYS (L) (relative to
Alloy (%) (hrs) (.degree. F.) (MPa) no TT) El % 38 83 0 None 319.5
-- 9.0 38 83 100 260 317.5 0.6% 10.5 38 83 100 300 306.5 4.1% 9.0
38 83 100 350 275.5 13.8% 9.0 38 83 100 400 262.3 17.9% 9.0 38 83
100 450 254.0 20.5% 9.0 38 83 100 500 245.0 23.3% 9.0 38 65 0 None
301.5 -- 8.0 38 65 100 260 302.8 -0.4% 10.0 38 65 100 300 298.5
1.0% 9.0 38 65 100 350 271.8 9.9% 9.0 38 65 100 400 260.3 13.7% 9.0
38 65 100 450 252.0 16.4% 9.0 38 65 100 500 242.0 19.7% 9.0 38 50 0
None 298.3 -- 8.0 38 50 100 260 300.3 -0.7% 10.0 38 50 100 300
289.8 2.8% 9.0 38 50 100 350 265.3 11.1% 9.5 38 50 100 400 249.3
16.4% 10.0 38 50 100 450 245.5 17.7% 10.0 38 50 100 500 241.5 19.0%
10.0 38 30 0 None 285.0 -- 8.0 38 30 100 260 291.3 -2.2% 10.0 38 30
100 300 281.0 1.4% 10.0 38 30 100 350 259.8 8.8% 10.0 38 30 100 400
244.3 14.3% 10.0 38 30 100 450 233.0 18.2% 10.0 38 30 100 500 227.5
20.2% 10.0 43 83 0 None 253.8 -- 6.0 43 83 100 260 259.8 -2.4% 8.0
43 83 100 300 252.0 0.7% 10.0 43 83 100 350 225.3 11.2% 9.0 43 83
100 400 201.3 20.7% 9.0 43 83 100 450 203.8 19.7% 9.0 43 83 100 500
199.8 21.3% 9.0 43 65 0 None 251.5 -- 8.0 43 65 100 260 259.5 -3.2%
10.0 43 65 100 300 246.5 2.0% 9.5 43 65 100 350 223.5 11.1% 10.0 43
65 100 400 195.0 22.5% 9.0 43 65 100 450 197.0 21.7% 9.5 43 65 100
500 200.8 20.2% 10.0 43 50 0 None 243.8 -- 9.0 43 50 100 260 253.5
-4.0% 9.0 43 50 100 300 242.0 0.7% 10.0 43 50 100 350 216.0 11.4%
10.0 43 50 100 400 204.3 16.2% 9.5 43 50 100 450 198.3 18.7% 10.0
43 50 100 500 199.3 18.3% 10.0 43 30 0 None 237.0 -- 8.0 43 30 100
260 240.8 -1.6% 10.0 43 30 100 300 240.0 -1.3% 10.0 43 30 100 350
213.3 10.0% 10.0 43 30 100 400 196.8 17.0% 10.0 43 30 100 450 191.5
19.2% 9.0 43 30 100 500 194.0 18.1% 9.0 48 83 0 None 354.8 -- 9.5
48 83 100 260 352.0 0.8% 10.0 48 83 100 300 338.5 4.6% 9.0 48 83
100 350 306.5 13.6% 9.0 48 83 100 400 290.8 18.0% 9.5 48 83 100 450
283.8 20.0% 10.0 48 83 100 500 275.8 22.3% 11.0 48 65 0 None 341.3
-- 10.0 48 65 100 260 343.5 -0.6% 10.0 48 65 100 300 325.3 4.7%
10.0 48 65 100 350 299.0 12.4% 11.0 48 65 100 400 284.5 16.6% 11.5
48 65 100 450 272.8 20.1% 11.5 48 65 100 500 264.8 22.4% 11.0 48 50
0 None 327.3 -- 10.0 48 50 100 260 325.5 0.5% 10.0 48 50 100 300
321.5 1.8% 10.0 48 50 100 350 293.8 10.2% 10.0 48 50 100 400 280.0
14.5% 11.0 48 50 100 450 263.8 19.4% 13.0 48 50 100 500 258.5 21.0%
13.0 48 30 0 None 312.0 -- 9.0 48 30 100 260 316.3 -1.4% 11.5 48 30
100 300 311.3 0.2% 11.5 48 30 100 350 286.5 8.2% 11.0 48 30 100 400
265.3 15.0% 1.0 48 30 100 450 252.8 19.0% 12.5 48 30 100 500 250.0
19.9% 13.5
Example 6
Additional Testing of Alloy Compositions
[0109] Additional book mold testing is conducted on low Mg, no Mn
5xxx aluminum alloys, with Sc+Zr, and sometimes with Cu. Fourteen
additional experimental book molds are produced using generally the
same practice described in Example 1. The compositions of the
additional book molds are provided in Table 13, below. Pieces of
the Example 6 alloys received no thermal treatment (piece "a") or
were annealed at 250.degree. F. for 6 hours (piece "b"). The
mechanical and corrosion data are provided in Table 14, below.
TABLE-US-00017 TABLE 13 Example 6 Alloy Compositions (all values in
weight percent) Alloy Mg Mn Sc Zr Cu Other 49 1.96 -- 0.15 0.14
0.21 -- 50 1.95 -- 0.15 0.11 0.21 0.088 Si; 0.10 Fe 51 1.95 -- 0.16
0.10 0.20 0.088 Si; 0.15 Fe 52 1.95 -- 0.16 0.11 0.20 0.13 Si; 0.14
Fe 53 2.00 -- 0.16 0.12 0.21 0.17 Si; 0.20 Fe 54 1.97 -- 0.17 0.12
0.21 0.21 Si; 0.24 Fe 55 3.46 -- 0.067 0.052 0.053 -- 56 3.40 --
0.07 0.055 0.094 -- 57 3.44 -- 0.068 0.045 0.15 -- 58 3.41 -- 0.075
0.059 0.34 -- 59 1.95 -- 0.15 0.12 0.21 0.03 Cr 60 1.95 -- 0.14
0.12 0.21 0.06 Cr 61 2.00 -- 0.16 0.11 0.21 0.14 Cr 62 1.96 -- 0.15
0.10 0.2 0.21 Cr
[0110] Unless otherwise indicated, other than the above-listed
ingredients, all of the experimental alloys 49-63 contained about
0.01 wt. % Ti, not greater than 0.05 wt. % Si as an impurity, not
greater than 0.10 wt. % Fe as an impurity, not greater than 0.01
wt. % Zn as an impurity, the balance being aluminum and other
elements, the combined amount of other elements not exceeding 0.05
wt. % each, and not more than 0.15 wt. % in total.
TABLE-US-00018 TABLE 14 Mechanical Properties of Example 6 Alloys
Elect. TYS Sensitization Cond. (L) UTS (L) NAMLT Piece Category (%
IACS) (MPa) (MPa) El % (mg/cm.sup.2) 49a A 40.6 340.3 344.5 4.0 --
49b A 43.5 320.5 348.0 5.5 0.83 49b B 42.4 325.5 360.3 6.0 0.83 49b
D 42.7 325.8 362.8 7.0 0.83 50a A 41.3 331.5 335.8 4.0 -- 50b A
43.4 312.8 338.3 6.0 0.89 50b B 42.4 316.5 349.5 6.0 0.89 50b D
42.3 316.8 353.0 6.0 0.92 51a A 40.5 332.0 339.5 4.0 -- 51b A 42.5
312.0 340.0 6.0 1.03 51b B 42.5 315.3 350.8 7.0 1.03 51b D 42.8
315.0 353.3 7.0 0.99 52a A 41.2 333.0 338.0 4.0 -- 52b A 43.4 313.0
339.8 7.0 1.02 52b B 42.8 314.8 349.3 7.0 1.04 52b D 43.2 314.5
350.8 7.0 1.07 53a A 41.5 327.0 332.8 3.5 -- 53b A 43.6 312.8 338.5
6.5 1.07 53b B 42.8 312.5 343.8 7.0 1.06 53b D 43.0 314.0 347.3 7.0
1.05 54a A 42.2 324.5 330.0 4.0 -- 54b A 44.2 307.0 334.0 7.0 1.14
54b B 43.4 311.3 343.3 7.0 1.14 54b D 43.4 307.0 346.8 7.0 1.13 55a
A 34.1 357.0 369.5 4.0 -- 55b A 35.7 308.3 350.0 7.0 2.77 55b B
35.4 309.3 356.8 8.0 12.41 55b D 35.9 305.0 353.8 8.0 15.31 56a A
34.2 367.0 379.0 4.0 -- 56b A 36.2 323.0 364.3 8.0 2.28 56b B 35.8
319.8 365.0 7.5 10.49 56b D 35.9 320.3 367.5 7.0 14.26 57a A 34.6
364.3 378.8 4.0 -- 57b A 36.6 328.0 369.0 8.0 2.12 57b B 36.4 325.8
373.3 9.0 9.03 57b D 36.7 320.5 370.8 9.0 12.93 58a A 33.8 386.3
400.8 4.0 -- 58b A 35.5 350.0 398.3 7.0 2.46 58b B 36.2 352.0 398.0
8.0 9.04 58b D 35.8 348.8 397.5 8.0 13.57 59a A 39.4 330.8 338.5
3.5 -- 59b A 41.2 319.8 346.0 7.0 0.95 59b B 40.9 316.3 353.8 7.0
0.92 59b D 41.0 320.8 359.5 8.5 0.93 60a A 38.1 345.5 350.0 3.0 --
60b A 39.7 317.3 344.0 8.0 0.92 60b B 39.3 321.8 357.3 8.0 0.93 60b
D 39.5 321.0 358.3 8.0 0.96 61a A 36.1 339.5 348.8 5.0 -- 61b A
37.7 319.8 351.3 6.0 0.94 61b B 37.1 324.8 359.8 7.0 0.97 61b D
37.1 324.5 362.0 8.0 1.00 62a A 34.1 342.0 351.0 5.0 -- 62b A 35.5
328.5 355.5 6.0 1.00 62b B 35.1 330.3 365.8 8.5 1.01 62b D 35.1
332.0 367.5 8.0 1.00
[0111] As shown in FIG. 20a, alloys having lower levels of silicon
and iron generally achieve a better combination of strength and
electrical conductivity. Alloy 54 with 0.21 wt. % Si and 0.24 wt. %
Fe achieved about 20 MPa lower strength than Alloy 49 with 0.04 wt.
% Si and 0.092 wt. % Fe. These results indicate that iron and
silicon levels should be maintained below 0.25 wt. %, such as any
of the amounts of Fe and Si described in the Summary, above.
[0112] As shown in FIG. 20b, alloys with about 3.5 wt. % Mg achieve
a lower electrical conductivity, around 35% IACS. These high Mg
alloys realize increasing strength with increasing copper, but
electrical conductivity is relatively unaffected. As shown in FIG.
20c, these alloys realize poorer corrosion resistance, generally
having a mass loss around 15 mg/cm.sup.2. These results indicate
that Mg should be maintained below 3.5 wt. %, such as not greater
than 3.25 wt. %, as shown above. For increased strength, copper may
be included in an amount of at least 0.05 wt. %, or more, as
described above. For corrosion resistance, copper should be
restricted to 0.50 wt. %, or less, such as any of the amounts
described in the Summary, above. Silver (Ag) is expected to have
the same strength impact as copper, but with a lesser impact on
corrosion resistance, and thus can be added as a substitute for
copper, or in combination with copper in the above identified
amounts, as well as in the amounts identified in the Summary,
above.
[0113] As shown in FIG. 20d, chromium should be avoided as it has a
detrimental impact on electrical conductivity. Alloy 62 with 0.21
wt. % Cr and about 0.01 wt. % Ti had a lower electrical
conductivity than the alloys with less chromium. Vanadium is known
to have a similar impact on electrical conductivity. These results
indicate that the alloys should contain not greater than 0.30 wt. %
total of Cr, V and Ti (i.e., the total combined amounts of Cr, V,
and Ti does not exceed 0.30 wt. %), such as any of the amounts of
Cr, V, and Ti described in the Summary, above. Ti may be beneficial
for grain refining, and thus the new 5xxx aluminum alloys may
include at least 0.005 wt. % Ti, in some instances. Nickel (Ni) and
cobalt (Co) are known to have a lesser impact on electrical
conductivity than chromium, and thus may be included in the new
5xxx aluminum alloy in an amount of up to 0.50 wt. % total Ni plus
Co (i.e., the total combined amounts of Ni and Co does not exceed
0.50 wt. %), such as any of the amounts of Ni plus Co described in
the Summary, above.
[0114] While various embodiments of the new technology described
herein have been described in detail, it is apparent that
modifications and adaptations of those embodiments will occur to
those skilled in the art. However, it is to be expressly understood
that such modifications and adaptations are within the spirit and
scope of the presently disclosed technology.
* * * * *