Aluminum Alloy Article Having Low Texture And Methods Of Making The Same

Abstract

Provided herein are aluminum alloys having a uniform surface recrystallization texture. The uniform surface recrystallization texture can be provided by methods described herein. Also provided herein are methods to produce aluminum alloys having a uniform surface recrystallization texture, which may include homogenizing and hot rolling an aluminum cast product to a final gauge at a temperature greater than or about a recrystallization temperature.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 62/515,714, filed on Jun. 6, 2017, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

[0002] The present disclosure relates to metallurgy generally and more specifically to metal manufacturing. In certain aspects, the disclosure provides rolled aluminum alloy articles having a rolled surface having low texture (e.g., recrystallization texture). In certain aspects, the disclosure also provides methods of making such articles. In certain other aspects, the disclosure provides various end uses of such articles, such as in automotive, transportation, electronics, and industrial applications.

BACKGROUND

[0003] Aluminum alloy articles are desirable for use in a number of different applications, such as those where strength and durability are especially desirable. For example, aluminum alloys are commonly used for automotive structural applications in place of steel. Because aluminum alloys are generally about 2.8 times less dense than steel, the use of such materials reduces the weight of the vehicle and allows for substantial improvements in its fuel economy. Even so, the use of currently available aluminum alloys in automotive and other applications poses certain challenges.

[0004] One such challenge relates to the emergence of recrystallization texture during the processing (e.g., rolling) of the aluminum alloy article, which leads to a high degree of anisotropy on the surface of the article. Thus, aluminum alloy rolled articles (e.g., aluminum alloy plates, aluminum alloy shates, and aluminum alloy sheets) can have significant amounts of recrystallization texture that develops during the course of processing.

SUMMARY

[0005] Texturing of aluminum alloy rolled articles can modify the mechanical, strength, and forming properties. Thus, it may be desirable to provide an aluminum alloy rolled article having a surface that is nearly isotropic and thus, possessing nearly uniform surface properties. The present disclosure provides aluminum articles with surfaces, or portions thereof, that are substantially free of recrystallization texture, as well as methods for making and using such articles.

[0006] The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings and each claim.

[0007] Embodiments of the present disclosure include an aluminum alloy rolled article comprising a rolled surface, such as a rolled surface that comprises a first surface portion that is substantially free of recrystallization texture. In some non-limiting examples, the first surface portion can have an isotropic texture, such as an isotropic texture that comprises a plurality of texture components. As examples, different texture components may comprise less than or about 1 volume percent (vol. %) of the first surface portion. In some aspects, the plurality of texture components comprise surface texture components selected from the group consisting of a cube component, a goss component, a brass component, an S component, and a copper component. For example, in one embodiment, an aluminum alloy rolled article comprises a rolled surface with at least a portion that is free or substantially free of recrystallization texture and includes less than or about 1 volume percent (i.e., between 0 and 1 volume percent) of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component.

[0008] Surfaces having significant amounts of cube or other texture components, in embodiments, may correspond to surfaces that do not have an isotropic texture. Stated another way, surfaces including significant amounts of cube or other texture components may exhibit Langford coefficients (R-value) that are lower in a direction diagonal from a longitudinal direction (rolling direction) of the surface than those along the longitudinal direction or along a transverse direction (perpendicular to the rolling direction). By generating an aluminum alloy rolled article with low amounts of surface texture or with randomized surface texturing, the articles can exhibit isotropic properties in which the Langford coefficients do not significantly vary as a function of angle from the longitudinal direction.

[0009] The first surface portion optionally has one or more surface texture ratios between 0.80 and 1.25. In embodiments, a surface texture ratio corresponds to a relationship between volume percentages of a first surface texture and a second surface texture. In some non-limiting examples, the first surface portion has a cube component to brass component ratio of from 0.80 to 1.25, a cube component to goss component ratio of from 0.80 to 1.25, a cube component to S component ratio of from 0.80 to 1.25, a cube component to copper component ratio of from 0.80 to 1.25, a goss component to brass component ratio of from 0.80 to 1.25, a goss component to S component ratio of from 0.80 to 1.25, a goss component to copper component ratio of from 0.80 to 1.25, a brass component to S component ratio of from 0.80 to 1.25, a brass component to copper component ratio of from 0.80 to 1.25, an S component to copper component ratio of from 0.80 to 1.25, a cube component to goss component to brass component ratio of from 0.80 to 1.25, a cube component to goss component to S component ratio of from 0.80 to 1.25, a cube component to goss component to copper component ratio of from 0.80 to 1.25, a goss component to brass component to S component ratio of from 0.80 to 1.25, a goss component to brass component to copper component ratio of from 0.80 to 1.25, a brass component to S component to copper component ratio of from 0.80 to 1.25, a cube component to goss component to brass component to S component ratio of from 0.80 to 1.25, a cube component to goss component to brass component to copper component ratio of from 0.80 to 1.25, a goss component to brass component to S component to copper component ratio of from 0.80 to 1.25, or a cube component to goss component to brass component to S component to copper component ratio of from 0.80 to 1.25. By controlling the amounts and ratios of different texture components, the aluminum rolled article may exhibit more isotropic properties.

[0010] In some non-limiting examples, the aluminum alloy rolled article can have any suitable width or length. Optionally, the alloy of the aluminum alloy rolled article is a 5xxx aluminum alloy or a 6xxx aluminum alloy. In some further examples, the aluminum alloy rolled article can be produced without cold rolling (i.e., hot rolled to a final gauge). Stated another way, the aluminum alloy rolled article may optionally be formed by a process that does not use cold rolling of the article to a final gauge or thickness. In some non-limiting examples, the aluminum alloy rolled article described herein can be formed by a process that comprises providing a molten aluminum alloy composition, continuously casting the molten aluminum alloy composition to form an aluminum alloy cast product, homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product, and rolling the homogenized aluminum alloy cast product to form the aluminum alloy rolled article having a thickness of no more than 7 mm, such as between 0.01 mm and 7 mm, between 0.01 mm and 6 mm, between 0.01 mm and 5 mm, between 0.01 mm and 4 mm, between 0.01 mm and 3 mm, or between 0.01 mm and 2 mm. Advantageously, the rolling may be carried out at a temperature of no less than 300.degree. C., such as between 300.degree. C. and 550.degree. C. Rolling at elevated temperatures may be useful, in embodiments, for preventing or reducing recrystallization and associated texturing of the aluminum alloy rolled article.

[0011] In some non-limiting examples, a method for making an aluminum alloy rolled article comprises providing a molten aluminum alloy composition, continuously casting the molten aluminum alloy composition to form an aluminum alloy cast product, homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product, and rolling the homogenized aluminum alloy cast product to form an aluminum alloy rolled article having a thickness of no more than 7 mm, such as between 0.01 mm and 7 mm, between 0.01 mm and 6 mm, between 0.01 mm and 5 mm, between 0.01 mm and 4 mm, between 0.01 mm and 3 mm, or between 0.01 mm and 2 mm, wherein the rolling is carried out at a temperature of no less than 300.degree. C., such as between 300.degree. C. and 550.degree. C. Following the rolling, the rolled aluminum alloy rolled article can optionally be subjected to quenching. In some examples, direct chill casting is not utilized. In some examples, the aluminum alloy rolled article is rolled to a final thickness during the rolling and a subsequent cold rolling process is not used to achieve the final thickness of the aluminum alloy rolled article.

[0012] Optionally, homogenizing the aluminum alloy cast product includes controlling a homogenization temperature of the aluminum alloy cast product, such as after exiting from a continuous caster. Optionally, the homogenization temperature is between 400.degree. C. and 600.degree. C., between 450.degree. C. and 600.degree. C., between 400.degree. C. and 500.degree. C., or between 500.degree. C. and 600.degree. C. In some examples, the aluminum alloy cast product is not cooled to below 400.degree. C. before the homogenizing (i.e., between the casting and the homogenizing). In other examples, however, the aluminum alloy cast product may be cooled to below 400.degree. C. before the homogenizing (i.e., between the casting and the homogenizing).

[0013] Optionally, rolling the homogenized aluminum alloy cast product includes controlling a rolling temperature during rolling. For example, a starting temperature of the rolling is optionally between 400.degree. C. and 550.degree. C. Optionally, an exit or finishing temperature of the rolling is between 300.degree. C. and 500.degree. C. In some examples, rolling the homogenized aluminum alloy cast product includes maintaining the temperature at or above a recrystallization temperature of the homogenized aluminum alloy.

[0014] In some non-limiting examples, provided herein is an aluminum alloy rolled article, which is formed by a process comprising providing a molten aluminum alloy composition, continuously casting the molten aluminum alloy composition to form an aluminum alloy cast product, homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product, and rolling the homogenized aluminum alloy cast product to form the aluminum alloy rolled article having a thickness of no more than 7 mm, such as between 0.01 mm and 7 mm, between 0.01 mm and 6 mm, between 0.01 mm and 5 mm, between 0.01 mm and 4 mm, between 0.01 mm and 3 mm, or between 0.01 mm and 2 mm, with the rolling carried out at a temperature of no less than 300.degree. C., such as between 300.degree. C. and 550.degree. C. In some non-limiting examples, the process does not comprise direct chill casting. In some further non-limiting examples, the continuously casting comprises using or use of twin-belt continuous casting. In some further non-limiting examples, the process does not comprise cold rolling.

[0015] In some aspects, the aluminum alloy rolled article comprises a first surface portion, such as a first surface portion that is substantially free of recrystallization texture. Optionally, the first surface portion has an isotropic texture, such as an isotropic texture that comprises a plurality of texture components. For example, each texture component of the plurality of texture components may optionally comprise less than 1 volume percent of the first surface portion. In some examples, the aluminum alloy rolled article may have an angularly uniform (isotropic) Langford coefficient (R-value), such as an R-value that does not vary appreciably (e.g., less than 10%, less than 5%, or less than 1%) along an angle relative to the rolling direction. For example, R-values for an angularly uniform rolled aluminum article may advantageously vary between 0% and 10% (e.g., 0%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10%) at directions parallel to the rolling direction (longitudinal), perpendicular to the rolling direction (transverse), and at directions between longitudinal and transverse directions (diagonal).

[0016] In some non-limiting examples, provided herein is an aluminum alloy article of manufacture. The aluminum alloy article of manufacture can be an automotive body part (e.g., a structural part or an outer panel). The aluminum alloy article of manufacture can be an electronics device housing, an aerospace body part, a transportation body part, or a container part (e.g., a storage tank or an aluminum can). Aluminum alloy articles of manufacture may optionally be formed from an aluminum alloy rolled article having a surface free or substantially free of recrystallization texture, such as by a technique involving subjecting an aluminum alloy rolled article having a surface free or substantially free of recrystallization texture to a stamping, drawing, or other forming process.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0018] FIG. 1 provides a schematic overview of a method of and system for making an aluminum alloy rolled article according to certain aspects of the present disclosure.

[0019] FIG. 2 is a graph comparing cube texture component to brass texture component of aluminum alloys produced according to certain aspects of the present disclosure.

[0020] FIG. 3 is a graph for AA6451 alloys comparing cube texture component, goss texture component, brass texture component, S texture component and copper texture component of aluminum alloys produced according to certain aspects of the present disclosure.

[0021] FIG. 4 is a graph for AA6111 alloys comparing cube texture component, goss texture component, brass texture component, S texture component and copper texture component of aluminum alloys produced according to certain aspects of the present disclosure.

[0022] FIG. 5 is a graph for AA5754 alloys comparing cube texture component, goss texture component, brass texture component, S texture component and copper texture component of aluminum alloys produced according to certain aspects of the present disclosure.

DETAILED DESCRIPTION

[0023] Certain aspects and features of the present disclosure relate to aluminum alloy articles having isotropic surface textures. Aluminum alloy articles having isotropic surface textures can further have isotropic mechanical properties, providing highly formable aluminum alloy articles. Further aspects and features of the present disclosure relate to methods to produce aluminum alloy articles having isotropic surface textures. Still further aspects and features of the present disclosure include aluminum alloy rolled articles having isotropic surface textures.

Definitions and Descriptions

[0024] The terms "invention," "the invention," "this invention" and "the present invention" used herein are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0025] In this description, reference is made to alloys identified by aluminum industry designations, such as "series" or "6xxx." For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot," both published by The Aluminum Association.

[0026] Aluminum alloys may described in terms of their elemental composition in weight percentage (wt. %) based on the total weight of the alloy. In certain examples of each alloy, the remainder is aluminum, with a maximum wt. % of 0.15% for the sum of the impurities.

[0027] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of "1 to 10" should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.

[0028] As used herein, the meaning of "a," "an," or "the" includes singular and plural references unless the context clearly dictates otherwise.

[0029] As used herein, a plate generally has a thickness greater than about 15 mm. For example, a plate may refer to an aluminum or aluminum alloy product or article having a thickness of greater than or about 15 mm, greater than or about 20 mm, greater than or about 25 mm, greater than or about 30 mm, greater than or about 35 mm, greater than or about 40 mm, greater than or about 45 mm, greater than or about 50 mm, or greater than or about 100 mm.

[0030] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

[0031] As used herein, a sheet generally refers to an aluminum (or aluminum alloy) cast product or article having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, less than about 0.3 mm (e.g., about 0.2 mm), or between 0.2 mm and 4 mm.

[0032] Reference may be is made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see "American National Standards (ANSI) H35 on Alloy and Temper Designation Systems." An F condition or temper refers to an aluminum alloy as fabricated. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0033] As used herein, the term "substantially free of surface texture" refers to a characteristic of all or a portion of a surface of a prepared metal plate, shate, or sheet wherein no one of a cube texture component, a goss texture component, a brass texture component, an S texture component, or a copper texture component is a predominant texture component found within the portion of the surface of the prepared metal plate, shate or sheet. For example, a surface substantially free of surface texture may have low volume or areal percentages of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component, such as less than or about 1 volume percent or less than or about 1 areal percent.

[0034] As used herein, the term "uniform thinning" refers to a rolling deformation wherein a thickness of a prepared metal plate, shate, or sheet is decreased during rolling such that the thickness of a first portion of the prepared metal plate, shate, or sheet remains within .+-.2% of a thickness of any other portion of the prepared metal plate, shate, or sheet. In some cases, uniform thinning may refer to a uniformity of the reduction of a thickness of a prepared metal plate, shate, or sheet upon being subjected to a tensile stress along a different directions (e.g., a longitudinal direction (rolling direction), a transverse direction (perpendicular to the rolling direction), or a diagonal direction (direction between the transverse and longitudinal directions). Optionally, a material that undergoes uniform thinning may have a Langford coefficient (R-value) that does not substantially vary as a function of angle (i.e., angle from the rolling direction).

[0035] As used herein, terms such as "cast product," "cast metal product," "cast aluminum product," "cast aluminum alloy product," "aluminum alloy cast product," and the like are interchangeable and may refer to a product produced by direct chill casting (including direct chill co-casting), semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.

Aluminum Alloy Rolled Articles

Aluminum Alloy Rolled Article Surface

[0036] In some non-limiting examples, an aluminum alloy rolled article having a rolled surface can have at least a first surface portion that has low volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component, such as volume fractions that are between 0% and 1%, or that is substantially free of recrystallization texture. In the context of the present disclosure, a surface portion that is substantially free of recrystallization texture refers to a surface portion that is uniform across an area defined as the surface portion, wherein no one recrystallization texture component is dominant. In some non-limiting examples, a surface portion that has low volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component, such as volume fractions that are between 0% and 1%, or that is substantially free of recrystallization texture may refer to a surface portion in which recrystallization textures that exhibit angularly dependent Langford coefficients are present only in minor amounts such that the overall Langford coefficient of the surface portion is isotropic (i.e., not substantially angularly dependent or substantially angularly uniform). In some non-limiting examples, a surface portion can have an isotropic texture, wherein the isotropic texture comprises a plurality of texture components, wherein each texture component comprises less than 1 volume percent (vol. %) of the surface portion. In some aspects, the plurality of texture components comprise surface texture components selected from the group consisting of a cube component, a goss component, a brass component, an S component, and a copper component.

[0037] In some cases, the aluminum alloy rolled article described herein can have an isotropic surface texture described as a ratio between each texture component. In some non-limiting examples, a surface portion can have a ratio of the cube component to the brass component (and likewise, a ratio of the brass component to the cube component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the brass component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the brass component can be less than 1.00.

[0038] In some non-limiting examples, the surface portion can have a ratio of the cube component to the goss component (and likewise, a ratio of the goss component to the cube component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the goss component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the goss component can be less than 1.00.

[0039] In some non-limiting examples, the surface portion can have a ratio of the cube component to the S component (and likewise, a ratio of the S component to the cube component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the S component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the S component can be less than 1.00.

[0040] In some non-limiting examples, the surface portion can have a ratio of the cube component to the copper component (and likewise, a ratio of the copper component to the cube component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the copper component can be less than 1.00.

[0041] In some non-limiting examples, the surface portion can have a ratio of the goss component to the brass component of from 0.80 to 1.25. For example, the surface portion can have a ratio of the goss component to the brass component (and likewise, a ratio of the brass component to the goss component) of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the goss component to the brass component can be less than 1.00.

[0042] In some non-limiting examples, the surface portion can have a ratio of the goss component to the S component (and likewise, a ratio of the S component to the goss component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the goss component to the S component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the goss component to the S component can be less than 1.00.

[0043] In some non-limiting examples, the surface portion can have a ratio of the goss component to the copper component (and likewise, a ratio of the copper component to the goss component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the goss component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the goss component to the copper component can be less than 1.00.

[0044] In some non-limiting examples, the surface portion can have a ratio of the brass component to the S component (and likewise, a ratio of the S component to the brass component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the brass component to the S component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the brass component to the S component can be less than 1.00.

[0045] In some non-limiting examples, the surface portion can have a ratio of the brass component to the copper component (and likewise, a ratio of the copper component to the brass component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the brass component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the brass component to the copper component can be less than 1.00.

[0046] In some non-limiting examples, the surface portion can have a ratio of the S component to the copper component (and likewise, a ratio of the copper component to the S component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the S component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the S component to the copper component can be less than 1.00.

[0047] In some non-limiting examples, the surface portion can have a ratio of the cube component to the goss component to the brass component (or any suitable ratio including the cube component, the goss component, and the brass component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the goss component to the brass component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the goss component to the brass component can be less than 1.00.

[0048] In some non-limiting examples, the surface portion can have a ratio of the cube component to the goss component to the S component (or any suitable ratio including the cube component, the goss component, and the S component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the goss component to the S component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the goss component to the S component can be less than 1.00.

[0049] In some non-limiting examples, the surface portion can have a ratio of the cube component to the goss component to the copper component (or any suitable ratio including the cube component, the goss component, and the copper component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the goss component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the goss component to the copper component can be less than 1.00.

[0050] In some non-limiting examples, the surface portion can have a ratio of the goss component to the brass component to the S component (or any suitable ratio including the goss component, the brass component, and the S component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the goss component to the brass component to the S component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the goss component to the brass component to the S component can be less than 1.00.

[0051] In some non-limiting examples, the surface portion can have a ratio of the goss component to the brass component to the copper component (or any suitable ratio including the goss component, the brass component, and the copper component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the goss component to the brass component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the goss component to the brass component to the copper component can be less than 1.00.

[0052] In some non-limiting examples, the surface portion can have a ratio of the brass component to the S component to the copper component (or any suitable ratio including the brass component, the S component, and the copper component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the brass component to the S component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the brass component to the S component to the copper component can be less than 1.00.

[0053] In some non-limiting examples, the surface portion can have a ratio of the cube component to the goss component to the brass component to the S component (or any suitable ratio including the cube component, the goss component, the brass component, and the S component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the goss component to the brass component to the S component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the goss component to the brass component to the S component can be less than 1.00.

[0054] In some non-limiting examples, the surface portion can have a ratio of the cube component to the goss component to the brass component to the copper component (or any suitable ratio including the cube component, the goss component, the brass component, and the copper component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the goss component to the brass component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the goss component to the brass component to the copper component can be less than 1.00.

[0055] In some non-limiting examples, the surface portion can have a ratio of the goss component to the brass component to the S component to the copper component (or any suitable ratio including the goss component, the brass component, the S component, and the copper component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the goss component to the brass component to the S component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the goss component to the brass component to the S component to the copper component can be less than 1.00.

[0056] In some non-limiting examples, the surface portion can have a ratio of the cube component to the goss component to the brass component to the S component to the copper component (or any suitable ratio including the cube component, the goss component, the brass component, the S component, and the copper component) of from 0.80 to 1.25. For example, the surface portion can have a ratio of the cube component to the goss component to the brass component to the S component to the copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cube component to the goss component to the brass component to the S component to the copper component can be less than 1.00.

[0057] In some aspects, an aluminum alloy article having a portion that has low volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component, such as volume fractions that are between 0% and 1%, or that is substantially free of recrystallization texture (e.g., an isotropic texture, or a texture-less surface) in any direction relative to a rolling direction of the aluminum alloy article (e.g., longitudinal, transverse or diagonal) can provide an aluminum alloy having isotropic mechanical properties in any direction relative to the rolling direction of the aluminum alloy article. For example, an aluminum alloy article having isotropic mechanical properties can provide an aluminum alloy article that does not exhibit anisotropic forming in, for example, the diagonal direction while exhibiting isotropic forming in the longitudinal and/or transverse direction.

[0058] In some examples, comparative aluminum alloy articles may correspond to an aluminum alloy article that can be direct chill cast from a molten aluminum alloy to form an aluminum alloy ingot. The aluminum alloy ingot can then be homogenized and hot rolled to an intermediate gauge aluminum alloy plate. The intermediate gauge aluminum alloy plate can optionally further be cold rolled to a final gauge aluminum alloy article. Comparative aluminum alloy articles can have a plurality of surface portions having a dominant texture component. For example, a first surface portion can be dominated by a cube texture and at least a second surface portion can be dominated by a goss texture component. Thus, the diagonal direction relative to the rolling direction of the comparative aluminum alloy article can have an anisotropic recrystallization texture, wherein a first surface portion can be dominated by cube texture and at least a second surface portion can be dominated by a goss texture component. A lower amount of thinning during rolling in the diagonal direction can be caused by splitting surface portions (e.g., pulling the first surface portion away from the at least second surface portion) in the diagonal direction relative to the rolling direction during forming. An exemplary aluminum alloy article, produced according to methods described below, can have an isotropic surface texture in any direction relative to the rolling direction and provide uniform thinning in any direction relative to the rolling direction.

Aluminum Alloy Rolled Article Gauges and Compositions

[0059] In some non-limiting examples, aluminum alloy rolled articles can be produced in a plate gauge, a shate gauge, or a sheet gauge, as described above. In some aspects, the aluminum alloy rolled article can be produced from a molten aluminum alloy. The molten aluminum alloy can be a 5xxx series aluminum alloy or a 6xxx series aluminum alloy.

[0060] Non-limiting exemplary AA5xxx series aluminum alloys include AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, and AA5088.

[0061] Non-limiting exemplary AA6xxx series aluminum alloys include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, and AA6092.

Methods of Making

[0062] An exemplary aluminum alloy rolled article can be formed by a process that includes providing a molten aluminum alloy composition, continuously casting the molten aluminum alloy composition to form an aluminum alloy cast product, homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product, and hot rolling the homogenized aluminum alloy cast product to form the aluminum alloy rolled article having a thickness of no more than 7 mm, such as between 0.01 mm and 7 mm, between 0.01 mm and 6 mm, between 0.01 mm and 5 mm, between 0.01 mm and 4 mm, between 0.01 mm and 3 mm, or between 0.01 mm and 2 mm. The rolling can be carried out at a temperature of no less than 300.degree. C. The exemplary aluminum alloy rolled article can be formed by a process that does not include cold rolling. Optionally, the exemplary aluminum alloy rolled article can be subjected to quenching after the rolling. FIG. 1 provides a schematic example of a method and system of making an aluminum alloy rolled article. In embodiments, FIG. 1 provides an overview of a process referred to as a hot roll to final gauge and temper.

Continuous Casting

[0063] The aluminum alloy products described herein can be cast using a continuous casting (CC) process. The continuous casting process can be performed, for example, by way of the use of twin belt casters, twin roll casters, or block casters.

[0064] As illustrated in FIG. 1, in some examples, a method of making an aluminum alloy rolled article includes providing a molten aluminum alloy 105 and continuously injecting the molten metal from a molten metal injector into a continuous caster 110 to form an aluminum alloy cast product 115. The method also can include withdrawing the aluminum alloy cast product, such as a cast aluminum alloy sheet, plate, or shate, from an exit of the continuous caster.

Rolling

[0065] The aluminum alloy cast product 115 can then be processed by any suitable means. Optionally, the processing steps can be used to prepare aluminum alloy rolled articles. Such processing steps include, but are not limited to, homogenization, which may occur as illustrated in FIG. 1 at block 120, and hot rolling, which may occur as illustrated in FIG. 1 at section 125. In some non-limiting examples, as explained in more detail below, a continuously cast aluminum alloy product, such as a 6xxx series aluminum alloy or a 5xxx series aluminum alloy, can be hot rolled to a final gauge. The processing can be performed without a cold rolling step (i.e., the cast product can be rolled to a final gauge without cold rolling). In some cases, hot rolling a continuously cast aluminum alloy product to a final gauge can provide an isotropic recrystallization texture within a surface of the aluminum alloy rolled article thereby formed. In some further cases, hot rolling a continuously cast aluminum alloy product to a final gauge can improve formability by providing an aluminum alloy rolled article having isotropic mechanical properties.

[0066] Optionally, homogenization can be performed immediately after casting. Optionally, the temperature of the aluminum alloy cast product 115 is not permitted to fall below 400.degree. C. between casting and homogenizing. The homogenization temperature can be between 400.degree. C. and 600.degree. C., for example. In some examples, homogenization may be useful for maintaining a temperature of the cast alloy at a particular value or between a range of values for a duration of time, such as up to 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 hours in some examples. In some examples, homogenization may be useful for providing the cast alloy to a hot rolling stage at a particular starting temperature. After homogenization is performed at block 120, the aluminum alloy cast product 115 may be referred to as a homogenized aluminum alloy cast product.

[0067] Optionally, the hot rolling step can be performed immediately after casting or following homogenization. The hot rolling temperature can be at least 300.degree. C., such as between 300.degree. C. and 550.degree. C. For example, the hot rolling temperature can be at least 300.degree. C., at least 310.degree. C., at least 320.degree. C., at least 330.degree. C., at least 340.degree. C., at least 350.degree. C., at least 360.degree. C., at least 370.degree. C., at least 380.degree. C., at least 390.degree. C., at least 400.degree. C., at least 410.degree. C., at least 420.degree. C., at least 430.degree. C., at least 440.degree. C., at least 450.degree. C., at least 460.degree. C., at least 470.degree. C., at least 480.degree. C., at least 490.degree. C., at least 500.degree. C., at least 510.degree. C., at least 520.degree. C., at least 530.degree. C., at least 540.degree. C., or up to 550.degree. C. Optionally, the hot rolling temperature can be or include the recrystallization temperature of the aluminum alloy. The homogenized aluminum alloy cast product or aluminum alloy cast product entering into the hot rolling stage can have a temperature of between 400.degree. C. and 550.degree. C., for example.

[0068] During the hot rolling step, the gauge of the aluminum alloy cast product is reduced in thickness. In some cases, the total amount of reduction of thickness during hot rolling can be at or less than 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, or 15%. In some cases, the cast product can be a metal sheet wherein the final gauge of the rolled article is 7 mm or less, 6 mm or less, 5 mm or less, 4 mm or less, 3 mm or less, 2 mm or less, 1.9 mm or less, 1.8 mm or less, 1.7 mm or less, 1.6 mm or less, 1.5 mm or less, 1.4 mm or less, 1.3 mm or less, 1.2 mm or less, 1.1 mm, 1.0 mm or less, 0.9 mm or less, 0.8 mm or less, 0.7 mm or less, 0.6 mm or less, 0.5 mm or less, 0.4 mm or less, 0.3 mm or less, 0.2 mm or less, or as small as 0.1 mm. Upon exiting the hot rolling stage, the aluminum alloy rolled article can have a temperature of between 300.degree. C. and 500.degree. C., for example.

Optional Processing Steps

[0069] The method can optionally include a step of quenching the aluminum alloy rolled article after hot rolling, as illustrated at element 130 of FIG. 1. The aluminum alloy rolled article can be cooled to a temperature at or below about 300.degree. C. in the quenching step, such as to a temperature between 50.degree. C. and 300.degree. C. For example, the aluminum alloy rolled article can be cooled to a temperature at or below 290.degree. C., at or below 280.degree. C., at or below 270.degree. C., at or below 260.degree. C., at or below 250.degree. C., at or below 240.degree. C., at or below 230.degree. C., at or below 220.degree. C., at or below 210.degree. C., at or below 200.degree. C., at or below 190.degree. C., at or below 180.degree. C., at or below 170.degree. C., at or below 160.degree. C., at or below 150.degree. C., at or below 140.degree. C., at or below 130.degree. C., at or about 120.degree. C., at or below 110.degree. C., or at or below 100.degree. C. The aluminum alloy rolled article can be quenched immediately after hot rolling or within a short period of time thereafter (e.g., within 10 hours or less, 9 hours or less, 8 hours or less, 7 hours or less, 6 hours or less, 5 hours or less, 4 hours or less, 3 hours or less, 2 hours or less, 1 hour or less, or 30 minutes or less). The aluminum alloy rolled article can optionally be coiled and stored after hot rolling and/or quenching, as illustrated at element 135 of FIG. 1.

Methods of Use

Automotive and Transportation

[0070] Aluminum alloy articles of manufacture produced from aluminum alloy rolled articles, such as sheets and shates, described herein can be used in automotive applications and other transportation applications, including aircraft and railway applications. For example, the aluminum alloy rolled articles can be used to prepare automotive structural parts, such as outer panels, inner panels, side panels, bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner hoods, outer hoods, or trunk lid panels. The aluminum alloy rolled articles and methods described herein can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels.

Electronics

[0071] The aluminum alloy rolled articles described herein can also be used in electronics applications. For example, the aluminum alloy rolled articles and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the aluminum alloy rolled articles can be used to prepare anodized quality sheets and materials.

Containment

[0072] The aluminum alloy rolled articles described herein can be used in container applications, including aluminum can body stock and aluminum can end stock.

Mechanical Properties

[0073] The aluminum alloy rolled articles described herein can have a surface that has low volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component, such as volume fractions that are between 0% and 1%, or that is substantially free of recrystallization texture. An aluminum alloy article having a surface of this nature (e.g., an isotropic surface) can provide an aluminum alloy article having isotropic mechanical properties (e.g., mechanical properties that can be uniform in any direction across the surface relative to a rolling direction of the aluminum alloy cast product). An aluminum alloy rolled article having isotropic mechanical properties can be subjected to forming processes that demand a high formability. In some non-limiting examples, the aluminum alloy rolled articles described herein can be subjected to complex forming processes. In some further examples, the aluminum alloy rolled articles described herein can be subjected to multi-step forming processes.

[0074] Various advantages may be achieved using the aluminum alloy cast products and aluminum alloy rolled articles and methods of making aluminum alloy cast products and aluminum alloy rolled articles described herein. For example, as noted above, the aluminum alloy rolled articles may exhibit advantageous mechanical properties, such as an isotropic surface. Additionally, the aluminum alloy rolled articles may exhibit isotropic thinning properties when subjected to strain, meaning that the aluminum alloy rolled articles may have a tendency to thin during straining by an approximately equal amount in all directions. This property may provide a benefit in forming articles of manufacture using the aluminum alloy rolled articles described herein.

[0075] For example, conventionally cold-rolled aluminum may exhibit mechanical anisotropy, meaning the mechanical properties of the cold-rolled aluminum are not uniform along different directions (e.g., rolling direction, transverse direction, diagonal direction, etc.). When cold-rolled aluminum is subjected to forming or drawing to generate an article of manufacture, the material may have a tendency to thin different amounts upon being subjected to strain along different directions. Depending on the shape and specific form of the article of manufacture, the article may thin significantly more in some locations than in others. When subjected to sufficient strain and thinning along directions that have a tendency to thin much more than others (e.g., along a diagonal direction), the article of manufacture may break, fracture, or otherwise fail at these critical points or along these critical directions.

[0076] Due to the isotropic mechanical properties, the presently described aluminum alloy cast products and aluminum alloy rolled articles overcome these and other processing difficulties. By having a surface that has low volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component, such as volume fractions that are between 0% and 1%, or that is substantially free of recrystallization texture, the surface can exhibit isotropic mechanical properties, such as the Langford coefficient (R-value), such that forming an article of manufacture using the presently described aluminum alloy rolled articles does not result in the same failure along the above-described critical directions or at the above-described critical points.

[0077] The following examples will serve to further illustrate the present invention without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort can be had to various embodiments, modifications and equivalents thereof which, after reading the description herein, can suggest themselves to those skilled in the art without departing from the spirit of the invention.

Example A

[0078] Aluminum alloy samples were provided according to methods described herein. Alloys 6111, 6451, and 5754 were produced by exemplary methods, including continuous casting, homogenization and hot rolling to a final gauge. Alloys 6451 and 5754 were further produced by an optional method for comparison, including continuous casting, homogenization and cold rolling to a final gauge. Alloys 6111, 6451, and 5754 were produced according to comparative methods, including direct chill casting, homogenization, hot rolling, and cold rolling. The aluminum alloy samples were analyzed for recrystallization texture. FIG. 1 is a bar chart showing results of recrystallization texture analysis. A cube texture component (left histogram in each pair) and a brass texture component (right histogram in each pair) are shown form comparison. Texture component volume fraction (%) is shown for cube and brass texture components. Continuously cast alloys are referred to herein as "CC" and direct chill cast alloys are referred to herein as "DC." Processing methods are described in Table 1 below:

TABLE-US-00001 TABLE 1 Processing Methods HRTGT Hot roll to final gauge and temper HR + CR Hot roll and cold roll CR Cold roll HR Hot roll

[0079] Hot roll to final gauge and temper indicates the exemplary method described herein, including continuous casting, homogenization, and hot rolling to a final gauge, as shown in FIG. 1. The exemplary method provided aluminum alloy rolled articles having a uniform distribution of texture components, as shown in FIGS. 2, 3, and 4 and described below. The comparative methods provided an aluminum alloy rolled article having an anisotropic recrystallization texture, wherein the surface was dominated by cube texture. Isotropic surface recrystallization texture was provided by the exemplary method described herein.

[0080] FIGS. 2, 3, and 4 are bar charts showing results of recrystallization texture analysis. A cube texture component (left histogram in each set), a goss texture component (second from the left histogram in each set), a brass texture component (center histogram in each set), an S texture component (fourth from the left histogram in each set) and a copper texture component (right histogram in each set) are shown for comparison. As evident in FIGS. 2, 3, and 4, the exemplary method provided aluminum alloy rolled articles having a uniform distribution of texture components, wherein no texture component was observed having a volume fraction greater than 1% within the surface of the aluminum alloy. The comparative methods provided an aluminum alloy rolled articles having an anisotropic recrystallization texture, wherein the surface was dominated by cube texture. Isotropic surface recrystallization texture was provided by the exemplary method described herein.

Examples 1-61

[0081] As used below, any reference to a series of examples is to be understood as a reference to each of those examples disjunctively (e.g., "examples 1-4" is to be understood as "examples 1, 2, 3, or 4").

[0082] Example 1 is an aluminum alloy rolled article comprising a rolled surface, wherein the rolled surface comprises a first surface portion, comprising at least a first surface portion, and wherein the first surface portion is substantially free of recrystallization texture or wherein the first surface portion has volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component that are between 0% and 1%.

[0083] Example 2 is the aluminum alloy rolled article of example 1, wherein the first surface portion has an isotropic texture, wherein the isotropic texture comprises a plurality of texture components, wherein each texture component comprises less than 1 volume percent of the first surface portion.

[0084] Example 3 is the aluminum alloy rolled article of example 2, wherein the plurality of texture components comprise surface texture components selected from the group consisting of a cube component, a goss component, a brass component, an S component, and a copper component.

[0085] Example 4 is the aluminum alloy rolled article of examples 1-3, wherein the first surface portion exhibits substantially uniform thinning during forming across the first surface portion in any direction relative to a rolling direction.

[0086] Example 5 is the aluminum alloy rolled article of examples 1-4, wherein the first surface portion has a cube component to brass component ratio of from 0.80 to 1.25.

[0087] Example 6 is the aluminum alloy rolled article of examples 1-5, wherein the first surface portion has a cube component to goss component ratio of from 0.80 to 1.25.

[0088] Example 7 is the aluminum alloy rolled article of examples 1-6, wherein the first surface portion has a cube component to S component ratio of from 0.80 to 1.25.

[0089] Example 8 is the aluminum alloy rolled article of examples 1-7, wherein the first surface portion has a cube component to copper component ratio of from 0.80 to 1.25.

[0090] Example 9 is the aluminum alloy rolled article of examples 1-8, wherein the first surface portion has a goss component to brass component ratio of from 0.80 to 1.25.

[0091] Example 10 is the aluminum alloy rolled article of examples 1-9, wherein the first surface portion has a goss component to S component ratio of from 0.80 to 1.25.

[0092] Example 11 is the aluminum alloy rolled article of examples 1-10, wherein the first surface portion has a goss component to copper component ratio of from 0.80 to 1.25.

[0093] Example 12 is the aluminum alloy rolled article of examples 1-11, wherein the first surface portion has a brass component to S component ratio of from 0.80 to 1.25.

[0094] Example 13 is the aluminum alloy rolled article of examples 1-12, wherein the first surface portion has a brass component to copper component ratio of from 0.80 to 1.25.

[0095] Example 14 is the aluminum alloy rolled article of examples 1-13, wherein the first surface portion has an S component to copper component ratio of from 0.80 to 1.25.

[0096] Example 15 is the aluminum alloy rolled article of examples 1-14, wherein the first surface portion has a cube component to goss component to brass component ratio of from 0.80 to 1.25.

[0097] Example 16 is the aluminum alloy rolled article of examples 1-15, wherein the first surface portion has a cube component to goss component to S component ratio of from 0.80 to 1.25.

[0098] Example 17 is the aluminum alloy rolled article of examples 1-16, wherein the first surface portion has a cube component to goss component to copper component ratio of from 0.80 to 1.25.

[0099] Example 18 is the aluminum alloy rolled article of examples 1-17, wherein the first surface portion has a goss component to brass component to S component ratio of from 0.80 to 1.25.

[0100] Example 19 is the aluminum alloy rolled article of examples 1-18, wherein the first surface portion has a goss component to brass component to copper component ratio of from 0.80 to 1.25.

[0101] Example 20 is the aluminum alloy rolled article of examples 1-19, wherein the first surface portion has a brass component to S component to copper component ratio of from 0.80 to 1.25.

[0102] Example 21 is the aluminum alloy rolled article of examples 1-20, wherein the first surface portion has a cube component to goss component to brass component to S component ratio of from 0.80 to 1.25.

[0103] Example 22 is the aluminum alloy rolled article of examples 1-21, wherein the first surface portion has a cube component to goss component to brass component to copper component ratio of from 0.80 to 1.25.

[0104] Example 23 is the aluminum alloy rolled article of examples 1-22, wherein the first surface portion has a goss component to brass component to S component to copper component ratio of from 0.80 to 1.25.

[0105] Example 24 is the aluminum alloy rolled article of examples 1-23, wherein the first surface portion has a cube component to goss component to brass component to S component to copper component ratio of from 0.80 to 1.25.

[0106] Example 25 is the aluminum alloy rolled article of examples 1-24, wherein the aluminum alloy rolled article has a width or length of from 6.5 mm to 40 m.

[0107] Example 26 is the aluminum alloy rolled article of examples 1-25, wherein the aluminum alloy rolled article comprises or is composed of a 5xxx aluminum alloy.

[0108] Example 27 is the aluminum alloy rolled article of examples 1-26, wherein the aluminum alloy rolled article comprises or is composed of a 6xxx aluminum alloy.

[0109] Example 28 is the aluminum alloy rolled article of examples 1-27, wherein the aluminum alloy rolled article is formed by a process that does not comprise cold rolling.

[0110] Example 29 is the aluminum alloy rolled article of examples 1-28, wherein the aluminum alloy rolled article is formed by a process that comprises: providing a molten aluminum alloy composition; continuously casting the molten aluminum alloy composition to form an aluminum alloy cast product; homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product; and rolling the homogenized aluminum alloy cast product to form the aluminum alloy rolled article having a thickness of between 0.01 mm and 7 mm, wherein the rolling is carried out at a temperature of between 300.degree. C. and 550.degree. C.

[0111] Example 30 is a method for making an aluminum alloy rolled article, comprising: providing a molten aluminum alloy composition; continuously casting the molten aluminum alloy composition to form an aluminum alloy cast product; homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product; and rolling the homogenized aluminum alloy cast product to form an aluminum alloy rolled article having a thickness of between 0.01 mm and 7 mm, wherein the rolling is carried out at a temperature of between 300.degree. C. and 550.degree. C.

[0112] Example 31 is the method of example 30, wherein homogenizing the aluminum alloy cast product includes controlling a homogenization temperature of the aluminum alloy cast product after exiting from a continuous caster, wherein the homogenization temperature is between 400.degree. C. and 600.degree. C.

[0113] Example 32 is the method of examples 30-31, wherein the aluminum alloy cast product is not cooled to below 400.degree. C. before the homogenizing.

[0114] Example 33 is the method of example 30-32, wherein rolling the homogenized aluminum alloy cast product includes controlling a rolling temperature during rolling, wherein a starting temperature of the rolling is between 400.degree. C. and 550.degree. C., and wherein an exit temperature of the rolling is between 300.degree. C. and 500.degree. C.

[0115] Example 34 is the method of examples 30-33, wherein rolling the homogenized aluminum alloy cast product includes maintaining the temperature at or above a recrystallization temperature of the homogenized aluminum alloy cast product.

[0116] Example 35 is the method of examples 30-34, further comprising, following the rolling, subjecting the aluminum alloy rolled article to quenching.

[0117] Example 36 is the method of examples 30-35, wherein the method does not comprise direct chill casting.

[0118] Example 37 is the method of examples 30-36, wherein the method does not comprise cold rolling the aluminum alloy rolled article to a final thickness.

[0119] Example 38 is the method of examples 30-37, wherein the aluminum alloy rolled article comprises at least a first surface portion, and wherein the first surface portion is substantially free of recrystallization texture or wherein the first surface portion has volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component that are between 0% and 1%.

[0120] Example 39 is an aluminum alloy rolled article, which is formed by a process comprising: providing a molten aluminum alloy composition; continuously casting the molten aluminum alloy composition to form an aluminum alloy cast product; homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product; and rolling the homogenized aluminum alloy cast product to form the aluminum alloy rolled article having a thickness of between 0.01 mm and 7 mm, wherein the rolling is carried out at a temperature of between 300.degree. C. and 550.degree. C.

[0121] Example 40 is the aluminum alloy rolled article of example 39, wherein homogenizing the aluminum alloy cast product includes controlling a homogenization temperature of the aluminum alloy cast product after exiting from a continuous caster, wherein the homogenization temperature is between 400.degree. C. and 600.degree. C.

[0122] Example 41 is the aluminum alloy rolled article of examples 39-40, wherein the aluminum alloy cast product is not cooled to below 400.degree. C. before the homogenizing.

[0123] Example 42 is the aluminum alloy rolled article of examples 39-41, wherein rolling the homogenized aluminum alloy cast product includes controlling a rolling temperature during rolling, wherein a starting temperature of the rolling is between 400.degree. C. and 550.degree. C., and wherein an exit temperature of the rolling is between 300.degree. C. and 500.degree. C.

[0124] Example 43 is the aluminum alloy rolled article of examples 39-42, wherein rolling the homogenized aluminum alloy cast product includes maintaining the temperature at or above a recrystallization temperature of the homogenized aluminum alloy cast product.

[0125] Example 44 is the aluminum alloy rolled article of examples 39-43, wherein the process further comprises, following the rolling, subjecting the aluminum alloy rolled article to quenching.

[0126] Example 45 is the aluminum alloy rolled article of examples 39-44, wherein the process does not comprise direct chill casting.

[0127] Example 46 is the aluminum alloy rolled article of examples 39-45, wherein the process does not comprise cold rolling the aluminum alloy rolled article to a final thickness.

[0128] Example 47 is the aluminum alloy rolled article of examples 39-46, comprising at least a first surface portion, and wherein the first surface portion is substantially free of recrystallization texture or wherein the first surface portion has volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component that are between 0% and 1%.

[0129] Example 48 is the aluminum alloy rolled article of example 47, wherein the first surface portion has an isotropic texture.

[0130] Example 49 is the aluminum alloy rolled article of example 48, wherein the isotropic texture comprises a plurality of texture components, and wherein each texture component comprises less than 1 volume percent of the first surface portion.

[0131] Example 50 is the aluminum alloy rolled article of examples 47-49, wherein the first surface portion exhibits substantially uniform thinning during forming across the first surface portion in any direction relative to a rolling direction.

[0132] Example 51 is an aluminum alloy article of manufacture, comprising an aluminum alloy rolled article of examples 1-29, an aluminum alloy rolled article of any one of examples 39-50, or an aluminum alloy rolled article formed by the method of any one of examples 30-38.

[0133] Example 52 is the aluminum alloy article of manufacture of example 51, wherein the aluminum alloy rolled article is subjected to a stamping, forming, or drawing process.

[0134] Example 53 is the aluminum alloy article of manufacture of examples 51-52, wherein the aluminum alloy article of manufacture is an automotive body part.

[0135] Example 54 is the aluminum alloy article of manufacture of example 53, wherein the automotive body part comprises a structural part.

[0136] Example 55 is the aluminum alloy article of manufacture of example 53, wherein the automotive body part is an outer panel.

[0137] Example 56 is the aluminum alloy article of manufacture of examples 51-52, wherein the aluminum alloy article of manufacture is an electronics device housing.

[0138] Example 57 is the aluminum alloy article of manufacture of examples 51-52, wherein the aluminum alloy article of manufacture is an aerospace body part.

[0139] Example 58 is the aluminum alloy article of manufacture of examples 51-52, wherein the aluminum alloy article of manufacture is a transportation body part.

[0140] Example 59 is the aluminum alloy article of manufacture of examples 51-52, wherein the aluminum alloy article of manufacture is a container part.

[0141] Example 60 is the aluminum alloy article of manufacture of example 59, wherein the aluminum alloy article of manufacture is a storage tank.

[0142] Example 61 is the aluminum alloy article of manufacture of example 59, wherein the aluminum alloy article of manufacture is an aluminum can end.

[0143] All patents, publications and abstracts cited above are incorporated herein by reference in their entirety. The foregoing description of the embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

1. A method for making an aluminum alloy rolled article, comprising: providing a molten aluminum alloy composition; continuously casting the molten aluminum alloy composition to form an aluminum alloy cast product; homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product; and rolling the homogenized aluminum alloy cast product to form an aluminum alloy rolled article having a thickness of between 0.01 mm and 7 mm, wherein the rolling is carried out at a temperature of between 300.degree. C. and 550.degree. C.

2. The method of claim 1, wherein homogenizing the aluminum alloy cast product includes controlling a homogenization temperature of the aluminum alloy cast product after exiting from a continuous caster, wherein the homogenization temperature is between 400.degree. C. and 600.degree. C.

3. The method of claim 1, wherein the aluminum alloy cast product is not cooled to below 400.degree. C. before the homogenizing.

4. The method of claim 1, wherein rolling the homogenized aluminum alloy cast product includes controlling a rolling temperature during rolling, wherein a starting temperature of the rolling is between 400.degree. C. and 550.degree. C., and wherein an exit temperature of the rolling is between 300.degree. C. and 500.degree. C.

5. The method of claim 1, wherein rolling the homogenized aluminum alloy cast product includes maintaining the temperature at or above a recrystallization temperature of the homogenized aluminum alloy cast product.

6. The method of claim 1, further comprising, following the rolling, subjecting the aluminum alloy rolled article to quenching.

7. The method of claim 1, wherein the method does not comprise direct chill casting.

8. The method of claim 1, wherein the method does not comprise cold rolling the aluminum alloy rolled article to a final thickness.

9. The method of claim 1, wherein the aluminum alloy rolled article comprises at least a first surface portion having volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component that are between 0% and 1%.

10. An aluminum alloy rolled article, which is formed by a process comprising: providing a molten aluminum alloy composition; continuously casting the molten aluminum alloy composition to form an aluminum alloy cast product; homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product; and rolling the homogenized aluminum alloy cast product to form the aluminum alloy rolled article having a thickness of between 0.01 mm and 7 mm, wherein the rolling is carried out at a temperature of between 300.degree. C. and 550.degree. C.

11. The aluminum alloy rolled article of claim 10, wherein homogenizing the aluminum alloy cast product includes controlling a homogenization temperature of the aluminum alloy cast product after exiting from a continuous caster, wherein the homogenization temperature is between 400.degree. C. and 600.degree. C.

12. The aluminum alloy rolled article of claim 10, wherein the aluminum alloy cast product is not cooled to below 400.degree. C. before the homogenizing.

13. The aluminum alloy rolled article of claim 10, wherein rolling the homogenized aluminum alloy cast product includes controlling a rolling temperature during rolling, wherein a starting temperature of the rolling is between 400.degree. C. and 550.degree. C., and wherein an exit temperature of the rolling is between 300.degree. C. and 500.degree. C.

14. The aluminum alloy rolled article of claim 10, wherein rolling the homogenized aluminum alloy cast product includes maintaining the temperature at or above a recrystallization temperature of the homogenized aluminum alloy cast product.

15. The aluminum alloy rolled article of claim 10, wherein the process further comprises, following the rolling, subjecting the aluminum alloy rolled article to quenching.

16. The aluminum alloy rolled article of claim 10, wherein the process does not comprise direct chill casting.

17. The aluminum alloy rolled article of claim 10, wherein the process does not comprise cold rolling the aluminum alloy rolled article to a final thickness.

18. The aluminum alloy rolled article of claim 10, comprising at least a first surface portion having volume fractions of a cube texture component, a goss texture component, a brass texture component, an S texture component, and a copper texture component that are between 0% and 1%.

19. The aluminum alloy rolled article of claim 18, wherein the first surface portion has an isotropic texture.

20. The aluminum alloy rolled article of claim 18, wherein the first surface portion exhibits substantially uniform thinning during forming across the first surface portion in any direction relative to a rolling direction.