# US 2025/0154635 A1 · Aluminum sheet materials, and production methods and alloy compositions therefor with reduced energy consumption and co2 emissions

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- Number: US 2025/0154635 A1
- Document ID: US20250154635A1
- Status: Published application
- Kind: A1
- Application number: 18/906,347
- Filed: 2024-10-04
- Published: 2025-05-15
- Earliest claimed: 2023-11-14
- Assignees: GM Global Technology Operations LLC
- Applicants: GM Global Technology Operations LLC
- Inventors: Henry ZHAN; Jiachen Pang; Michael Bugeaud
- Web page: https://patentgrep.com/patent/US20250154635A1

## CPC

- C22F 1/047: of alloys with magnesium as the next major constituent
- B22D 11/003: {Aluminium alloys}
- B22D 11/0622: {formed by two casting wheels}
- C22C 1/026: {Alloys based on aluminium}
- C22C 1/03: using master alloys
- C22C 21/02: with silicon as the next major constituent
- C22C 21/06: with magnesium as the next major constituent
- C22C 21/08: with silicon
- C22F: CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass, C23F17/00)
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- C22C: ALLOYS (treatment of alloys C21D, C22F)

## Abstract

A method of manufacturing aluminum sheet material includes melting secondary aluminum and adding primary aluminum and other alloying elements to the melt to achieve an alloy composition of from 2.5 wt % to 6.3 wt % Mg, from 0.6 wt % to 2.5 wt % Si, from 0.2 wt % to 0.4 wt % Fe, from 0.05 wt % to 0.2 wt % Cr, up to 0.6 wt % Mn, up to 0.1 wt % Cu, up to 0.1 wt % Zn, the balance being Al and unavoidable impurities, wherein the Si and Mg contents satisfy the relationship (Si wt. %>0.5*Mg wt. %-0.65 wt. %). The alloy is then continuously cast into an aluminum sheet. Aluminum sheet material made according to the process, and an aluminum alloy adapted for the process are also disclosed.

## Claims

### Claim 1

A method of manufacturing aluminum sheet material comprising the steps of:
melting secondary aluminum;
adding primary aluminum and other alloying elements to the melt to achieve a composition consisting essentially of from 2.5 wt % to 6.3 wt % Mg, from 0.6 wt % to 2.5 wt % Si, from 0.2 wt % to 0.4 wt % Fe, from 0.05 wt % to 0.2 wt % Cr, up to 0.6 wt % Mn, up to 0.2 wt % Cu, up to 0.2 wt % Zn, the balance being Al and unavoidable impurities, wherein the Si and Mg contents satisfy the relationship (Si wt %>0.5*Mg wt %-0.65 wt %); and
continuously casting the aluminum into aluminum sheet.

### Claim 2 (depends on 1)

The method of manufacturing aluminum sheet material according to claim 1 wherein the composition is from 2.5 wt % to 4.5% Mg and from 0.6 wt % to 1.6% Si.

### Claim 3 (depends on 2)

The method of manufacturing aluminum sheet according to claim 2 wherein there is from 0.20 wt % to 0.30 wt % Fe, 0.05 wt % to 0.15 wt % Cr, up to 0.4 wt % Mn, up to 0.1 wt % Cu, and up to 0.1 wt % Zn.

### Claim 4 (depends on 1)

The method of manufacturing aluminum sheet material according to claim 1 wherein the continuous casting is performed using a twin roll continuous caster.

### Claim 5 (depends on 1)

The method of manufacturing aluminum sheet material according to claim 1 wherein the continuous casting is performed using a twin belt continuous caster.

### Claim 6 (depends on 1)

The method of manufacturing aluminum sheet material according to claim 1 further comprising hot rolling the cast sheet, annealing the hot rolled sheet, cold rolling the annealed sheet, and annealing the cold rolled sheet.

### Claim 7 (depends on 1)

The method of manufacturing aluminum sheet material according to claim 1 further comprising homogenizing the cast sheet, cold rolling the homogenized sheet, and annealing the cold rolled sheet.

### Claim 8

An aluminum sheet material that has been continuously cast from an alloy consisting essentially of from 2.5 wt % to 6.3 wt % Mg, from 0.6 wt % to 2.5 wt % Si, from 0.2 wt % to 0.4 wt % Fe, from 0.05 wt % to 0.2 wt % Cr, up to 0.6 wt % Mn, up to 0.2 wt % Cu, up to 0.2 wt % Zn, the balance being Al and unavoidable impurities, wherein the Si and Mg contents satisfy the relationship (Si wt %>0.5*Mg wt %-0.65 wt %).

### Claim 9 (depends on 8)

The aluminum sheet material according to claim 8 wherein the composition of the alloy is from 2.5 wt % to 4.5% Mg and from 0.6 wt % to 1.6% Si.

### Claim 10 (depends on 9)

The aluminum sheet material according to claim 9 wherein the composition of the alloy is from 0.20 wt % to 0.30 wt % Fe, 0.05 wt % to 0.15 wt % Cr, up to 0.4 wt % Mn, up to 0.1 wt % Cu, and up to 0.1 wt % Zn.

### Claim 11 (depends on 8)

The aluminum sheet material according to claim 8 wherein the alloy was continuously cast using a twin roll continuous caster.

### Claim 12 (depends on 8)

The aluminum sheet material according to claim 8 wherein the alloy was continuous cast using a twin belt continuous caster.

### Claim 13

An aluminum alloy adapted for continuous casting, the aluminum alloy comprising from 2.5 wt % to 6.3 wt % Mg, from 0.6 wt % to 2.5 wt % Si, from 0.2 wt % to 0.4 wt % Fe, from 0.05 wt % to 0.2 wt % Cr, up to 0.6 wt % Mn, up to 0.2 wt % Cu, up to 0.2 wt % Zn, the balance being Al and unavoidable impurities, wherein the Si and Mg contents satisfy the relationship (Si wt %>0.5*Mg wt %-0.65 wt %).

### Claim 14 (depends on 13)

The aluminum alloy according to claim 13 wherein the composition of the aluminum alloy is from 2.5 wt % to 4.5% Mg and from 0.6 wt % to 1.6% Si.

### Claim 15 (depends on 14)

The aluminum alloy according to claim 14 wherein the composition of the aluminum alloy is from 0.20 wt % to 0.30 wt % Fe, 0.05 wt % to 0.15 wt % Cr, up to 0.4 wt % Mn, up to 0.1 wt % Cu, and up to 0.1 wt % Zn.

### Claim 16 (depends on 13)

The aluminum alloy according to claim 13 wherein the Si and Mg contents satisfy the relationship (Si wt %>0.5*Mg wt %-0.35 wt %).

### Claim 17 (depends on 13)

The aluminum alloy according to claim 13 wherein the aluminum alloy has a solidification range of less than 100° C.

### Claim 18 (depends on 17)

The aluminum alloy according to claim 17 wherein the aluminum alloy has a solidification range of less than 85° C.

### Claim 19 (depends on 13)

The aluminum alloy according to claim 13 consisting essentially of from 2.5 wt % to 4.5 wt % Mg, from 0.6 wt % to 1.6 wt % Si, from 0.2 wt % to 0.3 wt % Fe, from 0.05 wt % to 0.15 wt % Cr, up to 0.4 wt % Mn, up to 0.1 wt % Cu, up to 0.1 wt % Zn, the balance being Al and unavoidable impurities, wherein the Si and Mg contents satisfy the relationship (Si wt. %>0.5*Mg wt. %-0.35 wt. %).