Novelis, Inc.

Milan Felberbaum

Sazol Kumar Das

Robert Bruce Wagstaff

Rajeev G Kamat

Duane E Bendzinski

Tudor Piroteala

Simon William Barker

Rajasekhar Talla

Corrado Bassi

Samuel Robert Wagstaff

Aurèle Mariaux

Wayne J Fenton

Todd F Bischoff

Cyrille Bezencon

Tina J Kosmicki

Aude Celine Despois

Guillaume Florey

ChangOok Son

Theresa Elizabeth MacFarlane

Peter Lloyd Redmond

Yudie Yuan

Julio Malpica

Alp Manavbasi

Liangliang Li

Dewei Zhu

Dechao Lin

Brian Paradis

Luis Fanor Vega

Described herein are 6xxx series aluminum alloys with unexpected properties and novel methods of producing such aluminum alloys. The aluminum alloys are highly formable and exhibit high strength. The alloys are produced by continuous casting and can be hot rolled to a final gauge and/or a final temper. The alloys can be used in automotive, transportation, industrial, and electronics applications, just to name a few.

High strength 6XXX series aluminum alloys and methods of making the same

Provided herein are systems and methods for producing thick gauge aluminum alloy articles such as plates, shates, slabs, sheet plates or the like. A method for producing thick gauge aluminum alloy articles can include continuously casting an aluminum alloy article and hot or warm rolling the aluminum alloy article. Also provided herein is a continuous casting system for producing thick gauge aluminum alloy articles. The disclosed thick gauge aluminum alloy articles can be provided in any suitable temper.

Systems and methods for making thick gauge aluminum alloy articles

Described herein are 7xxx series aluminum alloys with unexpected properties and novel methods of producing such aluminum alloys. The aluminum alloys exhibit high strength and are highly formable. The alloys are produced by continuous casting and can be hot rolled to a final gauge and/or a final temper. The alloys can be used in automotive, transportation, industrial, and electronics applications, just to name a few.

High strength 7XXX series aluminum alloys and methods of making the same

Disclosed are aluminum alloy products and methods of making and processing such products. Thus, disclosed are aluminum alloy products exhibiting controllable surface properties, including excellent bond durability, low contact resistance, and corrosion resistance. Aluminum alloy products described herein include a migrant element, a subsurface portion having a concentration of the migrant element, and a bulk portion having a concentration of the migrant element. The aluminum alloy product comprises an enrichment ratio of 4.0 or less, wherein the enrichment ratio is a ratio of the migrant element concentration in the subsurface portion to the concentration in the bulk portion. Additionally, the aluminum alloy products surface and/or subsurface can contain phosphorus (e.g., elemental phosphorus or oxidized phosphorus). The phosphorus containing surface provides reduced electronic stress on an electrode tip of a resistance spot welding apparatus, and an extended service lifetime (e.g., weld cycles to failure) of the electrode tip.

Aluminum alloy products exhibiting improved bond durability and methods of making the same

A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.

Metal casting and rolling line

Systems and methods are disclosed for using magnetic fields (e.g., changing magnetic fields) to control metal flow conditions during casting (e.g., casting of an ingot, billet, or slab). The magnetic fields can be introduced using rotating permanent magnets or electromagnets. The magnetic fields can be used to induce movement of the molten metal in a desired direction, such as in a rotating pattern around the surface of the molten sump. The magnetic fields can be used to induce metal flow conditions in the molten sump to increase homogeneity in the molten sump and resultant ingot.

Non-contacting molten metal flow control

Provided herein are new aluminum alloy products and methods of making these alloys. The aluminum alloy products are age-hardenable, display high strength and formability, and allow for the use of recycled scrap. The aluminum alloys can serve as the core in a clad aluminum alloy product. The alloy products can be used in a variety of applications, including automotive, transportation, and electronics applications.

Age-hardenable and highly formable aluminum alloys and methods of making the same

Provided herein are high performance aluminum alloy products having desirable mechanical properties and methods of making the same. The high performance aluminum alloy products described herein contain a high content of recycled material and are prepared by casting an aluminum alloy to form a cast aluminum alloy product and processing the cast aluminum alloy product. The method of processing the cast aluminum alloy product can include two hot rolling steps.

High performance aluminum alloys having high amounts of recycled material and methods of making the same

Techniques are disclosed for casting high-strength and highly formable metal products from recycled metal scrap without the addition of substantial or any amounts of primary aluminum. Additional alloying elements, such as magnesium, can be added to metal scrap, which can be cast and processed to produce a desirable metal coil at final gauge having desirable metallurgical and mechanical properties, such as high strength and formability. Thus, inexpensive and recycled metal scrap can be efficiently repurposed for new applications, such as automotive applications and beverage can stock.

Casting recycled aluminum scrap

The present disclosure generally provides 6xxx series aluminum alloys and methods of making the same, such as through casting and rolling. The disclosure also provides products made from such alloys. The disclosure also provides various end uses of such products, such as in automotive, transportation, electronics, aerospace, and industrial applications, among others.

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Woodstock, GA, United States of America

Milan Felberbaum