阅读说明：本技术 来自制造废料的具有美观性的回收铝合金 (Recycled aluminum alloy with aesthetic properties from manufacturing scrap ) 是由 B·M·加布勒 周恒正 黄伟明 G·W·保罗 W·A·考恩兹 E·W·哈曼 K·L·萨萨 于 2019-08-09 设计创作，主要内容包括：本发明涉及来自制造废料的具有美观性的回收铝合金。本公开提供了一种铝合金,所述铝合金可包括至少0.10重量％的铁(Fe)、至少0.35重量％的硅(Si)和至少0.45重量％的镁(Mg)、量为至少0.005重量％的锰(Mn)以及附加元素,剩余的重量％为Al和附带杂质。(The present invention relates to a recycled aluminum alloy having aesthetic properties from manufacturing waste. The present disclosure provides an aluminum alloy that may include at least 0.10 wt.% iron (Fe), at least 0.35 wt.% silicon (Si), and at least 0.45 wt.% magnesium (Mg), manganese (Mn) in an amount of at least 0.005 wt.%, and additional elements, with the remaining wt.% being Al and incidental impurities.)

1. An aluminum alloy, comprising:

iron (Fe) in an amount of at least 0.10 wt.%,

Silicon (Si) in an amount of at least 0.35 wt.%,

Magnesium (Mg) in an amount of at least 0.45 wt.%,

Manganese (Mn) in an amount of 0 to 0.090 wt%,

An additional non-aluminum (Al) element in an amount of not more than 3.0 wt.%, and

the remaining weight% is Al and incidental impurities.

2. The alloy of claim 1, wherein

The amount of silicon (Si) is at least 0.43 wt%, and

the amount of magnesium (Mg) is at least 0.56 wt.%.

3. The alloy of claim 2, wherein Si is 0.43 to 0.80 wt%.

4. The alloy of claim 2, wherein Mg is 0.56 wt% to 0.95 wt%.

5. The alloy of claim 2, wherein Fe is 0.10 to 0.50 wt%.

6. The alloy of claim 2, further comprising 0 to 0.10 wt% titanium (Ti).

7. The alloy of claim 2, further comprising 0.005 to 0.090 weight percent manganese (Mn).

8. The alloy of claim 2, further comprising a non-aluminum element selected from the group consisting of:

0.010 to 0.050% by weight of copper (Cu),

0 to 0.10% by weight of chromium (Cr),

0 to 0.20% by weight of zinc (Zn),

0 to 0.20% by weight of gallium (Ga),

0 to 0.20% by weight of tin (Sn),

0 to 0.20% by weight of vanadium (V),

0 to 0.001% by weight of calcium (Ca),

0 to 0.002% by weight of sodium (Na),

0 to 0.01% by weight of boron (B),

0 to 0.01% by weight of zirconium (Zr),

0 to 0.01% by weight of lithium (Li),

0 to 0.01% by weight of cadmium (Cd),

0 to 0.01% by weight of lead (Pb),

0 to 0.01% by weight of nickel (Ni),

0 to 0.01% by weight of phosphorus (P), and

combinations thereof.

9. The alloy of claim 2, wherein the alloy is in the form of an extruded part and has an average grain size equal to or less than 160 μ ι η.

10. The alloy of claim 2, wherein the alloy is in the form of a sheet and has an average grain size equal to or less than 100 μ ι η.

11. The alloy of claim 2, wherein the alloy is in the form of an extruded part and has a yield strength of at least 205MPa and a tensile strength of at least 240 MPa.

12. The alloy of claim 2, wherein the alloy is in the form of a sheet and has a yield strength of at least 210MPa and a tensile strength of at least 230 MPa.

13. The alloy of claim 2, wherein the alloy is in the form of an extruded part and has a Vickers hardness of at least 80.

14. The alloy of claim 2, wherein the alloy is in the form of a sheet and has a Vickers hardness of at least 75.

15. A recycled 6000 series aluminum alloy comprising:

0.10 to 0.50% by weight of iron (Fe),

0.35 to 0.80% by weight of silicon (Si),

0.45 to 0.95% by weight of magnesium (Mg),

0.005 to 0.090% by weight of manganese (Mn),

An additional non-aluminium element in an amount of not more than 1.0 wt.%, and

the remaining weight% being Al and incidental impurities;

wherein the recycled aluminum alloy has a yield strength of 205MPa and a tensile strength of 240MPa after extrusion, or wherein the recycled 6000 series aluminum alloy has a yield strength of 210MPa and a tensile strength of 230MPa after sheet rolling.

16. The alloy of claim 15, wherein silicon (Si) is 0.43 to 0.80 wt%.

17. The recycled 6000 series aluminum alloy of claim 16, wherein the alloy is in the form of a sheet and has an average grain size equal to or less than 100 μ ι η.

18. The recycled 6000 series aluminum alloy of claim 16, wherein the alloy is in the form of an extruded part and has an average grain size equal to or less than 160 μ ι η.

19. The recycled 6000 series aluminum alloy of claim 16, wherein the alloy is in the form of a sheet and has a vickers hardness of at least 75.

20. The recycled 6000 series aluminum alloy of claim 16, wherein the alloy is in the form of an extruded part and has a vickers hardness of at least 80.

21. A method for recycling manufacturing waste, the method comprising:

(a) obtaining a first recycled aluminum alloy from a first source and a second recycled aluminum alloy from a second source;

(b) melting the first and second recycled aluminum alloys to form a molten recycled 6000 series aluminum alloy;

(c) casting the molten recycled 6000 series aluminum alloy to form a cast alloy;

(d) rolling to form a sheet or extruding to form an extrudate; and

(e) manufacturing the sheet or the extrudate to produce a product.

22. The method of claim 21, wherein the product has an average grain size equal to or less than 100 μ ι η after sheet rolling or equal to or less than 160 μ ι η after extrusion.

23. The method of claim 21, wherein the melting step comprises removing oxides from the first and second recycled aluminum alloys.

24. A method of preparing the aluminum alloy of claim 1 by performing the method of claim 21.

Technical Field

The present disclosure relates to recycling aluminum alloys and processes for recycling aluminum alloy scrap having aesthetic properties and applications including housings for electronic devices.

Background

Commercial aluminum alloys, such as 6063 aluminum (Al) alloy, have been used to manufacture housings for electronic devices. For the housing of an electronic device, aesthetics is very important.

Conventional recycling of manufacturing chip scrap (e.g., 6063Al) is often associated with reduced quality. Sometimes, in order to maintain the quality of the recovered product, the conventional recovery of the manufacturing chip waste can be limited to a specific source and limited amount of waste in the recovered material.

There remains a need to develop alloys and processes for recycling manufacturing waste to improve the aesthetics of recycled aluminum alloys.

Disclosure of Invention

In one aspect, the present disclosure provides an aluminum alloy including iron (Fe) in an amount of at least 0.10 wt.%, silicon (Si) in an amount of at least 0.35 wt.%, magnesium (Mg) in an amount of at least 0.45 wt.%, manganese (Mn) in an amount of 0 to 0.090 wt.%, non-aluminum (Al) elements in an amount of no more than 3.0 wt.%, with the remaining wt.% being Al and incidental impurities. In some variations, the aluminum alloy includes silicon (Si) in an amount of at least 0.43 wt.% and magnesium (Mg) in an amount of at least 0.56 wt.%.

In another aspect, a recycled 6000-series aluminum alloy may include 0.10 wt.% to 0.50 wt.% iron (Fe), 0.35 wt.% to 0.80 wt.% silicon (Si), and 0.45 wt.% to 0.95 wt.% magnesium (Mg), manganese (Mn) in an amount of 0.005 wt.% to 0.090 wt.%, the remaining wt.% being Al and incidental impurities, wherein the recycled aluminum alloy has the same aesthetics as the virgin Al 6063 alloy. In some variations, the aluminum alloy includes silicon (Si) in an amount of 0.43 wt.% to 0.80 wt.%.

In another embodiment, a process for recycling manufacturing waste is provided. The process can include (a) obtaining a first recycled aluminum alloy from a first source and a second recycled aluminum alloy from a second source; (b) melting the first and second recycled aluminum alloys to form a molten recycled 6000 series aluminum alloy; (c) casting the molten recycled 6000 series aluminum alloy to form a cast alloy; (d) rolling to form a sheet or extruding to form an extrudate; and (e) making the sheet or extrudate to produce a product.

Additional embodiments and features are set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the specification or may be learned from practice of the disclosed subject matter. A further understanding of the nature and advantages of the present disclosure may be realized by reference to the remaining portions of the specification and the drawings which form a part hereof.

Drawings

The specification will be more fully understood with reference to the following drawings and data diagrams, which are presented as various embodiments of the disclosure and which should not be considered a complete specification of the scope of the disclosure, wherein:

fig. 1 illustrates a recycling process from materials including manufacturing waste, according to an embodiment of the present disclosure.

Fig. 2 illustrates a cumulative iron (Fe) content versus a number of times the alloy is recovered according to an embodiment of the present disclosure.

Fig. 3 illustrates cumulative titanium (Ti) content versus number of times the alloy was recovered according to an embodiment of the disclosure.

Fig. 4A shows a post heat treated microstructure of a recycled 6000 series aluminum alloy according to embodiments of the present disclosure.

Fig. 4B illustrates component phase particles formed prior to aging the recovered 6000 series aluminum alloy of fig. 4A, according to embodiments of the present disclosure.

Fig. 4C shows Mg-Si precipitates formed during an aging process according to embodiments of the present disclosure.

Fig. 4D shows contaminant AlFeSi particles after heat treatment in a raw 6000 series aluminum alloy with Fe contamination according to embodiments of the present disclosure.

Fig. 4E shows contaminant AlFeSi particles after heat treatment in a primary 6000 series aluminum alloy with Fe and Ti contamination according to embodiments of the present disclosure.

Fig. 4F shows contaminant AlFeSiMn particles of a recovered 6000 series aluminum alloy after heat treatment according to embodiments of the present disclosure.

Fig. 5 illustrates a waste recovery process according to an embodiment of the present disclosure.

Fig. 6A shows yield strength of an extrudate sample formed from an example of the disclosed recycled 6000 series aluminum alloy, according to an embodiment of the present disclosure.

Fig. 6B shows tensile strength of an extrudate sample formed from an example of the disclosed recycled 6000 series aluminum alloy, according to an embodiment of the present disclosure.

Fig. 6C illustrates elongation of an extrudate sample formed from the disclosed example of a recycled 6000 series aluminum alloy, according to embodiments of the present disclosure.

Fig. 6D shows hardness of extrudate samples formed from disclosed examples of recycled 6000 series aluminum alloys, according to embodiments of the present disclosure.

Fig. 7A illustrates the yield strength of a sheet sample formed from the disclosed example of a recycled 6000 series aluminum alloy, according to an embodiment of the present disclosure.

Fig. 7B illustrates the tensile strength of a sheet sample formed from the disclosed example of a recycled 6000 series aluminum alloy, according to an embodiment of the present disclosure.

Fig. 7C illustrates the elongation of a sheet sample formed from the disclosed example of a recycled 6000 series aluminum alloy, according to an embodiment of the present disclosure.

Fig. 7D illustrates the hardness of sheet samples formed from the disclosed examples of recycled 6000-series aluminum alloys, according to embodiments of the present disclosure.

Fig. 8A illustrates an average grain size of an extrudate sample formed from an example of the disclosed recycled 6000 series aluminum alloy, according to an embodiment of the present disclosure.

Fig. 8B illustrates a maximum grain size of an extrudate sample formed from the disclosed example of a recycled 6000 series aluminum alloy, according to an embodiment of the present disclosure.

Fig. 8C illustrates a PCG layer depth of an extrudate sample formed from an example of the disclosed recycled 6000 series aluminum alloy, according to embodiments of the present disclosure.

Fig. 8D shows grain aspect ratios of extrudate samples formed from the disclosed examples of recycled 6000 series aluminum alloys, according to embodiments of the present disclosure.

Fig. 8E shows coarse grain size of extrudate samples formed from the disclosed examples of recycled 6000 series aluminum alloys, according to embodiments of the present disclosure.

Fig. 9A illustrates an average grain size of sheet samples formed from disclosed examples of recycled 6000-series aluminum alloys, according to embodiments of the present disclosure.

Fig. 9B illustrates the maximum grain size of a sheet sample formed from the disclosed example of recovering a 6000 series aluminum alloy, according to an embodiment of the present disclosure.

Fig. 9C illustrates coarse grain sizes of sheet samples formed from the disclosed examples of recycled 6000 series aluminum alloys, according to embodiments of the present disclosure.

Fig. 9D illustrates grain aspect ratios of sheet samples formed from the disclosed examples of recycled 6000-series aluminum alloys, according to embodiments of the present disclosure.

Detailed Description

The disclosure can be understood by reference to the following detailed description in conjunction with the accompanying drawings, which are described below. It should be noted that for clarity of illustration, certain elements in the various figures may not be drawn to scale.

SUMMARY

The present disclosure provides a recycled 6000 series aluminum alloy formed from scrap material. The scrap material may be collected from the manufacturing process of conventional aluminum alloys, such as 6000 series aluminum alloys or 6063 aluminum. The recycled 6000 series aluminum alloys surprisingly provide the same or similar aesthetics, mechanical properties, and microstructure as the primary aluminum alloys. The recycled 6000 series aluminum alloys may include higher Fe content, higher Mn content, and/or higher Si content than aluminum alloys made from primary aluminum.

Alloys formed from manufacturing scrap

In some variations, the disclosed 6000 series aluminum alloys are designed to withstand including up to 100% recycled 6000 series aluminum (such as casting scrap, extrusion scrap, manufacturing chip scrap, and the like). The disclosed 6000 series aluminum alloys can also be resistant to other series scrap materials (such as 1000 series scrap materials). The disclosed 6000 series aluminum alloys, also referred to as recycled 6000 series aluminum alloys, allow for the production of a closed loop of scrap material that can reduce the use of virgin aluminum and result in a significant reduction in emissions and associated carbon footprint. Conventional 6000 series Al may include small amounts of Si and Mg, and optionally include small amounts of Fe, Mn, Cu, Zr, Pb, Cr, Zn, and the like.

Fig. 1 illustrates an example of a recycling process from materials including manufacturing waste, according to an embodiment of the present disclosure. As shown in fig. 1, primary aluminum 102 is supplied to a material process 104. The material processing 104 may use recycled material containing waste from the module manufacturing 106 to build the chips. Module fabrication 106 then builds the module using the chips fabricated by material processing 104. The module manufacturing 106 may have a process roll-back 110 that provides scrap material to the material processing 104. The process may be closed loop. The present disclosure provides materials and methods for recycling waste materials from module manufacturing 106.

Customer 114 uses the modules from module manufacturing 106 to build a product that is available on site in operation 112. Recycled material 108 may be produced from the field used product. Recycled material 108 may also be provided to material processing 104.

The recycled aluminum alloy accumulates more iron than is normally present in the original aluminum alloy. The increase in iron may have a negative impact on the aesthetics of the aluminum alloy, in particular, making it more grey in color. Iron cannot be removed from the aluminum alloy by conventional industrial processes and once iron is included in the aluminum alloy, the amount of iron in the alloy cannot be reduced. The amount of iron in the recovered aluminum is higher than the amount of iron in the original aluminum due to the number of iron-containing contact points in a typical supply chain.

Iron produces an unattractive gray color and therefore has a negative impact on aesthetics. In addition to having a negative impact on aesthetics, iron also contributes to the formation of iron-aluminum-silicon particles during processing. The iron-containing particles will pick up Si, which reduces the amount of Si available for strengthening. Thus, more Si is added to the alloys disclosed herein. The disclosed alloys have increased silicon and increased iron. Contrary to expectations, various properties of the alloy are consistent with or better than alloys with such undesirable amounts of iron.

The disclosed recycled 6000 series aluminum alloys allow the use of recycled materials, such as manufacturing scrap from various sources. The disclosed recycled 6000 series aluminum alloys result in a significant reduction in carbon footprint associated with manufacturing.

The alloy can be described by various weight% elements and specific properties. In all descriptions of the alloys described herein, it is understood that the balance of the weight% of the alloy is Al and incidental impurities. Impurities may be present, for example, as a by-product of processing and manufacture. In various embodiments, incidental impurities may be no greater than 0.05% by weight of any one additional element (i.e., single impurity), and no greater than 0.10% by weight of the total of all additional elements (i.e., total impurities). The impurities may be less than or equal to about 0.1 wt%, or less than or equal to about 0.05 wt%, or less than or equal to about 0.01 wt%, or less than or equal to about 0.001 wt%.

In some variations, the alloy has at least 0.14 wt.% Fe. Further, in some variations, the alloy has at least 0.43 wt.% Si and at least 0.56 wt.% Mg. In a further variation, the alloy may have 0.20 wt% or less Fe. The alloy may have 0.62 wt.% or less Mg and 0.49 wt.% or less Si.

Fe content

As described above, scrap (e.g., chip scrap) includes more Fe than conventional 6000 series aluminum alloys. Fe can come from sources including molds and the like. The 6000 series aluminum alloys disclosed are designed to have more Fe than conventional 6000 series aluminum alloys or raw aluminum alloys currently used for aesthetic consumer electronics products.

The cumulative model was used to estimate the Fe content versus the number of times the alloy was recovered, as shown in fig. 2. The recycled aluminum alloy can be recycled for multiple times.

Fig. 2 illustrates a cumulative iron (Fe) content versus a number of times the alloy is recovered according to an embodiment of the present disclosure. As shown in fig. 2, the Fe content may increase as the number of times the alloy is recovered increases, and then reach a plateau of about 2000ppm after about 10 recoveries.

In some variations, the iron may be in a range of 0.10 wt% to 0.50 wt%.

In some variations, the iron may be equal to or greater than 0.10 wt%. In some variations, the iron may be equal to or greater than 0.14 wt%. In some variations, the iron may be equal to or greater than 0.15 wt%. In some variations, the iron may be equal to or greater than 0.16 wt%. In some variations, the iron may be equal to or greater than 0.17 wt%. In some variations, the iron may be equal to or greater than 0.18 wt%. In some variations, the iron may be equal to or greater than 0.19 wt%. In some variations, the iron may be equal to or greater than 0.20 wt%. In some variations, the iron may be equal to or greater than 0.25 wt%. In some variations, the iron may be equal to or greater than 0.30 wt%. In some variations, the iron may be equal to or greater than 0.35 wt%. In some variations, the iron may be equal to or greater than 0.40 wt%. In some variations, the iron may be equal to or greater than 0.45 wt%.

In some variations, the iron may be equal to or less than 0.50 wt%. In some variations, the iron may be equal to or less than 0.45 wt%. In some variations, the iron may be equal to or less than 0.35 wt%. In some variations, the iron may be equal to or less than 0.40 wt%. In some variations, the iron may be equal to or less than 0.35 wt%. In some variations, the iron may be equal to or less than 0.30 wt%. In some variations, the iron may be equal to or less than 0.25 wt%. In some variations, the iron may be equal to or less than 0.20 wt%. In some variations, the iron may be equal to or less than 0.19 wt%. In some variations, the iron may be equal to or less than 0.18 wt%. In some variations, the iron may be equal to or less than 0.17 wt%. In some variations, the iron may be equal to or less than 0.16 wt%. In some variations, the iron may be equal to or less than 0.15 wt%.

Ti content

The scrap may include more Ti than conventional 6000 series aluminum alloys. Ti may be added as a grain refiner during the casting process. In many cases, 6000 series aluminum alloys are designed to withstand more Ti than conventional aluminum alloys used for similar products.

The cumulative model was used to estimate the Ti content versus the number of times the alloy was recovered. Fig. 3 illustrates cumulative titanium (Ti) content versus number of times the alloy was recovered according to an embodiment of the disclosure. As shown in fig. 3, the Ti content may increase as the number of times the alloy is reclaimed is increased, and then reach a plateau of about 600ppm after about 10 recoveries.

In some variations, the titanium may be equal to or less than 0.10 wt%. In some variations, the titanium may be equal to or less than 0.09 weight percent. In some variations, the titanium may be equal to or less than 0.08 wt%. In some variations, the titanium may be equal to or less than 0.07 wt%. In some variations, the titanium may be equal to or less than 0.06 wt%. In some variations, the titanium may be equal to or less than 0.05 wt%. In some variations, the titanium may be equal to or less than 0.04 wt%. In some variations, the titanium may be equal to or less than 0.03 weight percent. In some variations, the titanium may be equal to or less than 0.025 wt%. In some variations, the titanium may be equal to or less than 0.020 wt%. In some variations, the titanium may be equal to or less than 0.015 wt%. In some variations, the titanium may be equal to or less than 0.010 weight percent. In some variations, the titanium may be equal to or less than 0.005 weight percent.

Mn content, Si content, Mg content and Mg/Si ratio

Additional Si is added to the disclosed alloys compared to typical aesthetic 6000 series alloys, without causing a loss of mechanical strength by forming Mg-Si particles.

Without wishing to be bound by any particular theory or mode of action, Mn may be added to decompose large contaminant Al-Fe-Si particles and form smaller Al-Fe-Si-Mn particles.

Fig. 4A shows a post heat treated microstructure of a recycled 6000 series aluminum alloy according to embodiments of the present disclosure. Fig. 4B illustrates component phase particles formed prior to aging the recovered 6000 series aluminum alloy of fig. 4A, according to embodiments of the present disclosure. As shown in fig. 4A, the post heat treated microstructure includes an area 402 within a grain boundary 401. The grain size within the grain boundaries 401 is about 100 μm. Region 402 includes compositionally phase Al-Fe-Si particles 404 and region 406 after aging includes compositionally phase Mg-Si particles 408 and 410, as shown in FIG. 4B. During the aging treatment, Mg-Si precipitates 408 and 410 are formed in the fine grain size, as shown in FIG. 4C.

Fig. 4C shows Mg-Si precipitates formed during an aging process according to embodiments of the present disclosure.

Fig. 4D shows contaminant AlFeSi particles after heat treatment in a raw 6000 series aluminum alloy with Fe contamination according to embodiments of the present disclosure. As shown in fig. 4D, contaminant AlFeSi particles 408 may be present in the primary aluminum alloy and embedded in aluminum 416. For illustrative purposes only, one contaminant AlFeSi particle 408 is shown within one grain boundary 414. The Mg-Si particles 404 are also embedded in the aluminum 416.

Fig. 4E shows contaminant AlFeSi particles after heat treatment in a primary 6000 series aluminum alloy with Fe and Ti contamination according to embodiments of the present disclosure. Iron contamination and titanium contamination are the consequence of the recovery of the primary aluminum alloy of FIG. 4D. As shown in fig. 4E, there may be more contaminant AlFeSi particles 408 in the primary aluminum alloy. For illustrative purposes only, five contaminating AlFeSi particles 408 are shown within five grain boundaries 414. As shown, there are fewer Mg-Si particles 404 than in fig. 4D. The reason for this may be because Si previously present in Mg-Si particles has been used to form particles with iron, so that there are fewer Mg-Si particles. Additionally, Ti educt 418 can be present in the recycled aluminum alloy 416.

Fig. 4F shows contaminant AlFeSiMn particles of a recovered 6000 series aluminum alloy after heat treatment according to embodiments of the present disclosure. The recycled aluminum alloy is formed from the primary aluminum alloy of fig. 4D. As shown, the addition of Mn to the recycled aluminum alloy helps break down the large AlFeSi particles 408 of the primary aluminum alloy of fig. 4D into smaller AlFeSiMn particles 412, which helps achieve better aesthetics. The volume fraction of Mg-Si particles 404 is similar to that of fig. 4D. The recycled aluminum alloy includes a higher Mn content and a higher Si content than the primary aluminum alloy.

In some variations, the silicon may range from 0.35 wt% to 0.80 wt%.

In some variations, the silicon may be equal to or less than 0.80 wt%. In some variations, the silicon may be equal to or less than 0.75 wt%. In some variations, the silicon may be equal to or less than 0.70 wt%. In some variations, the silicon may be equal to or less than 0.65 wt%. In some variations, the silicon may be equal to or less than 0.60 wt%. In some variations, the silicon may be equal to or less than 0.55 wt%. In some variations, the silicon may be equal to or less than 0.50 wt%. In some variations, the silicon may be equal to or less than 0.49 wt%. In some variations, the silicon may be equal to or less than 0.48 wt%. In some variations, the silicon may be equal to or less than 0.47 wt%. In some variations, the silicon may be equal to or less than 0.46 wt%. In some variations, the silicon may be equal to or less than 0.45 wt%. In some variations, the silicon may be equal to or less than 0.40 wt%. In some variations, the silicon may be equal to or less than 0.39 wt%. In some variations, the silicon may be equal to or less than 0.38 wt%. In some variations, the silicon may be equal to or less than 0.37 wt%. In some variations, the silicon may be equal to or less than 0.36 wt%.

In some variations, the silicon may be equal to or greater than 0.35 wt%. In some variations, the silicon may be equal to or greater than 0.36 wt%. In some variations, the silicon may be equal to or greater than 0.37 wt%. In some variations, the silicon may be equal to or greater than 0.38 wt%. In some variations, the silicon may be equal to or greater than 0.39 wt%. In some variations, the silicon may be equal to or greater than 0.40 wt%. In some variations, the silicon may be equal to or greater than 0.41 wt%. In some variations, the silicon may be equal to or greater than 0.42 wt%. In some variations, the silicon may be equal to or greater than 0.43 wt%. In some variations, the silicon may be equal to or greater than 0.44 wt%. In some variations, the silicon may be equal to or greater than 0.45 wt%. In some variations, the silicon may be equal to or greater than 0.46 wt%. In some variations, the silicon may be equal to or greater than 0.47 wt%. In some variations, the silicon may be equal to or greater than 0.48 wt%. In some variations, the silicon may be equal to or greater than 0.49 wt%. In some variations, the silicon may be equal to or greater than 0.50 wt%. In some variations, the silicon may be equal to or greater than 0.55 wt%. In some variations, the silicon may be equal to or greater than 0.60 wt%. In some variations, the silicon may be equal to or greater than 0.65 wt%. In some variations, the silicon may be equal to or greater than 0.70 wt%. In some variations, the silicon may be equal to or greater than 0.75 wt%.

The Mg can be designed to have the proper Mg/Si ratio to form Mg-Si precipitates for strengthening purposes. In some variations, the ratio of Mg to Si is typically 2:1, but other variations may be possible.

In some variations, the magnesium may range from 0.45 wt% to 0.95 wt%.

In some variations, the magnesium may be equal to or less than 0.95 wt%. In some variations, the magnesium may be equal to or less than 0.90 wt%. In some variations, the magnesium may be equal to or less than 0.85 wt%. In some variations, the magnesium may be equal to or less than 0.80 wt%. In some variations, the magnesium may be equal to or less than 0.75 wt%. In some variations, the magnesium may be equal to or less than 0.70 wt%. In some variations, the magnesium may be equal to or less than 0.65 wt%. In some variations, the magnesium may be equal to or less than 0.60 wt%. In some variations, the magnesium may be equal to or less than 0.55 wt%. In some variations, the magnesium may be equal to or less than 0.50 wt%.

In some variations, the magnesium may be equal to or greater than 0.50 wt%. In some variations, the magnesium may be equal to or greater than 0.55 wt%. In some variations, the magnesium may be equal to or greater than 0.60 wt%. In some variations, the magnesium may be equal to or greater than 0.65 wt%. In some variations, the magnesium may be equal to or greater than 0.70 wt%. In some variations, the magnesium may be equal to or greater than 0.75 wt%. In some variations, the magnesium may be equal to or greater than 0.80 wt%. In some variations, the magnesium may be equal to or greater than 0.85 wt%. In some variations, the magnesium may be equal to or greater than 0.90 wt%.

In some variations, the alloy may include Mn. Without wishing to be held to a particular mechanism, effect or mode of action, Mn may help to decompose coarse Al-Fe-Si particles or AlFeSi particles formed during casting.

In some variations, the manganese may be equal to or less than 0.090 wt%. In some variations, the manganese may be equal to or less than 0.085 wt%. In some variations, the manganese may be equal to or less than 0.080 wt%. In some variations, the manganese may be equal to or less than 0.075 weight percent. In some variations, the manganese may be equal to or less than 0.070 wt%. In some variations, the manganese may be equal to or less than 0.065 wt%. In some variations, the manganese may be equal to or less than 0.060 wt%. In some variations, the manganese may be equal to or less than 0.055 wt%. In some variations, the manganese may be equal to or less than 0.050 weight percent. In some variations, the manganese may be equal to or less than 0.045 wt%. In some variations, the manganese may be equal to or less than 0.040 weight percent. In some variations, the manganese may be equal to or less than 0.035 wt%. In some variations, the manganese may be equal to or less than 0.030 weight percent. In some variations, the manganese may be equal to or less than 0.025 wt%. In some variations, the manganese may be equal to or less than 0.020 wt%. In some variations, the manganese may be equal to or less than 0.015 wt%. In some variations, the manganese may be equal to or less than 0.010 weight percent. In some variations, the manganese may be equal to or less than 0.005 wt%.

In some variations, the manganese may be equal to or greater than 0.005 weight percent. In some variations, the manganese may be equal to or greater than 0.010 weight percent. In some variations, the manganese may be equal to or greater than 0.015 wt%. In some variations, the manganese may be equal to or greater than 0.020 wt%. In some variations, the manganese may be equal to or greater than 0.025 wt%. In some variations, the manganese may be equal to or greater than 0.030 weight percent. In some variations, the manganese may be equal to or greater than 0.035 wt%. In some variations, the manganese may be equal to or greater than 0.040 weight percent. In some variations, the manganese may be equal to or greater than 0.045 wt%. In some variations, the manganese may be equal to or greater than 0.050 weight percent. In some variations, the manganese may be equal to or greater than 0.055 wt%. In some variations, the manganese may be equal to or greater than 0.060 wt%. In some variations, the manganese may be equal to or greater than 0.065 wt%.

In some variations, the manganese may be equal to or greater than 0.070 wt%. In some variations, the manganese may be equal to or greater than 0.075 weight percent. In some variations, the manganese may be equal to or greater than 0.080 wt%. In some variations, the manganese may be equal to or greater than 0.085 wt%.

Additional non-aluminium elements

The disclosed 6000 series aluminum alloys can include other elements as disclosed below.

In some variations, the alloy may include Cu. Without wishing to be bound by any particular mechanism, effect, or mode of action, Cu may improve corrosion resistance, and/or Cu may affect the color of the anodized alloy.

In some variations, the copper may range from 0.010 wt% to 0.050 wt%.

In some variations, the copper may be equal to or less than 0.050 weight percent. In some variations, the copper may be equal to or less than 0.045 wt%. In some variations, the copper may be equal to or less than 0.040 weight percent. In some variations, the copper may be equal to or less than 0.035 wt%. In some variations, the copper may be equal to or less than 0.030 weight percent. In some variations, the copper may be equal to or less than 0.025 wt%. In some variations, the copper may be equal to or less than 0.020 wt%. In some variations, the copper may be equal to or less than 0.015 wt%.

In some variations, the copper may be equal to or greater than 0.010 weight percent. In some variations, the copper may be equal to or greater than 0.015 wt%. In some variations, the copper may be equal to or greater than 0.020 wt%. In some variations, the copper may be equal to or greater than 0.025 wt%. In some variations, the copper may be equal to or greater than 0.030 weight percent. In some variations, the copper may be equal to or greater than 0.035 wt%. In some variations, the copper may be equal to or greater than 0.040 weight percent. In some variations, the copper may be equal to or greater than 0.045 wt%.

In some variations, the chromium may be equal to or less than 0.10 wt%. In some variations, the chromium may be equal to or less than 0.08 wt%. In some variations, the chromium may be equal to or less than 0.06 wt%. In some variations, the chromium may be equal to or less than 0.04 wt%. In some variations, the chromium may be equal to or less than 0.03 weight percent. In some variations, the chromium may be equal to or less than 0.02 weight percent. In some variations, the chromium may be equal to or less than 0.01 wt%. In some variations, the chromium may be equal to or less than 0.008 wt%. In some variations, the chromium may be equal to or less than 0.006 wt%. In some variations, the chromium may be equal to or less than 0.004 weight percent. In some variations, the chromium may be equal to or less than 0.002 wt%.

In some variations, the zinc may be equal to or less than 0.20 wt%. In some variations, the zinc may be equal to or less than 0.15 wt%. In some variations, the zinc may be equal to or less than 0.10 wt%. In some variations, the zinc may be equal to or less than 0.08 wt%. In some variations, the zinc may be equal to or less than 0.06 wt%. In some variations, the zinc may be equal to or less than 0.04 wt%. In some variations, the zinc may be equal to or less than 0.03 weight percent. In some variations, the zinc may be equal to or less than 0.02 weight percent. In some variations, the zinc may be equal to or less than 0.01 weight percent. In some variations, the zinc may be equal to or less than 0.005 weight percent. In some variations, the zinc may be equal to or less than 0.001 weight percent.

In some variations, gallium may be equal to or less than 0.20 wt%. In some variations, gallium may be equal to or less than 0.15 wt%. In some variations, gallium may be equal to or less than 0.10 wt%. In some variations, gallium may be equal to or less than 0.08 wt%. In some variations, gallium may be equal to or less than 0.06 wt%. In some variations, gallium may be equal to or less than 0.04 wt%. In some variations, gallium may be equal to or less than 0.03 wt%. In some variations, gallium may be equal to or less than 0.02 wt%. In some variations, gallium may be equal to or less than 0.015 wt%. In some variations, gallium may be equal to or less than 0.01 wt%. In some variations, gallium may be equal to or less than 0.005 wt%. In some variations, gallium may be equal to or less than 0.001 wt%.

In some variations, the tin may be equal to or less than 0.20 wt%. In some variations, the tin may be equal to or less than 0.15 wt%. In some variations, the tin may be equal to or less than 0.10 wt%. In some variations, the tin may be equal to or less than 0.08 wt%. In some variations, the tin may be equal to or less than 0.06 wt%. In some variations, the tin may be equal to or less than 0.04 wt%. In some variations, the tin may be equal to or less than 0.01 weight percent. In some variations, the tin may be equal to or less than 0.008 wt%. In some variations, the tin may be equal to or less than 0.006 wt%. In some variations, the tin may be equal to or less than 0.004 weight percent. In some variations, the tin may be equal to or less than 0.002 wt%.

In some variations, the vanadium may be equal to or less than 0.20 wt%. In some variations, the vanadium may be equal to or less than 0.15 wt%. In some variations, the vanadium may be equal to or less than 0.10 wt%. In some variations, the vanadium may be equal to or less than 0.08 wt%. In some variations, the vanadium may be equal to or less than 0.06 wt%. In some variations, the vanadium may be equal to or less than 0.04 wt%. In some variations, the vanadium may be equal to or less than 0.02 wt%. In some variations, the vanadium may be equal to or less than 0.01 wt%. In some variations, the vanadium may be equal to or less than 0.005 wt%. In some variations, the vanadium may be equal to or less than 0.001 wt%.

In some variations, the calcium may be equal to or less than 0.001 wt%. In some variations, the calcium may be equal to or less than 0.0003 wt%. In some variations, the calcium may be equal to or less than 0.0002 wt%. In some variations, the calcium may be equal to or less than 0.0001 wt%.

In some variations, the sodium may be equal to or less than 0.002 wt%. In some variations, sodium may be equal to or less than 0.0002 wt%. In some variations, sodium may be equal to or less than 0.0001 wt%.

One or more of the other elements including chromium, boron, zirconium, lithium, cadmium, lead, nickel, phosphorus, etc. may be equal to or less than 0.01 wt%. One or more of the other elements including chromium, boron, zirconium, lithium, cadmium, lead, nickel, phosphorus, etc. may be equal to or less than 0.008 wt%. One or more of these other elements may be equal to or less than 0.006 wt%. One or more of these other elements may be equal to or less than 0.004 weight percent. One or more of the other elements may be equal to or less than 0.002 wt%.

In some variations, the total amount of other elements may not exceed 0.20 wt%. In some variations, the total amount of other elements may not exceed 0.10 wt%. In some variations, the total amount of other elements may not exceed 0.08 wt%. In some variations, the total amount of other elements may not exceed 0.06 wt%. In some variations, the total amount of other elements may not exceed 0.04 wt%.

Process for cleaning and removing oxides from waste

The scrap may have a large surface area to volume ratio compared to an alloy made from the raw materials. The large surface area of the waste material may include a large amount of oxides (such as alumina). The scrap may also include impurities (such as Fe or Ti, etc.) as compared to the conventional 6000 series aluminum alloy, 1000 series alloy, or 6000 series aluminum alloy.

The cleaning process may include removing oxides by re-melting the waste and flowing oxides and skimming the oxides. The cleaning process may also include the removal of organic contaminants by chemical solvents or chemical solutions or heating.

The disclosed recycled 6000 series aluminum alloys can be made from up to 100% Al scrap and can be used to form parts from extrusion and sheet rolling. The disclosed recycled 6000 series aluminum alloys may also include scrap extrudate or sheet material. The disclosed methods can include or exclude primary or virgin aluminum.

Fig. 5 illustrates a waste recovery process according to an embodiment of the present disclosure. As shown in fig. 5, process 500 includes a source 502 having scrap from two or more aluminum alloy sources (e.g., source a and source B, which may be from different supply chains).

In some embodiments, the alloy melt may be prepared by heating an alloy comprising the composition. As shown, the scrap material is melted at operation 504. After cooling the melt to room temperature, the alloy may be subjected to various heat treatments such as casting, homogenization, extrusion, sheet rolling, solution heat treatment, aging treatment, and the like.

The molten scrap may be billet cast at operation 506 and then homogenized. In some embodiments, the cast alloy may be homogenized by heating to an elevated temperature and holding at the elevated temperature for a period of time (such as at an elevated temperature of 520 ℃ to 620 ℃ for a period of time, for example 8 to 12 hours).

As shown in fig. 5, homogenization is used for both extrusion and sheet rolling. Homogenization refers to a process in which the alloy is soaked at an elevated temperature for a period of time. Homogenization can reduce chemical segregation or metallurgical segregation, which can occur as a natural result of the solidification of certain alloys. Homogenization can also be used to convert long, narrow AlFeSi particles into small, broken AlFeSi and AlFeSiMn particles. Those skilled in the art will appreciate that the heat treatment conditions (e.g., temperature and time) may vary.

The homogenized alloy may be extruded at operation 508. Extrusion is a process of converting a metal billet into various lengths of uniform cross-section by forcing the metal to flow plastically through a die orifice.

The assembly of components 518 may be formed from the extruded aluminum alloy obtained at operation 508. Additionally, the component may be formed from the aluminum alloy sheet obtained at operation 514.

In some embodiments, the extruded alloy may be preheated to an elevated temperature (e.g., about 400 ℃) and raised to a higher temperature (e.g., greater than 500 ℃) for extrusion. Extrusion and solution heat treatment may be performed simultaneously at a higher elevated temperature (e.g., about 500 ℃). Solution heat treatment can change the strength of the alloy.

The molten scrap from operation 504 may also be slab cast at operation 512, then homogenized, and subsequently sheet rolled at operation 514. The assembly of parts 518 may be formed from the rolled sheet from operation 514. As shown, the waste from operations 506,512,508,514 and 518 may be returned to operation 504 for re-melting.

Sheet rolling is a metal forming process in which metal is passed through one or more pairs of rollers to reduce and make uniform the thickness. Rolling is classified according to the temperature of the metal being rolled. If the temperature of the metal is above its recrystallization temperature, the process is called hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is called cold rolling.

To sheet roll the disclosed 6000 series aluminum alloys, the alloys are first hot rolled at about 250 to 450 ℃, then cold rolled, followed by solution treatment.

In some embodiments, the waste source 502 can include a portion of the disclosed 6000 series aluminum alloys in addition to waste from various sources.

After the solution treatment, the alloy may be aged at a temperature of 125 ℃ to 225 ℃ for a period of time (e.g., 6 to 10 hours) and then quenched with water. Referring again to fig. 4C, the aging treatment is a heat treatment at elevated temperatures and may cause precipitation reactions that form the precipitate Mg-Si. Those skilled in the art will appreciate that the heat treatment conditions (e.g., temperature and time) may vary.

In further embodiments, the disclosed 6000 series aluminum alloys may optionally be subjected to a stress relief treatment between the solution heat treatment and the aging heat treatment. The stress relief treatment may include a tensile alloy, a compressive alloy, or a combination thereof.

Aesthetic property

The aluminum alloys disclosed herein typically have more Fe than conventional aluminum alloys. Aluminum alloys with higher amounts of iron, in particular, appear to have a more gray color. The scrap may include more Fe than conventional 6000 series aluminum alloys. As noted above, the recycled aluminum alloys described herein have more iron than is typically present in the original aluminum alloys used for the alloys having aesthetic properties.

Iron produces an unattractive gray color and therefore has a negative impact on aesthetics. In addition to having a negative impact on aesthetics, iron also contributes to the formation of iron-aluminum-silicon particles during processing. The Fe particles pick up Si, which reduces the amount of Si available for strengthening. Thus, more Si is added to the alloys disclosed herein. The disclosed alloys have increased silicon and increased iron. Contrary to expectations, the performance of the alloy is consistent with or better than alloys with such undesirable amounts of iron.

In some embodiments, the disclosed 6000 series aluminum alloys may be anodized. Anodization is a metal surface treatment process that is most commonly used to protect aluminum alloys. Anodization uses electrolytic passivation to increase the thickness of a native oxide layer on the surface of a metal part. Anodization can increase corrosion and abrasion resistance and can also provide better adhesion to paint primers and glues than bare metal. Anodized films may also be used for aesthetic effects, for example, it may increase the interference effect on reflected light.

Surprisingly, the disclosed recycled 6000 series aluminum alloys have the same or improved aesthetics as those containing less iron, silicon, and magnesium. In particular, after anodization, they are not yellow or gray and do not have added appearance defects such as spots, texture lines, black lines, discoloration, white spots, oxidation, and line marks.

In some embodiments, the disclosed 6000 series aluminum alloys can form housings for electronic devices. The shell may be designed to have a grit blasted surface finish without striation lines. Grit blasting is a surface finishing process, such as smoothing a rough surface or roughening a smooth surface. Blasting may remove surface material by forcing a stream of abrasive media against a surface at high pressure.

Appearance, including color, gloss and haze, can be evaluated using standard methods. Assuming that the incident light is white light, the color of the object may be determined by the wavelength of the light that is reflected or transmitted without being absorbed. The visual appearance of an object may change with light reflection or transmission. Additional appearance attributes may be based on the directional luminance distribution of reflected or transmitted light, often referred to as gloss, sparkle, dull, transparent, hazy, and the like. Quantitative evaluation may be performed based on ASTM standards regarding color and appearance observation or ASTM E-430 standard test methods for measuring gloss of high gloss surfaces, including ASTM D523 (gloss), ASTM D2457 (plastic gloss), ASTM E430 (gloss on high gloss surfaces, haze), and ASTM D5767(DOI), among others. The measurement of gloss, haze and DOI can be performed by a testing apparatus (such as Rhopoint IQ).

In some embodiments, color is quantified by parameters L, a and b, where L represents lightness, a represents a color between red and green, and b represents a color between blue and yellow. For example, a high b value indicates an unattractive yellowish color, rather than a gold color. The parameters a and b, which are almost zero, represent neutral colors. A low L value indicates a dark brightness and a high L value indicates a high brightness. For color measurement, test equipment such as X-Rite Coloreye XTH, X-Rite Coloreye 7000 may be used. These measurements are according to CIE/ISO standards for illuminant, observer and L-, a-, and b-color scales. For example, the criteria include: (a) ISO11664-1:2007(E)/CIE S014-1/E: 2006: in conjunction with the ISO/CIE standard: colorimetry — part 1: CIE standard colorimetric observer; (b) ISO 11664-2:2007(E)/CIE S014-2/E: 2006: in conjunction with the ISO/CIE standard: colorimetry — part 2: CIE standard illuminants for colorimetry; (c) ISO 11664-3:2012(E)/CIE S014-3/E: 2011: in conjunction with the ISO/CIE standard: colorimetry — part 3: CIE tristimulus values; and (d) ISO 11664-4:2008(E)/CIE S014-4/E: 2007: in conjunction with the ISO/CIE standard: colorimetry — part 4: CIE 1976L, a, and b color space.

In some variations, L is 70 to 100. In some variations, L is at least 70. In some variations, L is at least 75. In some variations, L is at least 80. In some variations, L is at least 85. In some variations, L is at least 90. In some variations, L is at least 95. In some variations, L is less than or equal to 100. In some variations, L is less than or equal to 95. In some variations, L is less than or equal to 90. In some variations, L is less than or equal to 85. In some variations, L is less than or equal to 80. In some variations, L is less than or equal to 75.

In some variations, a is-2 to 2. In some variations, a is at least-2. In some variations, a is at least-1.5. In some variations, a is at least-1.0. In some variations, a is at least-0.5. In some variations, a is at least 0.0. In some variations, a is at least 0.5. In some variations, a is at least-0.5. In some variations, a is at least 1.0. In some variations, a is at least 1.5. In some variations, a is less than or equal to 2.0. In some variations, a is less than or equal to 1.5. In some variations, a is less than or equal to 1.0. In some variations, a is less than or equal to 0.5. In some variations, a is less than or equal to 0.0. In some variations, a is less than or equal to 2.0. In some variations, a is less than or equal to-0.5. In some variations, a is less than or equal to-1.0. In some variations, a is less than or equal to-1.5.

In some variations, b is-2 to 2. In some variations, b is at least-2. In some variations, b is at least-1.5. In some variations, b is at least-1.0. In some variations, b is at least-0.5. In some variations, b is at least 0.0. In some variations, b is at least 0.5. In some variations, b is at least-0.5. In some variations, b is at least 1.0. In some variations, b is at least 1.5. In some variations, b is less than or equal to 2.0. In some variations, b is less than or equal to 1.5. In some variations, b is less than or equal to 1.0. In some variations, b is less than or equal to 0.5. In some variations, b is less than or equal to 0.0. In some variations, b is less than or equal to 2.0. In some variations, b is less than or equal to-0.5. In some variations, b is less than or equal to-1.0. In some variations, b is less than or equal to-1.5.

Mechanical Properties

The yield strength of the alloy can be determined according to ASTM B557, which standard covers the test setup, test specimens and test procedures for tensile testing.

Referring again to fig. 5, a 6000 series aluminum alloy may be extruded or rolled using conventional processes for aluminum alloys to have the same mechanical properties including yield strength, tensile strength, elongation and hardness as an aluminum alloy without any scrap.

There is an upper limit to mechanical properties that allow the alloy to be formed with dimensional consistency. The disclosed recycled 6000 series aluminum alloys can exceed the upper tensile strength and hardness limits of other aesthetic aluminum alloys. However, the ranges of tensile strength and hardness remain unchanged, i.e. in the range between the lower and upper limits. The constant range allows for dimensional consistency during a forming process, such as rolling.

Data corresponding to the different preparations are presented in block diagrams as shown in fig. 6A to 6D, 7A to 7D, 8A to 8E, and 9A to 9D. Fig. 6A shows the yield strength of an extrudate sample formed from an example recycled 6000 series aluminum alloy, according to embodiments of the present disclosure.

Fig. 6B shows the tensile strength of extrudate samples formed from recycled 6000 series aluminum alloys according to embodiments of the present disclosure.

Fig. 6C shows the elongation of extrudate samples formed from recycled 6000 series aluminum alloys.

Fig. 6D shows the hardness of extrudate samples formed from recycled 6000 series aluminum alloys according to embodiments of the present disclosure.

Fig. 7A illustrates the yield strength of a sheet sample formed from a sample recovered 6000 series aluminum alloy according to an embodiment of the present disclosure.

Fig. 7B illustrates the tensile strength of a sheet sample formed from a recycled 6000 series aluminum alloy according to an embodiment of the present disclosure.

Fig. 7C illustrates the elongation of a sheet sample formed from a recycled 6000 series aluminum alloy according to embodiments of the present disclosure. As shown in fig. 7C, the recycled 6000 series aluminum alloy has an elongation with a 25% lower limit of about 15% and a 75% upper limit of about 16%. The exemplary recycled 6000 series aluminum alloy also had a maximum elongation of 17.5% and a minimum elongation of 13.5%.

Fig. 7D illustrates the hardness of a sheet sample formed from a recycled 6000 series aluminum alloy according to an embodiment of the present disclosure.

Part-to-part dimensional uniformity

Part-to-part dimensional consistency was evaluated for recycled 6000 series aluminum alloys from three different manufacturing contractors A, B and C. The results show that the dimensional consistency of the recycled 6000 series aluminum alloys all matched or exceeded the dimensional consistency of the primary or virgin aluminum alloys, regardless of the source of the scrap.

Thermal conductivity

The disclosed 6000 series aluminum alloys can also have a thermal conductivity of at least 175W/mK, which aids in heat dissipation from electronic devices. In various embodiments, the thermal conductivity of the recycled alloy may be at least 150W/mK. Thermal conductivity varies with alloy composition and heat treatment. The thermal conductivity measured for the disclosed alloys is in the range of 165W/mK to 200W/mK.

In various embodiments, the thermal conductivity of the recycled alloy may be equal to or greater than 165W/mK. In various embodiments, the thermal conductivity of the recycled alloy may be equal to or greater than 175W/mK. In various embodiments, the thermal conductivity of the recycled alloy may be equal to or greater than 185W/mK. In various embodiments, the thermal conductivity of the recycled alloy may be equal to or greater than 195W/mK.

In various embodiments, the thermal conductivity of the recycled alloy may be equal to and less than 200W/mK. In various embodiments, the thermal conductivity of the recycled alloy may be equal to and less than 190W/mK. In various embodiments, the thermal conductivity of the recycled alloy may be equal to and less than 180W/mK. In various embodiments, the thermal conductivity of the recycled alloy may be equal to and less than 170W/mK.

Microstructure

The microstructure may be characterized by an average grain size, a maximum grain size, a PCG layer depth, and a grain aspect ratio.

Fig. 8A shows the average grain size of extrudate samples formed from an example recycled 6000 series aluminum alloy. Fig. 8B shows the maximum grain size of an extrudate sample formed from an example recycled 6000 series aluminum alloy, according to embodiments of the present disclosure. Figure 8C illustrates a PCG depth of layer for an extrudate sample formed from an example recycled 6000 series aluminum alloy, according to embodiments of the present disclosure. Fig. 8D shows grain aspect ratios of extrudate samples formed from an example recycled 6000 series aluminum alloy, according to embodiments of the present disclosure. As shown in fig. 8D, the aspect ratio of the grains was between the minimum value of 0.8 and the maximum value of 1.17, with a median value of 0.97. Fig. 8E shows coarse grain size of extrudate samples formed from the disclosed examples of recycled 6000 series aluminum alloys, according to embodiments of the present disclosure.

Fig. 9A illustrates an average grain size of sheet samples formed from a recycled 6000 series aluminum alloy according to embodiments of the present disclosure. Fig. 9B illustrates the maximum grain size of a sheet sample formed from a recycled 6000 series aluminum alloy according to an embodiment of the present disclosure. Fig. 9C illustrates coarse grain sizes of sheet samples formed from recycled 6000 series aluminum alloys according to embodiments of the present disclosure. Fig. 9D illustrates grain aspect ratios of sheet samples formed from the disclosed examples of recycled 6000-series aluminum alloys, according to embodiments of the present disclosure.

The disclosed aluminum alloys and methods can be used to make electronic devices. An electronic device herein may refer to any electronic device known in the art. These devices may include, for example, wearable devices, such as watches (e.g.,

). The device may also be a telephone, such as a mobile telephone (e.g.,

) A wired telephone, or any communication device (e.g., an email transmission/reception device). These alloys may be part of a display, such as a digital display, a television monitor, an electronic book reader, a portable web browser (e.g.,

) And a computer monitor. These alloys can also be entertainment devices including portable DVD players, conventional DVD players, Blu-rayDisc players, video game consoles, music players such as portable music players (e.g., portable music players)) And the like. These alloys may also be part of a device that provides control, such as controlling images, video, audio streaming (e.g., Apple)) Or may be a remote control for the electronic device. These alloys may be part of a computer or its accessories, such as a hard disk tower enclosure or case of a MacBookAir or Mac Mini.

Any range recited herein is inclusive of the endpoints. The terms "substantially" and "about" are used throughout this specification to describe and account for small fluctuations. For example, they may refer to less than or equal to ± 5%, such as less than or equal to ± 2%, such as less than or equal to ± 1%, such as less than or equal to ± 0.5%, such as less than or equal to ± 0.2%, such as less than or equal to ± 0.1%, such as less than or equal to ± 0.05%.

Having described several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the invention. In addition, many well known processes and elements have not been described in detail in order to avoid unnecessarily obscuring the present invention. Accordingly, the above description should not be taken as limiting the scope of the invention.

Those skilled in the art will appreciate that embodiments of the present disclosure are taught by way of example and not limitation. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The following claims are intended to cover all statements of the scope of the present general and specific features, and methods and systems, as well as all statements of the scope of the present general and specific features, which, as a matter of language, might be said to fall therebetween.