CN118043488A

CN118043488A - Surface treatment of metal substrates concurrent with solution heat treatment or continuous annealing

Info

Publication number: CN118043488A
Application number: CN202280064452.9A
Authority: CN
Inventors: A·马纳夫巴西; C·阮; S·巴金哈姆; D·J·安德森; J·马尔皮卡
Original assignee: Novelis Inc Canada
Current assignee: Novelis Inc Canada
Priority date: 2021-09-24
Filing date: 2022-09-21
Publication date: 2024-05-14
Also published as: CA3228948A1; KR20240032087A; MX2024003243A; WO2023049722A1; EP4405512A1

Abstract

Methods and metal products for using superheated steam to simultaneously perform a solution heat treatment operation or a continuous annealing operation and a surface treatment operation to produce a processed metal product are described. The elongated metal substrate may be subjected to a solution heat treatment operation or a continuous annealing operation. In addition, the elongated metal substrate may be subjected to a surface treatment operation. The solution heat treatment operation or the continuous annealing operation and the surface treatment operation may be performed simultaneously using superheated steam to produce the processed metal product.

Description

Surface treatment of metal substrates concurrent with solution heat treatment or continuous annealing

Cross Reference to Related Applications

The present application claims the benefit and priority of U.S. provisional application No. 63/248,171 filed on 24, 9, 2021, which provisional application is hereby incorporated by reference in its entirety.

Technical Field

The present disclosure relates generally to metallurgy, and more particularly to techniques for simultaneously performing a surface treatment operation and a heat treatment operation or a continuous annealing operation on a metal substrate.

Background

A variety of treatment processes are available for converting a metal substrate into a processed metal product. The metal substrate may be subjected to one or more forming processes (e.g., roll forming, stamping, etc.). For example, the metal substrate may be subjected to a continuous annealing process, a solution heat treatment process, a surface treatment process, a quenching process, or other suitable process. The process may improve certain characteristics of the metal substrate. The characteristics may include bond durability, hardness, corrosion resistance, or other suitable characteristics. In conventional processing techniques, the described processes are typically performed sequentially (i.e., one process at a time, followed by subsequent processes, etc.). Such sequential execution of the process may result in a shaped metal product having characteristics or other performance metrics that are not optimal. In addition, performing the processes in a certain order may degrade the surface of the metal substrate. For example, performing solution heat treatment after surface treatment may undermine the effect of the surface treatment or otherwise degrade it.

Disclosure of Invention

The term embodiment and similar terms are intended to refer broadly to the subject matter of the present disclosure and the following claims. Statements containing these terms should not be construed as limiting the subject matter described herein or limiting the meaning or scope of the following claims. Embodiments of the disclosure encompassed herein are defined by the following claims rather than the present disclosure. This summary is a high-level overview of various aspects of the present disclosure and introduces some of the concepts that are further described in the detailed description section that follows. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining 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.

The present disclosure provides techniques, products, and methods for simultaneously performing a surface treatment operation and a solution heat treatment operation or a continuous annealing operation to produce a processed metal product. The elongated metal substrate may be subjected to a solution heat treatment operation or a continuous annealing operation. In addition, the elongated metal substrate may be subjected to a surface treatment operation. In some examples, for example, the solution heat treatment operation or the continuous annealing operation and the surface treatment operation may be performed simultaneously using superheated steam while also heating the elongated metal substrate. Optionally, the superheated steam may have a moisture content of less than or equal to 10%. Optionally, the elongated metal substrate may be transferred into a furnace, which may include one or more nozzles for spraying superheated steam onto the elongated metal substrate.

Optionally, the elongated metal substrate may comprise an aluminum alloy sheet (e.g., a sheet comprising a 2xxx alloy, a 5xxx alloy, a 6xxx alloy, a 7xxx alloy, etc.). Optionally, the elongated metal substrate may be subjected to a quenching agent that may include water. The water may optionally include additives such as Mn, ce, zr, mo, silicates, silanes, sealants, or combinations thereof. Treatment with the quenchant may optionally produce a surface layer on the elongated metal substrate that may include the additive. Optionally, the superheated steam may include a suppression material, such as Mn, ce, zr, mo, or a combination thereof, which may optionally be incorporated into or onto a surface or surface layer of the elongated metal substrate. Additionally, the surface layer may include the inhibiting material.

Optionally, the processed metal product may comprise a surface layer produced by the solution heat treatment process or the continuous annealing process and the surface treatment process. For example, the surface layer may include at least one of boehmite, bayerite, diaspore, or corundum. The surface layer may have a thickness that may be 10nm to 500nm (such as 10nm to 20nm, 20nm to 50nm, 50nm to 100nm, 100nm to 150nm, 150nm to 200nm, 200nm to 250nm, 250nm to 300nm, 300nm to 350nm, 350nm to 400nm, 400nm to 450nm, or 450nm to 500 nm).

Optionally, the elongated metal substrate may comprise an aluminum alloy sheet metal tube. Optionally, the aluminum alloy sheet metal tube may be prepared by roll forming an aluminum alloy sheet metal into a tubular shape and welding edges of the tubular shape together to encapsulate the aluminum alloy sheet metal tube, such as forming into a hollow cross-sectional shape. Optionally, the solution heat treatment process or the continuous annealing process and the surface treatment process may be performed using a combination of flame pyrolysis and induction heating. Optionally, the solution heat treatment process or the continuous annealing process and the surface treatment process may be performed after welding the elongated metal substrates to produce metal tubes. In some examples, the metal tube may be referred to as having a tubular shape or a tubular cross-sectional shape. In some examples, the metal tube may be referred to as a metal tubing. In some examples, the metal tube has a tubular or hollow cross-sectional shape. For example, the metal tube may have a circular or non-circular cross-sectional shape defined by the metal and including an opening or hollow region located within a perimeter defined by the metal. For example, the metal tube may have a circular, non-circular, oval, or polygonal (e.g., triangular, quadrilateral, pentagonal, hexagonal, heptagonal, octagonal, etc.) cross-sectional shape, including regular or irregular cross-sectional shapes. A metal tube having a non-circular cross-sectional shape may have a cross-sectional shape with linear sections or curved sections (including concave and/or convex curved sections). In some examples, the metal tube may have a star-shaped cross-section or other cross-sectional shape that includes both concave and convex regions. In some examples, a metal tube having a polygonal cross-sectional shape may have an imperfect shape, such as where corners of the shape are rounded. In some examples, the metal tube may have a D-shaped cross-sectional shape, a flat-sided oval cross-sectional shape, a rectangular cross-sectional shape, a square cross-sectional shape, or a circular cross-sectional shape.

The present disclosure provides a metal product, which may include: an aluminum alloy sheet metal substrate; and a surface layer on the aluminum alloy sheet metal substrate. The surface layer on the aluminum alloy sheet metal substrate may include at least one of boehmite, bayerite, diaspore, and corundum. The surface layer may have a thickness that may be 10nm to 500nm (such as 10nm to 20nm, 20nm to 50nm, 50nm to 100nm, 100nm to 150nm, 150nm to 200nm, 200nm to 250nm, 250nm to 300nm, 300nm to 350nm, 350nm to 400nm, 400nm to 450nm, or 450nm to 500 nm).

Optionally, the aluminum alloy sheet metal substrate may comprise a solution heat treated aluminum alloy sheet metal substrate. For example, the aluminum alloy sheet metal substrate may include one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy. Optionally, the surface layer may comprise at least one of Mn, ce, zr, mo, silicate, silane, or sealant. Optionally, the surface layer may be generated by subjecting the aluminum alloy sheet metal substrate to superheated steam, which may be characterized by a moisture content of less than or equal to 10%. Optionally, the superheated steam may include a suppression material, which may include at least one of Mn, ce, zr, and Mo. Optionally, the surface layer may be at least partially created by exposing the aluminum alloy sheet metal substrate to an aqueous quenching agent. Optionally, the quenching agent may include water and at least one of Mn, ce, zr, mo, silicate, silane, or sealant.

The present disclosure provides a roll formed metal product (such as a roll formed metal tube) that may include: roll forming aluminum alloy sheet metal; and a surface layer on the aluminum alloy sheet metal. The surface layer on the roll formed aluminum alloy sheet metal may include at least one of boehmite, bayerite, diaspore, and corundum. The surface layer may have a thickness that may be 10nm to 500nm (such as 10nm to 20nm, 20nm to 50nm, 50nm to 100nm, 100nm to 150nm, 150nm to 200nm, 200nm to 250nm, 250nm to 300nm, 300nm to 350nm, 350nm to 400nm, 400nm to 450nm, or 450nm to 500 nm).

Optionally, the roll formed aluminum alloy sheet metal may include one of a 2xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy. Optionally, the surface layer may comprise at least one of Mn, ce, zr, mo, silicate, silane, or sealant. Optionally, the roll formed aluminum alloy sheet metal can be prepared by roll forming an aluminum alloy sheet metal. Optionally, the roll-formed aluminum alloy sheet metal product may be a roll-formed aluminum alloy sheet metal tube prepared by roll forming an aluminum alloy sheet metal into a tubular shape and welding edges of the tubular shape together to encapsulate the aluminum alloy sheet metal tube. Optionally, the roll formed aluminum alloy sheet metal tube may comprise a treated aluminum alloy sheet metal tube. The treated aluminum alloy sheet metal tube may be subjected to a solution heat treatment or continuous annealing and surface treatment process using a combination of flame pyrolysis and induction heating, for example, after welding the edges of the tubular shape together.

Other objects and advantages will become apparent from the following detailed description of non-limiting examples.

Drawings

The present description makes reference to the accompanying drawings wherein like reference numerals are used to refer to like or similar parts throughout the various figures.

FIG. 1 provides a schematic illustration of an exemplary processing line for forming sheet metal from an elongated metal substrate that includes simultaneous solution heat treatment or continuous annealing and surface treatment operations.

FIG. 2 provides a schematic illustration of an exemplary processing line for roll forming sheet metal tubes from an elongated metal substrate including a concurrent solution heat treatment or continuous annealing process and surface treatment operation.

FIG. 3 provides a schematic diagram of a subsystem of the exemplary processing line of FIG. 2 for making a processed metal product using simultaneous solution heat treatment or continuous annealing and solution treatment operations.

FIG. 4 provides a cross-sectional side view of a furnace that may be used to perform solution heat treatment or continuous annealing and surface treatment operations simultaneously.

Fig. 5 provides a flow chart of a process for producing a processed metal product by using superheated steam to simultaneously perform solution heat treatment or continuous annealing and surface treatment operations.

Fig. 6 provides a cross-sectional side view of a processed metal product having a surface layer that may be created by simultaneously performing solution heat treatment or continuous annealing and surface treatment operations with respect to the processed metal product.

Detailed Description

Systems and methods for simultaneously performing a surface treatment operation and a solution heat treatment operation or a continuous annealing operation on a metal product, such as by using superheated steam while heating the metal product, are described herein. Solution heat treatment operations or continuous annealing and surface treatment operations may be performed simultaneously on one or more elongated metal substrates (e.g., aluminum alloy substrates). The superheated steam may be applied to the elongated metal substrate using various operations (e.g., flame pyrolysis, etc.) or using other suitable techniques while the elongated metal substrate is undergoing heating in a furnace (e.g., where the steam nozzle is included in the furnace). After the solution heat treatment operation or the continuous annealing operation and the surface treatment operation are performed simultaneously, the elongated metal substrate may be formed into various processed metal products. For example, the machined metal product may include sheet metal (e.g., an aluminum alloy sheet metal product), roll formed metal products (including tubes (e.g., roll formed and welded aluminum alloy tubes)), or other suitable machined metal products.

Optionally, the quenching operation may be performed in combination with a solution heat treatment operation or a continuous annealing operation and a surface treatment operation that are performed simultaneously. For example, the quenching operation may be performed after the solution heat treatment operation or the continuous annealing operation and the surface treatment operation are performed simultaneously. The quenching operation may produce a surface layer on the elongated metal substrate either alone or in combination with a concurrent solution heat treatment operation or a continuous annealing operation and surface treatment operation. In some examples, instead of or in addition to the quenching operation, a concurrent solution heat treatment operation or continuous annealing operation and surface treatment operation may create a surface layer on the elongated metal substrate. The surface layer may include various elements and materials for various purposes. For example, the surface layer may include an inhibitor for preventing or reducing corrosion, or may correspond to or include a stable phase (e.g., a stable aluminum phase) or a stable oxide or hydrolyzed oxide phase of a base metal alloy, or may include other suitable elements and materials for improving the characteristics or properties associated with the elongated metal substrate.

Definition and description

As used herein, the terms "invention," "the invention," "this invention," and "the invention" are intended to broadly refer to the subject matter of the present patent application and all of the following claims. Statements containing these terms should not be construed as limiting the subject matter described herein or limiting the meaning or scope of the following patent claims.

In this specification, reference is made to alloys identified by AA number and other related designations (such as "series" or "7 xxx"). For an understanding of the numbering system most commonly used for 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 AluminumAlloys in the Form ofCastings andIngot", both published by the aluminum association.

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

As used herein, a sauter board (also referred to as a sheet board) typically has a thickness of about 4mm to about 15 mm. For example, the sauter board can have a thickness of about 4mm, about 5mm, about 6mm, about 7mm, about 8mm, about 9mm, about 10mm, about 11mm, about 12mm, about 13mm, about 14mm, or about 15 mm.

As used herein, sheet generally refers to aluminum products having a thickness of less than about 4 mm. For example, the sheet may have a thickness of less than about 4mm, less than about 3mm, less than about 2mm, less than about 1mm, less than about 0.5mm, or less than about 0.3mm (e.g., about 0.2 mm).

In the present application, reference may be made to alloy tempering or conditions. For an understanding of the most commonly used alloy temper description, see "American National Standards (ANSI) H35 on Alloy and TemperDesignation Systems". The F state or temper refers to the aluminum alloy at the time of manufacture. O-temper or tempering refers to the aluminum alloy after annealing. Hxx temper (also referred to herein as H-temper) refers to non-heat treatable aluminum alloys with or without heat treatment (e.g., annealing) after cold rolling. Suitable H tempers include HX1, HX2, HX3, HX4, HX5, HX6, HX7, HX8 or HX9 tempers. T1 temper refers to an aluminum alloy that has cooled from a hot work and has undergone natural aging (e.g., at room temperature). T2 temper or temper refers to an aluminum alloy cooled from a hot work, subjected to a cold work and naturally aged. T3 temper or temper refers to an aluminum alloy that has been solution heat treated, cold worked and naturally aged. T4 temper or temper refers to a solution heat treated and naturally aged aluminum alloy. T5 temper refers to an aluminum alloy that has been cooled from a hot work and subjected to artificial aging (at high temperatures). T6 temper or temper refers to an aluminum alloy that has been solution heat treated and artificially aged. T7 temper or temper refers to an aluminum alloy that has been solution heat treated and artificially overaged. T8x temper or temper refers to solution heat treated, cold worked and artificially aged aluminum alloys. T9 temper or temper refers to an aluminum alloy that has been solution heat treated, artificially aged, and cold worked. W state or temper refers to the aluminum alloy after solution heat treatment.

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

As used herein, the meaning of "room temperature" may include temperatures from about 15 ℃ to about 30 ℃, such as about 15 ℃, about 16 ℃, about 17 ℃, about 18 ℃, about 19 ℃, about 20 ℃, about 21 ℃, about 22 ℃, about 23 ℃, about 24 ℃, about 25 ℃, about 26 ℃, about 27 ℃, about 28 ℃, about 29 ℃, or about 30 ℃. As used herein, the meaning of "ambient conditions" may include a temperature of about room temperature, a relative humidity of about 20% to about 100%, and a gas pressure of about 975 millibars (mbar) to about 1050 mbar. For example, the relative humidity may be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 96%, about 98%, about 95%, about 100% or any value therebetween. For example, the atmospheric pressure may be about 975mbar, about 980mbar, about 985mbar, about 990mbar, about 995mbar, about 1000mbar, about 1005mbar, about 1010mbar, about 1015mbar, about 1020mbar, about 1025mbar, about 1030mbar, about 1035mbar, about 1040mbar, about 1045mbar, about 1050mbar or any value in between.

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 including) the minimum value of 1 and the maximum value of 10; that is, all subranges start with a minimum value of 1 or more (e.g., 1 to 6.1) and end with a maximum value of 10 or less (e.g., 5.5 to 10). Unless otherwise specified, the expression "up to" when referring to the compositional quantity of an element means that the element is optional and includes zero percent composition of this particular element. All compositional percentages are weight percent (wt%) unless otherwise specified.

As used herein, the meaning of "a," "an," and "the" includes singular and plural referents unless the context clearly dictates otherwise.

In the examples below, aluminum alloy products and components thereof may be described in terms of their elemental composition expressed in weight percent (wt%). In each alloy, the remainder was aluminum, with the maximum wt% of the sum of all impurities being 0.15%.

Incidental elements (such as grain refiners and deoxidizers) or other additives may be present in the present invention and other properties may be self-added without departing from or significantly altering the properties of the alloys described herein or described herein.

Due to the inherent nature of aluminum or leaching that occurs from contact with processing equipment, small amounts of unavoidable impurities, including materials or elements, may be present in the alloy. Some alloys as described may contain no more than about 0.25 wt.% of any element in addition to the alloying elements, incidental elements, and unavoidable impurities.

Method for producing alloy and aluminum alloy products

The alloys described herein may be cast using any suitable casting method known to one of ordinary skill in the art. As a few non-limiting examples, the casting process may include a Direct Chill (DC) casting process or a Continuous Casting (CC) process. The continuous casting system may include a pair of moving opposing casting surfaces (e.g., moving opposing belts, rolls, or blocks), a casting cavity between the pair of moving opposing casting surfaces, and a molten metal injector. The molten metal injector may have an end opening from which molten metal may exit the molten metal injector and be injected into the casting cavity.

The cladding layer may be attached to the core layer by any means known to those of ordinary skill in the art to form a clad product. For example, the cladding layer may be attached to the core layer by: direct chill co-casting (i.e., fusion casting) as described, for example, in U.S. patent nos. 7,748,434 and 8,927,113, both of which are hereby incorporated by reference in their entirety; hot and cold rolled composite cast ingots as described in U.S. patent No. 7,472,740, incorporated herein by reference in its entirety; or roll bonding to achieve a metallurgical bond between the core and the cladding. The initial and final dimensions of the clad aluminum alloy products described herein may be determined by the desired properties of the overall final product.

The roll bonding process may be performed in different ways. For example, the roll bonding process may include both hot and cold rolling. Additionally, the roll-bonding process may be a one-step process or a multi-step process in which the gauge of the material is reduced during successive rolling steps. The individual rolling steps may optionally be separated by other processing steps including, for example, annealing steps, cleaning steps, heating steps, cooling steps, and the like.

The cast ingot, cast slab, or other cast product may be processed by any suitable means. Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, continuous annealing, solution heat treatment, and optionally pre-aging steps.

In the homogenizing step, the cast product is heated to a temperature in the range of about 400 ℃ to about 560 ℃. For example, the cast product may be heated to a temperature of about 400 ℃, about 410 ℃, about 420 ℃, about 430 ℃, about 440 ℃, about 450 ℃, about 460 ℃, about 470 ℃, about 480 ℃, about 490 ℃, about 500 ℃, about 510 ℃, about 520 ℃, about 530 ℃, about 540 ℃, about 550 ℃, or about 560 ℃. In some examples, the homogenizing is performed at a temperature within 50 ℃ of the solidus temperature of the cast product or alloy thereof. The product is then allowed to soak (i.e., remain at the indicated temperature) for a period of time to form a homogenized product. In some examples, the total time of the homogenization step (including the heating stage and the soaking stage) may be up to 24 hours. For example, for the homogenization step, the product may be heated up to 500 ℃ and soaked for a total time of up to 18 hours. Optionally, for the homogenization step, the product may be heated up to 490 ℃ and soaked for a total time of up to 18 hours. In some cases, the homogenizing step includes a plurality of processes. In some non-limiting examples, the homogenizing step includes heating the cast product to a first temperature for a first period of time, followed by heating to a second temperature for a second period of time. For example, the cast product may be heated to about 465 ℃ for about 3.5 hours, and then heated to about 480 ℃ for about 6 hours.

After the homogenization step, a hot rolling step may be performed. The homogenized product may be allowed to cool to a temperature between 300 ℃ and 450 ℃ before hot rolling begins. For example, the homogenized product may be allowed to cool to a temperature between 325 ℃ and 425 ℃ or from 350 ℃ to 400 ℃. The homogenized product may then be hot rolled at a temperature between 300 ℃ and 450 ℃ to form a hot rolled plate, hot rolled sauter plate, or hot rolled sheet having a gauge between 3mm and 200mm (e.g., ,3mm、4mm、5mm、6mm、7mm、8mm、9mm、10mm、15mm、20mm、25mm、30mm、35mm、40mm、45mm、50mm、55mm、60mm、65mm、70mm、75mm、80mm、85mm、90mm、95mm、100mm、110mm、120mm、130mm、140mm、150mm、160mm、170mm、180mm、190mm、200mm or any value in between).

Optionally, the cast product may be a continuous cast product that may be allowed to cool to a temperature between about 300 ℃ to about 450 ℃. For example, the continuously cast product may be allowed to cool to a temperature between 325 ℃ to 425 ℃ or 350 ℃ to 400 ℃. The continuously cast product may then be hot rolled at a temperature between 300 ℃ and 450 ℃ to form a hot rolled plate, hot rolled sauter plate, or hot rolled sheet having a gauge between 3mm and 200mm (e.g., ,3mm、4mm、5mm、6mm、7mm、8mm、9mm、10mm、15mm、20mm、25mm、30mm、35mm、40mm、45mm、50mm、55mm、60mm、65mm、70mm、75mm、80mm、85mm、90mm、95mm、100mm、110mm、120mm、130mm、140mm、150mm、160mm、170mm、180mm、190mm、200mm or any value in between). During hot rolling, the temperature and other operating parameters may be controlled such that the temperature of the hot rolled intermediate product upon exiting the hot rolling mill is no more than about 470 ℃, no more than about 450 ℃, no more than about 440 ℃, or no more than about 430 ℃.

Cold rolling mills can be used to cold roll cast, homogenized or hot rolled products into thinner products, such as cold rolled sheets. The cold rolled product may have a gauge of between about 0.5mm to 10mm (e.g., between about 0.7mm to 6.5 mm). Optionally, the cold rolled product may have a gauge of 0.5mm、1.0mm、1.5mm、2.0mm、2.5mm、3.0mm、3.5mm、4.0mm、4.5mm、5.0mm、5.5mm、6.0mm、6.5mm、7.0mm、7.5mm、8.0mm、8.5mm、9.0mm、9.5mm or 10.0 mm. Cold rolling may be performed to obtain a final gauge thickness that represents a gauge reduction of up to 85% (e.g., a reduction of up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, or up to 85%) compared to the gauge prior to the start of cold rolling. Optionally, an intermediate annealing step may be performed during the cold rolling step, such as wherein a first cold rolling process is applied, followed by an annealing process (intermediate annealing), followed by a second cold rolling process. The intermediate annealing step may be performed at a temperature of about 300 ℃ to about 450 ℃ (e.g., about 310 ℃, about 320 ℃, about 330 ℃, about 340 ℃, about 350 ℃, about 360 ℃, about 370 ℃, about 380 ℃, about 390 ℃, about 400 ℃, about 410 ℃, about 420 ℃, about 430 ℃, about 440 ℃, or about 450 ℃). In some cases, the intermediate annealing step includes multiple processes. In some non-limiting examples, the intermediate annealing step includes heating the partially cold rolled product to a first temperature for a first period of time, followed by heating to a second temperature for a second period of time. For example, a portion of the cold rolled product may be heated to about 410 ℃ for about 1 hour, and then heated to about 330 ℃ for about 2 hours.

Subsequently, the cast, homogenized or rolled product may be subjected to a solution heat treatment step. The solution heat treatment step may be any treatment suitable for sheet material that results in solutionizing of the soluble particles. The cast, homogenized, or rolled product may be heated up to a Peak Metal Temperature (PMT) of 590 ℃ (e.g., from 400 ℃ to 590 ℃) and soaked under the PMT for a period of time to form a hot product. For example, the cast, homogenized, or rolled product may be soaked at 480 ℃ for a soaking time of up to 30 minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10 minutes, 20 minutes, 25 minutes, or 30 minutes). After heating and soaking, the thermal product is rapidly cooled to a temperature between 500 ℃ and 200 ℃ at a rate greater than 200 ℃/s to form a heat treated product. In one example, the hot product is cooled at a quench rate of greater than 200 ℃/sec at a temperature between 450 ℃ and 200 ℃. Optionally, in other cases, the cooling rate may be faster.

After quenching, the heat treated product may optionally be subjected to a pre-ageing treatment by reheating prior to winding. The pre-ageing treatment may be performed at a temperature of about 70 ℃ to about 125 ℃ for a period of up to 6 hours. For example, the pre-ageing treatment may be performed at a temperature of about 70 ℃, about 75 ℃, about 80 ℃, about 85 ℃, about 90 ℃, about 95 ℃, about 100 ℃, about 105 ℃, about 110 ℃, about 115 ℃, about 120 ℃, or about 125 ℃. Optionally, the pre-aging treatment may be performed for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours. The pre-ageing treatment may be performed by passing the heat treated product through a heating device, such as a device emitting radiant heat, convective heat, inductive heat, infrared heat, etc.

The cast products described herein may be used to make products in the form of sheets, plates, or other suitable products. For example, a slab comprising a product as described herein may be prepared by processing an ingot in a homogenization step or performing a hot rolling step after casting the product in a continuous casting machine. In the hot rolling step, the cast product may be hot rolled to a gauge of 200mm thick or less (e.g., from about 10mm to about 200 mm). For example, the cast product may be hot rolled into a slab having a final gauge thickness of about 10mm to about 175mm, about 15mm to about 150mm, about 20mm to about 125mm, about 25mm to about 100mm, about 30mm to about 75mm, or about 35mm to about 50 mm. In some cases, the plate may be rolled into a thinner metal product, such as a sheet.

Method and system for producing metal products

Metal substrates (such as sheet metal, sauter board, and board) can be used in a variety of applications. In some cases, the metal substrate may be used to make a shaped metal product by one or more shaping processes (such as stamping or roll forming). Roll forming refers to a process in which a metal substrate, such as an elongated metal substrate, is subjected to a bending operation in which two or more rolls force the elongated metal substrate to undergo plastic deformation along the longitudinal or roll axis of the substrate as it moves between the rolls. The elongated metal substrate may be in the form of a sheet metal coil that may be used, for example, in a variety of applications including preparing sheet metal blanks that may be stamped, formed, or otherwise processed. Elongated metal substrates, such as sheet metal coils, are commonly used in roll forming operations because roll forming may be a continuous or semi-continuous process in which a longer length of metal substrate is processed to bend the metal substrate in the same manner along the longitudinal (i.e., longest) axis of the substrate. As used herein, an elongated metal substrate refers to a metal substrate having a length that is greater than a width. In some cases, the length of the elongated metal substrate may be 1.5-1000 times (or more) the width of the substrate. For example, the metal coil may be hundreds of meters long, but only a few meters or a fraction of meters wide. In some examples, the metal coil may be bent at one or more points along its width but entirely along its length by roll forming. In some cases, the elongated metal substrate may be referred to as a metal strip. The roll formed metal product may be slit into shorter pieces. The elongated metal substrate may be slit into smaller portions where the length and width may be comparable (e.g., the ratio of length to width may be about 0.5 to about 1.5), which may be referred to herein as a metal blank. A metal substrate (such as a metal blank) that is subjected to forming by stamping may be referred to herein as a stamped product or a stamped metal product. The metal substrate subjected to roll forming may be referred to herein as a roll formed product or a roll formed metal product.

The elongated metal substrate may be subjected to one or more processes either before or after the elongated metal substrate is formed, or generally as part of the manufacturing process of the elongated metal substrate. For example, the elongated metal substrate may be subjected to a continuous annealing process, a solution heat treatment process, a surface treatment process, a quenching process, or any combination thereof. In some examples, the elongated metal substrate may be subjected to the listed processes in a defined order (e.g., solution heat treatment process or continuous annealing process, then surface treatment process, then quenching process, etc.). However, performing the process alone may reduce the efficiency of producing roll-formed metal products. For example, the amount of time, energy, or other resources used to produce a roll-formed metal product may be excessive. In addition, by performing the process separately, additional processing may need to be performed to form a processed metal product, such as sheet metal or a roll formed metal object (such as a tube). For example, performing a solution heat treatment operation or a continuous annealing operation after a surface treatment operation may destroy or otherwise degrade the effectiveness of the surface treatment operation, and this may require additional surface treatment operations.

However, the techniques described herein allow more than one process to be performed simultaneously during the preparation of a processed metal product. For example, the solution heat treatment operation or the continuous annealing operation and the surface treatment operation may be performed simultaneously. By performing the solution heat treatment operation or the continuous annealing operation and the surface treatment operation simultaneously, the efficiency of producing the resulting processed metal product may be increased, and the processed metal product may include improved properties (e.g., bond durability, hardness, strength, surface properties, etc.).

Fig. 1 provides a schematic diagram of an exemplary processing line 100 for forming processed metal products from an elongated metal substrate. In some examples, the processing line 100 may be configured to produce a processed metal product that may include sheet metal (e.g., aluminum alloy or other suitable alloy sheet metal). The processing line 100 may include a furnace, step, station, or other suitable component that may perform solution heat treatment or continuous annealing and surface treatment operations simultaneously with respect to an elongated metal substrate.

As shown, the processing line 100 includes two starting coils (e.g., starting coil 102), various rollers 104, an elongated metal substrate 105, a furnace 106, a quenching station 108, a tension leveler 110, a pre-ageing station 112, and an ending coil 114. The elongated metal substrate 105 may extend from the starting coil 102 to the ending coil 114 (e.g., through each component of the processing line 100 for preparing processed metal products). The rollers 104 may assist in transporting the elongated metal substrate 105.

The furnace 106 may perform a solution heat treatment operation or a continuous annealing operation and a surface treatment operation. In some examples, the furnace 106 may perform a solution heat treatment operation or a continuous annealing operation and a surface treatment operation simultaneously. The solution heat treatment operation or continuous annealing operation may involve heating the elongated metal substrate 105 to a suitable temperature for dissolving alloying elements into the elongated metal substrate 105 for improving characteristics or properties with respect to the elongated metal substrate 105, for modifying tempering of the elongated metal substrate, or the like. The surface treatment operation may involve one or more operations for modifying the natural surface of the elongated metal substrate 105, such as to create a surface layer, to improve adhesion characteristics of the elongated metal substrate 105, and the like. In some examples, the furnace 106 may use superheated steam to perform heat treatment or continuous annealing and surface treatment operations simultaneously. The superheated steam may be applied to the elongated metal substrate 105 through a nozzle or other suitable source for the superheated steam. Optionally, the superheated steam may be defined by a low moisture content (e.g., less than 10%). In some examples, the superheated steam may include additives (e.g., inhibitors, acids, etc.) for performing surface treatment operations or for otherwise improving characteristics or properties of the elongated metal substrate 105. In some examples, no additional surface treatment operations may be required to produce a processed metal product using the processing line 100 in response to concurrent solution heat treatment or continuous annealing and surface treatment operations.

The quenching station 108 may apply water or other suitable quenching solution for quenching the elongated metal substrate 105. In some examples, the elongated metal substrate 105 may be subjected to a quenching process at a quenching station 108 after being subjected to solution heat treatment or continuous annealing and surface treatment operations simultaneously at a furnace 106. The quenching process may involve subjecting the elongated metal substrate 105 to water or a quenching solution for cooling the elongated metal substrate 105 without losing the improved characteristics or performance characteristics provided by the concurrent solution heat treatment or continuous annealing and surface treatment operations. In some examples, the quenching solution may include additives, such as inhibitors, acids, and the like, for improving the characteristics or performance characteristics of the elongated metal substrate 105.

Fig. 2 provides a schematic diagram of an exemplary process line 200 for roll forming a metal product from an elongated metal substrate 205. In some examples, the process line 200 may be configured to produce a processed metal product such as a metal tube (e.g., an aluminum alloy or other suitable alloy roll-formed metal tube) in which the ends of the roll-formed metal substrate are welded to produce a closed shape or other roll-formed metal product. Similar to the processing line 100, the processing line 200 may include a furnace, steps, stations that may perform solution heat treatment or continuous annealing and surface treatment operations simultaneously with respect to the elongated metal substrate 205.

As shown, the process line 200 includes a starting coil 201, a roll forming station 206, a welding station 208, an scarf station 210, a post weld heat treatment station 212, and a quench tank 214. The starting web 201 may be similar or identical to the starting web 102 of the processing line 100. The roll forming station 206 may include one or more roll forming stations that may be used to form an elongated metal substrate 205 into an elongated metal substrate 207, such as a tubular shape. The welding station 208 may perform one or more optional welding operations associated with the elongated metal substrate 205. For example, after forming the tubular shape at the roll forming station 206, the processing line 200 may use the welding station 208 to weld the elongated metal substrate 205 to produce a tubular shape (e.g., an open tube, a closed tube, or other suitable shape). Optionally, a forging process (e.g., using one or more roll forging stations) may be performed after the welding station 208. The docking station 210 may be used to dock with a surface of an elongated metal substrate 207 of tubular shape. The scarf joint may involve removing defects (e.g., burrs, scores, etc.) from one or more surfaces of the elongated metal substrate 205.

The heat treatment station 212 may optionally be used to perform heat treatment and surface treatment operations simultaneously. For example, the thermal treatment station 212 may use superheated steam to perform both thermal treatment and surface treatment operations. In some examples, the heat treatment station 212 optionally may be a post-weld heat treatment station. Although shown after the welding station 208, the heat treatment station 212 may be performed at any suitable point relative to the processing line 200. In some examples, the heat treatment station 212 may use flame pyrolysis, induction heating, exposure to superheated steam, or other suitable operations, or a combination thereof, to perform heat treatment and surface treatment operations simultaneously. In some examples, flame pyrolysis may involve burning a fuel (e.g., using a gas burner) to heat the elongated metal substrate 205. Flame pyrolysis may be used in combination with steam nozzles that may spray superheated steam onto the elongated metal substrate 205 to produce a stable phase of a substrate base alloy (e.g., aluminum alloy). In some examples, the combination of flame pyrolysis and steam nozzle may include inhibitors, acids, or other suitable additives used in applying additives to the surface of the elongated metal substrate 205 by steam nozzle or flame pyrolysis.

Quench tank 214 may include a quench solution. In some examples, the quench solution of quench tank 214 may be similar to or the same as the quench solution of quench station 108 of process line 100. For example, the quench solution optionally may include additives, such as inhibitors, acids, etc., for improving the characteristics or performance characteristics of the elongated metal substrate 205. After solution heat treatment or continuous annealing and surface treatment operations at the heat treatment station 212, the tubular elongated metal substrate 205 may be subjected to a quenching process relative to the quench tank 214. The quenching process may involve subjecting the elongated metal substrate 205 to a quenching solution for cooling the elongated metal substrate 205 without losing the improved characteristics or performance characteristics provided by the concurrent solution heat treatment or continuous annealing and surface treatment operations. In some examples, quench tank 214 may involve reactive quenching with a quench solution that includes one or more salts, decomposable surface treatment precursors (e.g., polymer precursors, etc.), other suitable reactive quench materials, or a combination thereof.

In some examples, the quench solution (e.g., of quench station 108 and/or quench tank 214) may include additives. The additives may include inorganic or organic surface enhancing components, which may include Zr, mn, ce, mo, silicates, phosphates, silanes, or other suitable surface enhancing components. The quenching solution with additives may be used to cool the elongated metal substrate 205 and seal the surface layer that may be created by a concurrent solution heat treatment or continuous annealing and surface treatment operations. In some examples, the quench solution may be used to include additives into the surface layer for improving performance characteristics (e.g., hardness, corrosion resistance, bond durability, etc.) of the elongated metal substrate 205.

Although described above as sheet metal, roll formed sheet metal product, roll formed sheet metal tube, or a combination thereof, the elongated metal substrate 105 or 205 may comprise a variety of materials, regardless of configuration. For example, the sheet metal configuration of the elongated metal substrate 105 may include one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy. Additionally, the roll-formed sheet metal tube configuration of elongated metal tube 207 may include one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy. The elongated metal substrate 105 may include additional other suitable alloys. In addition, the processed metal products produced from the processing lines 100 and 200 may exhibit similar performance characteristics. For example, the processing line 100 or 200 may produce a processed metal product that exhibits improved combined durability characteristics as compared to a processed metal product that is produced in substantially the same manner but that does not perform a surface treatment, such as where the elongated metal substrate is not subjected to superheated steam during a solution heat treatment or continuous annealing operation. In some examples, bond durability may be determined according to ASTM D3762 standard test or FLTM BV 101-07 standard test. In some examples, the processed metal product may exhibit a bond durability of 30 cycles to 65 cycles or more.

Fig. 3 provides a schematic diagram of a subsystem 300 for producing a process line 200 for processing metal products using simultaneous solution heat treatment or continuous annealing and solution treatment operations. The elongated metal substrate 205 is shown moving through the subsystem 300 in a direction 310. Subsystem 300 may include a roll forming station 305, an optional welding station 315, a set of magnetic field sources 320, a set of flame pyrolysis sources 335, and a set of steam nozzles 350. The bent metal product 330 may exit the subsystem 300 after passing through the subsystem 300. Although the elongated metal substrate 205 is shown as being derived from a coil, other configurations may include processing the elongated metal substrate 205 into a metal blank or metal strip. In addition, although the elongated metal substrate 205 is shown as a flat sheet, other configurations are possible (e.g., a tubular shaped elongated metal substrate 207, etc.).

The roll forming station 305 may include two or more rolls driven along separate axes of rotation in a configuration that receives and passes the elongated metal substrate 205 between the rolls. The rollers may include roller surfaces having surface profiles that are relatively oriented with respect to each other for bending the elongated metal substrate 205 in a direction different from direction 310 as it passes between the rollers in direction 310. Optionally, the roll forming station 305 may include a top roll having a top axis of rotation and a top roll surface and a bottom roll having a bottom axis of rotation and a bottom roll surface. Optionally, the roll forming station 305 may include other roll configurations, such as forming rolls having axes of rotation and surface contours oriented relative to the top or bottom rolls, positioned relative to the other rolls to bend the elongated metal substrate 205 as it passes through the roll forming station 305. The welding station 315 may be optional and may allow the elongated metal substrate 205 to be formed into various shapes. For example, the welding station 315 may allow the elongated metal substrate 205 to become an elongated metal substrate 207 of tubular shape or any other shape suitable for the elongated metal substrate 205.

Each magnetic field source 320 may generate a time-varying magnetic field to heat a portion of the elongated metal substrate 205 by induction heating. Each flame pyrolysis source 335 may expose a portion of the elongated metal substrate 205 to heat (or other suitable output from a flame pyrolysis system). Each steam nozzle 350 may expose a portion of the elongated metal substrate 205 to superheated steam and optionally various additives. Depending on the configuration, different portions of the elongated metal substrate 205 may be heated by different magnetic field sources 320, flame pyrolysis sources 335, and/or steam nozzles. The magnetic field source 320, flame pyrolysis source 335, and/or steam nozzle 350 may be positioned before and/or after the roll forming station 305. As shown, the magnetic field source 320, flame pyrolysis source 335, and steam nozzle 350 are positioned after the roll forming table 305, but they need not be, in other embodiments, and may be positioned in any suitable location relative to the subsystem 300. The magnetic field source 320, flame pyrolysis source 335, and/or steam nozzle 350 may be independently positioned on the top side or the bottom side of the elongated metal substrate 205. The location of the magnetic field source 320, flame pyrolysis source 335, and/or steam nozzle 350 may be governed at least in part by the particular bending operation that is accomplished by the roll forming table 305. For example, the inner curved surface of the elongated metal substrate 205 may face the magnetic field source 320, flame pyrolysis source 335, steam nozzle 350, or a combination thereof positioned behind the roll-forming station 305. Although a combination of the magnetic field source 320, flame pyrolysis source 335, and steam nozzle 350 is shown in the subsystem 300, the magnetic field source 320, flame pyrolysis source 335, and steam nozzle 350 may be used alone or in any desired number and combination. For example, the subsystem 300 may include one or more magnetic field sources 320, one or more steam nozzles 350, and a flameless pyrolysis source 335. As another example, the subsystem 300 may include one or more flame pyrolysis sources 335, one or more steam nozzles 350, and no magnetic field source 320.

In some examples, the steam nozzle 350 may apply superheated steam including additives (such as inhibitors) to the elongated metal substrate 205. The additives may include inhibitors such as Mn, ce, zr, mo, other suitable inhibiting elements or compounds, or combinations thereof. Additionally or alternatively, the additive may include an acid, HNO ₃, or other suitable acid or inhibiting compound. The additives may modify the natural surface of the elongated metal substrate 205, such as to create a surface layer, to improve adhesion characteristics of the elongated metal substrate 205, and the like.

Heating may involve performing solution heat treatment or continuous annealing and surface treatment operations. In this example, the heating may modify the natural surface of the elongated metal substrate 205, such as to create a surface layer, to improve adhesion characteristics of the elongated metal substrate 205, and the like. The heating may increase the temperature of a portion of the elongated metal substrate 205 to or above a temperature sufficient to temporarily or permanently increase the formability or plasticity of the portion of the elongated metal substrate 205. In some cases, the heating may have a sufficient duration to modify tempering of the portion of the elongated metal substrate 205. Optionally, the heating may overage the portion of the elongated metal substrate 205. The heating may raise the temperature of the portion of the elongated metal substrate 205 to, for example, between 50 ℃ and 400 ℃, such as between 100 ℃ and 300 ℃.

Fig. 4 provides a cross-sectional side view of a component 400 of a furnace (e.g., furnace 106 of process line 100) that may be used to perform solution heat treatment or continuous annealing and surface treatment operations simultaneously. Individual components 400 of the furnace are shown and may include a set of steam nozzles 402, a set of nozzle boxes 404 (e.g., containing natural gas burner nozzles), and other suitable components of the furnace. As shown, each steam nozzle 402 may be positioned opposite a nozzle box 404. In addition, as shown, the steam nozzles 402 and the nozzle boxes 404 alternate in the furnace, but this need not be the case, and other configurations are contemplated. The elongated metal substrate may be positioned in the middle of the furnace such that the steam nozzle 402 and the nozzle box 404 may apply superheated steam, heat, or other suitable output from the steam nozzle 402 or the nozzle box 404 to the elongated metal substrate 105. The elongated metal substrate may pass through the furnace and may receive tension such that the elongated metal substrate may be taut or otherwise flat for receiving superheated steam when the elongated metal substrate is in the furnace.

In some examples, the steam nozzle 402 may spray or otherwise suitably apply superheated steam to one or more portions of the elongated metal substrate. The superheated steam may be dry or may include a limited amount of moisture content (e.g., less than 10%). Superheated steam may be used to perform both heat treatment and surface treatment operations. The simultaneous heat treatment and surface treatment operations may cause a surface layer to be produced on the elongated metal substrate.

The surface layer may comprise a stable phase or otherwise suitable phase or modified layer of the base metal of the alloy of the elongated metal substrate. In examples where the elongated metal substrate comprises an aluminum alloy, the stabilizing phase may comprise an alumina or hydrolyzed alumina phase (e.g., boehmite, diaspore, etc.). The stable phase may be present as a surface layer and may optionally enhance corrosion resistance, adhesion to subsequent coatings, or bond durability performance metrics associated with the elongated metal substrate. In some examples, the superheated steam may include additives, such as the inhibitors described above. The inhibitor may be combined with stabilization of the surface layer and may further improve the properties of the elongated metal substrate or other suitable performance criteria. For example, the suppressant and stabilizing phase may be deposited simultaneously through the vapor nozzle 402 and the nozzle box 404 for improving the performance characteristics of the elongated metal substrate.

The nozzle box 404 may include nozzles separate from the steam nozzles 402, may include natural gas burners, or may include other components suitable for the nozzle box 404. The nozzle box 404 may provide heat to the elongated metal substrate 105, for example, by superheated steam, heat generated by burning natural gas, or other suitable heat source. Although four steam nozzles 402 and four nozzle boxes 404 are shown, any suitable amount of steam nozzles 402 and nozzle boxes 404 may be included in the furnace or any portion or sub-part thereof for simultaneous solution heat treatment or continuous annealing and surface treatment of the elongated metal substrate.

In some examples, the furnace may include more than one zone. For example, the components 400 shown in fig. 4 may be included in a first zone, and a second zone may include a second set of components, etc. The furnace may include any suitable number of zones. For example, the furnace may include nine zones, 10 zones, 11 zones, 12 zones, or other suitable number of zones for performing solution heat treatment or continuous annealing and surface treatment operations simultaneously. Optionally, cleaning the elongated metal substrate, such as by using hot water, alkaline cleaners, or the like, may be performed prior to the solution heat treatment or continuous annealing operation. In some examples, one or more zones within the furnace may be used for cleaning, such as to remove oil, dirt, dust, debris, etc., from a surface. After the cleaning process, surface treatment and solution heat treatment or continuous annealing may be performed simultaneously.

Fig. 5 provides a flow chart of a process 500 for producing a processed metal product by simultaneously performing solution heat treatment or continuous annealing and surface treatment operations using superheated steam. At block 502, an elongated metal substrate is subjected to a solution heat treatment operation or a continuous annealing operation. And, at block 504, the elongated metal substrate is subjected to a surface treatment operation. In some examples, the solution heat treatment or continuous annealing process of block 502 and the surface treatment operation of block 504 may be performed simultaneously.

In some examples, the solution heat treatment or continuous annealing process of block 502 and the surface treatment operation of block 504 may be performed using a furnace (e.g., using steam nozzle 402) using superheated steam, using a flame pyrolysis operation (e.g., using flame pyrolysis source 335), or using other suitable techniques. Superheated steam may be applied to a surface of the elongated metal substrate to create a surface layer of the elongated metal substrate. The surface layer may comprise one or more stable phases or layers of the base metal of the elongated metal substrate. For example, if the elongated metal substrate comprises an aluminum alloy, the stable phase included in the surface layer may comprise boehmite (γ -AlOOH), diaspore (α -AlOOH), or other suitable stable phase of aluminum.

At block 506, the elongated metal substrate is optionally subjected to a quenching solution. The quench solution may include pure water, water with additives, or other suitable quench solutions. The quenching solution may be used to cool the elongated metal substrate after the concurrent solution heat treatment or continuous annealing and surface treatment operations while maintaining the surface layer (and other performance index improvements) created by the operations of blocks 502 and 504.

In some examples, the additive may be included in superheated steam, a quenching solution, or other medium to which the elongated metal substrate may be subjected. The additives may include one or more inhibitors, organic surface enhancers, inorganic surface enhancers, or other suitable additives. Inhibitors may include Mn, ce, zr, mo, acids, or other suitable inhibiting elements or compounds. The organic and inorganic surface enhancers may include phosphates, silicates, silanes, or other suitable organic or inorganic surface enhancers. Additives may be included in the superheated steam, the quench solution, other medium to which the elongated metal substrate may be subjected, or a combination thereof, for use in combination with stabilization of the surface layer or otherwise improving performance metrics (e.g., corrosion resistance, bond durability, etc.) of the elongated metal substrate.

Fig. 6 provides a cross-sectional side view of a processed metal product 600 having a surface layer 602 that is created by simultaneously performing solution heat treatment or continuous annealing and surface treatment operations with respect to the processed metal product. The processed metal product 600 may additionally include a substrate 604, which may be part of the elongated metal substrate 105. The substrate 604 may comprise a metal alloy, such as an aluminum alloy. The surface layer 602 may include one or more stable phases of the base metal of the substrate 604. In examples where the substrate 604 comprises an aluminum alloy, the surface layer 602 may comprise a stable phase of aluminum (e.g., boehmite, diaspore, corundum, and the like). The surface layer 602 may additionally include inhibitors or other surface enhancers. For example, the superheated steam and quench solution applied to the elongated metal substrate during simultaneous solution heat treatment or continuous annealing and surface treatment operations may include inhibitors (e.g., mn, ce, zr, mo, acids, etc.), surface enhancers (e.g., phosphates, silicates, silanes, etc.), or combinations thereof. The inhibitor and the surface enhancer may be applied to the elongated metal substrate in combination with or in relation to stabilization for improving performance metrics or characteristics in relation to the processed metal product 600.

The substrate 604 may comprise an aluminum alloy or other suitable substrate material. For example, substrate 604 may include a 2xxx alloy, a 5xxx alloy, a 6xxx alloy, a 7xxx alloy, or other alloy suitable for substrate 604. In addition, the surface layer 602 may be generated on the substrate 604, and the thickness of the surface layer 602 may be 10nm to 500nm. For example, the surface layer 602 may be 10nm to 450nm, 10nm to 400nm, 10nm to 350nm, 10nm to 300nm, 10nm to 250nm, 10nm to 200nm, 10nm to 150nm,10nm to 100nm, 10nm to 50nm, 50nm to 100nm, 100nm to 150nm,150nm to 200nm, 200nm to 250nm, 250nm to 300nm, 300nm to 350nm, 350nm to 400nm, 400nm to 450nm, 450nm to 500nm, or other suitable ranges from 10nm to 500nm.

Method of using metal products

The aluminum alloy products described herein are useful in automotive applications and other transportation applications, including aircraft and railway applications. For example, the disclosed aluminum alloy products can be used to make automotive structural parts such as bumpers, side rails, roof rails, cross rails, pillar reinforcements (e.g., a-, B-, and C-pillars), interior panels, exterior panels, side panels, interior covers, exterior covers, or trunk lid panels. The aluminum alloy products and methods described herein can also be used in aircraft or rail vehicle applications to make, for example, exterior panels and interior panels.

The aluminum alloy products and methods described herein are also useful in electronic device applications. For example, the aluminum alloy products and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, aluminum alloy products may be used to prepare housings for mobile phones (e.g., smart phones), tablet chassis, and other portable electronic devices.

Method for treating metals and metal alloys

Methods of treating metals and metal alloys (including aluminum, aluminum alloys, magnesium alloys, magnesium composites, steel, and the like), and the resulting treated metals and metal alloys are described herein. In some examples, the metal used in the methods described herein includes an aluminum alloy, such as a 1xxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or an 8xxx series aluminum alloy. In some examples, the materials used in the methods described herein include non-ferrous materials including aluminum, aluminum alloys, magnesium-based materials, magnesium alloys, magnesium composites, titanium-based materials, titanium alloys, copper-based materials, composites, sheets used in composites, or any other suitable metal, nonmetal, or combination of materials. Monolithic materials as well as non-monolithic materials such as roll bonded materials, clad alloys, clad layers, composite materials such as but not limited to materials comprising carbon fibers, or various other materials may also be used with the methods described herein. In some examples, an aluminum alloy comprising iron may be used with the methods described herein.

By way of non-limiting example, an exemplary 1xxx series aluminum alloy for use in the methods described herein may include AA1100、AA1100A、AA1200、AA1200A、AA1300、AA1110、AA1120、AA1230、AA1230A、AA1235、AA1435、AA1145、AA1345、AA1445、AA1150、AA1350、AA1350A、AA1450、AA1370、AA1275、AA1185、AA1285、AA1385、AA1188、AA1190、AA1290、AA1193、AA1198 or AA1199.

Non-limiting exemplary 2xxx series aluminum alloys for use in the methods described herein may include AA2001、AA2002、AA2004、AA2005、AA2006、AA2007、AA2007A、AA2007B、AA2008、AA2009、AA2010、AA2011、AA2011A、AA2111、AA2111A、AA2111B、AA2012、AA2013、AA2014、AA2014A、AA2214、AA2015、AA2016、AA2017、AA2017A、AA2117、AA2018、AA2218、AA2618、AA2618A、AA2219、AA2319、AA2419、AA2519、AA2021、AA2022、AA2023、AA2024、AA2024A、AA2124、AA2224、AA2224A、AA2324、AA2424、AA2524、AA2624、AA2724、AA2824、AA2025、AA2026、AA2027、AA2028、AA2028A、AA2028B、AA2028C、AA2029、AA2030、AA2031、AA2032、AA2034、AA2036、AA2037、AA2038、AA2039、AA2139、AA2040、AA2041、AA2044、AA2045、AA2050、AA2055、AA2056、AA2060、AA2065、AA2070、AA2076、AA2090、AA2091、AA2094、AA2095、AA2195、AA2295、AA2196、AA2296、AA2097、AA2197、AA2297、AA2397、AA2098、AA2198、AA2099 or AA2199.

Non-limiting exemplary 3 xxx-series aluminum alloys for use in the methods described herein may include AA3002、AA3102、AA3003、AA3103、AA3103A、AA3103B、AA3203、AA3403、AA3004、AA3004A、AA3104、AA3204、AA3304、AA3005、AA3005A、AA3105、AA3105A、AA3105B、AA3007、AA3107、AA3207、AA3207A、AA3307、AA3009、AA3010、AA3110、AA3011、AA3012、AA3012A、AA3013、AA3014、AA3015、AA3016、AA3017、AA3019、AA3020、AA3021、AA3025、AA3026、AA3030、AA3130 or AA3065.

Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein may include AA4045、AA4004、AA4104、AA4006、AA4007、AA4008、AA4009、AA4010、AA4013、AA4014、AA4015、AA4015A、AA4115、AA4016、AA4017、AA4018、AA4019、AA4020、AA4021、AA4026、AA4032、AA4043、AA4043A、AA4143、AA4343、AA4643、AA4943、AA4044、AA4145、AA4145A、AA4046、AA4047、AA4047A or AA4147.

Non-limiting exemplary 5xxx series aluminum alloys for use in the methods described herein may include AA5182、AA5183、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 or AA5088.

Non-limiting exemplary 6xxx series alloys for use in the methods described herein may 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、AA6963、AA6064、AA6064A、AA6065、AA6066、AA6068、AA6069、AA6070、AA6081、AA6181、AA6181A、AA6082、AA6082A、AA6182、AA6091 or AA6092.

Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein may include AA7011、AA7019、AA7020、AA7021、AA7039、AA7072、AA7075、AA7085、AA7108、AA7108A、AA7015、AA7017、AA7018、AA7019A、AA7024、AA7025、AA7028、AA7030、AA7031、AA7033、AA7035、AA7035A、AA7046、AA7046A、AA7003、AA7004、AA7005、AA7009、AA7010、AA7011、AA7012、AA7014、AA7016、AA7116、AA7122、AA7023、AA7026、AA7029、AA7129、AA7229、AA7032、AA7033、AA7034、AA7036、AA7136、AA7037、AA7040、AA7140、AA7041、AA7049、AA7049A、AA7149、AA7204、AA7249、AA7349、AA7449、AA7050、AA7050A、AA7150、AA7250、AA7055、AA7155、AA7255、AA7056、AA7060、AA7064、AA7065、AA7068、AA7168、AA7175、AA7475、AA7076、AA7178、AA7278、AA7278A、AA7081、AA7181、AA7185、AA7090、AA7093、AA7095 or AA7099.

Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein may include AA8005、AA8006、AA8007、AA8008、AA8010、AA8011、AA8011A、AA8111、AA8211、AA8112、AA8014、AA8015、AA8016、AA8017、AA8018、AA8019、AA8021、AA8021A、AA8021B、AA8022、AA8023、AA8024、AA8025、AA8026、AA8030、AA8130、AA8040、AA8050、AA8150、AA8076、AA8076A、AA8176、AA8077、AA8177、AA8079、AA8090、AA8091 or AA8093.

The exemplifications set out herein illustrate various aspects of the invention, and such exemplifications are not to be construed as limiting the invention in any manner. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications, and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the present invention. Unless otherwise indicated, examples and embodiments described herein may also utilize conventional procedures. Some of the procedures are described herein for illustrative purposes.

Illustrative aspects

As used hereinafter, any reference to a series of aspects (e.g., "aspects 1-4") or an unrecited set of aspects (e.g., "any preceding or subsequent aspect") should be understood to be a separate reference to each of those aspects (e.g., "aspects 1-4" should be understood to be "aspect 1, aspect 2, aspect 3, or aspect 4").

Aspect 1 is a method comprising: subjecting an elongated metal substrate to a solution heat treatment process or a continuous annealing process; and subjecting the elongated metal substrate to a surface treatment process, wherein the surface treatment process and the solution heat treatment process or the continuous annealing process are performed simultaneously using superheated steam, thereby producing a processed metal product.

Aspect 2 is the method of any preceding or subsequent aspect, wherein the elongated metal substrate comprises an aluminum alloy sheet metal or an aluminum alloy sheet metal coil.

Aspect 3 is the method of any preceding or subsequent aspect, wherein the aluminum alloy sheet metal comprises one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.

Aspect 4 is the method of any preceding or subsequent aspect, further comprising: quenching the elongated metal substrate with a quenching agent comprising water and at least one of Mn, ce, zr, mo, a silicate, a silane, or a sealant, wherein the processed metal product comprises a surface layer comprising at least one of Mn, ce, zr, mo, the silicate, the silane, or the sealant.

Aspect 5 is the method of any preceding or subsequent aspect, wherein the superheated steam comprises a suppression material, wherein the suppression material comprises at least one of Mn, ce, zr, or Mo, and wherein at least one of Mn, ce, zr, or Mo is bound to a surface layer of the processed metal product.

Aspect 6 is the method of any preceding or subsequent aspect, wherein the processed metal product comprises a surface layer formed by the solution heat treatment process or the continuous annealing process and the surface treatment process, wherein the surface layer comprises at least one of boehmite, bayerite, diaspore, or corundum, and wherein the thickness of the surface layer is from 10nm to 500nm.

Aspect 7 is the method of any preceding or subsequent aspect, wherein the superheated steam has a moisture content of less than or equal to 10%.

Aspect 8 is the method of any preceding or subsequent aspect, wherein subjecting the elongated metal substrate to the solution heat treatment process or the continuous annealing process and the elongated metal substrate to the surface treatment process comprises transporting the elongated metal substrate into a furnace, and wherein the furnace comprises one or more nozzles for spraying superheated steam onto the elongated metal substrate.

Aspect 9 is the method of any preceding or subsequent aspect, wherein the elongated metal substrate comprises an aluminum alloy sheet metal tube.

Aspect 10 is a method as in any preceding or subsequent aspect, further comprising: the aluminum alloy sheet metal tube is prepared by: roll forming an aluminum alloy sheet metal into a tubular shape; and welding edges of the tubular shape together to encapsulate the aluminum alloy sheet metal tube.

Aspect 11 is the method of any preceding or subsequent aspect, wherein the aluminum alloy sheet metal tube has a circular or non-circular cross-sectional shape.

Aspect 12 is the method of any preceding or subsequent aspect, wherein the solution heat treatment process or the continuous annealing process and the surface treatment process are performed using a combination of flame pyrolysis and induction heating.

Aspect 13 is the method of any preceding or subsequent aspect, wherein the solution heat treatment process or the continuous annealing process and the surface treatment process are performed after welding the elongated metal substrate to form a metal tube.

Aspect 14 is a metal product comprising: an aluminum alloy sheet metal substrate; and a surface layer on the aluminum alloy sheet metal substrate, wherein the surface layer includes at least one of boehmite, bayerite, diaspore, and corundum, and wherein the thickness of the surface layer is 10nm to 500nm.

Aspect 15 is the metal product of any preceding or subsequent aspect, wherein the aluminum alloy sheet metal substrate comprises one of a 2xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.

Aspect 16 is the metal product of any preceding or subsequent aspect, wherein the aluminum alloy sheet metal substrate comprises a solution heat treated aluminum alloy sheet metal substrate or a continuously annealed aluminum alloy sheet metal substrate.

Aspect 17 is the metal product of any preceding or subsequent aspect, wherein the surface layer comprises at least one of Mn, ce, zr, mo, silicate, silane, or sealant.

Aspect 18 is the metal product of any preceding or subsequent aspect, wherein the surface layer is generated by subjecting the aluminum alloy sheet metal substrate to superheated steam characterized by a moisture content of less than or equal to 10%.

Aspect 19 is the metal product of any preceding or subsequent aspect, wherein the superheated steam comprises a suppression material, wherein the suppression material comprises at least one of Mn, ce, zr, and Mo.

Aspect 20 is the metal product of any preceding or subsequent aspect, wherein the surface layer is at least partially created by exposing the aluminum alloy sheet metal substrate to an aqueous quenchant.

Aspect 21 is the metal product of any preceding or subsequent aspect, wherein the aqueous quenching agent comprises water and at least one of Mn, ce, zr, mo, silicate, silane, or sealant.

Aspect 22 is the metal product of any preceding or subsequent aspect, wherein the metal product exhibits a bond durability of 30 cycles to 65 cycles or more according to ASTM D3762 standard test or FLTM BV 101-07 standard test.

Aspect 23 is a tubular metal product comprising: roll forming an aluminum alloy sheet metal tube; and a surface layer on the roll formed aluminum alloy sheet metal tube, wherein the surface layer comprises at least one of boehmite, bayerite, diaspore, and corundum, and wherein the surface layer is between 10nm and 500 nm.

Aspect 24 is the tubular metal product of any preceding or subsequent aspect, wherein the roll formed aluminum alloy sheet metal tube comprises one of a 2xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.

Aspect 25 is the tubular metal product of any preceding or subsequent aspect, wherein the surface layer comprises at least one of Mn, ce, zr, mo, silicate, silane, or sealant.

Aspect 26 is the tubular metal product of any preceding or subsequent aspect, wherein the roll formed aluminum alloy sheet metal tube is prepared by: roll forming an aluminum alloy sheet metal into a tubular shape; and welding edges of the tubular shape together to encapsulate the roll formed aluminum alloy sheet metal tube.

Aspect 27 is the tubular metal product of any preceding or subsequent aspect, wherein the roll formed aluminum alloy sheet metal tube comprises a treated aluminum alloy sheet metal tube that is subjected to a solution heat treatment or continuous annealing and surface treatment process using a combination of flame pyrolysis and induction heating after welding the edges of the tubular shape together.

Aspect 28 is the tubular metal product of any preceding or subsequent aspect, wherein the metal product exhibits a bond durability of 30 cycles to 65 cycles or more according to ASTM D3762 standard test or FLTM BV 101-07 standard test.

Aspect 28 is the tubular metal product of any preceding or subsequent aspect, wherein the roll formed aluminum alloy sheet metal tube has a circular or non-circular cross-sectional shape.

Claims

1. A method, comprising:

Subjecting an elongated metal substrate to a solution heat treatment process or a continuous annealing process; and

The elongated metal substrate is subjected to a surface treatment process, wherein the surface treatment process and the solution heat treatment process or the continuous annealing process are performed simultaneously using superheated steam, thereby generating a processed metal product.

2. The method of claim 1, wherein the elongated metal substrate comprises aluminum alloy sheet metal.

3. The method of claim 2, wherein the aluminum alloy sheet metal comprises one of a 2xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.

4. The method of claim 1, further comprising: quenching the elongated metal substrate with a quenching agent comprising water and at least one of Mn, ce, zr, mo, a silicate, a silane, or a sealant, wherein the processed metal product comprises a surface layer comprising at least one of Mn, ce, zr, mo, the silicate, the silane, or the sealant.

5. The method of claim 1, wherein the superheated steam comprises a suppression material, wherein the suppression material comprises at least one of Mn, ce, zr, or Mo, and wherein at least one of Mn, ce, zr, or Mo is bonded to a surface layer of the processed metal product.

6. The method of claim 1, wherein the processed metal product comprises a surface layer formed by the solution heat treatment process or the continuous annealing process and the surface treatment process, wherein the surface layer comprises at least one of boehmite, bayerite, diaspore, or corundum, and wherein the thickness of the surface layer is from 10nm to 500nm.

7. The method of claim 1, wherein the superheated steam has a moisture content of less than or equal to 10%.

8. The method of claim 1, wherein subjecting the elongated metal substrate to the solution heat treatment process or the continuous annealing process and subjecting the elongated metal substrate to the surface treatment process comprises transferring the elongated metal substrate into a furnace, and wherein the furnace comprises one or more nozzles for spraying superheated steam onto the elongated metal substrate.

9. The method of claim 1, wherein the elongated metal substrate comprises an aluminum alloy sheet metal tube.

10. The method of claim 9, further comprising: the aluminum alloy sheet metal tube is prepared by:

Roll forming an aluminum alloy sheet metal into a tubular shape; and

Edges of the tubular shape are welded together to encapsulate the aluminum alloy sheet metal tube.

11. The method of claim 9, wherein the aluminum alloy sheet metal tube has a circular or non-circular cross-sectional shape.

12. The method of claim 1, wherein the solution heat treatment process or the continuous annealing process and the surface treatment process are performed using a combination of flame pyrolysis and induction heating.

13. The method of claim 1, wherein the solution heat treatment process or the continuous annealing process and the surface treatment process are performed after welding the elongated metal substrate to form a metal tube.

14. A metal product, comprising:

An aluminum alloy sheet metal substrate; and

A surface layer on the aluminum alloy sheet metal substrate, wherein the surface layer includes at least one of boehmite, bayerite, diaspore, and corundum, and wherein the thickness of the surface layer is 10nm to 500nm.

15. The metal product of claim 14, wherein the aluminum alloy sheet metal substrate comprises one of a 2xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.

16. The metal product of claim 14, wherein the aluminum alloy sheet metal substrate comprises a solution heat treated aluminum alloy sheet metal substrate or a continuously annealed aluminum alloy sheet metal substrate.

17. The metal product of claim 14, wherein the surface layer comprises at least one of Mn, ce, zr, mo, silicate, silane, or sealant.

18. The metal product of claim 14, wherein the surface layer is generated by subjecting the aluminum alloy sheet metal substrate to superheated steam characterized by a moisture content of less than or equal to 10%.

19. The metal product of claim 18, wherein the superheated steam comprises a suppression material, wherein the suppression material comprises at least one of Mn, ce, zr, and Mo.

20. The metal product of claim 14, wherein the surface layer is generated at least in part by exposing the aluminum alloy sheet metal substrate to an aqueous quenchant.

21. The metal product of claim 20, wherein the aqueous quenching agent comprises water and at least one of Mn, ce, zr, mo, silicate, silane, or sealant.

22. The metal product of claim 14, wherein the metal product exhibits a bond durability of 30 cycles to 65 cycles or more according to ASTM D3762 standard test or FLTM BV 101,101-07 standard test.

23. A tubular metal product, comprising:

roll forming an aluminum alloy sheet metal tube; and

A surface layer on the roll formed aluminum alloy sheet metal tube, wherein the surface layer comprises at least one of boehmite, bayerite, diaspore, and corundum, and wherein the surface layer is between 10nm and 500 nm.

24. The tubular metal product of claim 23, wherein the roll formed aluminum alloy sheet metal tube comprises one of a 2xxx aluminum alloy, a 6xxx aluminum alloy, or a 7xxx aluminum alloy.

25. The tubular metal product of claim 23, wherein the surface layer comprises at least one of Mn, ce, zr, mo, silicate, silane, or sealant.

26. The tubular metal product of claim 23, wherein the roll formed aluminum alloy sheet metal tube is prepared by:

Roll forming an aluminum alloy sheet metal into a tubular shape; and

Edges of the tubular shape are welded together to encapsulate the roll formed aluminum alloy sheet metal tube.

27. The tubular metal product of claim 25, wherein the roll formed aluminum alloy sheet metal tube comprises a treated aluminum alloy sheet metal tube that is subjected to a solution heat treatment or continuous annealing and surface treatment process using a combination of flame pyrolysis and induction heating after welding the edges of the tubular shape together.

28. The tubular metal product of claim 23, wherein the metal product exhibits a bond durability of 30 cycles to 65 cycles or more according to ASTM D3762 standard test or FLTM BV standard test 101-07.

29. The tubular metal product of claim 23, wherein the roll formed aluminum alloy sheet metal tube has a circular or non-circular cross-sectional shape.