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(12) United States Patent (10) Patent No.: US 8,950.465 B2 Lin Et Al

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(12) United States Patent (10) Patent No.: US 8,950.465 B2 Lin Et Al USOO895.0465B2 (12) United States Patent (10) Patent No.: US 8,950.465 B2 Lin et al. (45) Date of Patent: Feb. 10, 2015 (54) ALUMINUMALLOYS, ALUMINUMALLOY (2013.01); C22C 21/00 (2013.01); C25D II/04 PRODUCTS AND METHODS FOR MAKING (2013.01); C25D 1 1/18 (2013.01) THE SAME USPC .......................... 164/113; 164/69.1; 164/76.1 (58) Field of Classification Search (71) Applicant: Alcoa Inc., Pittsburgh, PA (US) USPC ........................................ 164/69.1, 76.1, 113 See application file for complete search history. (72) Inventors: Jen C. Lin, Export, PA (US); James R. Fields, Export, PA (US); Albert L. Askin, Lower Burrell, PA (US); Xinyan (56) References Cited Yan, Murrysville, PA (US); Ralph R. U.S. PATENT DOCUMENTS Sawtell, Gibsonia, PA (US); Shawn Patrick Sullivan, Oakmont, PA (US); 2,612,666 A 10/1952 McGarigal ........................ 22.68 Janell Lyn Abbott, New Stanton, PA 2,885,286 A 5/1959 Weber et al. .................... 75/138 (US) (Continued) (73) Assignee: Alcoa Inc., Pittsburgh, PA (US) FOREIGN PATENT DOCUMENTS (*) Notice: Subject to any disclaimer, the term of this EP O845812 6, 1998 patent is extended or adjusted under 35 EP 12O5567 5, 2002 U.S.C. 154(b) by 0 days. (Continued) (21) Appl. No.: 13/694,457 OTHER PUBLICATIONS Filed: Dec. 3, 2012 Banghong, H., et al., “Development of Precision Forming Technolo (22) gies for Magnesium Components. Singapore Institute of Manufac (65) Prior Publication Data turing Technology, Precision Metal Forming Group, Process Tech nology Division, pp. 1-8, (2001). US 2013/O160963 A1 Jun. 27, 2013 (Continued) Related U.S. Application Data (62) Division of application No. 127657,099, filed on Jan. Primary Examiner — Kevin P Kerns 12, 2010, now Pat. No. 8,349,462. (74) Attorney, Agent, or Firm — Greenberg Traurig, LLP (60) Provisional application No. 61/187,183, filed on Jun. 15, 2009, provisional application No. 61/221,943, (57) ABSTRACT Decorative shape cast products and methods, systems, com (Continued) positions and apparatus for producing the same are described. Int. Cl In one embodiment, the decorative shape cast products are (51) nt. C. produced from an Al Ni or Al Ni-Mn alloy, with a tai B22D 7/00 (2006.01) lored microstructure to facilitate production of anodized B22D 25/00 (2006.01) decorative shape cast product having the appropriate finish C22C2L/00 (2006.01) and mechanical properties. (Continued) (52) U.S. C. 8 Claims, 60 Drawing Sheets CPC ................ B22D 25/00 (2013.01); B22D 1700 (29 of 60 Drawing Sheet(s) Filed in Color) raxWoxersawww.-------layered 342e A Prepare i- snai citer layer - - Strifice : Micrestructure iiaisie secord layer 3. tickass 3S M W- tos-s-serview - --- tailed blended finish Select alloy and/or ---wouvs. sier layer L. 3G ificestructure 3. woxox-wa-waxmwa or. yM-MmM Cior series 430 US 8,950.465 B2 Page 2 Related U.S. Application Data 2002/0185790 Al 12/2002 Klingensmith et al. ........ 266/81 2003/00004.09 A1 1/2003 Blake et al. ......... ... 101.454 filed on Jun. 30, 2009, provisional application No. 2003/0.138730 A1 7/2003 Bennett et al. .. 430,2721 61/269,660, filed on Jun. 26, 2009, provisional appli- 2003.0143485 A1 7/2003 Bennett et al. ............. 430,278.1 cation No. 61/160,631, filed on Mar. 16, 2009, provi- 2003/0194572 Al 10/2003 Cooper et al. ................ 428,457 S1onalional appapplication No. 61/145.416,s I u. Yu’s filed on Jan.• 16u. Yu’s 2004/02619162004/0011437 A1 12/20041/2004 Lin et al.al....... .. ... 148,549 2009. 2005.0167012 A1 8, 2005 Lin et al. .. ... 148,549 2005, 0191204 A1 9, 2005 Lin et al. .. ... 420,531 2005/0238528 A1 10, 2005 Lin et al. .. ... 420/.532 (51) Int. Cl. 2005/0238529 A1 10, 2005 Lin et al. .. ... 420,541 C25D II/04 (2006.01) 2006/0021683 A1 2/2006 Lin et al. ...... 148,549 C25D II/8 (2006.01) 2006/0027291 A1 2/2006 Matsuoka et al. ............ 148,550 2006/0093.829 A1 5/2006 Smith et al. ................... 428/413 2006/0204780 A1 9/2006 Vega et al. ... ... 428,687 (56) References Cited 2006/0289093 A1 12/2006 Yan et al. ... 148,549 2007, OO17604 A1 1/2007 Yan et al. ..... ... 148,549 U.S. PATENT DOCUMENTS 2007/0029207 A1 2/2007 Anglin et al. ... ... 205/300 3,107,1593.943,754. A 10,71962 1963 HollingsworthFetzer et al. .......... et al... 29,19520429 2007/00927393785. A1A 4,558, 2007 SNE"...O.E.Steele et al. ... 428,450 3,150,967 A 9/1964 Moltering ... ... T5,141 2007/O125460 A1 6, 2007 Lin et al. .. ... 148,549 3,151,948. A 10, 1964 Steeves et al. ... 29/145 2008/0066833 A1 3/2008 Lin et al. .. ... 148,549 3,326,728. A 6/1967 Robinson et al. ............ 1486.1 2008/0241573 A1 10, 2008 Askin et al. .. ... 428,612 3,704,209 A 1 1/1972 Patrie. 204.35N 2009/0026063 A1 1/2009 Skiles et al. ............... 204/157.3 3,704,210 A 1 1/1972 Patrie .......... 204.35N 2009/0061216 A1 3/2009 Levendusky et al. ......... 428/336 3,709,742 A 1/1973 Jacobs et al. ................... 148, 6.1 2009/0061218 A1 3/2009 Levendusky et al. ......... 428,336 3,769,180 A 10, 1973 Gedde. 20435N 2010/0008040 A1 1/2010 Weberetai, .361/679.56 3.989,548. A 1 1/1976 Morris.......................... 1482 2010/0047113 A 2.2010 Linet al. ... 420/.532 35; A RE NEA 33. 2010, 0183869 A1 7, 2010 Lin et al. ....................... 428,332 4,976,918 A * 12/1990 Nishi et al. ... 420,546 5,076,344. A 12/1991 Fields et al. 164,457 FOREIGN PATENT DOCUMENTS 5,246,055 A 9, 1993 Fields et al. ... 164/61 5,259,436 A 1 1/1993 Yun et al. ....... ... 164,97 FR 671737 12, 1929 5,290,424 A 3, 1994 MoZelewski et al. 205,116 FR 2128311 10, 1972 5,318,641 A 6, 1994 Masumoto et al. ........... 148,403 GB 1331413 9, 1973 5,370,171 A 12/1994 Fields et al. .................. 164/312 GB 2155.036 9, 1985 5,417,819 A 5, 1995 Askin et al. 428,687 GB 2321781 8, 1998 5,435,373 A 7, 1995 Drane et al. ... ... 164f72 JP O1-247549 10, 1989 5,472,788 A 12/1995 Benitez-Garriga 428,472.2 JP O2-295640 12/1990 5,478,414 A 12/1995 MoZelewski et al. 148,265 JP 04-032541 2, 1992 5.492, 166 A 2, 1996 Liu et al. ............ 164/312 JP 04-107236 4f1992 5,538,600 A 7, 1996 Schultz et al. ... 428/31 JP O6-322493 11, 1994 5,616,231 A 4, 1997 Askin et al. ........ 205,153 RU 2001145 10, 1993 5,637.404 A 6, 1997 Bombalski et al. 428/422 RU 2001147 10, 1993 5,697.422 A 12/1997 Righi et al. ... 164/120 TW 178648 2, 1992 5,725,683 A 3, 1998 Serafin et al. 148,243 TW 2004O9825. A 6, 2004 5,865,931 A 2f1999 Serafin et al. 156.269 WO WO2004/061.146 T 2004 5,955,147 A 9, 1999 Serafin ........ 427/286 WO WO2008/049010 4/2008 5,985,046 A 1 1/1999 Serafin et al. .. 148,243 6,051,327 A 4/2000 Serafin et al. .. 428,652 OTHER PUBLICATIONS 6,077,616 A 6, 2000 Serafin et al. 428,622 M 6,132,531 A 10/2000 Fang et al. .. 148/440 Barclay, R.S., et al., “Off-Eutectic Composite Solidification and 6,235,409 B1 5, 2001 Serafin et al. 428,654 Properties in Al-Niand Al-CoAlloys,” Journal of Materials Science 6,277,217 B1 8/2001 Yoshino et al. 148/440 6:1168-1173 (1971). 39:- R 1938, E.ennett et al.et al. ..... 420,543101,457 Gigliotti, M. F. X., Jr., et al. "A Temperature-Compositions Zone of 6,440,290 B1 8/2002 Vega et al. .................... 205/201 coupled Eutectic Growth in the Sn-Bi System.” Metallurgical Trans 6,503.292 B2 1/2003 Klingensmith et al. ........ T5/386 actions 1:1038-1041 (Apr. 1970). 6,517,954 B1 2/2003 Mergen et al. ..... ... 428,653 Kang, C-S, et al., “Thin-Wall Aluminum Die-Casting Technology for 6,521,391 B1 2/2003 Bennett et al. 430,275.1 Development of Notebook Computer Housing.” J. Mater: Sci. 6,560,845 B2 5, 2003 Serafin et al. .. ... 29,469.5 Technol. 24(1):65-69 (2008). 6,569,601 B1 5, 2003 Bennett et al. 430,273.1 Mondolfo, L. F. “Manganese in Aluminium Alloys.” pp. 25-26, 35. 6,673,5196,631,679 B2 10/20031/2004 Bennett et al. ...430,278.1 101.457 59-61.-01, 88-89,SS-89, 110-117,U-111, printed in Great Britain by Pagerage BBros. 6,715,420 B2 4/2004 Blake et al. 101.456 (Norwich) Ltd., Norfolk (1978), ISBN 3 1951 OOO 527 O10 S. 6,733,566 B1 5/2004 Fang et al. ...................... 75/709 Namahoot, J. "Effect of Deformation on Corrosion of Al-Mn Alloys.” 6,749,992 B2 6/2004 Bennett et al. .......... 430,272.1 thesis submitted o the University of Birmingham, Metallurgy and 6,773,666 B2 8/2004 Lin et al. ..... ... 420,546 Materials School of Engineering. The University of Birmingham, 6,783,730 B2 8/2004 Lin et al. ..... 420,550 Sep. 2004. 6,783,836 B2 8, 2004 Bennett et al. ... 428/149 Panseri, C., “Manuale di Fonnderia Dalluminio.” III Edizone, p. 839 7,067.232 B2 6/2006 Bennett et al.
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