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WO2004018124A1 - Coulage de métaux non ferreux - Google Patents

Coulage de métaux non ferreux Download PDF

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Publication number
WO2004018124A1
WO2004018124A1 PCT/US2003/018764 US0318764W WO2004018124A1 WO 2004018124 A1 WO2004018124 A1 WO 2004018124A1 US 0318764 W US0318764 W US 0318764W WO 2004018124 A1 WO2004018124 A1 WO 2004018124A1
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WO
WIPO (PCT)
Prior art keywords
strip
metal
casting
product
alloy
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2003/018764
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English (en)
Inventor
Ali ÜNAL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Alcoa Corp
Original Assignee
Alcoa Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alcoa Corp filed Critical Alcoa Corp
Priority to ES03737080T priority Critical patent/ES2423825T3/es
Priority to KR1020057002906A priority patent/KR101129489B1/ko
Priority to JP2004530797A priority patent/JP2005536354A/ja
Priority to AU2003236522A priority patent/AU2003236522A1/en
Priority to EP03737080.6A priority patent/EP1545812B1/fr
Publication of WO2004018124A1 publication Critical patent/WO2004018124A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0622—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by two casting wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0605—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by two belts, e.g. Hazelett-process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/10—Supplying or treating molten metal

Definitions

  • the present invention relates to casting of non-ferrous metal alloys, more particularly, to casting non-ferrous metal alloys to create a rapidly solidified shell or shells and a segregation-free center zone containing broken dendrites.
  • Twin roll casting traditionally is a combined solidification and deformation technique involving feeding molten metal into the bite between a pair of counter-rotating cooled rolls wherein solidification is initiated when the molten metal contacts the rolls.
  • Solidified metal forms as a "freeze front" of the molten metal within the roll bite and solid metal advances towards the nip, the point of minimum clearance between the rolls.
  • the solid metal passes through the nip as a solid sheet. The solid sheet is deformed by the rolls (hot rolled) and exits the rolls.
  • Aluminum alloys have successfully been roll cast into % inch thick sheet at about 4-6 feet per minute or about 50-70 pounds per hour per inch of cast width (lbs/hr/in). Attempts to increase the speed of roll casting typically fail due to centerline segregation. Although it is generally accepted that reduced gauge sheet (e.g., less than about inch thick) potentially could be produced more quickly than higher gauge sheet in a roll caster, the ability to roll cast aluminum at rates significantly above about 70 lbs/hr/in has been elusive.
  • Patent No. 5,518,064 (incorporated herein by reference) and depicted in Figs. 1 and 2.
  • a molten metal holding chamber H is connected to a feed tip T which distributes molten metal M between water-cooled twin rolls Ri and R 2 rotating in the direction of the arrows Ai and A 2 , respectively.
  • the rolls Ri and R 2 have respective smooth surfaces Ui and U 2 ; any roughness thereon is an artifact of the roll grinding technique employed during their manufacture.
  • the centerlines of the rolls Ri and R 2 are in a vertical or generally vertical plane L (e.g., up to about 15° from vertical) such that the cast strip S forms in a generally horizontal path.
  • Other versions of this method produce strip in a vertically upward direction.
  • the width of the cast strip S is determined by the width of the tip T.
  • the plane L passes through a region of minimum clearance between the rolls Ri and R 2 referred to as the roll nip N.
  • a solidification region exists between the solid cast strip S and the molten metal M and includes a mixed liquid-solid phase region X.
  • a freeze front F is defined between the region X and the cast strip S as a line of complete solidification.
  • the solid cast strip S is deformed by the rolls Ri and R 2 to achieve the final strip thickness.
  • Hot rolling of the solidified strip between the rolls Ri and R 2 according to conventional roll casting produces unique properties in the strip characteristic of roll cast aluminum alloy strip.
  • a central zone through the thickness of the strip becomes enriched in eutectic forming elements (eutectic formers) in the alloy such as Fe, Si, Ni, Zn and the like and depleted in peritectic forming elements (Ti, Cr, V and Zr).
  • the roll gap at the nip N may be reduced in order to produce thinner gauge strip S.
  • the roll separating force generated by the solid metal between the rolls Ri and R 2 increases.
  • the amount of roll separating force is affected by the location of the freeze front F in relation to the roll nip N.
  • the percentage reduction of the metal sheet is increased, and the roll separating force increases.
  • the relative positions of the rolls Ri and R 2 to achieve the desired roll gap cannot overcome the roll separating force, and the minimum gauge thickness has been reached for that position of the freeze front F.
  • the roll separating force may be reduced by increasing the speed of the rolls in order to move the freeze front F downstream towards the nip N.
  • the roll gap may be reduced.
  • This movement of the freeze front F decreases the ratio between the thickness of the strip at the initial point of solidification and the roll gap at the nip N, thus decreasing the roll separating force as proportionally 1 ess s olidified m etal i s b eing c ompressed and hot rolled.
  • a proportionally greater amount of metal is solidified and then hot rolled at thinner gauges.
  • roll casting of thin gauge strip is accomplished by first roll casting a relatively high gauge strip, decreasing the gauge until a maximum roll separating force is reached, advancing the freeze front to lower the roll separating force (by increasing the roll speed) and further decreasing the gauge until the maximum roll separating force is again reached, and repeating the process of advancing the freeze front and decreasing the gauge in an iterative manner until the desired thin gauge is achieved.
  • a 10 millimeter strip S may be rolled and the thickness may be reduced until the roll separating force becomes excessive (e.g., at 6 millimeters), necessitating a roll speed increase.
  • a major impediment to high-speed roll casting is the difficulty in achieving uniform heat transfer from the molten metal to the smooth surfaces U ⁇ and U 2 , i.e., cooling of the molten metal.
  • the surfaces Ui and U 2 include various imperfections which alter the heat transfer properties of the rolls.
  • such non-uniformity in heat transfer becomes problematic. For example, areas of the surfaces Ui and U 2 with proper heat transfer will cool the molten metal M at the desired location upstream of the nip N whereas areas with insufficient heat transfer properties will allow a portion of the molten metal to advance beyond the desired location and create non-uniformity in the cast strip.
  • Thin gauge steel strip has been successfully roll cast in vertical casters at high speeds (up to about 400 feet per minute) and low roll separating forces.
  • the rolls of a vertical roll caster are positioned side by side so that the strip forms in a downward direction.
  • molten steel is delivered to the bite between the rolls to form a pool of molten steel.
  • the upper surface of the pool of molten steel is often protected from the atmosphere by means of an inert gas.
  • vertical twin roll casting from a pool of molten metal is successful for steel, vertical casting of alloys sensitive to oxidation (e.g., aluminum) requires additional control.
  • each stream becomes one half of the thickness of the cast strip. In both cases, any variation in the gas pressure or delivery rate of the molten aluminum alloy results in non-uniformity in the cast strip.
  • the control parameters for this type of aluminum alloy roll casting are not practical on a commercial scale.
  • the casting belts converge directly opposite each other around the upstream rollers to form an entrance to the casting region in the nip between the upstream rollers.
  • the molten metal is fed directly into the nip.
  • the molten metal is confined between the moving belts and is solidified as it is carried along. Heat liberated by the solidifying metal is withdrawn through the portions of the two belts which are adjacent to the metal being cast. This heat is withdrawn by cooling the reverse surfaces of the belts by means of rapidly moving substantially continuous films of water flowing against and communicating with these reverse surfaces.
  • the operating parameters for belt casting are significantly different from those for roll casting.
  • Solidification o f the metal is completed in a distance o f about 12-15 inches (30-38 mm) downstream of the nip for a thickness of % inch.
  • the belts are exposed to high temperatures when contacted by molten metal on one surface and are cooled by water on the inner surface. This may lead to distortion of the belts.
  • the tension in the belt must be adjusted to account for expansion or contraction of the belt due to temperature fluctuations in order to achieve consistent surface quality of the strip.
  • Block casters include a plurality of chilling blocks mounted adjacent to each other on a pair of opposing tracks. Each set of chilling blocks rotates in the opposite direction to form a casting region therebetween into which molten metal is delivered. The chilling blocks act as heat sinks as the heat of the molten metal transfers thereto.
  • Solidification of the metal is complete about 12-15 inches downstream of the entrance to t he c asting r egion a t a t hickness o f % i nch.
  • T he h eat t ransferred t o t he c hilling blocks i s r emoved during the r eturn 1 oop.
  • U nlike b elts, the c hilling b locks are not functionally distorted by the heat transfer.
  • block casters require precise dimensional control to prevent gaps between the blocks which cause non-uniformity and defects in the cast strip.
  • the heat of the molten metal and the cast strip is transferred to the belts within the casting region (including downstream of the nip). The heat is then removed from the belts while the belts are out of contact with either of the molten metal or the cast strip. In this manner, the portions of the belts within the casting region (in contact with the molten metal and cast strip) are not subjected to large variations in temperature as occurs in conventional belt casters.
  • the thickness of the strip can be limited by the heat capacity of the belts between which casting takes place. Production rates of 2400 lbs/hr/in for 0.08-0.1 inch (2-2.5 mm) strip have been achieved.
  • Strip material of non-ferrous alloys are desirable for use as sheet product in the automotive and aerospace industries and in the production of can bodies and can end and tab stock.
  • Conventional manufacturing of can body stock employs batch processes which include an e xtensive s equence o f s eparate s teps.
  • an i ngot i s needed for further processing it is first scalped, heat treated to homogenize the alloy, cooled and rolled while still hot in a number of passes, hot finish rolled, and finally coiled, air cooled and stored.
  • the coil may be annealed in a batch step.
  • U.S. Patent Nos. 5,772,802 and 5,772,799 disclose belt casting methods in which can or lid stock and a method for its manufacture in which a low alloy content aluminum alloy is strip cast to form a hot strip cast feedstock, the hot feedstock is rapidly quenched to prevent substantial precipitation, annealed and quenched rapidly to prevent substantial precipitation of alloying elements and then cold rolled. This process has been successful despite the relatively low production rates achievable to date.
  • alloys other than aluminum such as magnesium alloys have not been continuously cast on a commercial scale.
  • Magnesium metal has a hexagonal crystal structure that severely restricts the amount of deformation that can be applied, particularly at low temperatures.
  • Production of wrought magnesium alloy products is therefore normally carried out by hot working in the range of 300°-500°C. Even under, those conditions, a multitude of rolling passes and intermediate anneals are needed. In the conventional ingot method, a total of up to 25 rolling passes with intermediate anneals are used to make a finished product of 0.5 mm gauge. As a result, magnesium wrought products tend to be expensive.
  • n eed r emains for a c ost-effective m ethod o f c asting of non-ferrous alloys that achieves uniformity in the cast surface.
  • the product exiting the casting apparatus includes a solid inner layer containing altered dendrites (which substantially avoids or minimizes centerline segregation) surrounded by the outer solid layer of alloy.
  • the product may be in the form of sheet, plate, slab, foil, wire, rod, bar or other extrusion.
  • Suitable end products include automotive sheet product, aerospace sheet product, beverage can body stock and beverage can end and tab stock.
  • the casting surfaces may be the surfaces of rolls in a roll caster or surfaces of belts in a belt caster or other conventional spaced apart casting surfaces which approach each other.
  • the step of solidifying the semi-solid layer is completed at a position of minimum distance between the casting surfaces.
  • the casting surfaces are surfaces of rotating rolls with a nip defined therebetween with completion of the solidifying step occuring at the nip.
  • the force applied by the rolls to the metal advancing therebetween is a maximum of about 300 pounds per inch of width of the product.
  • the casting surfaces are surfaces of belts traveling over rotating rolls, the rolls defining a nip therebetween, and completion of the solidifying step occurs at the nip.
  • the solidified product including the inner layer exits the position of minimum distance between the casting surfaces at a rate of about 25 to about 400 feet per minute or at a rate of at least about 100 feet per minute.
  • the present invention further includes product produced according to the method of the present invention.
  • the product may be in the form of metal strip having a thickness of about 0.06 to about 0.25 inch.
  • the thickness of the inner layer may constitute about 20 to about 30 percent of the thickness of the strip.
  • One result of the process of the present invention is that the composition of the solidified inner layer of metal differs from the composition of the outer layers of metal.
  • the broken dendrites of the inner layer of metal retain a globular (unworked) shape.
  • FIG. 1 is a schematic of a portion of a caster with a molten metal delivery tip and a pair of rolls;
  • FIG. 2 is an enlarged cross-sectional schematic of the molten metal delivery tip and rolls shown in Fig. 1 operated according to the prior art;
  • FIG. 3 is flow chart of steps of the casting method of the present invention.
  • FIG. 4 is a schematic of molten metal casting operated according to the present invention.
  • Fig. 5 i a s chematic of a c aster made in accordance with the present invention with a strip support mechanism and optional cooling means;
  • Fig. 6 i s a s chematic of a c aster made in accordance with the present invention with another strip support mechanism and optional cooling means.
  • the present invention includes a method of casting non-ferrous alloy which includes delivering molten non-ferrous alloy to a casting apparatus.
  • non- ferrous alloy it is meant an alloy of an element such as aluminum, magnesium, titanium, copper, nickel, zinc or tin.
  • Particularly suitable non-ferrous alloys for use in the present invention are aluminum alloys, magnesium alloys and titanium alloys.
  • aluminum alloys “magnesium alloys” and “titanium alloys” are intended to mean alloys containing at least 50 wt.% of the stated element and at l east one modifier element.
  • a luminum, magnesium, and titanium alloys are considered attractive candidates for structural use in aerospace and automotive industries because of their light weight, high strength to weight ratio, and high specific stiffness at both room and elevated temperatures.
  • Suitable aluminum alloys include alloys of the Aluminum Association 3xxx and 5xxx series.
  • systems of magnesium based alloys are Mg-Al system; Mg-Al-Zn system; Mg-Al-Si system; Mg- Al-Rare Earth (RE) system; Mg-Th-Zr system; Mg-Th-Zn-Zr system; Mg-Zn-Zr system; and Mg-Zn-Zr-RE system.
  • step 100 molten non-ferrous metal is delivered to a casting apparatus.
  • T he casting apparatus includes a pair of spaced apart advancing casting surfaces such as described in detail below.
  • step 102 the casting apparatus rapidly cools at least a portion of the non-ferrous alloy to solidify an outer layer of the non- ferrous alloy while maintaining a semi-solid inner layer.
  • the inner layer includes a molten metal component and a solid component of dendrites of the metal.
  • the solidified outer layer increases in thickness as the alloy is cast.
  • the dendrites of the inner layer are altered in step 104, such as by breaking the dendrites into smaller structures.
  • step 106 the inner layer is solidified.
  • the product exiting the casting apparatus includes the solid inner layer formed in step 106 containing the broken dendrites sandwiched within the outer s olid 1 ayer o f a Hoy. T he p roduct m ay b e i n various forms such as but not limited to sheet, plate, slab, and foil.
  • the product may be in the form of a wire, rod, bar or other extrusion. In either case, the product may be further processed and/or treated in step 108.
  • the order of steps 100-108 are not fixed in the method of the present invention and may occur sequentially or some of the steps may occur simultaneously.
  • the present invention b alances the rate of solidification of the molten metal, the formation of dendrites in the solidifying metal and alteration of the dendrites to obtain desired properties in the final product.
  • the cooling rate is selected to achieve rapid solidification of the outer layers of the metal.
  • cooling of the outer layers of metal may occur at a rate of at least about 100° C per minute.
  • Suitable casting apparatuses include cooled casting surfaces such as in a twin roll caster, a belt caster, a slab caster, or a block caster. Vertical roll casters may also be used in the present invention.
  • the casting surfaces In a continuous caster, the casting surfaces generally are spaced apart and have a region at which the distance therebetween is at a minimum. In a roll caster, the region of minimum distance between casting surfaces is the nip. In a belt caster, the region of minimum distance between casting surfaces of the belts may be the nip between the entrance pulleys of the caster.
  • operation of a casting apparatus in the regime of the present invention involves solidification of the metal at the location of a minimum distance b etween the casting surfaces. While the method of present invention is described below as performed using a twin roll caster, this is not meant to be limiting. Other continuous casting surfaces may be used to practice the invention.
  • a roll caster (Fig. 1) may be operated to practice the present invention as shown in detail in Fig. 4.
  • Fig. 1 which generically depicts horizontal continuous casting according to the prior art and according to the present invention
  • the present invention is practiced using a pair of counter-rotating cooled rolls Ri and R 2 rotating in the directions of the arrows Ai and A 2 , respectively.
  • horizontal it is meant that the cast strip is produced in a horizontal orientation or at an angle of plus or minus about 30° from horizontal.
  • Fig. 1 which generically depicts horizontal continuous casting according to the prior art and according to the present invention
  • a feed tip T which may be made from a refractory or other ceramic material, distributes molten metal M in the direction of arrow B directly onto the rolls Ri and R 2 rotating in the direction of the arrows A ⁇ and A 2 , respectively.
  • Gaps Gi and G 2 between the feed tip T and the respective rolls Ri and R 2 are maintained as small as possible to prevent molten metal from leaking out and to minimize the exposure of the molten metal to the atmosphere along the rolls Ri and R 2 yet avoid contact between the tip T and the rolls Ri and R 2 .
  • a suitable dimension of the gaps Gi and G 2 is about 0.01 inch (0.25 mm).
  • a plane L through the centerline of the rolls Ri and R 2 passes through a region of minimum clearance between the rolls Ri and R 2 referred to as the roll nip N.
  • Molten metal M is provided to the casting surfaces of the roll caster, the cooled rolls Ri and R 2 .
  • the molten metal M directly contacts the rolls RT and R 2 at regions 2 and 4, respectively.
  • the metal M Upon contact with the rolls Ri and R 2 , the metal M begins to cool and solidify.
  • the cooling metal solidifies as an upper shell 6 of solidified metal adjacent the roll Ri and a lower shell 8 of solidified metal adjacent to the roll R 2 .
  • the thickness of the shells 6 and 8 increases as the metal M advances towards the nip N. Large dendrites 10 of solidified metal (not shown to scale) are produced at the interfaces between each of the upper and lower shells 6 and 8 and the molten metal M.
  • the large dendrites 10 are broken and dragged into a center portion 12 of the slower moving flow of the molten metal M and are carried in the direction of arrows and C 2 .
  • the dragging action of the flow can cause the large dendrites 10 to be broken further into smaller dendrites 14 (not shown to scale).
  • the metal M is semi-solid and includes a solid component (the solidified small dendrites 14) and a molten metal component.
  • the metal M in the region 16 has a mushy consistency due in part to the dispersion of the small dendrites 14 therein.
  • the central portion 12 is a solid central layer 18 containing the small dendrites 14 sandwiched between the upper shell 6 and the lower shell 8.
  • the small dendrites 14 may be about 20 to about 50 microns in size and have a generally globular shape.
  • the solid inner portion may constitute about 20 to about 30 percent of the total thickness of the strip. While the caster of Fig. 4 is shown as producing strip S in a generally horizontal orientation, this is not meant to be limiting as the strip S may exit the caster at an angle or vertically.
  • step 102 Molten metal delivered in step 100 to the roll caster begins to cool and solidify in step 102.
  • the cooling metal develops outer layers of solidified metal 6 and 8 near or adjacent the cooled casting surfaces (Ri and R 2 ).
  • the thickness of the solidified layers 6 and 8 increases as the metal advances through the casting apparatus.
  • dendrites 10 form in the metal in an inner layer 12 that is at least partially surrounded by the solidified outer layers 6 and 8.
  • the outer layers 6 and 8 substantially surround the inner layer 12 as a sandwich of the inner layer 12 between the two outer layers 6 and 8. In other casting apparatuses the outer layer may completely surround the inner layer.
  • the dendrites 10 are altered, e.g., broken into smaller structures 14.
  • the metal is semi-solid and includes a solid component (the solidified small dendrites 14) and a molten metal component.
  • the metal at this stage has a mushy consistency due in part to the dispersion of the small dendrites 14 therein.
  • the solidified product includes an inner portion 18 containing the small dendrites 14 at least partially surrounded by an outer portion.
  • the thickness of the inner portion may be about 20 to about 30 percent of the thickness of the product.
  • the small dendrites may be about 20 to about 50 microns in size and are substantially unworked by the casting apparatus and thus have a generally globular shape.
  • molten metal in the inner layer 12 is squeezed in a direction opposite to its flow through a casting apparatus (as described in reference to casting between rolls) and/or may be forced into the outer layers 6 and 8 and reach the exterior surfaces of the outer layers 6 and 8. This feature of squeezing and/or forcing the molten metal in the inner layer occurs in any of the casting apparatuses described herein.
  • Breakage of the dendrites in the inner layer in step 104 is achieved when casting between rolls by the shear forces resulting from speed differences between the inner layer of molten metal and the outer layer.
  • Roll casters operated at conventional speeds of 1 ess t han 1 0 f eet p er m inute d o n ot g enerate t he s hear forces r equired t o break any such dendrites.
  • An important aspect of the present invention is breakage of dendrites in the inner layer. Breakage of the dendrites minimizes or avoids centerline segregation and results in improved formability and elongation properties in the finished product by virtue of the reduction or absence of coarse constituents as would be present in conventional roll cast or belt cast product exhibiting centerline segregation.
  • Other suitable mechanisms for breaking dendrites in the inner layer include application to the liquid of mechanical stirring (e.g., propeller), electromagnetic stirring including rotational stator stirring and linear stator stirring, and high frequency ultrasonic vibration.
  • the casting surfaces serve as heat sinks for the heat of the molten metal.
  • the cooled casting surfaces may be made from steel or copper and may be textured and include surface irregularities which contact the molten metal.
  • the surface irregularities may serve to increase the heat transfer from the surfaces of the cooled casting surfaces. Imposition of a controlled degree of non-uniformity in the surfaces of the cooled casting surfaces can result in uniform heat transfer across the surfaces thereof.
  • the surface irregularities may be in the form of grooves, dimples, knurls or other structures and may be spaced apart in a regular pattern of about 20 to about 120 surface irregularities per inch or about 60 irregularities per inch.
  • the surface irregularities may have a height of about 5 to about 50 microns or about 30 microns.
  • the cooled casting surfaces may be coated with a material such as chromium or nickel to enhance separation of the cast product therefrom.
  • the casting surfaces generally heat up during casting and are prone to oxidation at elevated temperatures.
  • Non-uniform oxidation of the casting surfaces during casting can change the heat transfer properties thereof.
  • the casting surfaces may be oxidized prior to use to minimize changes thereof during casting.
  • Brushing the casting surfaces from time to time or continuously is beneficial in removing debris which builds up during casting of non-ferrous alloys. Small pieces of the cast product may break free from the product and adhere to the casting surfaces. These small pieces of non-ferrous alloy product are prone to oxidation, which result in non-uniformity in the heat transfer properties of the casting surfaces. Brushing of the casting surfaces avoids the non-uniformity problems from debris which may collect on the casting surfaces.
  • the control, maintenance and selection of the appropriate speed of the rolls Ri and R 2 may impact the operability of the present invention.
  • the roll speed determines the speed that the molten metal M advances towards the nip N. If the speed is too slow, the large dendrites 10 will not experience sufficient forces to become entrained in the central portion 12 and break into the small dendrites 14. Accordingly, the present invention is suited for operation at high speeds such as about 25 to about 400 feet per minute or about 100 to about 400 feet per minute or about 150 to about 300 feet per minute.
  • the linear rate per unit area that molten aluminum is delivered to the rolls Ri and R 2 may be less than the speed of the rolls Ri and R 2 or about one quarter of the roll speed.
  • High-speed continuous casting according to the present invention may be achievable in part because the textured surfaces Di and D 2 ensure uniform heat transfer from the molten metal M.
  • the roll s eparating force may b e an important parameter in practicing the present invention.
  • a significant benefit of the present invention is that solid strip is not produced until the metal reaches the nip N.
  • the thickness is determined by the dimension of the nip N between the rolls Ri and R 2 .
  • the roll separating force may be sufficiently great to squeeze molten metal upstream and away from the nip N. Excessive molten metal passing through the nip N may cause the layers of the upper and lower shells 6 and 8 and the solid central portion 18 to fall away from each other and become misaligned. Insufficient molten metal reaching the nip N causes the strip to form prematurely as occurs in conventional roll casting processes.
  • Suitable roll separating forces are about 25 to about 300 pounds per inch of width cast or about 100 pounds per inch of width cast.
  • slower casting speeds may be needed when casting thicker gauge non-ferrous alloy in order to remove the heat from the thick alloy. Unlike conventional roll casting, such slower casting speeds do not result in excessive roll separating forces in the present invention because fully solid non-ferrous strip is not produced upstream of the nip.
  • Non-ferrous alloy strip may be produced at thicknesses of about 0.1 inch or less (e.g., 0.06 inch) at casting speeds of about 25 to about 400 feet per minute.
  • Thicker gauge non-ferrous alloy strip may also be produced using the method of the present invention, for example at a thickness of about 0.25 inch.
  • C asting at linear rates contemplated by the present invention i.e., about 25 to about 400 feet per minute solidifies the non-ferrous alloy product about 1000 times faster than non- ferrous alloy cast as an ingot and improves the properties of the product over non- ferrous alloys cast as an ingot.
  • the present invention further includes non-ferrous alloy product cast according to the present invention.
  • the non-ferrous alloy product includes an inner portion substantially surrounded by an outer portion.
  • the concentration of alloying elements may differ between the inner portion and the outer portion.
  • the molten alloy may have an initial concentration of alloying elements including peritectic forming alloying elements and eutectic forming alloying elements.
  • the concentration of alloying elements may differ b etween the outer p ortion and the inner portion.
  • T he inner portion of the product may be depleted in certain elements (such as eutectic formers) and enriched in other elements (such as peritectic formers) in comparison to the concentration of the eutectic formers and the peritectic formers in each of the metal and the outer portion.
  • the grains in the non-ferrous alloy product of the present invention are substantially undeformed, i.e., have an equiaxial structure, such as globular. In the absence of hard particles in the inner portion of the product, centerline segregation and cracking typical in many cast non-ferrous alloys is minimized or avoided.
  • One support mechanism shown in Fig. 5 includes a continuous conveyor belt B positioned beneath a strip S exiting rolls Ri and R 2 .
  • the belt B travels around pulleys P and supports the strip S for a distance that may be about 10 feet.
  • the length of the belt B between the pulleys P may be determined by the casting process, the exit temperature of the strip S and the alloy of the strip S.
  • Suitable materials for the belt B include fiberglass and metal (e.g., steel) in solid form or as a mesh.
  • metal e.g., steel
  • the support mechanism may include a stationary support surface J such as a metal shoe over which the strip S travels while it cools.
  • the shoe J may be made of a material to which the hot strip S does not readily adhere.
  • the strip S may be cooled at locations E with a fluid such as air or water.
  • the strip S exits the rolls Ri and R 2 at about 1100° F, and it may be desirable to lower the aluminum alloy strip temperature to about 1000° F within about 8 to 10 inches of nip N.
  • One suitable mechanism for cooling the strip at locations E to achieve that amount of cooling is described in U.S. Patent No. 4,823,860, incorporated herein by reference.
  • Example 1 shows properties obtained in the as-rolled condition after coil cooling. The combination of high strength and good formability (elongation) is notable. The combination of high yield strength and elongation achieved in Examples 1 and 2 has heretofore not been achieved in 5xxx series aluminum-magnesium alloys. By way of comparison, aluminum alloy 5182, at best, has a yield strength of 54 ksi and elongation of 7%.
  • Example 2 shows properties obtained after the sheet was solution heat treated and aged at 275° F in the laboratory. Good yield strength and superior bending properties were achieved. Table 1
  • non-ferrous cast alloy products may be produced with improved yield strength and elongation compared to conventional cast products. Such improved properties allow for production of thinner product that is desirable in the market.
  • the product exiting the casting apparatus may be shaped, such as by subsequent rolling, into another form or otherwise treated to manufacture can sheet, tab stock, automotive sheet and other end products including lithographic sheet and bright sheet.
  • Subsequent processing of the product exiting the casting apparatus may be done by in-line rolling to benefit from the heat in the as-cast sheet (per the following U.S. Patent Nos., each incorporated herein by reference: 5,772,799; 5,772,802; 5,356,495; 5,496,423; 5,514,228; 5,470,405; 6,344,096 and 6,280,543).
  • the as-cast sheet may be cooled and rolled subsequently off-line.
  • Other processing of the sheet may be performed according to one or more of the aforesaid patents.
  • the product may be in the form of sheet, plate, slab, foil, wire, rod, bar or extrusion.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)

Abstract

L'invention concerne un procédé de coulage continu de métaux non ferreux consistant à distribuer un alliage fondu non ferreux (M) à un appareil de coulage. Ledit appareil refroidit rapidement au moins une partie de l'alliage à une vitesse d'environ 100° C par minute, ce qui permet de solidifier une couche extérieure (6, 8) de l'alliage non ferreux entourant une couche intérieure (16) d'un composant fondu et un composant solide de dendrites (14). Les dendrites (14) sont modifiées afin de produire un produit coulé présentant une bonne résistance au craquelage.
PCT/US2003/018764 2002-08-21 2003-06-13 Coulage de métaux non ferreux Ceased WO2004018124A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
ES03737080T ES2423825T3 (es) 2002-08-21 2003-06-13 Colada de metales no ferrosos
KR1020057002906A KR101129489B1 (ko) 2002-08-21 2003-06-13 비철 금속의 주조 방법
JP2004530797A JP2005536354A (ja) 2002-08-21 2003-06-13 非鉄金属の鋳造
AU2003236522A AU2003236522A1 (en) 2002-08-21 2003-06-13 Casting of non-ferrous metals
EP03737080.6A EP1545812B1 (fr) 2002-08-21 2003-06-13 Coulage de metaux non ferreux

Applications Claiming Priority (14)

Application Number Priority Date Filing Date Title
US40535902P 2002-08-21 2002-08-21
US40533302P 2002-08-21 2002-08-21
US60/405,333 2002-08-21
US60/405,359 2002-08-21
US40645302P 2002-08-28 2002-08-28
US40650502P 2002-08-28 2002-08-28
US40650702P 2002-08-28 2002-08-28
US40650402P 2002-08-28 2002-08-28
US40650602P 2002-08-28 2002-08-28
US60/406,504 2002-08-28
US60/406,505 2002-08-28
US60/406,453 2002-08-28
US60/406,506 2002-08-28
US60/406,507 2002-08-28

Publications (1)

Publication Number Publication Date
WO2004018124A1 true WO2004018124A1 (fr) 2004-03-04

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ID=31950967

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2003/018764 Ceased WO2004018124A1 (fr) 2002-08-21 2003-06-13 Coulage de métaux non ferreux

Country Status (6)

Country Link
EP (1) EP1545812B1 (fr)
JP (1) JP2005536354A (fr)
KR (2) KR20110026026A (fr)
AU (1) AU2003236522A1 (fr)
ES (1) ES2423825T3 (fr)
WO (1) WO2004018124A1 (fr)

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JP2005536358A (ja) * 2002-08-29 2005-12-02 コモンウェルス　サイエンティフィック　アンド　インダストリアル　リサーチ　オーガニゼーション マグネシウム及びマグネシウム合金の双子ロール鋳造
CN100366380C (zh) * 2005-07-20 2008-02-06 哈尔滨工业大学 等径推弯角挤连续制备合金半固态棒材的装置及方法
WO2008128061A1 (fr) * 2007-04-11 2008-10-23 Alcoa Inc. Feuille composite à gradient fonctionnel présentant une matrice métallique
WO2013133978A1 (fr) * 2012-03-07 2013-09-12 Alcoa Inc. Alliages d'aluminium améliorés contenant du magnésium, du silicium, du manganèse, du fer et du cuivre, et procédés de production de ceux-ci
WO2013133976A1 (fr) * 2012-03-07 2013-09-12 Alcoa Inc. Alliages d'aluminium de la série 6xxx améliorés et leurs procédés de production
WO2013133960A1 (fr) * 2012-03-07 2013-09-12 Alcoa Inc. Alliages d'aluminium de la série 7xxx améliorés et leurs procédés de production
DE102012209568A1 (de) 2012-06-06 2013-12-24 Technische Universität Bergakademie Freiberg Verfahren zum Gießwalzen von Magnesiumdrähten
WO2013172912A3 (fr) * 2012-03-07 2014-02-20 Alcoa Inc. Alliages d'aluminium-lithium améliorés et leurs procédés de production
WO2013172910A3 (fr) * 2012-03-07 2014-03-13 Alcoa Inc. Alliages d'aluminium 2xxx améliorés et procédés de production correspondants
WO2014130088A1 (fr) * 2013-02-19 2014-08-28 Alcoa Inc. Alliages d'aluminium traitable thermiquement comprenant du magnésium et du zinc et leurs procédés de fabrication
US8956472B2 (en) 2008-11-07 2015-02-17 Alcoa Inc. Corrosion resistant aluminum alloys having high amounts of magnesium and methods of making the same
US8999079B2 (en) 2010-09-08 2015-04-07 Alcoa, Inc. 6xxx aluminum alloys, and methods for producing the same
AU2013204114B2 (en) * 2012-03-07 2016-04-14 Arconic Inc. Improved 2XXX aluminum alloys, and methods for producing the same
CN114990389A (zh) * 2022-04-27 2022-09-02 永杰新材料股份有限公司 具有层次结构的铝合金带材的制备方法及铝合金带材

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US8403027B2 (en) * 2007-04-11 2013-03-26 Alcoa Inc. Strip casting of immiscible metals
KR20100038809A (ko) * 2008-10-06 2010-04-15 포항공과대학교 산학협력단 고성형성 마그네슘 합금 판재 및 그 제조방법

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US4915158A (en) * 1987-11-09 1990-04-10 Hazelett Strip-Casting Corporation Belt composition for improving performance and flatness of thin revolving endless flexible casting belts in continuous metal casting machines
US5983980A (en) * 1993-11-18 1999-11-16 Isahikawajima-Harima Heavy Industries Co., Ltd. Casting steel strip
US5482107A (en) * 1994-02-04 1996-01-09 Inland Steel Company Continuously cast electrical steel strip
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Cited By (30)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2005536358A (ja) * 2002-08-29 2005-12-02 コモンウェルス　サイエンティフィック　アンド　インダストリアル　リサーチ　オーガニゼーション マグネシウム及びマグネシウム合金の双子ロール鋳造
CN100366380C (zh) * 2005-07-20 2008-02-06 哈尔滨工业大学 等径推弯角挤连续制备合金半固态棒材的装置及方法
WO2008128061A1 (fr) * 2007-04-11 2008-10-23 Alcoa Inc. Feuille composite à gradient fonctionnel présentant une matrice métallique
US7846554B2 (en) 2007-04-11 2010-12-07 Alcoa Inc. Functionally graded metal matrix composite sheet
CN101678440B (zh) * 2007-04-11 2015-05-06 美铝公司 功能梯度金属基复合材料板
US8956472B2 (en) 2008-11-07 2015-02-17 Alcoa Inc. Corrosion resistant aluminum alloys having high amounts of magnesium and methods of making the same
US9359660B2 (en) 2010-09-08 2016-06-07 Alcoa Inc. 6XXX aluminum alloys, and methods for producing the same
US9249484B2 (en) 2010-09-08 2016-02-02 Alcoa Inc. 7XXX aluminum alloys, and methods for producing the same
US9194028B2 (en) 2010-09-08 2015-11-24 Alcoa Inc. 2xxx aluminum alloys, and methods for producing the same
US8999079B2 (en) 2010-09-08 2015-04-07 Alcoa, Inc. 6xxx aluminum alloys, and methods for producing the same
AU2013204114B2 (en) * 2012-03-07 2016-04-14 Arconic Inc. Improved 2XXX aluminum alloys, and methods for producing the same
AU2013202789B2 (en) * 2012-03-07 2016-04-21 Arconic Inc. Improved aluminum alloys containing magnesium, silicon, manganese, iron, and copper, and methods for producing same
CN104271289A (zh) * 2012-03-07 2015-01-07 美铝公司 含有镁、硅、锰、铁和铜的改良铝合金及其制备方法
CN104284745A (zh) * 2012-03-07 2015-01-14 美铝公司 改良的6xxx铝合金及其制备方法
US9926620B2 (en) 2012-03-07 2018-03-27 Arconic Inc. 2xxx aluminum alloys, and methods for producing the same
WO2013172910A3 (fr) * 2012-03-07 2014-03-13 Alcoa Inc. Alliages d'aluminium 2xxx améliorés et procédés de production correspondants
WO2013172912A3 (fr) * 2012-03-07 2014-02-20 Alcoa Inc. Alliages d'aluminium-lithium améliorés et leurs procédés de production
AU2013202557B2 (en) * 2012-03-07 2017-06-15 Arconic Inc. Improved 6XXX aluminum alloys and methods for producing the same
WO2013133978A1 (fr) * 2012-03-07 2013-09-12 Alcoa Inc. Alliages d'aluminium améliorés contenant du magnésium, du silicium, du manganèse, du fer et du cuivre, et procédés de production de ceux-ci
AU2013203144B2 (en) * 2012-03-07 2016-04-14 Alcoa Inc. Improved aluminum-lithium alloys, and methods for producing the same
WO2013133960A1 (fr) * 2012-03-07 2013-09-12 Alcoa Inc. Alliages d'aluminium de la série 7xxx améliorés et leurs procédés de production
WO2013133976A1 (fr) * 2012-03-07 2013-09-12 Alcoa Inc. Alliages d'aluminium de la série 6xxx améliorés et leurs procédés de production
DE102012209568B4 (de) * 2012-06-06 2016-01-14 Technische Universität Bergakademie Freiberg Verfahren und Vorrichtung zum Gießwalzen von Magnesiumdrähten
DE102012209568A1 (de) 2012-06-06 2013-12-24 Technische Universität Bergakademie Freiberg Verfahren zum Gießwalzen von Magnesiumdrähten
DE102012209568A8 (de) * 2012-06-06 2014-03-13 Technische Universität Bergakademie Freiberg Verfahren zum Gießwalzen von Magnesiumdrähten
WO2014130088A1 (fr) * 2013-02-19 2014-08-28 Alcoa Inc. Alliages d'aluminium traitable thermiquement comprenant du magnésium et du zinc et leurs procédés de fabrication
CN105121690A (zh) * 2013-02-19 2015-12-02 美铝公司 包含镁和锌的可热处理铝合金及其制备方法
US9587298B2 (en) 2013-02-19 2017-03-07 Arconic Inc. Heat treatable aluminum alloys having magnesium and zinc and methods for producing the same
CN114990389A (zh) * 2022-04-27 2022-09-02 永杰新材料股份有限公司 具有层次结构的铝合金带材的制备方法及铝合金带材
CN114990389B (zh) * 2022-04-27 2023-06-16 永杰新材料股份有限公司 具有层次结构的铝合金带材的制备方法及铝合金带材

Also Published As

Publication number Publication date
EP1545812A1 (fr) 2005-06-29
JP2005536354A (ja) 2005-12-02
EP1545812A4 (fr) 2006-04-05
KR20110026026A (ko) 2011-03-14
KR20050058402A (ko) 2005-06-16
AU2003236522A1 (en) 2004-03-11
KR101129489B1 (ko) 2012-03-28
EP1545812B1 (fr) 2013-05-01
ES2423825T3 (es) 2013-09-24

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