EP1545812B1 - Coulage de metaux non ferreux - Google Patents
Coulage de metaux non ferreux Download PDFInfo
- Publication number
- EP1545812B1 EP1545812B1 EP03737080.6A EP03737080A EP1545812B1 EP 1545812 B1 EP1545812 B1 EP 1545812B1 EP 03737080 A EP03737080 A EP 03737080A EP 1545812 B1 EP1545812 B1 EP 1545812B1
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- European Patent Office
- Prior art keywords
- metal
- casting
- product
- nip
- strip
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- 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
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- 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
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- 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
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- 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 0.63 cm (1 ⁇ 4inch) thick sheet at at about 1-22 - 1.83 m/min (4-6 feet per minute) or about 0.89 - 1.25 kg per hour per cm of cas width (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 0.63 cm (1 ⁇ 4 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 1.25 kg/hr/cm (70 lbs/hr/in) has been elusive.
- a molten metal holding chamber H is connected to a feed tip T which distributes molten metal M between water-cooled twin rolls R 1 and R 2 rotating in the direction of the arrows A 1 and A 2 , respectively.
- the rolls R 1 and R 2 have respective smooth surfaces U 1 and U 2 ; any roughness thereon is an artifact of the roll grinding technique employed during their manufacture.
- the centerlines of the rolls R 1 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.
- 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 R 1 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 heat of the molten metal M is transferred to the rolls R 1 and R 2 such that the location of the freeze front F is maintained upstream of the nip N. In this manner, the molten metal M solidifies at a thickness greater than the dimension of the nip N.
- the solid cast strip S is deformed by the rolls R 1 and R 2 to achieve the final strip thickness. Hot rolling of the solidified strip between the rolls R 1 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).
- eutectic formers i.e., alloying elements other than Ti, Cr, V and Zr
- This enrichment of eutectic formers (i.e., alloying elements other than Ti, Cr, V and Zr) in the central zone occurs because that portion of the strip S corresponds to a region of the freeze front F where solidification occurs last and is known as "centerline segregation". Extensive centerline segregation in the as-cast strip is a factor that restricts the speed of conventional roll casters.
- the as-cast strip also shows signs of working by the rolls. Grains which form during solidification of the metal upstream of the nip become flattened by the rolls. Therefore, roll cast aluminum includes grains elongated at
- 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 R 1 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 roll gap is reduced, the percentage reduction of the metal sheet is increased, and the roll separating force increases.
- the relative positions of the rolls R 1 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 less solidified metal is being compressed and hot rolled. In this manner, as the position of the freeze front F moves toward the nip N, 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 1 and U 2 , i.e., cooling of the molten metal.
- the surfaces U 1 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 U 1 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 122 m/min (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. In this vertical orientation, 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.
- 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 of the metal is completed in a distance of about 12-15 inches (30-38 mm) downstream of the nip for a thickness of 1.89 cm (3 ⁇ 4 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.
- Casting of aluminum alloys on a belt caster has been used to d ate mainly for products having minimal surface quality requirements or for products which are subsequently painted.
- 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 30 - 37.5 cm (12-15 inches) downstream of the entrance to the casting region at a thickness of 1.875 cm (3 ⁇ 4 inch).
- the heat transferred to the chilling blocks is removed during the return loop.
- the shilling blocks 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.
- 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 429 kg/hr/cm (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 extensive sequence of separate steps. When an ingot 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. The coiled sheet stock is then further reduced to final gauge by cold rolling using unwinders, rewinders and single and/or tandem rolling mills.
- These batch processes typically used in the aluminum industry require many different material handling operations to move ingots and coils between what are typically separate processing steps.
- 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.
- US-2,693,012 discloses a process for fabricating sheet stock from molten metal.
- Molten metal is fed continuously to the bight of a pair of cooled rolls driven at high rotation speed to produce a sheet with thickness 1.65 mm.
- a retaining skin of metal adjacent to the roll is formed and a plastic condition in the central portion of the remaining metal is created.
- the plastic metal is mechanically worked and finally frozen completely immediately before the instant the sheet metal passes through the bight of the rolls.
- 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.
- a method of continuously casting molten metal into a metal product comprising the steps of:
- the metal is an alloy of magnesium or titanium.
- the product exits the nip at least 30.5 metres per minute (100 feet per minute).
- the thickness of the solidified inner layer comprises 20% to 30% of thickness of the product.
- the casting surfaces are textured to provide surface irregularities which contact the molten metal.
- said surface irregularities are in the form of grooves, dimples or knurls.
- said surface irregularities are spaced apart in a regular pattern of 20 to 120 irregularities per inch (8 to 48 irregularities per cm.)
- said surface irregularities are spaced apart in a regular pattern of 60 irregularities per inch (24 irregularities per cm.)
- said surface irregularities have a height of 5 to 50 micrometres.
- said surface irregularities have a height of 30 micrometres.
- the casting surfaces are continuously brushed in regions remote from the product to remove debris which might build up.
- 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-sectioned 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 is a schematic of a caster made in accordance with the present invention with a strip support mechanism and optional cooling means;
- Fig. 6 is a schematic of a caster 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 magnesium, titanium, copper, nickel, zinc or tin.
- Particularly suitable non-ferrous alloys for use in the present invention are magnesium alloys and titanium alloys.
- magnesium alloys and “titanium alloys” are intended to mean alloys containing at least 50 wt% of the stated element and at least one modifier element. 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.
- 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.
- the 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 solid layer of alloy.
- the product may bein 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 balances 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. In a continuous caster, the casting surfaces generally are spaced apart and have a region at which the distance therebetween is at a minimum.
- the region of minimum distance between casting surfaces is the nip.
- 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 between 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 R 1 and R 2 rotating in the directions of the arrows A 1 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 R 1 and R 2 rotating in the direction of the arrows A 1 and A 2 , respectively.
- Gaps G 1 and G 2 between the feed tip T and the respective rolls R 1 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 R 1 and R 2 yet avoid contact between the tip T and the rolls R 1 and R 2 .
- a suitable dimension of the gaps G 1 and G 2 is about 0.01 inch (0.25 mm).
- a plane L through the centerline of the rolls R 1 and R 2 passes through a region of minimum clearance between the rolls R 1 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 R 1 and R 2 .
- the molten metal M directly contacts the rolls R 1 and R 2 at regions 2 and 4, respectively.
- the metal M Upon contact with the rolls R 1 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 R 1 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 C 1 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.
- the casting process described in relation to Fig. 4 follows the method steps outlined above.
- 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 (R 1 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 less than 3.3 m/min (10 feet per minute) do n ot generate the s hear forces required t o break any such dendrites.
- high speed (at least 8.2 m/min (25 feet per minute)) operation of a conventional roll caster with control of solidification a s described above allows for casting in the regime of the present invention, other conventional casting apparatuses may also be adapted for operating in a manner which results in the process of the invention.
- 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.
- heat is transferred from the molten metal to the cooled casting surface in a uniform manner to ensure uniformity in the surface of the cast product
- 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 8 to 47 surface irregularities per cm (about 20 to about 120 surface irregularities per inch) or about 24 irregularities per cm (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 R 1 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 7.62 to about 122 m/min (25 to about 400 feet per minute) or about 30.5 to 122 m/min (100 to about 400 feet per minute) or about 46 to about 91 m/min (150 to about 300 feet per minute).
- the linear rate per unit area that molten aluminum is delivered to the rolls R 1 and R 2 may be less than the speed of the rolls R 1 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 D 1 and D 2 ensure uniform heat transfer from the molten metal M.
- the roll separating force m ay b e an important parameter in practising 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 R 1 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.
- a prematurely formed strip 20 may be deformed by the rolls R 1 and R 2 and experience centerline segregation.
- Suitable roll separating forces are about 44 to about 525 N/cm (about 25 to about 300 pounds per inch) of width cast or about 175 N per cm (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 roil 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 0.25 cm (0.1 inch) or less (e.g., 0.152 cm (0.06 inch)) at casting speeds of about 7.62 to about 1.22 m/min) 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 0.63 cm (0.25 inch). Casting 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 non-ferrous alloy product produced by method of the invention 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 between the outer portion and the inner portion.
- the 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 R 1 and R 2 , The belt B travels around pulleys P and supports the strip S for a distance that may be about 3.05 m (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. Alternatively, as shown in Fig.
- 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 R 1 and R 2 at about 593°C (1100° F), and it may be desirable to lower the aluminum alloy strip temperature to about 538°C (1000° F) within about 20.3 to 25.4 cm (8 to 10 inches) of nip N.
- a fluid such as air or water.
- the strip S exits the rolls R 1 and R 2 at about 593°C (1100° F), and it may be desirable to lower the aluminum alloy strip temperature to about 538°C (1000° F) within about 20.3 to 25.4 cm (8 to 10 inches) of nip N.
- One suitable mechanism for cooling the strip at locations E to achieve that amount of colling is described in U.S. Patent No. 4,823,86
- 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. Bay way of comparison, aluminum alloy 5182, at best, has a yield strength of 372 MPa (54 ksi) and elongation of 7%.
- 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.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.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Continuous Casting (AREA)
Claims (11)
- Procédé de coulée continue d'un métal fondu en produit en métal, comprenant les étapes suivantes :alimenter en métal fondu non ferreux une paire de surfaces de coulée avançantes espacées l'une de l'autre ;solidifier le métal fondu sur les surfaces de coulée tout en faisant avancer le métal entre les surfaces de coulée pour produire des couches extérieures de métal solide adjacentes aux surfaces de coulée et une couche intérieure semi-solide contenant des dendrites globulaires du métal entre les couches extérieures de métal solide ;solidifier la couche intérieure semi-solide pour produire un produit de métal solide comprenant la couche intérieure et les couches extérieures ; etretirer le produit de métal solide d'entre les surfaces de coulée, les surfaces de coulée étant des surfaces de cylindres rotatifs munis d'une zone de pincement entre eux, ou les surfaces de coulée étant des surfaces de courroies se déplaçant sur des cylindres rotatifs, les cylindres délimitant une zone de pincement entre eux, caractérisé par le fait que le métal est un alliage de magnésium, titane, cuivre, nickel, zinc ou étain et par le fait que le produit est amené à sortir de la zone de pincement à une vitesse de 25 à 400 pieds/minute (7,6 à 122 mètres/minute) ; la force exercée par les cylindres sur le métal avançant entre eux n'est pas supérieure à 300 Ibs/pouce de largeur du produit (525 N/cm de largeur du produit), et le produit comprend une bande de métal de 0,06 à 0,25 pouces (0,15 à 0,64 cm) d'épaisseur, le procédé étant exécuté de manière à ce que la fin de ladite étape de solidification se produit dans la zone de pincement, et par le fait que dans ce procédé les dendrites sont brisées dans la couche intérieure semi-solide avant la fin de ladite étape de solidification et où lesdites dendrites ne sont pas travaillées.
- Procédé conforme à la revendication 1, où le métal est un alliage de magnésium ou de titane.
- Procédé conforme à la revendication 1, où le produit sort de la zone de pincement à au moins 30,5 mètres/minute (100 pieds/minute).
- Procédé conforme à une quelconque des revendications précédentes, où l'épaisseur de la couche intérieure solidifiée représente 20 % à 30 % de l'épaisseur du produit.
- Procédé conforme à une quelconque des revendications précédentes, où les surfaces de coulée sont texturées pour fournir des irrégularités de surface en contact avec le métal fondu.
- Procédé conforme à la revendication 5, où lesdites irrégularités de surface sont en forme de rainures, de dépressions ou de crans.
- Procédé conforme à la revendication 5 ou la revendication 6, où lesdites irrégularités de surface sont espacées selon un schéma régulier de 20 à 120 irrégularités/pouce (8 à 48 irrégularités/cm).
- Procédé conforme à la revendication 5 ou la revendication 6, où lesdites irrégularités de surface sont espacées selon un schéma régulier de 60 irrégularités/ pouce (24 irrégularités/cm).
- Procédé conforme à une quelconque des revendications 5 à 8, où lesdites irrégularités de surface ont une hauteur de 5 à 50 micromètres.
- Procédé conforme à une quelconque des revendications 5 à 8 où lesdites irrégularités de surface ont une hauteur de 30 micromètres.
- Procédé conforme à une quelconque des revendications précédentes, où les surfaces de coulée sont brossées en continu dans les zones éloignées du produit pour éliminer les débris pouvant s'accumuler.
Applications Claiming Priority (15)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US40535902P | 2002-08-21 | 2002-08-21 | |
| US40533302P | 2002-08-21 | 2002-08-21 | |
| US405359P | 2002-08-21 | ||
| US405333P | 2002-08-21 | ||
| US40650702P | 2002-08-28 | 2002-08-28 | |
| US40650502P | 2002-08-28 | 2002-08-28 | |
| US40645302P | 2002-08-28 | 2002-08-28 | |
| US40650402P | 2002-08-28 | 2002-08-28 | |
| US40650602P | 2002-08-28 | 2002-08-28 | |
| US406505P | 2002-08-28 | ||
| US406453P | 2002-08-28 | ||
| US406504P | 2002-08-28 | ||
| US406507P | 2002-08-28 | ||
| US406506P | 2002-08-28 | ||
| PCT/US2003/018764 WO2004018124A1 (fr) | 2002-08-21 | 2003-06-13 | Coulage de métaux non ferreux |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| EP1545812A1 EP1545812A1 (fr) | 2005-06-29 |
| EP1545812A4 EP1545812A4 (fr) | 2006-04-05 |
| EP1545812B1 true EP1545812B1 (fr) | 2013-05-01 |
Family
ID=31950967
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP03737080.6A Expired - Lifetime EP1545812B1 (fr) | 2002-08-21 | 2003-06-13 | Coulage de metaux 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) |
Families Citing this family (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU2002951075A0 (en) * | 2002-08-29 | 2002-09-12 | Commonwealth Scientific And Industrial Research Organisation | Twin roll casting of magnesium and magnesium alloys |
| 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 |
| US8403027B2 (en) * | 2007-04-11 | 2013-03-26 | Alcoa Inc. | Strip casting of immiscible metals |
| US7846554B2 (en) * | 2007-04-11 | 2010-12-07 | Alcoa Inc. | Functionally graded metal matrix composite sheet |
| KR20100038809A (ko) * | 2008-10-06 | 2010-04-15 | 포항공과대학교 산학협력단 | 고성형성 마그네슘 합금 판재 및 그 제조방법 |
| 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 |
| JP2013542319A (ja) | 2010-09-08 | 2013-11-21 | アルコア インコーポレイテッド | 改良された7xxxアルミニウム合金及びその製造方法 |
| 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 |
| WO2013172912A2 (fr) * | 2012-03-07 | 2013-11-21 | Alcoa Inc. | Alliages d'aluminium-lithium améliorés et leurs procédés de production |
| AU2013204114B2 (en) * | 2012-03-07 | 2016-04-14 | Arconic Inc. | Improved 2XXX aluminum alloys, and methods for producing the same |
| AU2013205742B2 (en) * | 2012-03-07 | 2016-04-07 | Arconic Inc. | Improved 7XXX aluminium alloys, and methods for producing the same |
| KR20140132002A (ko) * | 2012-03-07 | 2014-11-14 | 알코아 인코포레이티드 | 개선된 6xxx 알루미늄 합금, 및 이의 제조 방법 |
| WO2013172910A2 (fr) * | 2012-03-07 | 2013-11-21 | Alcoa Inc. | Alliages d'aluminium 2xxx améliorés et procédés de production correspondants |
| DE102012209568B4 (de) | 2012-06-06 | 2016-01-14 | Technische Universität Bergakademie Freiberg | Verfahren und Vorrichtung zum Gießwalzen von Magnesiumdrähten |
| US9587298B2 (en) * | 2013-02-19 | 2017-03-07 | Arconic Inc. | Heat treatable aluminum alloys having magnesium and zinc and methods for producing the same |
| 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 |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2693012A (en) * | 1950-09-08 | 1954-11-02 | Gen Motors Corp | Method and apparatus for manufacturing sheet material |
| JPS6027450A (ja) | 1983-07-26 | 1985-02-12 | Ishikawajima Harima Heavy Ind Co Ltd | 鋼板の連続鋳造法 |
| US4751958A (en) * | 1985-10-04 | 1988-06-21 | Hunter Engineering Company, Inc. | Continuous casting aluminum alloy |
| 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 |
| US5772802A (en) | 1995-10-02 | 1998-06-30 | Kaiser Aluminum & Chemical Corporation | Method for making can end and tab stock |
| US5772799A (en) | 1995-09-18 | 1998-06-30 | Kaiser Aluminum & Chemical Corporation | Method for making can end and tab stock |
-
2003
- 2003-06-13 EP EP03737080.6A patent/EP1545812B1/fr not_active Expired - Lifetime
- 2003-06-13 AU AU2003236522A patent/AU2003236522A1/en not_active Abandoned
- 2003-06-13 KR KR1020117004617A patent/KR20110026026A/ko not_active Abandoned
- 2003-06-13 WO PCT/US2003/018764 patent/WO2004018124A1/fr not_active Ceased
- 2003-06-13 KR KR1020057002906A patent/KR101129489B1/ko not_active Expired - Fee Related
- 2003-06-13 JP JP2004530797A patent/JP2005536354A/ja active Pending
- 2003-06-13 ES ES03737080T patent/ES2423825T3/es not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| KR20050058402A (ko) | 2005-06-16 |
| WO2004018124A1 (fr) | 2004-03-04 |
| KR101129489B1 (ko) | 2012-03-28 |
| EP1545812A4 (fr) | 2006-04-05 |
| AU2003236522A1 (en) | 2004-03-11 |
| EP1545812A1 (fr) | 2005-06-29 |
| JP2005536354A (ja) | 2005-12-02 |
| ES2423825T3 (es) | 2013-09-24 |
| KR20110026026A (ko) | 2011-03-14 |
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