Roll Casting of Recycled AA5182

Roll casting of the model alloy of recycled AA5182 aluminum alloy was investigated. Fe up to 0.6% was added to the AA5182 to make the model alloys of recycled AA5182. Increase of 0.6% of Fe means that the recycle was three times operated. A vertical type high speed twin roll caster was used. Some devices were operated on the twin roll caster to increase the cooling rate in order to make impurity fine. The roll speed could be increased up to 80m/min. The roll-castability did not become worse by the addition of the Fe. The LDR (limiting Drawing Ratio) was 1.9 when the Fe addition was 0.6. The deterioration of the mechanical properties by the addition of impurity Fe was very small.

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Inline Rolling of 5182 Aluminum Alloy Strip Cast by a Vertical Type High Speed Twin Roll Caster

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.139-141.477 ◽

2010 ◽

Vol 139-141 ◽

pp. 477-480

Author(s):

Ryoji Nakamura ◽

Shuya Hanada ◽

Shinji Kumai ◽

Hisaki Watari

Keyword(s):

Aluminum Alloy ◽

High Speed ◽

Rolling Speed ◽

Center Line ◽

Alloy Strip ◽

Ripple Mark ◽

Roll Casting ◽

Strip Cast ◽

Twin Roll Caster ◽

Twin Roll

An inline hot rolling was operated on 5182 aluminum alloy strip cast using a vertical type high speed caster (VHSTRC) at the speed of 60 m/min. A porosity existing at center line of the thickness and a ripple mark on the surface, these are typical defects of the strip cast by the VHSTRC, could be improved by the inline rolling. The rolling speed was as same as the roll-casting-speed of 60m/min. The temperature of the strip, when the inline rolling was operated, was 450oC. The reduction of the strip of the inline rolling was 35%.

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Roll Casting of Al-40%Sn-1%Cu Strip

Defect and Diffusion Forum ◽

10.4028/www.scientific.net/ddf.382.147 ◽

2018 ◽

Vol 382 ◽

pp. 147-154

Author(s):

Toshio Haga ◽

Ryusuke Onishi ◽

Hisaki Watari ◽

Shinichi Nishida

Keyword(s):

Aluminum Alloy ◽

Molten Metal ◽

Solidification Time ◽

Roll Speed ◽

Strip Surface ◽

Sliding Bearings ◽

Roll Casting ◽

Twin Roll Caster ◽

Metal Microstructure ◽

Twin Roll

Strip casting of Al-40%Sn-1%Cu, which is an aluminum alloy used for sliding bearings, was attempted using an unequal diameter twin roll caster. The conditions required to cast sound strips, including the roll speed, molten temperature, roll load, solidification length, melt head, and use of an upper plate, were investigated. The roll load required to make a stable strip surface was 0.01 kN/mm, and the porosity was minimum when the solidification time was less than 0.6 s. The solidification time was controlled by the roll speed and the solidification length. The casting temperature must be set below 670°C to properly solidify the molten metal, and the metal microstructure became finer as the melt head decreased.

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High Speed Twin-Roll Casting of Al-Mg Alloys

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.154-155.1544 ◽

2010 ◽

Vol 154-155 ◽

pp. 1544-1548 ◽

Cited By ~ 2

Author(s):

Kosuke Komeda ◽

Ryoji Nakamura ◽

Shinji Kumai

Keyword(s):

Heat Transfer ◽

Aluminum Alloy ◽

High Speed ◽

Aluminum Alloy 5182 ◽

Roll Casting ◽

Twin Roll Caster ◽

Deep Drawing Test ◽

Study Heat Transfer ◽

Twin Roll ◽

Steel Rolls

The disadvantages of the conventional twin-roll caster for aluminum alloy are low casting speeds and limited choices of alloys that are castable by this processing. It is known that strip casting of aluminum alloy 5182 is very difficult because of their wider freezing zones. The vertical-type high-speed twin-roll caster used in the present study was devised to overcome these disadvantages. Features of the high speed twin roll casters are as below. Mild steel rolls were used in order to increase the casting speed and to be made at a lower equipment cost. Roll coating is produced in casting of Al-Mg alloy. Therefore lubricant, that resists heat transfer, was not used in the present study. Heat transfer between melt and the roll was improved by hydrostatic pressure of the melt. Low superheat casting was carried out in order to improve microstructure of the strip. In the present study, effectiveness of a high-speed twin roll caster for recycling aluminum alloy was investigated. The effects of the high-speed twin roll caster on alleviating the deterioration of mechanical properties by impurities were investigated. Properties of the cast strip were investigated by metalography, a tension test, and a deep drawing test.

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High Speed Roll Casting of Aluminum Alloy Strip

Materials Science Forum ◽

10.4028/www.scientific.net/msf.475-479.343 ◽

2005 ◽

Vol 475-479 ◽

pp. 343-348 ◽

Cited By ~ 5

Author(s):

Ryoji Nakamura ◽

Hisaki Watari ◽

Shinji Kumai

Keyword(s):

Mechanical Properties ◽

High Speed ◽

The Other ◽

Alloy Strip ◽

Cast Ingot ◽

Cast Strip ◽

Cooling Slope ◽

Roll Casting ◽

Twin Roll Caster ◽

Twin Roll

Two kinds of roll casters, which were suitable for high speed roll casting, were devised. One was a vertical type twin roll caster, and the other was an unequal diameter twin roll caster. The semisolid roll casting using a cooling slope was adopted to these roll casters. The solid fraction was smaller than 5%. 3 mm thickness of 6111 strip was cast at 60 m/min by the vertical type twin roll caster, and 5 mm thickness of 6111 strip was cast at 30 m/min by the unequal diameter twin roll caster. The microstructure of the as-cast strip was equiaxed and spherical, not columnar. The mechanical properties of the strip rolled from roll-cast strip were almost as same as that of the strip made from cast ingot.

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Roll Casting of Aluminum Alloy Strip by a Single Roll Caster Equipped with a Scraper

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.445.307 ◽

2012 ◽

Vol 445 ◽

pp. 307-312 ◽

Cited By ~ 1

Author(s):

Toshio Haga ◽

Kazuya Akitsu ◽

Shinji Kumai ◽

Hisaki Watari

Keyword(s):

Aluminum Alloy ◽

Contact Surface ◽

Rolled Strip ◽

Drawing Ratio ◽

Cast Strip ◽

Roll Casting ◽

Single Side ◽

Twin Roll Caster ◽

Deep Drawing Test ◽

Twin Roll

A single roll caster equipped with a scraper was devised to cast the strip with sound free solidified surface. A property of this single caster is equipment of the scraper. Semisolid metal on the free solidified surface was scribed by a scraper and the surface became flat. Center line segregation did not occur as the strip was solidified from single side. The AA5182 aluminum alloy could be cast at speeds up to 40m/min. Thickness was about 3mm. Pressure of the unit width from the scraper was ranging from 0.1N/mm to 1.0N/mm, and these pressure was enough to make the free solidified surface flat. Roll cast strip could be cold rolled down to 1mm. There was not difference between roll contact surface and the free solidified surface after cold rolling by a visual examination. Result of tension test of the roll cast strip was as same as that of D.C. cast and rolled strip. Deep drawing test was operated at the conditions both of the roll contact surface and the free solidified surface was outside. LDR (limited drawing ratio) was same at both conditions and they were 1.8. Thickness of the strip was controlled by the roll speed, solidification length (length of the melt pool) and pressure of the scraper. The single roll caster is simpler than a twin roll caster. Rigidity for rolling was not needed for the single roll caster. Cost of the roll is half comparing a twin roll caster. The equipment cost of the single roll caster is more economy than that of the twin roll caster.

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Application of Vertical-Type High-Speed Twin-Roll Casting for Up-Grade Recycling and Clad Sheets Fabrication of Aluminum Alloys

Materials Science Forum ◽

10.4028/www.scientific.net/msf.877.56 ◽

2016 ◽

Vol 877 ◽

pp. 56-61 ◽

Cited By ~ 2

Author(s):

Shinji Kumai ◽

Yusuke Takayama ◽

Ryoji Nakamura ◽

Daisuke Shimosaka ◽

Yohei Harada ◽

...

Keyword(s):

Mechanical Properties ◽

Aluminum Alloy ◽

High Speed ◽

Cast Aluminum Alloy ◽

Cast Aluminum ◽

Casting Method ◽

Twin Roll Casting ◽

Roll Casting ◽

Twin Roll Cast ◽

Twin Roll

A horizontal-type twin roll casting method has been popular for producing aluminum alloy strips, however, it is characterized by a relatively low productivity (1~6 m/min). In contrast, a vertical-type high-speed twin-roll casting method possesses an extremely high productivity (60~120 m/min (1~2 m/s)) and an excellent heat extraction ability. The rapid cooling effect provided significant microstructure refinement and mechanical properties improvement in various kinds of cast aluminum alloy products. Not only “product to product recycling” but also “up-grade recycling” can be achieved by making good use of these merits. Two examples of application showing the potential of vertical-type high-speed twin roll casting method are presented. (1) Several kinds of Al-Si base alloy were cast into the strips. Not only strength and toughness but also formability was increased in the twin roll cast products. In particular, great improvement in deformability shows the potential of the twin-roll cast aluminum alloy products as substitutes for some wrought aluminum alloy products. (2) The vertical-type tandem twin-roll caster was able to fabricate a clad strip by single step. The A4045/A3003/A4045 aluminum alloy clad sheets produced by the twin-roll casting showed better mechanical properties than the conventional hot-roll bonded clad sheets.

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High Speed Roll Caster for Aluminum Alloy

Metals ◽

10.3390/met11030520 ◽

2021 ◽

Vol 11 (3) ◽

pp. 520

Author(s):

Toshio Haga

Keyword(s):

Thermal Conductivity ◽

Aluminum Alloy ◽

Copper Alloy ◽

High Speed ◽

The Other ◽

Center Line ◽

Cast Strip ◽

Roll Casting ◽

Twin Roll Caster ◽

Twin Roll

Two types of high-speed twin-roll casters and a single-roll caster equipped with a scraper were proposed. One of the twin-roll casters is a vertical-type high-speed twin-roll caster, and the other twin-roll caster is an unequal-diameter twin-roll caster. The vertical-type high-speed twin-roll caster can cast strip at speeds of up to 120 m/min. The unequal-diameter twin-roll caster casts strip at speeds up to 60 m/min. The unequal-diameter twin-roll caster is superior to the vertical-type high-speed twin-roll caster at the point of conveyance of the cast strip. A single-roll caster equipped with a scraper can cast strip without center-line segregation at speeds of up to 40 m/min. The use of a copper alloy roll and the non-use of a parting material enable high-speed roll casting. Since the roll loads of these casters are smaller than 0.1 kN/mm, soft copper alloy roll can be used. The strip does not stick to the roll without the parting material because of the use of the copper alloy roll with high thermal conductivity and the small roll load. The cooling rate near the surface is higher than 2000 °C/s.

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Improvement of Porosity of Strip Using a Scraper on the Casting by a Vertical Type High Speed Roll Caster

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.146-147.1108 ◽

2010 ◽

Vol 146-147 ◽

pp. 1108-1113 ◽

Cited By ~ 3

Author(s):

Ryoji Nakamura ◽

Yusuke Shiotsu ◽

Kosuke Komeda ◽

Shinji Kumai ◽

Hisaki Warari

Keyword(s):

Aluminum Alloy ◽

High Speed ◽

Alloy Strip ◽

Roll Speed ◽

Strip Cast ◽

Twin Roll Caster ◽

Twin Roll

Porosity occurred in the 5182 aluminum alloy strip cast by a vertical type high speed twin roll caster. The porosity was caused by high-roll-speed and low-roll-load. Improvement of the porosity was tried by a scraper. The scraper was mounted on the roll, and the scraper was moveable depend on the thickness of the solidified layer on the roll. The scraper scribed the semisolid layer to improve the porosity. The scraper was useful to decrease the porosity of roll cast 5182 aluminum alloy strip.

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