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

2011 ◽  
Vol 264-265 ◽  
pp. 1905-1910 ◽  
Author(s):  
Ryoji Nakamura ◽  
Toshio Haga ◽  
Shinji Kumai ◽  
Hisaki Watari
Keyword(s):  
Alloy Strip ◽  
Gravity Segregation ◽  
Cu Alloy ◽  
Roll Casting ◽  
Continuously Cast ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
Twin Roll ◽  
Better Than ◽  
Cooling Ability

In this study, the roll casting of Al-40%Sn-1%Cu alloy was tried by an unequal diameter twin roll caster. The unequal diameter twin roll caster could continuously cast the strip. The casting load of the roll was small to prevent the flow out of the Sn. The roll-load was 0.1kN/mm(unit width). The roll casting of 400mm-width strip of 8mm-thick was tried, and it was attained. The gravity segregation of Sn did not occur. The as-cast strip could be cold rolled down to 1mm. However, this strip had much porosity. The rapid solidification was useful to prevent the porosity. The copper roll was better than steel roll to increase cooling ability. The copper roll was suitable to prevent the porosity. The temperature of solidified metal was important factor which influenced the porosity. The 4mm-thickness strip with little porosity was could be cast at the speed of 30m/min.

Semisolid Roll Casting of Aluminum Alloy Strip and Its Properties

2006 ◽  
Vol 116-117 ◽  
pp. 379-382 ◽  
Author(s):  
Ryoji Nakamura ◽  
Hideki Inui ◽  
Hisaki Watari ◽  
Shinji Kumai
Keyword(s):  
Tension Test ◽  
Semisolid Slurry ◽  
Alloy Strip ◽  
Proof Stress ◽  
Cooling Slope ◽  
Roll Casting ◽  
Heat Treated ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
Twin Roll

A356 was cast into the strip by the semisolid strip casting using an unequal diameter twin roll caster. This process was one of the rheocasting. The semisolid slurry was made by a cooling slope. Solid fraction was about 5%. The casting speed was 20 m/min, and the thickness was 4.4 mm. The as-cast strip could be cold rolled down to 1 mm. The result of tension test of 1mm-thickness-T4 heat-treated strip was as below. Tensile stress was 223 MPa, 0.2 proof stress was 123 MPa and elongation was 21.8%. Deep drawing could be operated to 1 mm-thickness T4 sheet, and L.D.R was attained to 2.0. In some condition, 180 degrees bending could be operated without crack at outer surface. These results mean that semisolid roll cast A356 strip may be able to use for press forming.

Roll Casting of Al-25mass%Si

2010 ◽  
Vol 97-101 ◽  
pp. 1057-1060 ◽  
Author(s):  
Ryoji Nakamura ◽  
Masayuki Saito ◽  
Shinji Kumai ◽  
Hisaki Watari
Keyword(s):  
Aluminum Alloy ◽  
Casting Speed ◽  
Alloy Strip ◽  
Thickness Direction ◽  
Near Surface ◽  
Roll Casting ◽  
Eutectic Si ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
Twin Roll

Roll casting of Al-25mass%Si hyper eutectic aluminum alloy strip was tried by an unequal diameter twin roll caster. The casting speed was 10m/min. The thickness of the strip was about 2mm. The eutectic Si and primary crystallized Si were very fine by the effect of the rapid solidification. The size of the primary crystallized Si was not uniform at the thickness direction. The primary crystallized Si at the near surface was finer than that of inside. The eutectic Si was finer than 2μm. The strip could be cold rolled after hot rolling and annealing.

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

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%.

Roll Casting and Die Casting of Si-Added Al-Mg Alloy

2020 ◽  
Vol 1007 ◽  
pp. 12-17
Author(s):  
Toshio Haga ◽  
Shinichiro Imamura ◽  
Hiroshi Fuse ◽  
Hisaki Watari ◽  
Shinichi Nishida
Keyword(s):  
High Speed ◽  
Die Casting ◽  
Sheet Forming ◽  
Mg Alloy ◽  
Tension Tests ◽  
Roll Casting ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
Si Content ◽  
Twin Roll

Si ranging from 0.2 mass% to 2.0 mass% was added to Al-5%Mg alloy (5182) and strip was cast by a vertical type high-speed twin-roll caster at a speed of 80 m/min. The as-cast strip was cold-rolled down to 1 mm thickness and annealed. The mechanical properties were investigated using cup tests and tension tests. The limiting draw ratio (LDR) of the 5182 alloy was 2.0 and the LDR became smaller as the Si content increased. When the Si content was 2.0 mass%, the LDR was 1.8, which shows that Si-added 5182 can be used for sheet forming, if the Si content is less than 2.0 mass%. The tensile strength and elongation were almost constant when the Si content was less than 1 mass%, but decreased at 2.0 mass% Si. However, the elongation was greater than 20% at 2.0 mass% Si. For die casting, 2.0 mass% Si was determined as the appropriate content from the results of the tension tests. When the Si content is in the range from 1.0 mass% to 2.0 mass%, then the Si added Al-5%Mg has the ability to be used for both die casting and sheet forming.

High Speed Roll Casting of Aluminum Alloy Strip

2005 ◽  
Vol 475-479 ◽  
pp. 343-348 ◽  
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.

Roll Casting of Al-SiCp Strip

2011 ◽  
Vol 675-677 ◽  
pp. 811-814 ◽  
Author(s):  
Toshio Haga ◽  
Teppei Nakamura ◽  
S. Kumai ◽  
H. Watari
Keyword(s):  
Hot Rolling ◽  
High Speed ◽  
Strip Casting ◽  
Cast Strip ◽  
Fine Grain ◽  
Roll Casting ◽  
Speed Up ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
Twin Roll

The strip casting of Al-SiCp alloy was operated by a high speed twin roll caster. The content of SiCp was 20Vol% and 30Vol%. Both of Al-20Vol%SiCp and Al-30Vol%SiCp strips could be cast continuously at the speed up to 90m/min. The SiCp particle distributed uniformly. This was the effect of fine grain of the strip. The as-cast strip of Al-20Vol%SiCp could be cold rolled after homogenization. The as-cast strip of Al-30Vol%SiCp could be cold rolled after once hot rolling and annealing. The as-cast strip of Al-20Vol%SiCp could be coiled at the diameter of 460mm.

Roll Casting of Al-SiCp Composite Strip

2010 ◽  
Vol 139-141 ◽  
pp. 481-484
Author(s):  
Ryoji Nakamura ◽  
Teppei Nakamura ◽  
Ryoji Nakamura ◽  
Hideto Harada ◽  
Shinji Kumai ◽  
...  
Keyword(s):  
Cold Rolling ◽  
High Speed ◽  
Alloy Strip ◽  
Thickness Direction ◽  
Composite Alloy ◽  
Cast Strip ◽  
Roll Casting ◽  
Twin Roll Caster ◽  
Twin Roll ◽  
Steel Rolls

Roll casting of Al-SiCp composite alloy strip was tried using a vertical type high speed twin roll caster equipped with mild steel rolls. The Al-20vol% SiCp and Al-30vol%SiCp alloy could be roll-cast to the strip. The casting speed was 30m/min. The thickness of as-cast strip was thinner than 2.5mm. The SiCp powder was dispersed uniformly at the thickness direction. The as-cast strip could be thin down to 1mm by the hot rolling and the cold rolling without broken.

Roll Casting of Three Layers Clad Strip

2010 ◽  
Vol 443 ◽  
pp. 128-133 ◽  
Author(s):  
Ryoji Nakamura ◽  
Masakazu Sawai ◽  
Ryoji Nakamura ◽  
Takanori Yamabayashi ◽  
Shinji Kumai ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Cold Rolling ◽  
Molten Metal ◽  
Casting Speed ◽  
Roll Casting ◽  
Continuous Bending ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
Twin Roll

A roll caster, which could cast the three layers of clad strip directly from the molten metal, was designed, assembled and tested. The base strip was AA3003 aluminum alloy and overlay strips were AA4045 aluminum alloy. An unequal diameter twin roll caster was modified to cast clad strip. Two small rolls were amounted on a large roll. A scraper plate was used to prevent the mixture of the different kinds of melts. The casting of three strips and the connecting of strips could be operated by one roll caster. The interfaces between the strips were clear, and the mixture of the melt did not occur. The clad strip could be cold rolled without the annealing. The clad strip did not peel at connecting surface by the cold rolling and continuous bending. The strips were connected strictly. The casting speed was 20m/min, and this speed was much higher than the casting speed of the conventional twin roll caster for aluminum alloys.

Roll Casting of 400 mm Width Al-40%Sn-1%Cu Clad Strip

2017 ◽  
Vol 904 ◽  
pp. 3-8 ◽  
Author(s):  
Toshio Haga ◽  
Kento Ikeda ◽  
Takafumi Nakano
Keyword(s):  
Aluminum Alloy ◽  
Contact Condition ◽  
Molten Metals ◽  
Full Contact ◽  
Roll Casting ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
Twin Roll

A 400 mm width of clad strip consisting of Al-40%Sn-1%Cu and 1070 aluminum alloy could be cast directly from molten metals at a speed of 10 m/min by an unequal diameter twin roll caster equipped with a scraper. An interface clearly existed between the two strips of the clad strip. As-cast clad strip could be cold rolled down to 1 mm without peeling at the interface. The as-cast clad strip could also be bent in the full contact condition without peeling at the interface.

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