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

2012 ◽  
Vol 445 ◽  
pp. 307-312 ◽  
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.

Single Roll Caster Equipped with a Scraper

2012 ◽  
Vol 504-506 ◽  
pp. 1243-1248 ◽  
Author(s):  
Toshio Haga ◽  
Kazuya Akitsu ◽  
Keisuke Kamakura ◽  
Shinji Kumai ◽  
Hisaki Watari
Keyword(s):  
Contact Surface ◽  
Outer Side ◽  
Rolled Strip ◽  
Drawing Ratio ◽  
Cast Strip ◽  
Strip Cast ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
Deep Drawing Test ◽  
Twin Roll

A scraper was developed and attached to the single roll caster in order to improve the free solidified surface of as-cast strip cast. Semisolid metal on the free solidified surface was flattened by the scraper and the surface became flat. The AA5182 aluminum alloy could be cast at speeds up to 40m/min. Thickness was about 3mm. Pressure of the unit width of the scraper was ranging from 0.1N/mm to 1.0N/mm, and these pressure was enough to make the free solidified surface flat. Center line segregation did not occur as the strip was solidified from single side at the strip cast by the single roll caster. Roll-cast strip could be cold rolled down to 1mm. There was not difference between the roll contact surface and the free solidified surface of the strip after cold rolling judging by a visual examination. Result of tension test of the roll cast and cold rolled 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 were outer side. 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 required 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.

High Speed Twin-Roll Casting of Al-Mg Alloys

2010 ◽  
Vol 154-155 ◽  
pp. 1544-1548 ◽  
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.

scholarly journals High Speed Roll Caster for Aluminum Alloy

Metals ◽  
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.

Roll Casting of Recycled AA5182

2011 ◽  
Vol 121-126 ◽  
pp. 4667-4670
Author(s):  
Toshio Haga ◽  
Kosuke Komeda ◽  
Kenta Mtsuoka ◽  
Shinji Kumai ◽  
Hisaki Watari
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
High Speed ◽  
Model Alloy ◽  
Drawing Ratio ◽  
Roll Speed ◽  
Roll Casting ◽  
Twin Roll Caster ◽  
Twin Roll ◽  
Fe Addition

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.

Prevention of Solidification of Al-40%Sn-1%Cu in Melt Pool on the Roll Casting Using Unequal Diameter Twin Roll Caster

2018 ◽  
Vol 382 ◽  
pp. 160-166 ◽  
Author(s):  
Toshio Haga ◽  
Ryusuke Onishi ◽  
Hisaki Watari ◽  
Shinichi Nishida
Keyword(s):  
Aluminum Alloy ◽  
Contact Surface ◽  
Defect Formation ◽  
Metal Casting ◽  
Roll Speed ◽  
Melt Pool ◽  
Roll Casting ◽  
Twin Roll Caster ◽  
Twin Roll ◽  
Vibrating Plate

Among the problems encountered when roll casting Al-405Sn-1%Cu, which is an aluminum alloy used for sliding plate bearings in large maritime diesel engines, are solidified chips embedded in the strip and scratch marks on the lower roll contact surface. In this study, three different improvement methods aimed at eliminating these particular defects—vibrating the side plates and back dam plate, adding a vibrating plate, and varying the casting conditions—are examined. Vibrating the side plates and dam plate was found to be effective for preventing these defects, while adding another vibrating plate was comparatively less effective. As for casting conditions, it was also determined that the occurrence of these defects could be reduced by increasing the roll speed, and that the molten metal casting temperature had little or no influence on defect formation.

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 of Al-40%Sn-1%Cu Strip

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.

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.

Casting of Clad Strip by a Twin Roll Caster

2014 ◽  
Vol 794-796 ◽  
pp. 772-777 ◽  
Author(s):  
Toshio Haga
Keyword(s):  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Bending Test ◽  
Outer Side ◽  
Drawing Ratio ◽  
Casting Aluminum Alloy ◽  
Twin Roll Caster ◽  
Casting Aluminum ◽  
Wrought Aluminum ◽  
Twin Roll

Clad strip consisting of 5182 aluminum alloy and other aluminum alloys could be cast using a twin roll caster equipped with a scraper. This twin roll caster could carry out the strip casting and the bonding of the strips. The equipment, that was developed to prevent the contact between the bonding surface of the strip and oxidizing environment, was adopted. The developed equipment was a scraper. The 5182 strip could be bonded to other aluminum alloy strips by the effect of the scraper. Aluminum alloys for casting has poor formability, especially, bending ability is poor. The clad strip consisting of A356 casting aluminum alloy and 3003 wrought aluminum alloy was cast. 180 degree bending test was carried out on this clad strip. In the condition that the 3003 strip was outer side and A356 strip was inner side, the crack did not occur at the outer 3003 strip. In the deep drawing test or the clad strip, LDR (Limiting Drawing Ratio) was 1.8. These results mean that the casting aluminum alloy has ability to be used for the sheet forming, if the casting aluminum alloy is cladded with the wrought aluminum alloy.

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