Direct Molten Metal Rolling of Aluminum Alloy A3003

2017 ◽  
Vol 735 ◽  
pp. 13-17
Author(s):  
Hiroto Ohashi ◽  
Shinichi Nishida ◽  
Yuta Kashitani ◽  
Junshi Ichikawa ◽  
Naoshi Ozawa ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Molten Metal ◽  
Casting Process ◽  
Alloy Sheet ◽  
Strip Casting ◽  
Roll Speed ◽  
Pouring Temperature ◽  
Strip Surface ◽  
High Productivity ◽  
Direct Rolling

This paper describes a production process for aluminum alloy sheet metal. Direct molten metal rolling, in other words strip casting process for aluminum alloy A3003 sheet was operated. Strip casting process is able to produce the metal sheet from molten metal directly. Thus this process has possibility of improving the productivity of sheet because of shortening operation of rolling. In this study, experimental device was designed for direct molten metal rolling. Aluminum alloy A3003 was chosen. A3003 is for aluminum can body, and the sheet required the high productivity. The effect of roll speed on the produced strip surface and strip thickness was investigated. Roll speed were 1, 2 and 3 m/min. It was possible to produce A3003 strip by direct rolling at the conditions of roll speed 3 m/min, pouring temperature 700 °C, solidification length 15 mm and nozzle exit width 15 mm. Obtained strip surface was flatten and had a metallic luster.

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.

Experimental Study on the Distribution of Heat Flux along Contact Arc in Twin-Roll Continuous Strip Casting

2016 ◽  
Vol 693 ◽  
pp. 761-766 ◽  
Author(s):  
Guang Ming Zhu ◽  
C. Zhang ◽  
P.G. Xu ◽  
G.C. Bai
Keyword(s):  
Heat Flux ◽  
Molten Metal ◽  
Casting Process ◽  
Strip Casting ◽  
Pouring Temperature ◽  
Interfacial Heat Flux ◽  
Twin Roll ◽  
Contact Arc ◽  
Continuous Strip

Heat flux between molten metal and casting rolls plays a key role in improving the quality of the strip, studying on the interfacial heat flux has very important theoretical significance and practical value. According to the contact form and the heat flux characteristics of molten metal and casting rolls in twin-roll strip casting process, a set of measuring equipments has been developed, which are used to measure the heat flow of the interface between the molten metal and solid, and a relevant software system has been exploited to acquire and analyze the experiment data. Using the method of combining experimental and numerical computation, we analyze the influence of pouring temperature on the contact interface heat flux. The experimental results show that the higher the pouring temperature , the greater the summit of heat flux density and the shorter time to the summit heat flux are, but when the pouring temperature reaches a certain critical value, the summit of heat flux will decrease with the increase of pouring temperature.

Casting of Al-Mg Strip Using Single Roll Caster Equipped with a Scraper

2021 ◽  
Vol 880 ◽  
pp. 49-56
Author(s):  
Toshio Haga ◽  
Kosuke Tsukuda ◽  
Keisuke Oida ◽  
Hisaki Watari ◽  
Shinichi Nishida
Keyword(s):  
Molten Metal ◽  
Thickness Distribution ◽  
Surface Characteristics ◽  
Strip Thickness ◽  
Optimal Conditions ◽  
Roll Speed ◽  
Pouring Temperature ◽  
Strip Cast ◽  
Cold Rolled ◽  
Twin Roll

A scraper was attached to an unequal-diameter twin-roll caster without requiring large modifications. This caster was used as a 1000 mm diameter single roll caster equipped with a scraper, and its strip casting ability was tested. The effects of the scraper angle and load, the roll speed, and the pouring temperature of the molten metal on the scribed surface, thickness distribution and average strip thickness were investigated. The scribed surface characteristics were sound and the thickness distribution was flat when the scraper angle was 60° and the scraper load was in the range of 1 to 4 kg. When the scraper load was more than 1 kg, the thickness distribution was uneven. The average strip thickness decreased as the roll speed increased. The pouring temperature of the molten metal influenced the evenness of the solidified layer thickness. The solidified layer became even as the molten metal temperature was decreased. A strip cast with the determined optimal conditions was then cold rolled down to 1 mm to improve its surface quality.

Three-Layer Clad Strip Casting Using a Vertical Type Tandem Twin Roll Caster

2018 ◽  
Vol 773 ◽  
pp. 171-178
Author(s):  
Toshio Haga ◽  
Kentaro Okamura ◽  
Hisaki Warari ◽  
Shinichi Nishida
Keyword(s):  
Aluminum Alloy ◽  
Strip Casting ◽  
Tensile Shear ◽  
Shear Testing ◽  
Roll Speed ◽  
Solidification Temperature ◽  
Twin Roll Caster ◽  
Twin Roll

This paper shows improvements made to a vertical type tandem twin roll caster and the appropriate casting conditions necessary to cast three-layer clad strips, the base strip of which has a lower solidification temperature than the overlay strip. In experiments, 4045 aluminum alloy was used for the base strip and 3003 aluminum alloy was used for the overlay strips. The roll speed was 30 m/min. By connecting the overlay strips to the base strip one at a time and cooling the base strip to between 450 and 530°C after applying the first overlay strip, a sound three-layer clad strip – defined as one in which the interfaces between strips are clear and do not separate during bending-to-failure tests – could be cast. The tensile shear testing between the base and second overlay strip was improved as the base-strip temperature was increased to 450-530°C range.

Numerical Simulation of Casting Deformation and Stress of A356 Aluminum Alloy Thin-Walled Frame Casting

2021 ◽  
Vol 1033 ◽  
pp. 24-30
Author(s):  
Yi Dan Zeng ◽  
Li Tong He ◽  
Jin Zhang
Keyword(s):  
Aluminum Alloy ◽  
Casting Process ◽  
Mold Temperature ◽  
Hot Cracking ◽  
Thin Wall ◽  
A356 Aluminum Alloy ◽  
Pouring Temperature ◽  
Thin Walled ◽  
Alloy Castings ◽  
A356 Aluminum

One of the main reasons for the scrap of cast thin-wall frame aluminum alloy castings is deformation and cracking. It is an effective method for solving the problem by predicting the distribution of casting stress, clarifying the size of the deformation and the location of the crack, and taking necessary measures in the process. This paper uses the ProCAST software to simulate the thermal stress coupling of A356 thin-walled frame castings, analyzes the influence of pouring temperature, pouring speed and mold temperature on the stress field distribution of castings, predicts the hot cracking trend and deformation, and optimizes Casting process..

Formation of Globular Microstructure in A380 Aluminum Alloy by Cooling Slope Casting

2011 ◽  
Vol 264-265 ◽  
pp. 272-277 ◽  
Author(s):  
Nurşen Saklakoğlu ◽  
S. Gencalp ◽  
Şefika Kasman ◽  
İ.E. Saklakoğlu
Keyword(s):  
Aluminum Alloy ◽  
Slope Angle ◽  
Casting Process ◽  
Solid Particles ◽  
Inclined Plate ◽  
Pouring Temperature ◽  
Cooling Slope ◽  
Semi Solid ◽  
Cooling Slope Casting ◽  
The Many

Thixoforming and related semi-solid processing (SSP) methods require thixotropic materials. One of the many SSP techniques is the cooling slope (CS) casting process, which is simple and has minimal equipment requirements, and which is able to produce feedstock materials for semisolid processing. When the feedstock is reheated to the semisolid temperature range, non-dendritic, spheroidal solid particles in a liquid matrix suitable for thixoforming are obtained. In this study, equipment for the CS technique was first established, and then the effects of the pouring temperature and inclined slope angle on the microstructures of A380 aluminum alloy (ISOAlSi8Cu3Fe) were studied. Optimum parameters for thixoforming experiments were selected, and it was found that the microstructure produced by the inclined plate depended on its angle and the pouring temperature.

Improvement of Surface Roughness of Al-Si Alloy Cast Strip by Vertical Melt Drag Process

2011 ◽  
Vol 383-390 ◽  
pp. 3954-3959 ◽  
Author(s):  
Shinichi Nishida ◽  
Kazuki Fukudome ◽  
H. Furusawa ◽  
M. Motomura ◽  
H. Watari
Keyword(s):  
Surface Roughness ◽  
Casting Process ◽  
Strip Casting ◽  
Rolled Strip ◽  
Strip Surface ◽  
Cast Strip ◽  
Negative Effect ◽  
Hot Rolled ◽  
Twin Roll ◽  
Alloy Cast

Strip casting process is possible to shorten for producing strip. Strip is produced from molten metal continuously and directly by strip casting process. Melt drag process is one of the single roll strip casting process. Melt drag process is simpler than general twin roll strip casting process. One of defect of cast strip is surface conditions, for example surface roughness. Cast strip surface roughness is larger than hot rolled strip. Large strip surface roughness is negative effect for cold rolling after strip casting or hot rolling. The aim of this study is improvement of cast strip surface roughness by melt drag process. We suggested vertical melt drag process. And investigations were operated such us producing conditions of Al-Si alloy strip, surface roughness of cast strip and microstructures.

Thermomechanical Treatment of Aluminum Alloy Fin Stock for Heat Exchanger Produced by Twin Roll Strip Casting Process

2010 ◽  
Vol 638-642 ◽  
pp. 241-246 ◽  
Author(s):  
Suk Bong Kang ◽  
Dong Bae Kim ◽  
Sang Su Jung ◽  
Kwang Jun Euh
Keyword(s):  
Thermal Conductivity ◽  
Aluminum Alloy ◽  
Heat Exchanger ◽  
Cold Rolling ◽  
Heat Exchangers ◽  
Casting Process ◽  
Strip Casting ◽  
Manufacturing Cost ◽  
Intermediate Annealing ◽  
Twin Roll

Aluminum alloys are commonly used as a material for heat exchangers due to their higher thermal conductivity and specific strength among various metallic materials. The lightweightening heat exchangers for automobile application are requisite for reducing the evolution of CO2 and improving the efficiency of fuel. The twin roll strip casting process is considered to produce the high quality and low manufacturing cost aluminum alloy fin stock for automobile heat exchangers. Thermomechamical treatment has carried out to obtain optimum processes for initial cold rolling, intermediate annealing and final cold rolling, which can meet the requirements for high strength and high thermal conductivity after brazing heat treatment. Mechanical properties and thermal condutivity have been evaluated before and after simulated brazing process. The nuclei of recrystallization might be formed along shear deformation bands during initial cold rolling and should be grown during intermediate annealing to enhance the permeation of molten brazings for the following brazing process. Final cold rolling has allowed strain hardening and controlling of sagging amount as fin stock materials of heat exchanger. In the present study the suitable thermomechnical treatment was suggested to balance the properties of strength, thermal conductivity, brazing behavior and sagging in Al-Fe-Mn-Si-Zn based alloys produced by twin roll strip casting process.

Optimization of Tilt-Casting of Aluminum Alloy Automobile Drain Pipes through Numerical Simulation

2013 ◽  
Vol 762 ◽  
pp. 633-638
Author(s):  
Ye Wang ◽  
Shi Ping Wu ◽  
Xiang Xue ◽  
Jing Jie Guo
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Solidification Process ◽  
Casting Process ◽  
Test Methods ◽  
Orthogonal Test ◽  
Single Factor ◽  
Pouring Temperature ◽  
Preheating Temperature ◽  
Lower Temperature

The effect of major parameters, such as pouring temperature, tilt time and preheating temperature of mold, on the tilt casting of aluminum alloy automobile drain pipes is studied through numerical simulation using single factor and orthogonal test methods. The simulation results of single factor test indicate that the increase in the pouring temperature and mold preheating temperature could effectively reduce the shrinkage tendency and the shortage of tilt time would cause lower temperature gradient of casting at the beginning of solidification, thus would lead the extension of solidification time. And the results of orthogonal test showed that the sequence of factors having effect on the filling and solidification process, are pouring temperature, tilt time and preheating temperature of mold. Finally, combined the result of single factor test with orthogonal test, an optimized tilt-casting process was proposed by investigating the velocity distribution at each stage of the filling process and the isolated area distribution of liquid phase in the solidification process, and by predicting the position of porosity in the casting. The effectiveness of the proposed process parameters in producing high quality castings is also proved through numerical simulation.

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