Novel Direct Cladding of Magnesium and Aluminum Alloys Using a Horizontal Twin Roll Caster

2021 ◽  
Vol 880 ◽  
pp. 17-22
Author(s):  
Geng Yan Feng ◽  
Hisaki Watari ◽  
Mayumi Suzuki ◽  
Toshio Haga ◽  
Toru Shimizu
Keyword(s):  
Melting Point ◽  
Aluminum Alloys ◽  
Mixed Layer ◽  
Mixing Layer ◽  
Reduction Rate ◽  
Bonding Interface ◽  
Shearing Strength ◽  
One Step ◽  
Twin Roll Caster ◽  
Twin Roll

This study introduces the direct cladding of magnesium and aluminum alloys using a horizontal twin roll caster in one step. A horizontal twin roll caster can cast a Mg/Al clad strip with thickness exceeding 5mm at a roll speed of 8m/min in one step, which is difficult for a vertical twin roll caster. Therefore, it is possible to cast a thick clad strip with different melting point alloys using a horizontal twin roll caster at low speed. It is also possible to cast clad strips using as the overlay an alloy that has a higher melting point than that of the base strips. The thickness of the Mg/Al clad strip is 6.5mm, and the ratio of the Mg layer to the Al layer is 3:2. The surface of the clad strip is good, and there is no void between bonding interfaces. The mixing layer of the bonding interface is deeply related to the reduction rate. As the reduction rate increases, the mixing layer becomes more balanced and the thickness of the mixed layer decreases to 68μm. By observation of the interface of the cladded material, the mixed layer of the bonding interface is divided into two layers. It has been found the mixed layer near the Al layer has the highest hardness (up to 228HV), and the tensile shearing strength of the manufactured Mg/Al clad strip was 44MPa.

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.

A Vertical Type Tandem Twin Roll Caster for Clad Strip Equipped with a Scraper

2014 ◽  
Vol 611-612 ◽  
pp. 623-628 ◽  
Author(s):  
Toshio Haga ◽  
Hiroshi Tsuge ◽  
Takuya Ishihara ◽  
Shinji Kumai ◽  
Hisaki Watari
Keyword(s):  
Melting Point ◽  
Lower Melting ◽  
Lower Melting Point ◽  
Twin Roll Caster ◽  
Twin Roll

A vertical type tandem twin roll caster equipped with a scraper for the clad strip was invented. This roll caster could cast three layers clad strip which base strip had lower melting point than that of the overlay strips. The base strip was cast by an upper twin roll caster and the overlay strips were cast by a lower twin roll caster. The scrapers were attached to the lower twin roll caster, and were innovated to cast this type of three layers of clad strip. Solidification layers those became the overlay strips were pulled from between the scraper and the roll. The melt of the alloy which was as same as the base strip was poured between the scraper and the base strip. This melt connect the overlay strip and the base strip. The base strip was not re-melted. The scraper enabled that the solidification layer of the overlay strip contact to the melt of the base strip without mixing of the melt of the base and overlay strip. In this way, the sound three layers clad strip which base strip had lower melting point than that of the overlay strip could be cast by the vertical type tandem twin roll caster equipped with a scraper.

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.

Casting of Clad Strip of Al-SiCp, Magnesium Alloy Hard-Brittle Light Material by a Twin Roll Caster

2017 ◽  
Vol 893 ◽  
pp. 262-266 ◽  
Author(s):  
Toshio Haga ◽  
Kentaro Okamura ◽  
Hisaki Watari ◽  
Shinichi Nishida
Keyword(s):  
Aluminum Alloy ◽  
Magnesium Alloy ◽  
Aluminum Alloys ◽  
Magnesium Alloys ◽  
The Other ◽  
Roll Speed ◽  
Oxidizing Atmosphere ◽  
Twin Roll Caster ◽  
Light Material ◽  
Twin Roll

Casting of clad strip consisting of Al-30vol%SiCp and 1070 aluminum alloy, and clad strip consisting of AM60 magnesium alloy and AZ121 magnesium alloy was carried out in an oxidizing atmosphere by two types of twin roll casters. One was the vertical type twin roll caster equipped with a scraper and the other was the melt drag type vertical type twin roll caster, both operating at a speed of 30 m/min and a roll load of 0.2 kN/mm. The clad strip of the aluminum alloys could be cast by both twin roll casters. The clad strip of the magnesium alloys could be cast only by the vertical caster equipped with a scraper. The clad strips were bonded strongly at the interface in spite of the high roll speed and the low roll load.

An Unequal Diameter Twin Roll Caster for Aluminum Alloys Casting

2004 ◽  
pp. 199-204
Author(s):  
Toshio Haga ◽  
Masaaki Ikawa ◽  
Hisaki Watari ◽  
Shinji Kumai
Keyword(s):  
Aluminum Alloys ◽  
Twin Roll Caster ◽  
Twin Roll

A Roll Caster to Cast Clad Strip

2013 ◽  
Vol 554-557 ◽  
pp. 1902-1909 ◽  
Author(s):  
Toshio Haga ◽  
Hiroshi Tsuge ◽  
Shinji Kumai ◽  
Hisaki Watari
Keyword(s):  
Melting Point ◽  
Hot Rolling ◽  
Direct Chill ◽  
Al Alloys ◽  
Mg Alloy ◽  
Lower Melting ◽  
Lower Melting Point ◽  
Dc Casting ◽  
Twin Roll Caster ◽  
Twin Roll

A tandem-type roll caster that can cast a three-layered clad strip was developed by mounting one twin roll caster on another twin roll caster. In this caster, the base strip is cast by the upper twin roll caster, and the overlay strips are cast by the lower caster. The three strips are metallurgically bonded by the lower caster. This study investigated three aspects of this caster. First, the clad ratio could be controlled by the solidification lengths of strips from the upper and lower twin roll casters, and a clad ratio of 1:8:1 was attained. Second, although it is known that fabrication of clad strips from Al-Mg alloy and other Al alloys is very difficult, the clad strip with the Al-Mg alloy as the base strip or the overlay strip could be cast. Finally, by adding scrapers, the caster could cast the clad strip with a base strip having a lower melting point than the overlay strip. Element strips of the clad strip are made by many processes, such as direct chill (DC) casting, scraping of the ingot surface, heat treatment, hot rolling, and cold rolling. Typically, surface treatment and hot rolling are used to clad the strips. Since many processes are required, clad strips require consume much energy. Therefore, producing clad strips is expensive. A vertical-type tandem twin roll caster was developed to cast clad strips. This caster has the advantages of process saving and energy saving, and so can fabricate economical clad strips. In the fabrication of clad strips, control of the clad ratio is very important. In the brazing sheet for automobile radiators, the base strip is made from AA3003 and the overlay strips are made from AA4045, and the clad ratio is usually 1:8:1. In the present study, a clad strip with a clad ratio of 1:8:1 was attained. The cladding by hot rolling of Al-Mg and other aluminum alloys, which is considered to be a very difficult process, was also investigated. Clad strips with either a base strip or an overlay strip of an Al-Mg alloy were cast by the roll caster. Although the cladding was not easy, the Al-Mg alloy could be cast into the clad strip. In addition, a clad strip with a base strip having a lower melting point than that of the overlay strip was investigated. Such cladding cannot be cast by the vertical-type tandem twin roll caster as mentioned above because the base strip is re-melted from the heat of the overlay strips. In the present study, a scraper was developed and adopted to cast a clad strip with a base having a lower melting point than that of the overlay strips. This type of clad strip could be cast because the scrapers prevented the re-melting of the base strip. In this paper, these three aspects of fabrication are reported.

Casting of a Wire Inserted Strip Using a Twin Roll Caster Equipped with Two Nozzles

2011 ◽  
Vol 337 ◽  
pp. 556-559 ◽  
Author(s):  
Toshio Haga ◽  
Kenta Takahashi ◽  
Shinji Kumai ◽  
Hisaki Warari
Keyword(s):  
Aluminum Alloys ◽  
Thickness Direction ◽  
Strip Cast ◽  
Twin Roll Caster ◽  
The Wire ◽  
Twin Roll

Casting of a wire inserted strip was investigated using a downward melt drag twin roll caster. A nozzle was mounted to each roll. The wire was inserted between the lower and upper strip. Effect of use of two nozzles on the insertion of the wire was investigated. The insertion of the wire by the two nozzles was easier than one nozzle. The surfaces of the wire inserted strip cast using two nozzles was more sound than that cast using one nozzle. The position of the wire at thickness direction was almost center. When different aluminum alloys were poured from an upper nozzle and from a lower nozzle, a wire inserted clad strip could be cast.

Strip Casting of Recycled Aluminum Alloys by a Twin Roll Caster

2012 ◽  
Vol 3 (4) ◽  
pp. 419-424 ◽  
Author(s):  
Toshio Haga ◽  
Shinji Kumai ◽  
Hisaki Watari
Keyword(s):  
Aluminum Alloys ◽  
Strip Casting ◽  
Twin Roll Caster ◽  
Twin Roll

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%.

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