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.

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.

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.

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.

Kiss-Point Position Control of Solidification Layer and Process Optimization for Twin-Roll Casting of Magnesium Alloys

2011 ◽  
Vol 189-193 ◽  
pp. 3844-3851
Author(s):  
Wen Ping Weng ◽  
Kang Deng ◽  
Zhong Ming Ren ◽  
Qi Chen ◽  
Zhi Dong Chi ◽  
...  
Keyword(s):  
Magnesium Alloy ◽  
Magnesium Alloys ◽  
Process Optimization ◽  
Strip Thickness ◽  
Alloy Strip ◽  
Roll Speed ◽  
Twin Roll Casting ◽  
Roll Casting ◽  
Twin Roll

The solidification and process optimization for twin-roll casting of magnesium alloys have been studied. Effects of roll speed, roller diameter, setback length and strip thickness on the position of the solidification front and the surface quality of strip were analyzed through experiments. A kiss-point model which considers the strip thickness, set-back length and roll speed was established to optimize process and enhance the surface quality of magnesium alloy strip. Results showed that the twin-roll casting process could be effectively stabilized and optimized under the direction of the model, and the defectless magnesium alloy strip was obtained.

Strip Casting of 6061 and Recycled 6061 Alloy by an Unequal Diameter Twin Roll Caster

2011 ◽  
Vol 264-265 ◽  
pp. 1911-1916 ◽  
Author(s):  
Toshio Haga ◽  
Hideki Inui ◽  
Ryoji Nakamura ◽  
Shinji Kumai ◽  
Hisaki Watari
Keyword(s):  
Aluminium Alloy ◽  
Surface Condition ◽  
Bending Test ◽  
Cast Strip ◽  
Fe Content ◽  
Strip Cast ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
6061 Aluminium Alloy ◽  
Twin Roll

A 6061 aluminium alloy and an alloy with increased Fe content, representing recycled 6061 aluminium alloy were cast into strips at speed of 30m/min by an unequal diameter twin roll caster. The Fe content of 6061 aluminium alloy and the model of recycled 6061 aluminium alloy was 0.36 mass% and 0.59 mass%, respectively. Ripple marks, which are typical surface defect of roll cast strips, did not occur on the surface of both as-cast strips. Fe content did not influence the surface condition of the roll-cast-strip. The as-cast strip was cold rolled down to 1 mm, T4 heat treatment was conducted, and then subjected to180 degrees bending test. The result of 180 degrees bending test shows that roll cast 6061 aluminium alloy and 6061 aluminium alloy with increased Fe as recycled had bending ability as same as that of roll-cast 6022 aluminium alloy. In the strip cast by the twin roll caster of the present study, increased Fe content did not influence on the result of the180 degrees bending test.

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

2010 ◽  
Vol 146-147 ◽  
pp. 1108-1113 ◽  
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.

Clad Strip Casting by a Roll Caster

2011 ◽  
Vol 52-54 ◽  
pp. 755-758 ◽  
Author(s):  
Toshio Haga ◽  
Ryoji Nakamura ◽  
Sinji Kumi ◽  
Hisaki Watari
Keyword(s):  
Strip Casting ◽  
Roll Speed ◽  
Melt Temperature ◽  
Cold Rolled ◽  
Twin Roll

Casting of clad strip, which was one of the composite alloys, was tried using a roll caster. A vertical tandem type twin roll casters for clad strip were designed and assembled to cast the clad strip. Three layers of clad strip could be cast. The interface between the base strip and overlay strip was clear. The as-cast clad strip could be cold rolled without peeling at the interface. The element of the each strip did not diffuse to another strip at the interface. The effects of the roll speed and melt temperature of the overlay strip on the cladding of the strip were investigated.

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.

In-Line Rolling of Aluminum Alloy Strip Cast by a High Speed Twin Roll Caster

2010 ◽  
Vol 654-656 ◽  
pp. 795-798 ◽  
Author(s):  
Ryoji Nakamura ◽  
Shuuya Hanada ◽  
Sinji Kumi ◽  
Hisaki Watari
Keyword(s):  
High Speed ◽  
Surface Defects ◽  
Rolling Speed ◽  
Rolled Strip ◽  
Ripple Mark ◽  
Strip Cast ◽  
Trace Line ◽  
Cold Rolled ◽  
Twin Roll Caster ◽  
Twin Roll

In-line rolling was operated on the as-cast strip cast by a vertical type high speed twin roll caster. The AA6022 and AA6111 strip was tested. The casting and rolling speed was 60m/min. Reduction was from 20% to 55%. The temperature of the rolling was within from 400oC to 450oC. The porosity and crack in the strip were improved by the in-line rolling. The in-line as rolled strip was cold rolled down to 1mm, and T4 heat treatment was operated. The microstructure of the strip, on which in-line rolling was operated, became uniform at thickness direction than the microstructure of the strip on which only the cold rolling was operated. The surface defects like the ripple mark and trace line of the nozzle were improved.

Si-STEEL THIN-STRIP PREPARED BY TWIN-ROLL CONTINUOUS CASTING

2011 ◽  
Vol 18 (03n04) ◽  
pp. 97-102 ◽  
Author(s):  
YU YI ◽  
ZEHUA ZHOU ◽  
ZEHUA WANG ◽  
SHAOQUN JIANG ◽  
WEIDONG HUANG
Keyword(s):  
Continuous Casting ◽  
Strip Thickness ◽  
Thin Strip ◽  
Quality Factors ◽  
Pouring Temperature ◽  
Steel Strips ◽  
Si Content ◽  
Twin Roll ◽  
The Relationship

The fabrication process of Si -steel thin-strip by twin-roll continuous casting was described and the quality of the obtained Si -steel thin-strip was measured. Si -steel strips with 0.5–6.5 wt.% Si content were successfully prepared, and proper parameters including pouring temperature, height of molten pool, casting speed and pouring head mode were optimized, and their mechanisms were discussed. The relationship between quality factors of Si -steel including cracks, strip thickness, impurity and process parameters such as Si content and so on were discussed. The morphologies of the strips with different Si content were studied.

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