Casting of Clad Strip Consisting of Al-Sn Alloy and Pure Aluminum

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1007.23 ◽

2020 ◽

Vol 1007 ◽

pp. 23-28

Author(s):

Toshio Haga

Keyword(s):

Electron Probe ◽

Pure Aluminum ◽

Liquidus Line ◽

Molten Metals ◽

Tensile Shear ◽

Shear Tests ◽

Solidus Line ◽

Cu Alloy ◽

Twin Roll Caster ◽

Twin Roll

Casting of clad strip consisting of Al-40%Sn-1%Cu alloy and 1050 pure aluminum from molten metals was attempted using an unequal diameter twin-roll caster equipped with a scraper. The liquidus line and solidus line of the Al-40% Sn-1% Cu alloy are 620 °C and 220 °C, respectively. The liquidus line and solidus line of the 1050 are 657 °C and 646 °C, respectively. Therefore, solidification temperatures of the two aluminum alloys are much different. When an Al-40%Sn-1%Cu solidification layer was bonded to a solidification layer of the 1050 alloy, the temperature of the 1050 solidification layer surface was higher than the solidus line of Al-40% Sn-1% Cu. However, the Al-40% Sn-1% Cu alloy could be bonded to the 1050 strip and a two-layer clad strip could be cast. The interface between the two strips was very clear. Electron Probe Microanalysis (EPMA) indicated that Sn in the Al-40% Sn-1% Cu alloy did not diffuse into the 1050 alloy. Tensile shear tests were conducted using the as cast clad strip, and no breakage occurred at the interface between the strips but only in the Al-40% Sn-1% Cu layer. This result confirmed that the two strips were strongly bonded at the interface.

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Direct Cladding from Molten Metals of Aluminum and Magnesium Alloys Using a Tandem Horizontal Twin Roll Caster

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.772.250 ◽

2015 ◽

Vol 772 ◽

pp. 250-256 ◽

Cited By ~ 5

Author(s):

Hideto Harada ◽

Shin Ichi Nishida ◽

Mayumi Suzuki ◽

Hisaki Watari ◽

T. Haga

Keyword(s):

Surface Condition ◽

Hardness Test ◽

Al Alloys ◽

Mg Alloy ◽

Al Alloy ◽

Molten Metals ◽

Electron Probe Micro Analyzer ◽

Twin Roll Caster ◽

Aluminum And Magnesium Alloys ◽

Twin Roll

This paper describes direct cladding of magnesium (Mg) and aluminum (Al) alloys using a tandem horizontal twin roll caster that has three pairs of upper and lower rolls. Manufacturing conditions that are appropriate for fabricating Al/Mg and Al/Mg/Al cladded material were investigated. The surface condition of the cladded cast strip was examined. An electron probe micro analyzer was used to observe the interface between Al alloy and Mg alloy. The thickness of the mixed layer of Al and Mg alloy was 15μm, and how the materials were connected was clarified. Microscopic observation and backscattered electron analysis were used to investigate the cladding mechanisms of the Al and Mg alloy layers. Average hardness was determined using the Vickers hardness test at the Al layer and at the diffused layer between Mg and Al alloys. Cladding of Al/Mg alloy and A/Mg/Al alloy was possible using a tandem twin-roll caster. In addition, Al3Mg2 and Al12Mg17 phase precipitation at the interface of the Al and Mg alloys was confirmed during direct cladding from molten metals.

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

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.773.171 ◽

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.

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Clad Strip Casting Using a Twin Roll Casters

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.189-193.4037 ◽

2011 ◽

Vol 189-193 ◽

pp. 4037-4040

Author(s):

Ryoji Nakamura ◽

Toshio Haga ◽

H. Tsuge ◽

S. Kumai ◽

H. Watari

Keyword(s):

Molten Metal ◽

Liquidus Line ◽

Strip Casting ◽

Melt Temperature ◽

Twin Roll Caster ◽

Twin Roll

The three layers clad strip was fabricated by a vertical type tandem twin roll caster for clad strip (VTTCC). The effect of the casting conditions of the base strip and the overlay strip on the interface between the base strip and the overlay strip was investigated. The temperature of the molten metal and roll-load were investigated casting conditions. Base strip was AA8079 and overlay strip was AA6022. The proper melt temperature of the overlay strip was around the liquidus line of the base strip. The proper roll-load, which was smaller than rolling, was existed.

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Effect of Base Strip Temperature on Bonding of Three-Layer Clad Strip Cast by a Vertical-Type Tandem Twin Roll Caster

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.792.8 ◽

2018 ◽

Vol 792 ◽

pp. 8-15

Author(s):

Toshio Haga ◽

Kentaro Okamura ◽

Hisaki Warari ◽

Shinichi Nishida

Keyword(s):

Shear Stress ◽

Aluminum Alloy ◽

Cold Rolling ◽

Shear Test ◽

Tensile Shear ◽

Bonding Condition ◽

Strip Cast ◽

Twin Roll Caster ◽

Twin Roll

The effect of the base strip temperature on the bonding between base strip and overlay strips in a three-layer clad strip cast by a vertical-type tandem twin roll caster was investigated. The base strip was 3003 aluminum alloy and the overlay strip was 4045 aluminum alloy. The bonding was investigated for base strip temperatures ranging from 200 °C to 550 °C. The bonding condition was investigated by cold-rolling, bending-to-failure test and tensile shear test. The shear stress increased with the base strip temperature. Sound bonding was achieved at base strip temperatures higher than 450 °C. The results of this study indicated that the second caster is not required to be set below the first roll caster.

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

Materials Science Forum ◽

10.4028/www.scientific.net/msf.904.3 ◽

2017 ◽

Vol 904 ◽

pp. 3-8 ◽

Cited By ~ 2

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

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.1905 ◽

2011 ◽

Vol 264-265 ◽

pp. 1905-1910 ◽

Cited By ~ 1

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.

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

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.139-141.477 ◽

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

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.880.17 ◽

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.

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