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.

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.

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.

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.

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.

Formability of Roll Cast Recycled Aluminum Alloy

2007 ◽  
Vol 340-341 ◽  
pp. 605-610
Author(s):  
Ryoji Nakamura ◽  
Masaki Ikawa ◽  
Shinji Kumai ◽  
Hisaki Watari
Keyword(s):  
Aluminum Alloy ◽  
Outer Surface ◽  
High Speed ◽  
Tension Test ◽  
Bending Test ◽  
Heat Treated ◽  
6016 Aluminum Alloy ◽  
Twin Roll Caster ◽  
Twin Roll ◽  
Fe Impurity

Fe was added to 6016 aluminum alloy as the impurity, and this alloy was used as the model of the recycled 6016 aluminum alloy. The content of the Fe was from 0.18 mass% up to 1.0 mass%. 6016 including impurity-Fe was cast into the strip using a high speed twin roll caster at speed of 60 m/min. The increase of the content of impurity-Fe makes castability better rather than worse. The formability was investigated by tension test and 180 degrees bending test. The increase of Fe did not have influence on the bending test. There was no crack at outer surface of T4-heat treated strip after 180 degrees bending. The formability of 6016 strip including impurity-Fe cast by the high speed twin roll caster was enough for hem forming. The ductility of Fe added 6016 was improved by the high speed twin roll caster. It is thought that Al-Si-Fe impurity became fine by the effect of the rapid solidification, and deterioration could be improved.

Mechanical Property of Roll Cast Al-11%Si Alloy

2014 ◽  
Vol 794-796 ◽  
pp. 461-466
Author(s):  
Toshio Haga
Keyword(s):  
Deep Drawing ◽  
High Speed ◽  
Bending Test ◽  
Drawing Ratio ◽  
Drawing Test ◽  
Fe Content ◽  
Eutectic Si ◽  
Twin Roll Caster ◽  
Deep Drawing Test ◽  
Twin Roll

Al-11%Si (-0.44%Fe-0.16%Cu-0.14%Mg) was cast into the strip using a vertical type high speed twin roll caster at speed of 60m/min. Cooling rate of the strip was ranging from 2000OC/s at surface to 1000OC/s at center of thickness. The eutectic Si was smaller than 2μm. The homogenization, cold rolling down to 1mm, and annealing were carried out before the tension test, 180 degrees bending test and deep drawing test. Tensile stress was 192MPa, 0.2%proof stress was 84MPa, and elongation was 23.8%. Roll cast Al-11%Si had excellent elongation. The specimen was not broken by the 180 degree bending. LDR (Limiting Drawing Ratio) of the deep drawing test was 1.8. The ductility was drastically improved by the high speed twin roll caster. These results show that roll cast Al-11%Si has ability to be used for sheet forming. Moreover, Fe was increased up to 1.0% as the model of recycled alloy. The elongation was 15.9% and LDR was 1.7 in the condition that Fe content was 1.0%. Al-Si-Fe intermetallic became fine by the effect of rapid solidification. As the result, deterioration of the ductility was improved.

Simulation of Microstructures in Solidification of Continuous Casting Aluminum Alloy Thin Strip

2011 ◽  
Vol 399-401 ◽  
pp. 1750-1754
Author(s):  
Shou Dong Chen ◽  
Jing Chao Chen ◽  
Lian Hao Lv
Keyword(s):  
Aluminum Alloy ◽  
Continuous Casting ◽  
Solidification Process ◽  
Solidification Structure ◽  
Thin Strip ◽  
Metal Solidification ◽  
Casting Aluminum Alloy ◽  
Casting Aluminum ◽  
Twin Roll ◽  
Kinetics Of

Based on the research on the solidification of twin-roll continuous casting aluminum alloy thin strip, the analytical model of heterogeneous nucleation, the growth kinetics of tip (KGT) of twin-roll continuous casting aluminum alloy thin strip solidification are established by means of the principle of metal solidification, meantime based on the cellular automaton, the emulational model of twin-roll continuous casting aluminum alloy thin strip solidification is established. The foundation for the emulational simulation of twin-roll continuous casting thin strip solidification structure is laid. Meanwhile has confirmed the mathematical simulation feasibility by using the solidification process of twin-roll continuous casting aluminum alloy Thin Strip.

Casting of an Mg Alloy Clad Strip Using a Twin Roll Caster Equipped with a Scraper

2016 ◽  
Vol 879 ◽  
pp. 671-676 ◽  
Author(s):  
Toshio Haga ◽  
Kentaro Okamura ◽  
Shinichi Nishida ◽  
Hisaki Watari ◽  
Kunio Matsuzaki
Keyword(s):  
Casting Speed ◽  
The Other ◽  
Mg Alloy ◽  
Bending Test ◽  
Outer Side ◽  
Roll Speed ◽  
Twin Roll Caster ◽  
Twin Roll ◽  
Very High ◽  
Erichsen Test

Casting of an Mg alloy clad strip was attempted with a twin roll caster equipped with a scraper in an oxidizing atmosphere. The base strip was AM60 and the overlay strip was AZ121. The AM60 strip was cast with a roll, and the upper side of the strip was scribed by the scraper. The molten AZ121 was poured on the scribed AM60 strip. The scribed surface of AM60 contacted the molten metal of AZ121 without exposure to the atmosphere. Therefore, the scribed surface was not oxidized. Most of the AZ121 strip was solidified by the other roll. The casting speed was 30 m/min. The roll load was 0.05 kN/mm. The roll speed was very high and the roll load was very small. However, the strips were bonded, and they did not peel with bending until breaking. The interface between the two strips was clear. When AM60 was on the outer side, the results of the V-bending test and the Erichsen test were better. These results mean that the ductility of AZ121 was improved by cladding with AM60.

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