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

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 Three Layers Clad Strip

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.443.128 ◽

2010 ◽

Vol 443 ◽

pp. 128-133 ◽

Cited By ~ 2

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.

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Roll Casting of Al-25mass%Si

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.97-101.1057 ◽

2010 ◽

Vol 97-101 ◽

pp. 1057-1060 ◽

Cited By ~ 4

Author(s):

Ryoji Nakamura ◽

Masayuki Saito ◽

Shinji Kumai ◽

Hisaki Watari

Keyword(s):

Aluminum Alloy ◽

Casting Speed ◽

Alloy Strip ◽

Thickness Direction ◽

Near Surface ◽

Roll Casting ◽

Eutectic Si ◽

Cold Rolled ◽

Twin Roll Caster ◽

Twin Roll

Roll casting of Al-25mass%Si hyper eutectic aluminum alloy strip was tried by an unequal diameter twin roll caster. The casting speed was 10m/min. The thickness of the strip was about 2mm. The eutectic Si and primary crystallized Si were very fine by the effect of the rapid solidification. The size of the primary crystallized Si was not uniform at the thickness direction. The primary crystallized Si at the near surface was finer than that of inside. The eutectic Si was finer than 2μm. The strip could be cold rolled after hot rolling and annealing.

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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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Roll Casting and Die Casting of Si-Added Al-Mg Alloy

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1007.12 ◽

2020 ◽

Vol 1007 ◽

pp. 12-17

Author(s):

Toshio Haga ◽

Shinichiro Imamura ◽

Hiroshi Fuse ◽

Hisaki Watari ◽

Shinichi Nishida

Keyword(s):

High Speed ◽

Die Casting ◽

Sheet Forming ◽

Mg Alloy ◽

Tension Tests ◽

Roll Casting ◽

Cold Rolled ◽

Twin Roll Caster ◽

Si Content ◽

Twin Roll

Si ranging from 0.2 mass% to 2.0 mass% was added to Al-5%Mg alloy (5182) and strip was cast by a vertical type high-speed twin-roll caster at a speed of 80 m/min. The as-cast strip was cold-rolled down to 1 mm thickness and annealed. The mechanical properties were investigated using cup tests and tension tests. The limiting draw ratio (LDR) of the 5182 alloy was 2.0 and the LDR became smaller as the Si content increased. When the Si content was 2.0 mass%, the LDR was 1.8, which shows that Si-added 5182 can be used for sheet forming, if the Si content is less than 2.0 mass%. The tensile strength and elongation were almost constant when the Si content was less than 1 mass%, but decreased at 2.0 mass% Si. However, the elongation was greater than 20% at 2.0 mass% Si. For die casting, 2.0 mass% Si was determined as the appropriate content from the results of the tension tests. When the Si content is in the range from 1.0 mass% to 2.0 mass%, then the Si added Al-5%Mg has the ability to be used for both die casting and sheet forming.

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

Defect and Diffusion Forum ◽

10.4028/www.scientific.net/ddf.382.147 ◽

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.

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High Speed Twin-Roll Casting of Al-Mg Alloys

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.154-155.1544 ◽

2010 ◽

Vol 154-155 ◽

pp. 1544-1548 ◽

Cited By ~ 2

Author(s):

Kosuke Komeda ◽

Ryoji Nakamura ◽

Shinji Kumai

Keyword(s):

Heat Transfer ◽

Aluminum Alloy ◽

High Speed ◽

Aluminum Alloy 5182 ◽

Roll Casting ◽

Twin Roll Caster ◽

Deep Drawing Test ◽

Study Heat Transfer ◽

Twin Roll ◽

Steel Rolls

The disadvantages of the conventional twin-roll caster for aluminum alloy are low casting speeds and limited choices of alloys that are castable by this processing. It is known that strip casting of aluminum alloy 5182 is very difficult because of their wider freezing zones. The vertical-type high-speed twin-roll caster used in the present study was devised to overcome these disadvantages. Features of the high speed twin roll casters are as below. Mild steel rolls were used in order to increase the casting speed and to be made at a lower equipment cost. Roll coating is produced in casting of Al-Mg alloy. Therefore lubricant, that resists heat transfer, was not used in the present study. Heat transfer between melt and the roll was improved by hydrostatic pressure of the melt. Low superheat casting was carried out in order to improve microstructure of the strip. In the present study, effectiveness of a high-speed twin roll caster for recycling aluminum alloy was investigated. The effects of the high-speed twin roll caster on alleviating the deterioration of mechanical properties by impurities were investigated. Properties of the cast strip were investigated by metalography, a tension test, and a deep drawing test.

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Roll Casting of Al-SiCp Strip

Materials Science Forum ◽

10.4028/www.scientific.net/msf.675-677.811 ◽

2011 ◽

Vol 675-677 ◽

pp. 811-814 ◽

Cited By ~ 1

Author(s):

Toshio Haga ◽

Teppei Nakamura ◽

S. Kumai ◽

H. Watari

Keyword(s):

Hot Rolling ◽

High Speed ◽

Strip Casting ◽

Cast Strip ◽

Fine Grain ◽

Roll Casting ◽

Speed Up ◽

Cold Rolled ◽

Twin Roll Caster ◽

Twin Roll

The strip casting of Al-SiCp alloy was operated by a high speed twin roll caster. The content of SiCp was 20Vol% and 30Vol%. Both of Al-20Vol%SiCp and Al-30Vol%SiCp strips could be cast continuously at the speed up to 90m/min. The SiCp particle distributed uniformly. This was the effect of fine grain of the strip. The as-cast strip of Al-20Vol%SiCp could be cold rolled after homogenization. The as-cast strip of Al-30Vol%SiCp could be cold rolled after once hot rolling and annealing. The as-cast strip of Al-20Vol%SiCp could be coiled at the diameter of 460mm.

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Roll Casting of Aluminum Alloy Strip by a Single Roll Caster Equipped with a Scraper

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.445.307 ◽

2012 ◽

Vol 445 ◽

pp. 307-312 ◽

Cited By ~ 1

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.

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