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1

Roll casting of a clad strip consisting of 5182 aluminium alloy

Haga T.

Archives of Materials Science and Engineering

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2015

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Vol. 73, nr 1

33--43

EN

Purpose: The investigation of the casting ability of the two layers and three layers clad strips consisting of the 5182 (Al-Mg) strip by the vertical type twin roll caster equipped with a scraper and the vertical type tandem twin roll caster at the speed higher than 30 m/min is one of the purposes. Another purpose is investigation of the casting conditions that affect the bonding condition of the 5182 strip to another aluminium alloy strip. Design/methodology/approach: A twin roll caster equipped with a scraper and a vertical type tandem twin roll caster were designed, assembled, and the castings of clad strips consisting the 5182 strip were tried. The interface between the strips were observed by the optical microscope. The bonding strength between strips was investigated by the continuous bending test. Findings: In the casting of the 5182 strip and the 3003 strip, the temperature of the 3003 strip influenced the bonding. When the temperature of the 3003 strip was lower, the 5182 strip was not bonded to the 3003 strip. In the casting of the 5182 strip and the 4045 strip, the porosity occurred near the interface. The temperature of the 5182 strip at the roll bite influenced the occurrence of the porosity. When the temperature of the 5182 strip was low, the porosity did not occur. The vertical type twin roll caster equipped with a scraper was suitable for the clad strip consisting of the 5182 and the 3003, and consisting of the 5182 and the 4045. The sound clad strips of the 5182 and the 3003, of the 5182 and 4045 could be cast using the vertical type twin roll caster equipped with a scraper. Research limitations/implications: The size of the roll was laboratory size. Moreover, the amount of the poured molten metal was less 3kg. Therefore, there was no information about the commercial size clad strip in this paper. Practical implications: The aluminium clad strip can be used to make component of the automobile by the press forming. Originality/value: The twin roll casters that could cast two and three layers clad strips were original invention. It is shown that the clad strips consisting of the 5182 (Al-Mg) strip could be cast using the twin roll caster. The elucidation of the casting conditions that affects the bonding and porosity near the interface is original result.

2

A vertical type twin roll caster for an aluminium alloy clad strip

Haga T., Nakamura R., Kumai S., Watari H.

Archives of Materials Science and Engineering

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2013

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Vol. 62, nr 1

36--44

EN

Purpose: of this paper: Twin roll casters that can cast two layers and three layers clad strip of aluminium alloys were invented. One of the purposes of this paper is to report that the two layers and three layers clad strip could be cast by the twin roll caster of this study. The investigation of the characters of these casters and the clad strips was purpose of this paper, too. The connecting at the interface between the strips was most important in the casting of the clad strip. Therefore, the attention was paid on the conditions of the interface. Design/methodology/approach: A vertical type tandem twin roll caster and a twin roll caster equipped with a scraper were designed, assembled and tested. Castings of the two layers clad strip and the three layers clad strip directly from molten metal were tried using these twin roll casters. The connecting strength between strips was investigated by the continuous bending test and the cold rolling. The diffusion and re-melting at the interface was investigated by the SEM-EPMA. Findings: The twin roll casters invented in this study could cast the two layers and three layers clad strips directly from molten metal. These clad strips had clear interface between the strips. This means that the mixing of the two alloys did not occur at the interface. The diffusion of elements of the each strip into another strip did not occur at the interface. The connecting strength was enough to endure the peeling at the interface by continuous bending. The clad ratio could be controlled by the solidification length up to 10:1. Two layers clad strip assembled from Al-Mg alloy strip and another aluminium alloy strip could be cast without defect by the effect of the scraper. The three layers clad strip which base strip had lower melting point than that of the overlay strip could be cast. Practical implications: The three layers clad strip, which base strip is 3003 aluminium alloy and overlay strips are 4045 aluminium alloy, can be used for the brazing sheet of the radiator of the automobile. The twin roll caster of this paper could cast this type of clad strip. The process saving and the energy saving can be attain by the twin roll caster of this paper. The clad ratio between the base strip and the overlay strip was smaller than 10:1. Originality/value: The twin roll casters that could cast two and three layers clad strips were original invention. using the twin roll caster.

3

Development of a twin roll caster for light metals

Haga T.

Journal of Achievements in Materials and Manufacturing Engineering

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2010

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Vol. 43, nr 1

393--402

EN

Purpose: Purpose of this paper is to show the development of a twin roll caster for aluminium alloy. One of the developments was the increase of the roll speed. The increase of the roll speed was essential to improve the low productivity of the twin roll caster. Limitation of the alloys, which can be cast into the strip, could be enlarged by the method to increase the roll speed. The method to increase the roll speed was useful to increase the cooling rate of the cast strip. The devices to increase the roll speed were shown in this paper. Other development was invention of the twin roll caster to cast clad strip. The twin roll casters to cast two layers clad strip, three layers clad strip and five layers clad strip were invented. Design/methodology/approach: Increase of roll speed was attained by the use of a copper roll and a nozzle, operation of the low temperature casting and non-use of parting material. A scraper was adopted to the twin roll caster for clad strip to prevent the mixture of the molten metals and to control the surface condition. The devices to increase the roll speed were useful for the roll caster to cast clad strip. Findings: The aluminium alloy strip could be cast at the speeds up to 90 m/min. The aluminium alloy which has wide freezing zone like Al-25%Si could be cast into the strip. Two layers, three layers and five layers of clad strips could be cast. Research limitations/implications: The roll casters were laboratory size. Therefore, it was not clear of the ability of the casting of the long size and wide size strips. Practical implications: The productivity of aluminium alloy strip is increased. The property of the aluminium alloy strip is improved. The aluminium alloy, which was too brittle to be formed into the plate, will be cast into strip directly from melt. The process and energy to make the brazing sheet will be saved by the roll caster of the present study. Originality/value: The invented roll casters, devices for casting and properties of the cast strips are original.

4

Clad strip casting by a twin roll caster

Haga T., Nakamura R., Kumai S., Watari H.

Archives of Materials Science and Engineering

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2009

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Vol. 37, nr 2

117-124

EN

Purpose: Of this paper is to realize the casting of the clad strip by only one process. Therefore, the investigation of the ability of the casting of the clad strip by a vertical type twin roll caster was operated. The aim of the use of the twin roll caster to make clad strip was in the reduction of the production-energy of the clad strip. Design/methodology/approach: Used in the present study was a vertical type twin roll caster with the scriber. The scriber was used to prevent the mixture of the two kinds of the melts. The scriber was set at roll-bite, and the scriber contacted to the one of solidification layer. The melt was stopped by the scriber and the only the solidification layer was dragged by the roll. Findings: The clad strip with the clear interface could be by the vertical type twin roll caster with the scriber. The scriber was useful to drag only the solid and semisolid layer. The two kinds of strips were connected strictly at the interface of the clad strip. The clad strip was not broken at the interface by the continuous bending. Research limitations/implications: Are that 100 mm width-strip was cast in the present study. Ability of the clad strip that is wider than 100 mm was not clear. The control of the clad ratio was not investigated. Practical implications: The twin roll caster devised and investigated in this report is useful to cast clad strip like the brazing sheet for the radiator of the automobile. Originality/value: The vertical type twin roll cater to cast clad strip is original process. The scriber was used to prevent the mixture of the two kinds of melts. The scriber was not used in the previous research to cast clad strip at the twin roll caster, and use of the scriber was the first try.

5

Otrzymywanie warstwowych taśm ze stopów aluminium z przeznaczeniem na wymienniki cieplne.

Szymański W., Lech-Grega M., Kłyszewski A.

Rudy i Metale Nieżelazne

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1998

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R. 43, nr 11

662-665

PL

Przeprowadzono próby walcowania odlewniczego stopu Al-7%Si oraz jego łączenia w procesie walcowania ze stopami 3003 i 7005. Określono kryteria przygotowania materiałów i prowadzenia procesu walcowania w celu otrzymania taśmy walcowej.

EN

Rolling tests were made with the Al-7%Si casting alloy and the tests of its combining with the 3003 and 7005 alloys during the rolling process. Guidelines for the material preparation and control of the rolling process aimed at obtaining the clad strips have been determined.