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Development of manufacturing process of wrought magnesium alloy sheets by twin roll casting

Watari H., Paisarn R., Haga T., Noda K., Davey K., Koga N.

Journal of Achievements in Materials and Manufacturing Engineering

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2007

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Vol. 20, nr 1-2

515-518

EN

Purpose: The purpose of the work is to development of a strip casting technology for manufacturing magnesium alloy sheets. The aim of the work is to establish a manufacturing process and technology to facilitate the economical manufacture of high-strength magnesium sheet alloys. Design/methodology/approach: A horizontal type twin roll caster was used to manufacture magnesium alloy sheets. Pair of copper alloy roll, pure copper roll and steel roll was used for the horizontal type twin roll caster. The diameter of the rolls was 300 mm and the width of rolls was 100 and 150 mm. Findings: The magnesium alloy sheets could be successfuly manufactured by the horizontal twin roll caster. The product sheet thickness in the present experiment was 2.0 to 5.0 mm. The equiaxed microstructure was observed in cast magnesium alloys when a pair of copper and copper alloy rolls were used. The mean grain size of the cast magnesium alloys strip was from 30 to 60 micrometers. After hot rolling process, the grain size was reduced to about 10 micrometers. The obtained magnesium alloy sheet indicated a good plastic formability by a warm-drawing test. Research limitations/implications: The superheat in the experiment was between 15 and 30 degrees centigrade, also an appropriate hot rolling temperature was 250 degrees centigrade for AZ31, AZ61 and AM60, 300 degrees centigrade for AZ91. Practical implications: The proposed manufacturing process was effective from the view point of economical manufacturing process as well as of formation of rapid solidification microstructures. Introducing the twin roll casting technology enable to manufacture magnesium sheet alloys with high aluminium contents, such as AZ61, AM60 and AZ91. Originality/value: AZ31, AM60, AZ61 and AZ91 wrought magnesium alloy sheets can be manufactured economically by twin roll casting. These cast sheet can be hot rolled and the proposed manufacturing process enables manufacturer to manufacture thin magnesium alloy sheets with high aluminium contents such as AM60, AZ61 and AZ91.

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Twin roll casting of magnesium alloys with high aluminum contents

Watari H., Haga T., Shibue Y., Davey K., Koga N.

Journal of Achievements in Materials and Manufacturing Engineering

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2006

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Vol. 18, nr 1-2

419--422

EN

Purpose: The purpose of the work is to establish a manufacturing process and technology to facilitate the economical manufacture of high-quality magnesium sheet alloys with high aluminum contents, such as AZ61 and AZ91. The aim of the work is to establish a twin roll casting technology to facilitate the manufacture of AZ61 and AZ91 magnesium sheet alloys economically whilst maintaining high quality. Design/methodology/approach: A horizontal type twin roll caster was used to manufacture thin magnesium alloy sheets of AZ61 and AZ91. Pair of copper alloy roll and pure copper roll was used for the horizontal type twin roll caster. A closed type tundish was set to the roll caster to keep stable contact of molten magnesium with upper and lower rolls. Findings: The experiment results clarified that AZ61 and AZ91 sheets can be manufactured by twin roll casting process. The product sheet thickness in the present experiment is 2.0 to 4.5 mm for AZ91, 2.5 to 5.0mm for AZ61. Mill stiffness and a method of predicting the cast sheet’s thickness were investigated to determine the appropriate manufacturing conditions. The microstructure of AZ61 cast strips was equiaxed structure and the crystal sizes are different depending on cross section observed. The dendric and equiaxed microstructure were seen in the microstructure of AZ91 cross section. The intermetllic Mg17Al12 was seen in the grain boundary in AZ91 when roll speed was very slow. The grain size of the manufactured wrought magnesium alloys sheet was less than 10 micrometers. The obtained magnesium alloy sheet exhibited an equivalent limiting drawing ratio in a warm-drawing test. The limiting drawing ratio of AZ61 was 2.6 and 2.4 for AZ91. Research limitations/implications: The suitable roll speed was from 9m/min to 15m/min in manufacturing AZ91 and AZ61 strip using copper alloy rolls. When in use of pure copper roll, strips were cast between 6m/min and 20m/min for manufacturing AZ61 and AZ91. The superheats in the experiment were 15ºC and 30ºC. The cast strips should be hot rolled at 300ºC. Originality/value: value In this experiment, it is clarified that AZ61, AZ91 sheets can be manufactured by twin roll casting. These cast sheet can be hot rolled and the manufacturing process by twin roll casting enable to manufacure thin magnesium sheet alloys with high aluminum contents. It has been found that the manufactured cast AZ61 and AZ91 have good formability by a warm deep drawing test.

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Effects of production parameters on characteristics of magnesium alloy sheets manufactured by twin-roll casting

Watari H., Haga T., Davey K., Koga N., Yamazaki T.

Journal of Achievements in Materials and Manufacturing Engineering

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2006

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Vol. 16, nr 1-2

171--176

EN

Purpose: The purpose of the work is to establish a manufacturing process and technology to facilitate the economical manufacture of high-quality magnesium sheet alloys. Design/methodology/approach: Magnesium alloy AZ31B was used to investigate the appropriate manufacturing conditions for use in twin-roll strip casting. Temperatures of the molten materials and roll speeds were varied to find the appropriate manufacturing conditions. The effects of manufacturing conditions on possible forming were clarified in terms of roll speeds and roll gaps between upper and lower rolls. Findings: In the hot-rolling process, a temperature exceeding 200°C was chosen to keep cast products from cracking. An appropriate annealing temperature was effective for homogenizing the microstructure of the rolled cast sheets after the strip casting process. The grain size of the manufactured wrought magnesium alloys sheet was less than 10 micrometers. The obtained magnesium alloy sheet exhibited an equivalent limiting drawing ratio in a warm-drawing test. Research limitations/implications: AZ31 were used to investigate the appropriate manufacturing conditions for use in twin-roll strip casting. Casting temperatures were varied from 630°C to 670°C to find the best casting conditions. Roll casting speeds were varied from 5m/min to 30 m/min in order to examine which roll speed was appropriate for solidifying the molten magnesium. Practical implications: It was found that the cast magnesium sheet manufactured by roll strip casting could be used for plastic forming if the appropriate magnesium sheets were produced after the roll casting process. Originality/value: This paper showed the effectiveness of twin roll casting for magnesium alloys by a horizontal roll caster.