BR112019005256B1 - HEAT TREATMENT LINE, AND, CONTINUOUS HEAT TREATMENT METHOD - Google Patents

Abstract

This is a compact heat treatment line that can include a short heating zone to rapidly heat a metal strip to a solution temperature using magnetic rotors such as permanent magnet magnetic rotors. A fast and effective embedding zone can be obtained by using magnetic rotors to levitate the metal strip inside a gas-filled chamber. Magnetic rotors can additionally levitate the metal strip through a quench zone, and can optionally reheat the metal strip prior to final winding. The magnetic rotors used to heat and/or levitate the metallic strip can also provide tension control, can facilitate the initial pass of the metallic strip, and can cure coatings and/or promote uniformity of coatings/lubricants applied to the metallic strip without overheating. This heat treatment line can provide continuous annealing and solution heat treatment in a much more compact space than traditional processing lines.

Description

CROSS-REFERENCE TO RELATED ORDERS

[001] This application claims the benefit of Provisional Patent Application No. U.S. 62/400,426 entitled "ROTATING MAGNET HEAT INDUCTION" and filed on September 27, 2016; and Provisional Patent Application No. 62/505,948 entitled "ROTATION MAGNET HEAT INDUCTION" and filed May 14, 2017, the disclosures of which are incorporated herein by reference in their entirety.

[002] Additionally, the present application relates to Non-Provisional Patent Application No. U.S. 15/716,887 by Antoine Jean Willy Pralong, et al. titled "ROTATING MAGNET HEAT INDUCTION" filed September 27, 2017; U.S. Patent Application No. 15/716,559 by Antoine Jean Willy Pralong, et al. entitled "SYSTEMS AND METHODS FOR NON-CONTACT TENSIONING OF A METAL STRIP" filed September 27, 2017; Non-Provisional Patent Application No. 15/716,577 by David Michael Custers, entitled "PRE-AGEING SYSTEMS AND METHODS USING MAGNETIC HEATING", filed September 27, 2017; Non-Provisional Patent Application No. 15/716,692 by David Anthony Gaensbauer, et al. entitled "MAGNETIC LEVITATION HEATING OF METAL WITH CONTROLLED SURFACE QUALITY" filed September 27, 2017; and Non-Provisional Patent Application No. U.S. 15/717,698 by Andrew James Hobbis, et al. entitled "SYSTEMS AND METHODS FOR THREADING A HOT COIL ON MILL" filed on September 27, 2017, the disclosures of which are incorporated herein by reference in their entirety.

FIELD OF TECHNIQUE

[003] The present disclosure relates to general metallurgy and, more specifically, to the heat treatment of metallic articles, such as aluminum metallic strips.

BACKGROUND

[004] Various metals such as aluminum alloys are used extensively for various purposes such as automotive components, structural components and many other uses. Traditionally, metals are cast by direct ice or continuously cast. Often, an ingot, plate, or strip of metal is rolled into a final gauge that is distributable to a customer (eg, an automobile manufacturer or parts processing plant). In some cases, metals may need to undergo some type of heat treatment to obtain desirable tempering properties. For example, annealing can improve the formability of a metallic article and heat treating the solution can improve the strength of the metallic article.

[005] The heat treatment of annealing and solution involves heating and cooling the metallic article to specific temperatures and keeping them at such temperatures for specific periods of time. The temperature and time profile of a metallic article can largely affect the resulting strength and ductility of the metallic article. In some cases, solution heat treating of aluminum alloys may involve heating the metallic article to an elevated temperature until the precipitated alloying elements are dissolved in solid solution in the metallic article, then quenching the metallic article to lock these elements in place. a supersaturated solid solution. After solution heat treatment, the metal can be hardened at room temperature (e.g. naturally aged) for a period, hardened for a duration at a slightly elevated temperature (e.g. artificially aged or pre-aged) and/or processed (e.g. cleaned, pre-treated, coated or otherwise processed).

[006] To obtain a high yield volume, metal articles can be continuously annealed and treated with thermal solution in a continuous processing line. Traditionally, these continuous processing lines occupy very large buildings and require expensive and complicated equipment. For example, some of these continuous annealing solution heat treatment lines require passing a metallic strip through several sections to raise the temperature of the metallic strip sufficiently and maintain it at a solution temperature, sometimes requiring lines of up to 800 meters or more. Often the low voltage must be maintained while the metallic strip is at high temperature so that the metallic strip does not deform under the stress and temperature, thereby requiring the use of forced air to keep the metallic strip properly suspended in the multiple sections so that the metal strip does not inadvertently come into contact with any surrounding equipment or structure. If the metal strip makes physical contact with equipment or structures, it can damage the equipment or structure, as well as damage the surface of the metal strip, necessitating a shutdown and dismantling of the damaged metal strip, as well as any metal in the metal strip processing line. 800 meters that is affected and any metal needed to start a new processing run (for example, another 800 meters or more). Furthermore, to maintain the desired temperatures, the forced air used to suspend the metal strip must also be heated.

[007] Current technology to perform continuous heat treatment on a metal strip involves the use of substantial equipment, substantial energy (e.g. to heat large volumes of hot air) and substantial space (e.g. to accommodate 800 meters or more of equipment and support equipment).

SUMMARY

[008] The term modality and similar terms are intended to refer broadly to the entire subject of the present disclosure and the claims below. Statements containing these terms are not to be construed as limiting the subject matter described herein or limiting the meaning or scope of the claims below. Embodiments of the present disclosure encompassed herein are defined by the claims below, not by this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are described further in the Detailed Description section below. This summary is not intended to identify key or essential features of claimed subject matter, nor should it be used alone to determine the scope of claimed subject matter. The subject matter is to be understood by reference to the appropriate portions of the entire specification of the present disclosure, any or all drawings and each claim.

[009] Aspects of the present disclosure include a heat treatment line, comprising: a heating zone for accepting a metal strip moving in a downstream direction, a heating zone comprising a plurality of magnetic rotors for inducing eddy currents in the metal strip for heating the metal strip to a metal peak temperature, wherein each of the plurality of magnetic rotors rotates about an axis of rotation perpendicular to the downstream direction and parallel to a lateral width of the metal strip; a soaking zone positioned downstream of the heating zone to accept the metallic strip and maintain the peak temperature of the metal for a period of time; and a quench zone positioned downstream of the soak zone for rapidly quenching the metal strip from the peak metal temperature. In some cases, the heat treatment line additionally includes a reheat zone after the quench zone to pre-age the metallic strip before it is wound into a final coil.

[0010] In some instances, the plurality of magnetic rotors include a plurality of pairs of magnetic rotors, each of the pairs of magnetic rotors including a bottom magnetic rotor positioned opposite the metal strip of a top magnetic rotor. In some cases, each of the plurality of magnetic rotors comprises a plurality of permanent magnets positioned to rotate about the axis of rotation. In some cases, the embedding zone includes an additional plurality of magnetic rotors for levitating the metal strip, each additional plurality of magnetic rotors rotating about an axis of rotation perpendicular to the downstream direction and parallel to the lateral width of the strip. metallic. In some cases, the embedding zone further comprises chamber walls positioned between the metallic strip and the additional plurality of magnetic rotors, wherein the chamber walls define a chamber for accepting the metallic strip, wherein the chamber is attachable to a supply of gas. In some cases, the chamber walls are not metallic. In some cases, the soaking zone additionally comprises one or more quenching devices to compensate for temperature increases induced in the metallic strip by rotation of the additional plurality of magnetic rotors. In some cases, the heat treatment line additionally comprises an uncoiler positioned upstream of the heating zone to supply the metallic strip to the heating zone from a coil; a leveling cylinder positioned downstream of the quench zone to control the leveling of the metal strip; and a reheat zone positioned downstream of the leveling cylinder for heating the metal strip, the reheat zone including one or more additional magnetic rotors. In some cases, the reheat zone is positioned after the quench zone to pre-age the metallic strip before drawing the metallic strip into a final coil. In some cases, the heat treatment line additionally comprises a tension adjustment zone for adjusting the tension in the metallic strip, wherein the tension adjustment zone comprises one or more magnetic rotors rotating about an axis of rotation perpendicular to the downstream direction and parallel to the lateral width of the metal strip. In some cases, the heat treatment line additionally comprises an unwinder positioned upstream of the heating zone to supply the metal strip to the heating zone from a starting coil and a rewinder positioned downstream of the quench zone to receive the metal strip after heat treatment and winding the metal strip into a final coil; wherein a passage line is defined between the unwinder and the retriever along which the metallic strip passes through the heating zone, the soaking zone and the quenching zone without passing through an accumulator. In some cases, the heat treatment line further comprises a movable welder or other joining device placed upstream of the heating zone to weld or otherwise join a subsequent metallic strip to the metallic strip during displacement of the metallic strip.

[0011] Aspects of the present disclosure include a continuous heat treatment method, comprising: passing from an adjacent metal strip to a plurality of magnetic rotors in the downstream direction; rotating the plurality of magnetic rotors, wherein rotating a magnetic rotor includes rotating the magnetic rotor about an axis of rotation perpendicular to the downstream direction and parallel to a lateral width of the metallic strip, and wherein rotating the plurality of magnetic rotors induces eddy currents in the metal strip to heat the metal strip to a metal peak temperature; passing the metal strip through a soak zone, wherein passing the metal strip through the soak zone comprises maintaining the peak metal temperature of the metal strip for a period of time; and quenching the metal strip from the peak metal temperature.

[0012] In some cases, the plurality of magnetic rotors includes a plurality of pairs of magnetic rotors, wherein each pair of magnetic rotors includes a bottom magnetic rotor and a top magnetic rotor separated by a gap, and wherein the metallic strip is adjacent to the plurality of rotors comprising passing the metallic strip through gaps of the plurality of pairs of magnetic rotors. In some cases, rotating a magnetic rotor of the plurality of magnetic rotors includes rotating a plurality of permanent magnets about the axis of rotation. In some cases, passing the metallic strip through the embedding zone comprises levitating the metallic strip, in which case levitating the metallic strip comprises rotating an additional plurality of magnetic rotors adjacent the metallic strip. In some cases, passing the metallic strip through the embedding zone comprises: passing the metallic strip through a chamber defined by chamber walls positioned between the metallic strip and the additional plurality of magnetic rotors; and supplying the chamber with gas from a gas supply. In some cases, maintaining the peak metal temperature comprises applying a quench fluid to the metal strip to compensate for temperature increases induced in the metal strip by rotation of the additional plurality of magnetic rotors. In some cases, the method additionally includes unwinding the metallic strip from a starting coil; leveling the metal strip after tempering the metal strip; and reheating the metallic strip after leveling the metallic strip, wherein reheating the metallic strip comprises rotating one or more additional magnetic rotors adjacent the metallic strip. In some cases, the method further comprises passing the metallic strip, wherein passing the metallic strip comprises: magnetic rotors rotating in a downstream direction, wherein the magnetic rotors are selected from the group consisting of the plurality of magnetic rotors and a additional set of magnetic rotors; passing one end of the metal strip through the magnetic rotors; and reversing rotation of the magnetic rotors to rotate the magnetic rotors in an upstream direction. In some cases, the method further comprises unwinding the metal strip from a starter coil before passing the adjacent metal strip to the plurality of magnetic rotors; backing up the metal strip into an ending coil after quenching the metal strip, wherein the metal strip on the final coil has been heat treated; and not passing the metallic strip through an accumulator between unwinding the metallic strip and rewinding the metallic strip. In some cases, the method further comprises welding or otherwise joining the metallic strip to a subsequent metallic strip, wherein welding or otherwise joining the metallic strip comprises: bringing the metallic strip and the subsequent metallic strip into contiguity with a joint during displacement of the metal strip; pass a mobile welder or other fastener over the joint during the path of the metal strip; and welding/joining the joint during the path of the metal strip.

[0013] Other purposes and advantages will be evident from the following detailed description of non-limiting examples.

BRIEF DESCRIPTION OF THE FIGURES

[0014] The descriptive report refers to the following attached Figures, in which the use of identical numerical references in different Figures is intended to illustrate similar or analogous components.

[0015] Figure 1 is a schematic representational diagram depicting a processing line for continuous heat treatment in accordance with certain aspects of the present disclosure.

[0016] Figure 2 is a schematic diagram depicting a side view of a processing line for continuous heat treatment in accordance with certain aspects of the present disclosure.

[0017] Figure 3 is a schematic diagram depicting a side view of a processing line for continuous heat treatment having a magnetic soaking furnace in accordance with certain aspects of the present disclosure.

[0018] Figure 4 is a schematic combination diagram and temperature graph depicting a heating zone and soaking zone of a processing line in accordance with certain aspects of the present disclosure.

[0019] Figure 5 is a cutaway side view of a permanent magnetic rotor in accordance with certain aspects of the present disclosure.

[0020] Figure 6 is a flow chart depicting a process for continuously heat treating a metal strip in accordance with certain aspects of the present disclosure.

[0021] Figure 7 is a flowchart depicting a process for threading a metallic strip into a continuous heat treatment line in accordance with certain aspects of the present disclosure.

[0022] Figure 8 is a side view schematic diagram depicting an initial stage of passing a metal strip in a continuous heat treatment line in accordance with certain aspects of the present disclosure.

[0023] Figure 9 is a side view schematic diagram depicting a secondary stage of passing a metal strip in a continuous heat treatment line in accordance with certain aspects of the present disclosure.

[0024] Figure 10 is a side view schematic diagram depicting a metal strip after being passed through a continuous heat treatment line in accordance with certain aspects of the present disclosure.

[0025] Figure 11 is a top view schematic diagram depicting a metallic strip and a subsequent metallic strip during a pre-welding phase in accordance with certain aspects of the present disclosure.

[0026] Figure 12 is a top view schematic diagram depicting a metallic strip and a subsequent metallic strip during a welding step in accordance with certain aspects of the present disclosure.

[0027] Figure 13 is a top view schematic diagram depicting a metallic strip and a subsequent metallic strip during a post-soldering phase in accordance with certain aspects of the present disclosure.

[0028] Figure 14 is a flowchart depicting a process for joining a metallic strip to a subsequent metallic strip during travel of the metallic strip in accordance with certain aspects of the present disclosure.

[0029] Figure 15 is a schematic top view in partial cutaway of a section of a processing line depicting a metallic strip levitated over a magnetic rotor assembly having laterally separated magnetic sources in accordance with certain aspects of the present disclosure.

[0030] Figure 16 is a schematic partial cut-away top view of a section of a processing line depicting a metal strip levitated over a set of magnetic rotors having magnetic sources close to full width in accordance with certain aspects of the present revelation.

DETAILED DESCRIPTION

[0031] Certain aspects and features of the present disclosure relate to a compact heat treatment line that includes a short heating zone with the ability to quickly bring the metal strip to a suitable solubilization temperature through the use of magnetic rotors such as permanent magnet magnetic rotors. A fast and effective embedding zone can also be achieved, such as through the use of magnetic rotors to levitate the metallic strip inside a gas-filled chamber. Magnetic rotors can additionally levitate the metal strip through a quench zone, and can optionally reheat the metal strip prior to final winding. Magnetic rotors used to heat and/or levitate the metal strip can also provide tension control and facilitate the initial run of the metal strip. This heat treatment line can provide continuous annealing and solution heat treatment in a much more compact space than traditional processing lines.

[0032] The compact heat treatment line can be a continuous annealing and solution heat treatment (CASH) line, with the ability to solubilize and/or anneal a continuous metal strip. After the metal strip has been heat treated on the heat treatment line, the metal strip can be given a desirable temper, such as a T temper (for example, T4, T6 or T8). Certain aspects of the present disclosure may be especially useful for heat treating a metallic aluminum strip. In some cases, thicker or thinner metal articles other than a metal strip can be processed. As used herein, reference to a metal strip in connection with certain aspects and features of the present disclosure may be replaced by reference to a metal article or any specific thicker or thinner metal articles, as appropriate. In some cases, certain aspects of the present disclosure may be especially useful for heat treating a metal strip approximately 1 mm thick, approximately 0.2 mm to approximately 6 mm, approximately 0.5 mm to approximately 3 mm, or approximately 0.7 mm to approximately 2 mm.

[0033] While normal CASH lines may require large projection areas and have a processing length (e.g., length through which the metal strip travels on the CASH line) that extends to approximately 800 meters or more, certain aspects of this development may occupy a smaller projection area and have a processing length equal to or less than approximately 100 meters, approximately 90 meters, approximately 80 meters, approximately 70 meters, approximately 60 meters, approximately 50 meters, approximately 40 meters, approximately 30 meters, approximately 25 meters, approximately 20 meters, or approximately 15 meters. In some cases, a heat treatment line, as disclosed herein, may be positioned in a horizontal direction, with the metal strip running primarily in a horizontal direction. However, this is not necessary, and one or more elements of the heat treatment line can direct the metallic strip in a vertical direction or another direction.

[0034] A heat treatment line may include a heating zone, a soaking zone and a quenching zone. In some cases, the heat treatment line may also include a reheat zone. In some cases, other zones and/or elements may also be used, such as any combination of an unwinder, a first tension adjustment zone, a leveling and/or microtexturing zone, a coating and/or lubrication zone, a second zone tension adjustment and a winder. In some cases, the heat treatment line may include other zones and/or elements such as flatteners, connectors, notches, levelers, lubricants and trays.

[0035] Certain aspects and features of the present disclosure use magnetic rotors. A magnetic rotor can rotate around a geometric axis of rotation. Spinning magnets can be rotated by any suitable method, including via a rotor motor (e.g. electric motor, air motor or other) or sympathetic motion from a nearby magnetic source (e.g. another spinning magnet or changing magnetic field ). A rotating power source can be directly or indirectly coupled to a magnetic rotor to rotate the magnetic rotor. The axis of rotation of a magnetic rotor can be in any suitable direction, although it may be advantageous to position an axis of rotation approximately parallel to a lateral width of the metal strip and approximately perpendicular to a longitudinal axis (e.g. length) of the strip. metal strip at or approximately perpendicular to a downstream direction of the processing line. Approximately perpendicular may include perpendicular or within 1°, 2°, 3°, 4°, 5°, 6°, 7°, 8°, 9° or 10° of perpendicular, or the like, as appropriate. Positioning an axis of rotation in this way can be useful for controlling the tension in the metal strip. Stress management can be very important in the successful processing of metallic articles (eg metal strip) in a controlled manner on a processing line.

[0036] A magnetic rotor may include one or more magnetic sources such as electromagnets or permanent magnets. For example, a single rotor can include a single magnetic source and therefore contain two magnetic poles, or a single rotor can include multiple magnetic sources and therefore contain multiple magnetic poles. In some cases, single rotor magnetic sources can be arranged to produce asymmetric magnetic fields in a directionally manner, such as permanent magnet magnetic sources arranged in a Halbach arrangement to direct magnetic fields away from an outer circumference of the magnetic rotor. Magnetic rotors may generally contain permanent magnets only, although in some cases spinning magnets may contain electromagnets or a combination of electromagnets and permanent magnets. Permanent magnet magnetic rotors may be preferable in some cases and may have the ability to achieve more effective results than magnetic rotors that rely on electromagnets. Magnetic sources can extend the full width of the magnetic rotor or less than the full width of the magnetic rotor. In some cases, a magnetic rotor may include laterally separated magnetic sources. Laterally separated magnetic sources can thus include a gap in the width of the magnetic rotor, in which no magnetic sources reside. A magnetic rotor with laterally separated magnetic sources can include a magnetic rotor having two or more arrays of magnetic sources that are laterally separated from one another, each array containing one or more magnetic sources. Magnetic rotors with laterally separated magnetic sources can be especially effective in levitating a metallic strip while minimizing the amount of heat induced in the metallic strip.

[0037] The rotational motion of a magnetic rotor causes its magnetic source (or magnetic sources) to induce a moving or changing magnetic field adjacent to the magnetic rotor through which a metallic strip can pass. When used in a pair with an upper rotor and a lower rotor, the pair of magnetic rotors can define a gap between the upper rotor and the lower rotor, in which the changing magnetic field is generated and through which the metal strip can pass. When used as a single magnetic rotor, the metal strip can pass adjacent the magnetic rotor within an effective distance from the magnetic rotor within which the varying magnetic field generated by the magnetic rotor provides a desirable effect. As used herein, the term "an array of magnetic rotors" can include a single magnetic rotor, a single pair of magnetic rotors, two or more magnetic rotors, or two or more pairs of magnetic rotors.

[0038] Magnetic rotors can be used on any suitable article with the ability to generate eddy currents in the presence of moving and time-varying magnetic fields. In some cases, the magnetic rotors described herein may be used with conductive materials, including aluminum, aluminum alloys, magnesium, magnesium-based materials, titanium, titanium-based materials, copper, copper-based materials, steel , steel-based materials, bronze, bronze-based materials, brass, brass-based materials, composites, foils used in composites, or any other suitable metal, non-metal or combination of materials. The article may include monolithic materials as well as non-monolithic materials such as laminate bonded materials, coated materials, composite materials (such as, but not limited to, materials containing carbon fiber) or various other materials. In a non-limiting example, magnetic rotors can be used to heat metal articles such as aluminum metal strips, plates or other articles made from aluminum alloys, including iron-containing aluminum alloys. Magnetic rotors can be used to heat and/or levitate a metallic article such as a metallic strip. As a metallic article passes through the changing magnetic field generated by a rotating magnetic rotor, eddy currents can be generated or induced in the metallic article. These eddy currents can thereby heat the metallic article as they flow through the resistance of the metallic article. Additionally, eddy currents generated in the metallic article can create magnetic fields that oppose the magnetic fields of the magnetic rotors, thereby creating a repulsion that can be used to levitate the metallic article. In addition to heating and/or levitating the metallic article, magnetic rotors can be used to control the tension in the metallic strip and direct the movement of the metallic strip in a downstream direction.

[0039] Magnetic rotors can be controlled in various ways, such as by manipulating various factors associated with magnetic rotors, including the strength of magnetic sources, number of magnetic sources, orientation of magnetic sources, size of magnetic sources, size of the magnet itself rotating magnet (e.g. including any housing), rotating magnet speed (e.g. rotational speed), vertical spacing between vertically offset magnetic rotors (e.g. vertically offset rotors in a single rotor assembly), laterally offset placement of vertically offset magnetic rotors (e.g., laterally offset placement of rotors in a single rotor assembly), longitudinal gap between adjacent magnetic rotors, metal strip thickness, vertical distance between each rotating magnet and metal strip, metal strip composition, presence of magnetic shielding elements (for example, focusing elements or flux shielding), thickness and/or permeability of the magnetic shield, speed of advance of the metallic strip and number of magnetic rotors used. Other factors can also be controlled. The control of these and other factors can be static (eg set before a heat treatment process) or dynamic (eg unstable during a heat treatment process). In some cases, control of one or more of the factors mentioned above, among others, may be based on a computer model, operator feedback, or automatic feedback (for example, based on real-time sensor signals). A controller can be operatively coupled (eg, by wire or wireless connection) to the magnetic rotors to dynamically adjust the tension in the metal strip, the speed of the metal strip, or other aspects of the movement of the metal strip through the heat treatment line.

[0040] The control of the magnetic rotors can allow the control of the tension in the metallic strip. In some cases, controlling the magnetic rotors may allow controlling the speed of movement of the metal strip in a downstream direction. In some cases, precise voltage and/or speed control can be used to facilitate desirable heat treatment, for example by controlling the amount of time a metal strip spends in a heating and/or cooling zone or, more specifically, the amount of time the metallic strip spends at a desired temperature (eg, a solubilization temperature).

[0041] The magnetic rotors can rotate in the "downstream" direction or in the "upstream" direction. As used herein, a magnetic rotor rotating in a downstream direction rotates such that the surface of the magnetic rotor closest to the metallic strip at any point in time is moving in the direction of travel of the metallic strip (e.g., from generally in the downstream direction). For example, looking at a strip of metal from the side with the strip of metal moving in its longitudinal direction of displacement to the right, a magnetic rotor positioned above the strip of metal that rotates in a downstream direction can rotate counterclockwise. counterclockwise while a magnetic rotor positioned below the metal strip and rotating in a downstream direction can rotate clockwise. As used herein, a magnetic rotor rotating in an upstream direction rotates such that the surface of the magnetic rotor closest to the metallic strip at any point in time is moving in the opposite direction to the course of the metallic strip (e.g., from generally in the upstream direction). For example, looking at a metal strip from the side with the metal strip moving in its longitudinal direction of displacement to the right, a magnetic rotor positioned above the metal strip that rotates in an upstream direction can rotate clockwise while a magnetic rotor positioned below the metal strip and rotating in an upstream direction can rotate counterclockwise.

[0042] In a heating zone, the metal strip can be rapidly heated to a desired temperature, such as an annealing temperature or a solubilization temperature. For example, for certain aluminum alloys, the heating zone can heat the metallic strip to temperatures between 400°C and 600°C, or more specifically to temperatures equal to or less than approximately 560°C, 565°C, 570°C , 575 °C, 580 °C, 585 °C, 590 °C, 595 or 600 °C and, even more desirably, at approximately 565 °C. In some cases, for certain aluminum alloys, the heating zone can heat the metal strip to temperatures between approximately 500 °C and 560 °C. The metal strip can be levitated and/or supported by an array of magnetic rotors within the heating zone. In some cases, however, one or more pairs of magnetic rotors can be used to simultaneously levitate and heat the metal strip. A pair of magnetic rotors may include an upper rotor positioned opposite the metal strip from a lower rotor. A gap can be defined between the pair of magnetic rotors. In some cases, a single pair of magnetic rotors may be capable of raising the temperature of the metal strip by approximately 40 °C to approximately 80 °C, approximately 50 °C to approximately 70 °C, approximately 60 °C to approximately 70 °C, or approximately 70 °C. In some cases, a pair of magnetic rotors has the ability to achieve these temperature increases as the metal strip passes through the magnetic rotors at speeds of approximately 40 to 80 m/min, approximately 50 to 70 m/min or approximately 60 m /min. Precise control of the temperature rise in the metallic strip can be achieved by controlling the alternating magnetic field, such as by adjusting the rotational speed of the magnetic rotors or the size of the gap between the magnetic rotors of the pair of magnetic rotors. Several pairs of magnetic rotors can be used sequentially to obtain a desired temperature rise. As used herein, reference to a metal strip temperature may include a metal peak temperature of the metal strip. The heating zone can include magnetic rotors to heat the metallic strip and, optionally, additional magnetic rotors to levitate the metallic strip. Magnetic rotors used specifically to levitate the metallic strip can provide some degree of heating for the metallic strip.

[0043] In some cases, additional heating devices may be used in the heating zone, except magnetic rotors, in place of magnetic rotor pairs or in addition to magnetic rotor pairs. Examples of additional heating devices might include induction coils, direct flame impact devices, hot gas devices, infrared devices or the like. In some cases, additional heating devices can provide supplemental heat to the metallic strip to reach a desired temperature and/or to maintain a more uniform temperature distribution along a lateral width of the metallic strip. For example, in some cases where magnetic rotors heat the metallic strip, hot and/or cold spots may exist on the metallic strip after passing the magnetic rotors, when supplemental heating devices can be used to heat the cold spots temperature distribution across the lateral width of the metal strip. In some examples, cooling devices can be used to cool hot spots to even out the temperature distribution across the lateral width of the metal strip.

[0044] In some cases, non-rotating electromagnets may be used in the heating zone in addition to or instead of magnetic rotors. However, the use of magnetic rotors, as opposed to stationary electromagnets, to generate varying magnetic fields can provide greater efficiency as well as more uniform heating of the metal strip. The use of stationary electromagnets to vary the inductive fields transmitted across the width of the metallic strip can generate localized hot spots in the metallic strip. Inductive fields of various strengths can be caused by the natural variation in the windings of different stationary electromagnets. Variations in electromagnetic windings can result in some locations generating more heat than adjacent lateral locations. Localized hot spots can deform the metallic strip unevenly and cause other manufacturing defects. On the other hand, although permanent magnets may include some level of inherent magnetic variance across dimensions or from one magnet to another, some or all of these variations may be calculated automatically due to the rotation of magnetic sources in the magnetic rotor. No single permanent magnet is being held in any laterally stationary position and therefore an average magnetic field is applied by the rotating permanent magnets. In this way, the rotating magnetic rotor has the ability to heat the metal strip uniformly in a more controlled manner. When electromagnets are used in a rotating magnetic heater, variations between different electromagnets can be calculated out due to the rotation of the magnetic rotor. This average of variations does not occur with stationary electromagnets.

[0045] A soaking zone may include a soaking kiln, such as a tunnel kiln or other suitable kiln. Within the soaking zone, the metal strip can be maintained at a desired temperature (e.g., solubilization temperature) for a desired period. Maintaining the temperature at the desired temperature may include maintaining the temperature within 6%, 7%, 8%, 9%, 10%, 11% or 12% of the desired temperature, but preferably within 0.5%, 1%, 1.5%, 2%, 3%, 4%, 5% or 6% of the desired temperature. The desired duration may depend on the alloy used, the type of result desired, and previous mechanical thermal processing steps, such as the way the metal article is shaped or any hot or cold rolling performed on the metal article. For example, continuously cast metal articles may have the ability to obtain desirable results using a much shorter duration than a chilled direct cast metal article. In some instances, the metal strip can be soaked for a duration of between about 0 and about 40 seconds, or longer. In some cases, certain aspects and features of the present disclosure are especially useful with continuously cast metallic articles. In some cases, a soaking zone can also facilitate placing the metal strip at the desired temperature.

[0046] Any suitable oven can be used in the soaking zone to maintain the peak metal temperature of the metal strip, such as a hot air oven, an oven based on a magnetic rotor, an infrared oven or a combination thereof . For example, the soaking furnace can use heated gas to maintain the temperature of the metal strip. In some cases, an arrangement of magnetic rotors can be used in addition to or instead of heated gas to provide enough heat into the metallic strip to maintain the temperature of the metallic strip at the desired temperature.

[0047] The embedding zone may include an arrangement of magnetic rotors to levitate the metallic strip within the embedding zone. The arrangement of magnetic rotors can transmit some degree of heat to the metallic strip. In some cases, this transmitted heat can be used to maintain the temperature of the metal strip at the desired temperature. In some cases, such as if the magnetic rotors generate too much heat, the transmitted heat can be compensated for by using one or more cooling devices in the soaking zone. Examples of suitable cooling devices include controllable cooling heads or cooling nozzles for dispensing a coolant (eg liquid or gas) onto the metal strip. The coolant can be dispensed at any temperature at or below the desired temperature to be maintained on the metallic strip within the soaking zone. The quench devices can be controlled to distribute coolant as needed to facilitate maintaining the temperature of the metal strip at the desired temperature throughout the soaking zone. In some cases, the embedding zone may be approximately 50 m, 40 m, 30 m, 20 m, 15 m, 10 m or 5 m in length or less.

[0048] In some cases, the embedding zone may include a gas-filled chamber through which the metal strip passes. The gas-filled chamber can be large enough (eg in height) to enclose any surrounding magnetic rotors used to levitate the metal strip. However, the gas-filled chamber may preferably be small enough in height to surround the metal strip without surrounding any surrounding magnetic rotors. In some cases, the gas-filled chamber is approximately 50 to 250 mm high, such as 50 to 200 mm or 100 mm, or anywhere in between. In some cases, the gas-filled chamber can be approximately 250 mm high or more. The gas-filled chamber may include chamber walls, such as a top wall and a bottom wall, as well as side walls, allowing the metal strip to be continuously fed into an upstream end of the chamber and continuously fed from a downstream end. of the chamber. Chamber walls can be made of a non-conductive, heat-resistant material, such as Kevlar® or other para-aramids, or NOMEX® or other meta-aramids. The chamber walls, and more specifically the bottom wall, can be positioned between the metallic strip and the magnetic rotors used to levitate the metallic strip within the embedding zone.

[0049] The chamber may include one or more ports for supplying the chamber with gas from a gas supply. In some cases, ports can be arranged to allow gas flowing into the chamber to provide additional support for levitating the metal strip. In some cases, the gas supply may feed gas into the chamber through one or more ends of the chamber. In some cases, an inert gas (eg nitrogen or argon) or minimally reactive gas (eg dry air) can be used inside the chamber. In some cases, other gases can be used, such as treatment gases (eg methane or a silane gas to induce passivation of the metal strip surface). In some cases, the gas may be preheated to a desirable temperature to facilitate maintaining the desired temperature of the metallic strip within the soaking zone, however, in some cases the gas may be minimally preheated or not preheated at all. . In some cases, hot gases can be supplied to supplement the heating of the rotating magnets. These hot gases can be inert or minimally reactive gases. Hot gases can be supplied through ports directed to regions of the metal strip where magnetic heating does not fully heat the metal strip. Hot gases can facilitate temperature equalization in the metallic article as well as provide an inert or minimally reactive atmosphere within the chamber.

[0050] In some cases, the chamber extends for a length that is equal to or approximately equal to the length of the embedding zone. In some cases, the chamber may extend at least partially into the heating zone. For example, in some cases, the metallic strip may be located within the chamber when it is heated by some or all of the pairs of magnetic rotors in the heating zone.

[0051] In some cases, especially when the temperature distribution across the lateral width of the metal strip is very uniform when leaving the heating zone, the heat treatment line may not include any soaking furnace. In such cases, the soaking zone may extend from a heating zone to a quenching zone with the metal strip exposed to ambient air and/or ambient temperature. A series of magnetic rotors can even be used to levitate the metal strip as it passes between the heating zone and the quenching zone. A soaking zone without a soaking oven can also have a duration depending on the speed of movement of the metal strip and the length between the heating zone and the quenching zone.

[0052] In a quench zone, coolant may be supplied to the metallic strip in any suitable manner, such as by means of a quench tank or bath or through the use of one or more cooling heads or nozzles (for example, linear nozzles) to deliver coolant to the metallic strip. Any suitable refrigerant can be used, such as a liquid (eg water), a gas (eg air) or a combination of the two. As used herein, supplying coolant can include delivering coolant to a metal strip or passing a metal strip through coolant. Coolant may be supplied sufficiently to rapidly cool the metal strip's peak metal temperature, such as at speeds between approximately 50 °C/sec and 400 °C/sec, approximately 100 °C/sec and 300 °C/sec, and approximately 200 °C/s. In some cases, the metallic strip is rapidly cooled at rates greater than at least 200 °C/s. In some cases, the metallic strip can be quenched to a temperature of approximately 250°C, although other temperatures can be used, such as temperature between approximately 50°C and 500°C or between approximately 200°C and 500°C. Control over the quench that occurs in the quench zone can be achieved by controlling the temperature and/or distribution of the refrigerant. For example, valves associated (eg, attached) to cooling heads and/or nozzles can provide control over refrigerant delivery. In some cases, coolant heads or nozzles may be adjustable as a single unit across a side width of the metal strip, or individually adjustable at different locations along the side width of the metal strip (e.g. to deliver more coolant to certain parts of the metal strip than other portions).

[0053] The controller (or controllers) and sensor (or sensors) (for example, non-contact temperature sensors) may be used at any suitable location along the heat treatment line to provide feedback control for the heat treatment line . Suitable locations may include within, adjacent to, upstream or downstream of one or more of any of the zones or elements of the heat treatment line. Any suitable controllers and/or sensors can be used. For example, temperature sensors located in, adjacent to, or immediately downstream of the heating zone can provide temperature information (e.g., signals) to a controller, which can use the temperature information to control any controllable aspect of the heating zone. heating such as speeds and/or space height of magnetic rotor pairs. Likewise, temperature sensors located within, adjacent to, or immediately downstream of the soak zone may provide temperature information (e.g. signals) to a controller (e.g. the same or a different controller), which may use the information temperature controls to control any aspects of the soak zone, such as valves associated with coolant nozzles or coolant heads in the soak zone. In another example, flatness sensors can be used after the quench zone to provide flatness information (e.g. signals) to a controller (e.g. the same or a different controller), which can then use the flatness information to improve the flatness of the metallic strip, such as by controlling valves associated with cooling nozzles or cooling heads in the quench zone.

[0054] In some cases, one or more coolant removal devices may be used to remove residual coolant from the metal strip as it exits the quench zone. Examples of suitable refrigerant removal devices include squeegees (such as rubber squeegees), air knives, or other contact or non-contact refrigerant removal devices.

[0055] An arrangement of magnetic rotors can be used to levitate the metal strip while within the quench zone.

[0056] An unwinder may be used upstream of the heating zone to unwind or unwind a metal strip from an incoming coil (eg a coil of metal strip to be passed through the heat treatment line). In some cases, the unwinder may feed the metal strip through an unwind cylinder before the metal strip enters the heating zone. The decapping cylinder may include load cells to determine a tension in the metal strip. Load cells can be coupled to one or more controllers to provide feedback that can be used by the controllers to adjust the voltage on the metal strip as needed. The metallic strip coming out of the unwinder can be fed directly into a heating zone or it can be first fed into a tension adjustment zone. Magnetic rotors can be used to control the tension on the metal strip in the heating zone or in the tension adjustment zone. For example, a magnetic rotor rotating in a downstream direction can apply downstream force on the metallic strip, while a magnetic rotor rotating in an upstream direction can apply upstream force on the metallic strip. Multiple longitudinally separated (eg, sequentially separated) magnetic rotors can neutralize some or all of the stresses induced in the metal strip by each other. For example, a first magnetic rotor that rotates to induce longitudinal stress in a metal strip can be separated from a second magnetic rotor that rotates in an opposite direction, so that longitudinal stress can be reduced or eliminated. In this way, the tension in the metallic strip can be controlled by controlling the magnetic rotors, as described in this document (for example, by adjusting the position, speed, direction, resistance, distance between the opposing rotors of a pair of magnetic rotors and other parameters). When a tension adjustment zone is used, the tension adjustment zone may include an array of magnetic rotors used to levitate the metal strip. In some cases, the voltage adjustment zone includes pairs of magnetic rotors designed to impart voltage changes in the metallic strip without significantly heating the metallic strip, such as through the use of multiple laterally separated magnetic sources in a single magnetic rotor where the magnetic sources occupy less or substantially less space than the full width of the magnetic rotor. In the tension adjustment zone, the tension in the metal strip can be gradually decreased from a starting voltage (for example, between the unwinder and the beginning of the tension adjustment zone) to a low tension that can be especially desirable for heat treatment. .

[0057] In some cases, there is a welding zone or junction between the unwinder and the heating zone. In some cases, the solder or joint zone may form part of the voltage adjustment zone. In the welding or joining zone, a mobile welder or other joining device can be used to weld or join the ends of metal strips (for example, a metal strip that is processed and a subsequent metal strip) quickly, while the metal strips are travel through the heat treatment line. Although magnetic rotors can be used to levitate the ends of metal strips and drive the ends of metal strips, other equipment such as contact rolls and conveyors can also be used. Since the trailing end of the metal strip being processed is unwound from the input spool, a leading end of a subsequent metal strip can be unwound from its own input spool (e.g. with the use of a second unwinder) and routed to the rear end of the metal strip. In the welding or joining zone, the front end of the subsequent metal strip and the rear end of the metal strip can be joined together in a joint. The use of magnetic rotors or contacting devices (eg cylinders or conveyors) can help keep the ends of metal strips together or close together. As the metal strips move in the downstream direction, a weldment or other joining device can be moved in the same downstream direction and at the same speed as the metal strips, allowing the welding or other joining device to remain aligned with the weldment. or otherwise joins the board. Any suitable joining device can be used, such as arc welding apparatus (e.g. gas metal arc welding apparatus or gas tungsten arc welding apparatus), fuel-based welding apparatus (e.g. oxyhydrogen welding apparatus) or other welders or joining devices. The solder or joint device may run along a set of rails or may otherwise be suspended above or below the metal strip. In some cases, the welding or jointing device can weld/join an entire side width of metal strip at one time. In some cases, the solder or joint device may also shift laterally as it welds/joins the metal strip. Since magnetic rotors have the ability to control the speed of movement of the metal strip, magnetic rotors can slow down the speed of movement of the metal strip during a welding or joining process. For example, under normal operating conditions, the metal strip can pass through the heat treatment line at speeds of around 60 m/min, while during welding/joining, the metal strip can travel at speeds of approximately 5 m/min. at 20 m/min, approximately 7 m/min to 15 m/min, or approximately 10 m/min.

[0058] In some cases, the heat treatment system may include a leveling and/or microtexturing zone. The leveling and/or microtexturing zone may include one or more rollers in addition to those through which the metal strip is passed to level and/or texturize the metal strip. The metal strip can pass through a gap between a pair of leveling and/or microtexturing rollers. In some cases, the flattening and/or microtexturing rollers may apply force to the metallic strip sufficient to flatten and/or texturize the metallic strip, but insufficient to reduce the overall thickness of the metallic strip (e.g., reducing the thickness of the strip metallic at or less than 0.5%, 0.6%, 0.7%, 0.8%, 0.9% or 1%). For example, the amount of force applied through the leveling and/or microtexturing cylinders may be below the yield strength of the metal strip. In some cases, force is applied through each leveling and/or microtexturing cylinder from one or more work cylinders. In some cases, the microtexture cylinder may have at least two different textures, which may or may not overlap. In some cases, a controller can be used to adjust the leveling and/or microtexturing cylinders to produce a desired leveling and/or microtexturing result.

[0059] In some cases, the heat treatment line may include a coating and/or lubrication zone. The coating and/or lubrication zone can be located downstream of the quench zone. In some cases, the coating and/or lubrication zone may be located downstream of a leveling and/or microtexturing zone. In the coating and/or lubrication zone, a coating and/or lubrication can be applied to the metal strip. A coating and/or lubrication can be applied by any suitable technique, such as spray coating, roll coating, lamination or other techniques.

[0060] In some cases, the heat treatment line may include a reheat zone. In some cases, the reheating zone is located downstream of a leveling and/or microtexturing zone. In some cases, the reheat zone is located downstream of a coating and/or lubrication zone. The reheat zone may include one or more heating devices to raise the temperature of the metal strip after cooling in the quench zone. In some cases, one or more heating devices may include an array of magnetic rotors used to heat the metal strip. In some cases, the reheat zone may include an array of magnetic rotors (e.g., the same array for heating the metal strip or another arrangement) to levitate the metal strip through the reheat zone. In some cases, when a reheat zone is positioned downstream of a coating and/or lubrication zone, the reheat zone can be used to cure a coating and/or facilitate the flow of lubricant applied to the coating and/or lubrication zone. lubrication, such as heating the metal strip sufficiently to cure the coating and/or facilitate lubricant flow from the heat of the metal strip. Heating the metal strip coating and/or lubricant can reduce the likelihood of damaging the coating or lubricant, as can happen if overheating occurs, a hazard in today's gas ovens. In some cases, the reheat zone may raise the temperature of the metallic strip to a pre-aging or artificial aging temperature in preparation for winding the metallic strip onto a final coil and aging the metallic strip while being wound. Such a pre-aging or artificial aging temperature may be a temperature from about 60°C to about 150°C. For example, the pre-aging treatment can be carried out at a temperature of about 60°C, 65°C, 70°C, about 75°C, about 80°C, about 85°C, about 90°C, around 95°C, around 100°C, around 105°C, around 110°C, around 115°C, around 120°C, around 125°C, around 130° C, about 135°C, about 140°C, about 145°C, or about 150°C.

[0061] The heat treatment line may include a winder used to wind or wind the metal strip into a final coil (for example, a coil of heat-treated metal strip). The winder can be positioned at the downstream end of the heat treatment line. In some cases, such as when a mobile welding/joining apparatus is used to provide continuous heat treatment of consecutive metallic strips, the winder may include a cutter to cut the metallic strip, allowing the subsequent metallic strip to be wound separately from the metallic strip. The cutter may include feedback equipment (eg cameras, distance sensors or other sensors) to ensure that the metal strips are separated as close to the joint as possible.

[0062] In some cases, a final tension adjustment zone can be located immediately upstream of the winder. The final tension adjustment zone may include a series of magnetic rotors to levitate the metallic strip and help adjust the tension in the metallic strip prior to winding the metallic strip. For example, while the magnetic rotors along the heat treatment line may attempt to minimize the stress on the metal strip, at least within the heating zone, the final voltage adjustment zone may increase the stress as the metal strip enters the winder. In some cases, the winder may work better when at least a minimal amount of tension is on the metal strip.

[0063] In some cases, magnetic rotors positioned along the heat treatment line can be used to facilitate the passage of a metal strip in the heat treatment line. Rotation of the magnetic rotors in a downstream direction can act to increase the tension in the metallic strip and levitate the free end of the metallic strip above any equipment or structure below the metallic strip. In some cases, the free end of the metal strip can be guided through the heat treatment line by any suitable technique. In some cases, a conveyor may be slidably located on rails that extend past some or all of the heat treatment line. The carriage can hold the free end of the metal strip and help guide it through the heat treatment line, while rotating magnets levitate the metal strip. Since the metal strip is levitated through the heat treatment line, it is possible to pass the entire heat treatment line with much less scraping of the metal strip than would be possible with conventional technology.

[0064] After the pass has been completed, at least some of the magnetic rotors can reverse in the direction of rotation to rotate in an upstream direction, thereby helping to minimize stresses in the metal strip. The ability of the magnetic rotors to reverse direction provides significant benefits to the ability for a metallic strip to be passed through the heat treatment line.

[0065] In some cases, the passage can be facilitated by turning the upper magnetic rotors in a pair of magnetic rotors at a speed slightly greater than the speed of the lower magnetic rotors. This excess speed can help counteract the gravitational pull on the free end of the metal strip. In some cases, other techniques, such as forced air, can be used to counteract the gravitational pull on the free end of the metal strip to prevent the metal strip from bending around one of the magnetic rotors.

[0066] Certain aspects of a heat treatment line as disclosed in this document can provide for the transportation, levitation and heating of metallic strips in a non-contact manner - without coming into contact with the metallic strip or with minimal contact with the metallic strip .

[0067] As used herein, the terms "above", "below", "top", "bottom", "vertical" and "horizontal" are used to describe relative orientations in relation to a metallic article, such as strip metallic, as if the metallic article were moving in a horizontal direction with its top and bottom surfaces generally parallel to the ground. The term "vertical" as used herein may refer to a direction perpendicular to a surface (eg, top or bottom surface) of the metal article, regardless of the orientation of the metal article. The term "horizontal", as used herein, may refer to a direction parallel to a surface (e.g., top or bottom surface) of the metal article, such as a direction parallel to the direction of travel of a metal article. moving, regardless of the orientation of the metallic article. The terms "above" and "below" may refer to locations beyond the top or bottom surfaces of a metallic article, regardless of the orientation of the metallic article. However, when used with reference specifically to magnetic levitation, the term "below" can refer to locations closer to Earth's gravitational pull. A metal strip can be processed in any suitable direction, including horizontal, vertical, or other directions such as diagonal.

[0068] As used herein, the terms vertical, longitudinal and lateral may be used with reference to the metallic article to be heated. The longitudinal direction may extend along a direction of travel of a metallic article through processing equipment, such as along a pass line through a continuous annealing solution heat treatment (CASH) line. The longitudinal direction may be parallel to the top and bottom surfaces of the metallic article. The longitudinal direction can be perpendicular to the lateral direction and the vertical direction. The lateral direction may extend between the lateral edges of the metallic article. The lateral direction can extend in a direction perpendicular to the longitudinal direction and the vertical direction. The vertical direction may extend between the top and bottom surfaces of the metallic article. The vertical direction can be perpendicular to the longitudinal direction and the lateral direction.

[0069] Certain aspects and features of the present disclosure may be used with any suitable metallic articles, such as in the form of metallic sheets, sheets, strips, plates, plates, planks or other metallic articles. However, it may be preferable to use various aspects and features of the present disclosure with metallic strips. Aspects and features of the present disclosure may be especially suitable for any metallic article that has flat surfaces (e.g. flat top and bottom surfaces). Aspects and features of the present disclosure may be especially suitable for any metallic product with approximately parallel parallel or opposing surfaces (e.g., top and bottom surfaces). Approximately parallel may include parallel to or within 1°, 2°, 3°, 4°, 5°, 6°, 7°, 8°, 9° or 10° of parallel, or the like, as appropriate.

[0070] Aspects and features of the present disclosure may be used with metallic articles of any suitable metal. In some cases, the metallic article is aluminum, such as an aluminum alloy. In some cases, the metallic article may be an iron-containing aluminum alloy. Certain aspects and features of the present disclosure may be especially suitable for use with 6xxx or 5xxx series aluminum alloys, although other alloys such as 1xxx, 2xxx, 3xxx, 4xxx, 7xxx or 8xxx series alloys may be used. The 6xxx and 5xxx series aluminum alloys can have conductivity of approximately 10,000,000 Siemens per meter (10 MS/m). In some cases, alloys with higher conductivities, such as 15 MS/m or 20 MS/m, may result in less effective heating through rotating magnets, due, at least in part, to the generation of lower secondary magnetic flux (e.g. , magnetic flux generated by the metallic article) to oppose the primary flux (e.g., magnetic flux generated by rotating magnets).

[0071] The magnetic rotors can be positioned above or below the metallic article (for example, above or below the pass line or above or below the chamber). As used herein, reference to an element that is positioned relative to the metal article may refer to such element being positioned relative to a line of passage (e.g., the desired line of passage along which the article metallic is desired), as appropriate. In some cases, the set of magnetic rotors for heating the metallic article may include magnetic rotors positioned both below and above the metallic article. In some cases, these magnetic rotors are placed in matched pairs, with similar magnetic rotors (e.g., similar or the same size, strength, rotation speed and/or direction of rotation upstream or downstream) positioned directly opposite the line of rotation. pass each other. When opposing magnetic rotors are placed on opposite sides of the metallic article and rotating in the same direction downstream or upstream, whereby one of the two magnetic rotors can rotate clockwise while the other of the two magnetic rotors can rotate in the opposite direction. counterclockwise.

[0072] Magnetic rotors may have a length that is approximately equal to or greater than the width of the metallic article, whereas magnetic sources have a length that is approximately equal to or greater than the width of the metallic article. In some cases, the magnetic rotors and/or the magnetic sources used for heating can be laterally displaced to occupy less than 100% of the lateral width of the metal strip. Magnetic rotors and/or magnetic sources in magnetic rotors used for levitation (e.g. magnetic rotors in the embedding zone) may occupy less than 100% of the side width of the metal strip, such as at or less than approximately 95%, 90% , 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15% or 10% of the width side of the metal strip. In some cases, a single magnetic rotor in the embedded zone can house two or more magnetic sources laterally separated from each other. In some cases, the lateral position of magnetic sources within sequential magnetic rotors (eg longitudinally separated and sequential magnetic rotors) used for levitation can be offset from each other, resulting in a staggered arrangement of magnetic sources. The staggered nature of magnetic sources can help minimize unwanted and uneven heating during strip levitation.

[0073] In some cases, a series of magnetic rotors to levitate the metal strip can be positioned just below the metal strip, although this is not necessary. In some cases, magnetic rotors can be positioned above the metallic strip to assist in directing or driving the metallic strip. For example, magnetic rotors can be placed at or near the edges of the metal strip, including just the edges of the metal strip, and rotated along an axis of rotation parallel to the longitudinal axis of the metal strip to induce forces toward a longitudinal centerline of the desired path through the heat treatment line or any specific zone or equipment. These magnetic rotors can facilitate the centering of the metallic strip. These magnetic centering rotors can be placed in any suitable location. In some cases, magnetic centering rotors can be used to stabilize the metal strip, especially when under low stress (e.g. within the heating zone and/or the embedding zone) or when the metal strip is under compression ( e.g. adjacent to the unwinder and winders).

[0074] In some cases, when magnetic rotors are used below and above the metallic strip, the magnetic rotors positioned above the metallic strip can be actuated between a closed position and an open position. In the closed position, the magnetic rotors and, optionally, the upper walls of the chamber (eg in the soaking zone), can be in position for normal operation. In the open position, any top magnetic rotor and/or upper chamber walls (e.g. in the embedding zone) can be moved away from a normal operating position to provide more space for a metal strip to be loaded or passed in the feed line. heat treatment. Once the metallic strip has been loaded, any top magnetic rotors and/or any upper chamber walls can be moved back to the closed position for normal operation.

[0075] In some cases, magnetic flux focusing elements can be used adjacent to the magnetic rotors to redirect the magnetic flux to the opposite direction or to certain regions. A magnetic flux focusing element can be any suitable material with the ability to redirect magnetic flux, including magnetic flux concentration. Magnetic flux focusing elements can receive magnetic flux from magnetic sources on the magnetic rotors that are not close to or directly facing the article and redirect that magnetic flux toward the article (e.g., in a direction perpendicular to a top surface or background of the article). Magnetic flux focusing elements can also provide the benefit of providing magnetic shielding between the magnetic rotor and adjacent equipment other than the metallic article that is heated. For example, magnetic flux focusing elements can allow adjacent, longitudinally shifted magnetic rotors to be placed closer together with less magnetic interaction between the two. The magnetic flux focusing elements can be made of any suitable material, including silicon alloy steel (eg electrical steel). A magnetic flux focusing element can comprise multiple laminations. The magnetic flux focusing elements can be flux diverters, flux controllers or flux concentrators. When magnetic flux focusing elements are used, the magnetic rotors may have the ability to achieve effective results at lower rotational speeds and the magnets may have the ability to be placed further away from the metallic article.

[0076] Certain aspects and features of the present disclosure provide a heat treatment line with the ability to provide heating faster than conventional ovens, such as approximately five times faster than conventional ovens, and with high energy efficiency (eg approximately 80% effective). Additionally, magnetic rotors can provide nearly instantaneous on/off heat control. Additionally, certain aspects and features of the present disclosure provide for the ability to float the metallic strip along most, if not all, of the heat treatment line, including at least during heating and/or soaking of the metallic strip, optimizing , therefore, the quality of the surface. Certain aspects and features of the present disclosure also have the capacity to provide several benefits in a very compact size. Not only can the longitudinal length of the heat treatment line be minimized due to rapid magnetic heating, but magnetic heating and magnetic levitation can allow a chamber containing the inert atmosphere to be made very small, thereby improving the efficiency of using energy. gas. In some cases, certain aspects and features of the present disclosure have the ability to provide other metallurgical benefits to the metallic strip, such as reduced surface oxidation and faster dissolution or redistribution of intermetallic phases. In some cases, certain aspects and features of the present disclosure have the ability to minimize undesirable magnesium migration during certain heating processes.

[0077] In this descriptive report, reference is made to alloys identified by AA numbers and other related designations, such as "series" or "7xxx". For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot", both published by The Aluminum Association.

[0078] As used in this document, the term board generally refers to a thickness in the range of 5 mm to 50 mm. For example, a plate can refer to an aluminum product with a thickness of 5mm, 10mm, 15mm, 20mm, 25mm, 30mm, 35mm, 40mm, 45mm or 50mm.

[0079] As used herein, a plank (also called sheet board) generally has a thickness of about 4 mm to about 15 mm. For example, a board may have a thickness of about 4mm, about 5mm, about 6mm, about 7mm, about 8mm, about 9mm, about 10mm, about 11mm, about 12mm, about 13mm, about 14mm or about 15mm.

[0080] As used herein, a sheet generally refers to an aluminum product with a thickness of less than about 4 mm. For example, a sheet can have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, less than about 0.3 mm, or less than about 0.1 mm.

[0081] Reference is made in this application to temper or alloy condition. For an understanding of the most commonly used alloy temper descriptions, see "American National Standards Institute (ANSI) H35 on Alloy and Temper Designation Systems". An F condition or temper refers to an aluminum alloy as manufactured. A condition or temper O refers to an aluminum alloy after annealing. A T4 condition or temper refers to an aluminum alloy after solution heat treatment (ie, solubilization) followed by natural aging. A T6 condition or temper refers to an aluminum alloy solution after solution heat treatment by artificial aging. A T7 condition or temper refers to an aluminum alloy after solution heat treatment and then followed by superaging or stabilization. A T8 condition or temper refers to an aluminum alloy after solution heat treatment, followed by cold working and then artificial aging. A T9 condition or temper refers to an aluminum alloy after solution heat treatment, followed by artificial aging and then cold working. An H1 condition or temper refers to an aluminum alloy after strain hardening. An H2 condition or temper refers to an aluminum alloy after strain hardening followed by partial annealing. An H3 condition or temper refers to an aluminum alloy after strain hardening and stabilization. A second digit following the HX condition or temper (for example, H1X) indicates the final degree of strain hardening.

[0082] As used herein, the meaning of "ambient temperature" may include a temperature of about 15 °C to about 30 °C, for example, about 15 °C, about 16 °C, about 17°C, around 18°C, around 19°C, around 20°C, around 21°C, around 22°C, around 23°C, around 24°C, around 25° C, about 26°C, about 27°C, about 28°C, about 29°C or about 30°C. As used herein, the meaning of "environmental conditions" may include temperatures close to ambient temperature, relative humidity from about 20% to about 100%, and barometric pressure of about 97.5 kPa (975 millibar (mbar)) at about 105 kPa (1050 mbar). For example, the relative humidity might be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about of 98%, about 99%, or about 100%, or anywhere in between. For example, the barometric pressure can be about 97.5 kPa (975 mbar), about 98 kPa (980 mbar), about 98.5 kPa (985 mbar), about 99 kPa (990 mbar), about of 99.5 kPa (995 mbar), about 100 kPa (1,000 mbar), about 100.5 kPa (1,005 mbar), about 101 kPa (1,010 mbar), about 101.5 kPa (1,015 mbar), about 102 kPa (1020 mbar), about 102.5 kPa (1025 mbar), about 103 kPa (1030 mbar), about 103.5 kPa (1035 mbar), about 104 kPa (1040 mbar), about 104.5 kPa (1045 mbar), about 105 kPa (1050 mbar), or anywhere in between. Environmental conditions can vary depending on location, so what is "environment" in one location may be different from what is "environment" in another location. Thus, the environment is not a fixed temperature or a defined range.

[0083] All ranges disclosed herein shall be understood to encompass any and all subranges included therein. For example, a stated range of "1 to 10" includes any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges that start with a minimum value of 1 or more, for example, 1 to 6.1, and that end with a maximum value of 10 or less, for example, 5.5 to 10. Unless otherwise noted , the phrase "up to" when referring to the composition amount of an element means that the element is optional and includes zero percent composition of that particular element. Unless otherwise noted, all composition percentages are in percent by weight (% by weight).

[0084] As used herein, the meaning of "an", "an", "the" and "the" includes singular and plural references, unless the context clearly indicates otherwise.

[0085] The alloys described herein can be cast using any suitable casting method known to those skilled in the art. As some non-limiting examples, the casting process can include a direct coolant (DC) casting process or a continuous casting (DC) process. The continuous casting system may include a pair of moving opposing casting surfaces (eg moving opposing belts, cylinders or blocks), a casting cavity between the moving pair of opposing casting surfaces, and a molten nozzle. The molten metal injector may have an end opening from which molten metal can exit the molten metal injector and be injected into the pouring cavity. In some cases, aspects of the present disclosure may be especially suited for use with a continuous cast metal article.

[0086] The aluminum alloy products described in this document may be used in automotive applications and other transportation applications, including aircraft and rail applications, or any other suitable application. For example, the disclosed aluminum alloy products can be used to prepare automotive structural parts such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g. A-pillars, B-pillars and C-pillars) , inner panels, outer panels, side panels, inner covers, outer covers, or trunk lid panels. The aluminum alloy products and methods described herein can also be used in aircraft and rail vehicle applications, to prepare, for example, external and internal panels. Certain aspects and features of the present disclosure can provide metallic articles with improved surface qualities and metallurgy, which can result in an improved sizing ability and formability, which can be especially desirable for any of the applications mentioned herein, as well as others. .

[0087] The aluminum alloy products and methods described in this document can also be used in electronic applications. For example, the aluminum alloy products and methods described herein can be used to prepare housings for electronic devices, including cell phones and tablet computers. In some examples, aluminum alloy products can be used to prepare housings for the outer casing of mobile phones (eg smartphones), tabletop chassis and other portable electronic devices.

[0088] These illustrative examples are presented to introduce the reader to the general subject matter discussed in this document and are not intended to limit the scope of the concepts disclosed. The following sections describe various additional features and examples with reference to the drawings in which like numerals indicate like elements, and directional descriptions are used to describe the illustrative embodiments, but, like the illustrative embodiments, are not to be used to limit the present disclosure. . Elements included in the illustrations in this document may not be drawn to scale and certain dimensions may be exaggerated for illustrative purposes.

[0089] Figure 1 is a schematic representational diagram depicting a processing line 100 for continuous heat treatment in accordance with certain aspects of the present disclosure. The processing line 100 may be a heat treatment line for processing a metallic strip 120 or other metallic article. The metallic strip may proceed in a downstream direction 146 through various zones or elements of the processing line 100. In some cases, the processing line 100 includes each of the zones depicted in Figure 1, however, this need not be the case. case. Any suitable combination of zones can be used. In some cases, a processing line 100 includes at least one heating zone 106, a soaking zone 108, and a quench zone 110. In some cases, processing line 100 also includes at least one reheating zone 114. While the arrangement of zones and/or elements can be adjusted as needed, certain aspects of the present disclosure include the quench zone 110 immediately following the soak zone 108, which immediately follows the heating zone 106.

[0090] The metallic strip 120 may be initially unwound from a starting coil by an unwinder 102. The unwinder may pass the metallic strip 120 to a tension adjustment zone 104. Within the tension adjustment zone 104, a The magnetic rotor arrangement can levitate the metal strip 120 and control the tension in the metal strip. During a pass-through operation, the tension adjustment zone 104 can increase the tension in the metal strip 120 (e.g., increase the tension from left to right in the downstream direction 146), even during standard heat treatment processing, in that tension adjustment zone 104 can decrease (e.g., slow down) the tension in metal strip 120.

[0091] In some cases, a welding zone or junction 170 can be placed with the voltage adjustment zone. Welding or joining zone 170 may include a mobile welding apparatus or other joining device capable of welding or joining free ends of consecutive metal strips, allowing processing line 100 to operate continuously through multiple coils of metal strip 120 .

[0092] The metallic strip 120 may pass to a heating zone 106, in which one or more magnetic rotor arrangements may heat and levitate the metallic strip 120. The metallic strip 120 may be heated to a desired temperature, such as a temperature of solubilization. The metallic strip 120 leaving the heating zone 106 at the desired temperature may enter a soak zone 108, in which the temperature of the metallic strip 120 (e.g., metal peak temperature) is maintained at the desired temperature for a period ( for example, the duration of the soaking zone 108). One or more magnetic rotor arrangements can levitate the metallic strip 120 within the embedding zone 108, such as without the need for fluid-based levitation. In some cases, the soaking zone 108 may include a gas-filled chamber through which the metallic strip 120 passes, which may be filled with an inert gas, a minimally reactive gas, or a treatment gas.

[0093] After exiting the soaking zone 108, the metal strip 120 can enter a quench zone 110, in which the metal strip 120 can be rapidly quenched. Quench zone 110 may include one or more coolant nozzles to distribute the coolant into the metal strip. Additionally, an array of magnetic rotors can levitate the metal strip through quench zone 110. In some cases, a closed loop grading control system can be used in quench zone 110 that includes a sensor to measure the leveling and one or more controls for adjusting coolant distribution to achieve desired leveling. In some cases, a closed loop grading control system is downstream of quench zone 110.

[0094] The metallic strip 120 can pass through a leveling and/or microtexturing zone 112, which can be located downstream of a quenching zone 110. In the leveling and/or microtexturing zone 112, the metallic strip can pass between one or more sets of cylinders designed to level and/or texturize the metal strip 120, such as without significantly or substantially reducing the overall thickness of the metal strip 120. A series of magnetic rotors can levitate the metal strip 120 in the leveling zone and /or microtexturing 112 on the upstream and downstream side of the rollers, and can facilitate tension control of the metal strip 120 as it passes through the rollers.

[0095] The metallic strip 120 can pass through a coating and/or lubrication zone 113, which can be located downstream of the quench zone 110 and can be located downstream of a leveling and/or microtexturing zone 112. Upon passage through the coating and/or lubrication zone 113, the metal strip 120 may be coated with any suitable coating and/or lubricated with any suitable lubricant, such as a fluid or solid coating and/or lubricant. An array of magnetic rotors can levitate the metal strip 120 through the coating and/or lubrication zone 113.

[0096] The metallic strip 120 can pass through a reheating zone 114, which can be located downstream from the quench zone 110, can be located downstream from a leveling and/or microtexturing zone 112, and can be located from downstream of a coating and/or lubrication zone 113. In the reheat zone 114, the metal strip 120 may be heated, such as to a temperature for coiling, storage and/or aging. Any suitable heating device may be used, although in some cases, the reheat zone 114 includes an array of magnets that heat the metallic strip 120. One or more arrays of magnetic rotors, which may include the array of magnetic rotors for heating the metal strip 120, can levitate the metal strip 120 through the reheat zone 114. In some cases where the metal strip passes through a coating and/or lubrication zone 113, the reheat zone 114 can heat the metal strip 120 sufficiently to cure the coating and/or lubricant and/or facilitate flow so that it spreads evenly without overheating.

[0097] The metal strip 120 can be wound onto a final coil by a winder 118. The winder 118 can receive the heat-treated metal strip 120 directly from a quench zone 110, a reheat zone 114, a final tension adjustment 116, or any other appropriate zone. Magnetic rotors in the immediately upstream region, such as a final tension adjustment zone 116, can control the tension in the metallic strip 120. Generally speaking, these magnetic rotors can increase the tension in the metallic strip to facilitate winding by the winder 118. In some cases, the magnetic rotors can also step down the voltage if needed.

[0098] Figure 2 is a schematic diagram depicting a processing line 200 for continuous heat treatment in accordance with certain aspects of the present disclosure. Processing line 200 is an example of a processing line similar to processing line 100 of Figure 1. An unwinder 202 can unwind metallic strip 220 which can then be passed through a tension adjustment zone 204, a heating zone 206, a soaking zone 208, a quenching zone 210, a leveling and/or microtexturing zone 212, and a final tension adjustment zone 116, before being wound by a winder 218.

[0099] Next to the unwinder 202, an unwinding cylinder 222 can direct the metal strip 220 in the direction of a desired pass line through the processing line 200. The unwinding cylinder 222 can also include load cells for measuring tension in the metal strip 220. Unwind cylinder 222 can provide tension measurements to a controller 236, which can use the measurements to control magnetic rotors 224 of tension adjustment zone 204 to obtain a desirable tension in metal strip 220 suitable for unwinding. The tension adjustment zone 204 can also act to reduce the tension in the metal strip 220 so that sufficient tension is maintained upstream of the tension adjustment zone 204 for unwinding and low voltage is maintained downstream of the tension adjustment zone. 204 strain for improved heat treatment.

[00100] In the heating zone 206, the metallic strip 220 can pass through gaps between multiple pairs of magnetic rotors 226. As shown in Figure 2, the magnetic rotors 226 for heating can have a larger diameter than the magnetic rotors 224 used for heating. levitation or tension control. Magnetic rotors 226 for heating may have other differences from magnetic rotors 224 for levitation or voltage control, such as magnetic resistance, position, speed of rotation, flux concentrators, or other differences such as those described herein. As the metal strip 220 passes through the heating zone 206, the metal strip 220 can be heated and levitated by each of the magnetic rotors 226. Upon exiting the heating zone 206, the metal strip 220 can be at a temperature desired temperature, such as a solubilization temperature. Sensors in heating zone 206 can provide temperatures and/or other measurements to controller 236, which can use the measurements to adjust magnetic rotors 226 in heating zone 206 to obtain the desired temperature.

[00101] The metallic strip 220 can leave the heating zone 206 to a soaking zone 208, in which the metallic strip 220 can pass through a soaking oven 228. The soaking oven 228 can be a gas oven, oven hot air or other suitable oven to maintain the temperature of the metal strip 220. In some cases, the soaking oven 228 includes one or more magnetic rotors 224 to levitate the metal strip and optionally provide some heat to facilitate maintenance of the desired temperature. The soaking furnace 228 may be of sufficient length for the metal strip 220 to maintain the desired temperature for a desired time at the rate that the metal strip 220 moves through the soaking furnace 228 in the downstream direction 246. Soak oven 208 can provide temperature and/or other measurements to controller 236, which can use the measurements to adjust soak oven 228 to ensure that metal strip 220 is maintained at the desired temperature.

[00102] Upon leaving the soaking zone 208, the metallic strip 220 can enter the quenching zone 210. In the quenching zone 210, the metallic strip 220 can optionally be levitated by a series of magnetic rotors 224. quench 210, one or more coolant nozzles 230 can deliver coolant fluid 232 to metal strip 220 to rapidly quench metal strip 220. Sensors in quench zone 210 can provide temperature and/or other measurements to the controller 236, which can then adjust the coolant nozzles 230 to ensure that a desired quench rate is maintained. In some cases, a flatness sensor 234 may be positioned in or downstream of the quench zone 210. Measurements from the flatness sensor may be provided to the controller 236, which may use the measurements to adjust the coolant nozzles 230 to obtain a desired profile of the coolant 232 dispensing across the lateral width of the metal strip 220 which can improve the flatness of the metal strip 220.

[00103] The metallic strip 220 can pass through a leveling and/or microtexturing zone 112. In the leveling and/or microtexturing zone 112, the metallic strip 220 can pass between one or more sets of leveling and/or microtexturing cylinders 238. The leveling and/or microtexturing rollers 238 can impart a desirable texture to the surface of the metal strip 220 and/or facilitate the leveling of the metal strip 220. In some cases, sensors in the leveling and/or microtexturing zone 112 can provide feedback to controller 236, which can use the measurements to control leveling and/or microtexturing cylinders 238 to facilitate improved leveling of metal strip 220.

[00104] The metal strip 220 can pass through a reheat zone 214 in which the metal strip 220 can be heated by a set of magnetic rotors 226. The magnetic rotors 226 in the reheat zone 214 can be smaller or otherwise , different from the magnetic rotors 226 of the heating zone 206. In some cases, the magnetic rotors 226 in the reheat zone 214 may be identical to the magnetic rotors 224 used for levitation in other zones. Sensors in reheat zone 214 can provide temperature and/or other measurements to controller 236, which can use the measurements to adjust magnetic rotors 226 in reheat zone 214 to obtain a desired reheat temperature.

[00105] As shown in the processing line 200 of Figure 2, the reheating zone 214 also acts as a final voltage adjustment zone 216. The control of the magnetic rotors 226 of the reheating zone 214 can reheat the metallic strip 220 and control tension in the metal strip so as to obtain adequate tension for rewinding by winder 218. Metal strip 220 may pass through a winding cylinder 240 before being wound by winder 218. The winding cylinder 240 may provide measurements of voltage to a controller 236, which can adjust the magnetic rotors 224 of the final tension adjustment zone 216 (e.g., the reheat zone 214) to obtain a tension in the metal strip 220 suitable for winding. The final tension adjustment zone 216 can also act to increase the tension in the metal strip 220 so that low tension is maintained upstream of the final tension adjustment zone 216 for improved heat treatment and sufficient tension is maintained downstream. of the final tension adjustment zone 216 for winding.

[00106] Figure 3 is a schematic diagram depicting a processing line 300 for continuous heat treatment having a magnetic soaking furnace 328 in accordance with certain aspects of the present disclosure. Processing line 300 is an example of a processing line similar to processing line 100 of Figure 1. An unwinder 302 can unwind metallic strip 320 which can then be passed through a tension adjustment zone 304 and a combined heating zone 306, a soaking zone 308, a quenching zone 310, a leveling and/or microtexturing zone 312, and a final tension adjustment zone 116, before being wound by a winder 318.

[00107] Next to the unwinder 302, an unwinding cylinder 322 can direct the metal strip 320 in the direction of a desired pass line through the processing line 300. The unwinding cylinder 322 can also include load cells for measuring tension in the metal strip 320. The unwind cylinder 322 can provide tension measurements to a controller 336, which can use the measurements to control the magnetic cylinders 326 of the tension adjustment zone 304 (e.g., the heating zone 306) to obtain a Desirable tension in metal strip 320 suitable for unwinding. The tension adjustment zone 304 can also act to reduce the tension in the metal strip 320 so that sufficient tension is maintained upstream of the tension adjustment zone 304 for unwinding and low voltage is maintained downstream of the tension adjustment zone. 304 strain for improved heat treatment.

[00108] In the heating zone 306, the metallic strip 320 can pass through gaps between multiple pairs of magnetic rotors 326. As shown in Figure 3, the magnetic rotors 326 for heating can have a larger diameter than the magnetic rotors 324 used for heating. levitation or tension control. Magnetic rotors 326 for heating may have other differences from magnetic rotors 324 for levitation or voltage control, such as magnetic resistance, position, speed of rotation, flux concentrators, or other differences such as those described herein. As the metal strip 320 passes through the heating zone 306, the metal strip 320 can be heated and levitated by each of the magnetic rotors 326. Upon exiting the heating zone 306, the metal strip 320 can be at a temperature desired temperature, such as a solubilization temperature. Sensors in heating zone 306 can provide temperatures and/or other measurements to controller 336, which can use the measurements to adjust magnetic rotors 326 in heating zone 306 to obtain the desired temperature.

[00109] The metal strip 320 can exit the heating zone 306 to a soaking zone 308, in which the metal strip 320 can pass through a soaking furnace 328. The soaking furnace 328 can be a rotor-based furnace magnetic to maintain the temperature of the metallic strip 320. An array of magnetic rotors 324 can be positioned adjacent the metallic strip 320 to levitate the metallic strip 320 through the embedding zone 308. In some cases, the magnetic rotors 324 can also generate an amount of heat to help facilitate the maintenance of the desired temperature in the metal strip. In some cases, the soaking furnace 328 includes a chamber defined, at least in part, by an upper wall 342 and a lower wall 344. Side walls may be included and are not visible in Figure 3. The chamber may be supplied with a gas from a gas supply 368. The metal strip 320 can be held in the gas-filled chamber through the soak zone 308. The soak oven 328 can be long enough for the metal strip 320 to maintain the desired temperature for a desired time at speed that the metal strip 320 moves through the soaking furnace 328 in the downstream direction 346. Sensors in the soaking zone 308 can provide temperature and/or other measurements to the controller 336, which can use the measurements to adjust the soaking furnace 328 to ensure that the metal strip 320 is maintained at the desired temperature. Such adjustments may include adjusting a temperature of the gas supply 368, adjusting one or more of the magnetic rotors 324 in the soak zone 308, adjusting one or more cooling nozzles within the gas-filled chamber, or performing other actions.

[00110] Upon exiting the soaking zone 308, the metallic strip 320 can enter the sudden cooling zone 310. In the sudden cooling zone 310, the metallic strip 320 can optionally be levitated by a series of magnetic rotors 324. quench zone 310, one or more coolant nozzles 330 can deliver coolant fluid 332 to metal strip 320 to rapidly quench metal strip 320. Sensors in quench zone 310 can provide temperature and/or other measurements to the quench zone 310. controller 336, which can then adjust coolant nozzles 330 to ensure that a desired quench rate is maintained. In some cases, a flatness sensor 334 may be positioned in or downstream of the quench zone 310. Measurements from the flatness sensor may be provided to the controller 336, which may use the measurements to adjust the coolant nozzles 330 to obtain a desired profile of the coolant 332 dispensing across the lateral width of the metal strip 320 which can improve the flatness of the metal strip 320.

[00111] The metal strip 320 can pass through a leveling and/or microtexturing zone 112. In the leveling and/or microtexturing zone 112, the metal strip 320 can pass between one or more sets of leveling and/or microtexturing cylinders 338. The leveling and/or microtexturing cylinders 338 can impart a desirable texture to the surface of the metal strip 320 and/or facilitate the leveling of the metal strip 320. In some cases, sensors in the leveling and/or microtexturing zone 112 can provide feedback to controller 336, which can use the measurements to control leveling and/or microtexturing cylinders 338 to facilitate improved leveling of metal strip 320.

[00112] The metal strip 320 can pass through a reheat zone 314 in which the metal strip 320 can be heated by a set of magnetic rotors 326. The magnetic rotors 326 in the reheat zone 314 can be smaller or otherwise , different from the magnetic rotors 326 of the heating zone 306. In some cases, the magnetic rotors 326 in the reheat zone 314 may be identical to the magnetic rotors 324 used for levitation in other zones. Sensors in reheat zone 314 can provide temperature and/or other measurements to controller 336, which can use the measurements to adjust magnetic rotors 326 in reheat zone 314 to obtain a desired reheat temperature.

[00113] As shown in the processing line 300 of Figure 3, the reheating zone 314 also acts as a final voltage adjustment zone 316. The control of the magnetic rotors 326 of the reheating zone 314 can reheat the metallic strip 320 and control tension in the metal strip so as to obtain adequate tension for rewinding by winder 318. Metal strip 320 may pass through a winding cylinder 340 before being wound by winder 318. The winding cylinder 340 may provide measurements of voltage to a controller 336, which can adjust the magnetic rotors 324 of the final tension adjustment zone 316 (e.g., the reheat zone 314) to obtain a tension in the metal strip 320 suitable for winding. The final tension adjustment zone 316 can also act to increase the tension in the metal strip 320 so that low tension is maintained upstream of the final tension adjustment zone 316 for improved heat treatment and sufficient tension is maintained downstream. of the final tension adjustment zone 316 for winding.

[00114] Figure 4 is a schematic combination diagram and temperature graph 448 depicting a heating zone 406 and soaking zone 408 of a processing line in accordance with certain aspects of the present disclosure. Temperature graph 448 is aligned with heating zone 406 and soaking zone 408 to display an approximate temperature 450 (e.g., peak metal temperature) of metal strip 420 at different times and/or distances along the line of processing. The heating zone 406 and the soaking zone 408 of Figure 4 may be the heating zone 106 and the soaking zone 108 of Figure 1. A metal strip 420 may travel through the heating zone 406 and the soaking zone 408 in a downstream direction 446.

[00115] In the heating zone 406, an array of magnetic rotors 426 can heat the metal strip 420 to raise the temperature of the metal strip 420. The array of magnetic rotors 426 includes six pairs of magnetic rotors 436 separated longitudinally from each other, in that each pair of magnetic rotors 436 includes opposing top and bottom magnetic rotors on opposite sides of metallic strip 420. In some cases, the set of magnetic rotors 426 may include other numbers of magnetic rotors in other configurations and/or orientations. Temperature graph 448 shows that the temperature 450 of the metal strip 420 increases as the metal strip 420 passes each of the pairs of magnetic rotors 436. The temperature 450 of the metal strip 420 increases from an inlet temperature 454 to a desired temperature. of setpoint 452 (e.g., a solubilization temperature) within heating zone 406.

[00116] In the soaking zone 408, an arrangement of magnetic rotors 424 levitates the metallic strip 420, allowing the metallic strip 420 to be soaked at the desired setpoint temperature 452 for a desired time. Optional coolant dispensers may be used to help maintain the temperature 450 at the desired setpoint temperature 452, to compensate for any heating effects of the magnetic rotor array 424. The magnetic rotor array 424 may include multiple magnetic rotors 424, such as 31 magnetic rotors 424. Each magnetic rotor 424 may include one or more laterally spaced magnetic sources that occupy less than the full width of metallic strip 420 (e.g., at or less than approximately 95%, 90%, 85%, 80% , 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15% or 10% of the lateral width of the metal strip 420) .

[00117] A chamber for containing an inert atmosphere can be defined in part by an upper wall 442 and a lower wall 444, as well as side walls (not shown). Each of the top wall 442 and bottom wall 444, as well as, optionally, the side walls, may be made of a non-conductive, thermally insulating material. The metallic strip 420 can pass between the upper wall 442 and the lower wall 444 as it moves through the heating apparatus 400. The magnetic rotors 426 in the heating zone 406 and the magnetic rotors 424 in the soaking zone 408 can be positioned outside the chamber, opposite the upper wall 442 and/or the lower wall 444 of the metal strip 420. As depicted in Figure 4, the chamber walls 442, 444 extend longitudinally along the heating zone 406 and the soaking zone 408. In some other cases, as depicted in Figure 3, the chamber walls cannot extend into the heating zone. The soak zone 408 may be of sufficient length to achieve a desired soak duration 456. The soak duration 456 may be the duration of time during which the peak metal temperature of the metallic strip 420 is at or near the temperature of desired setpoint 452.

[00118] Figure 5 is a side cutaway view of a permanent magnet rotor 500 in accordance with certain aspects of the present disclosure. Permanent magnetic rotor 500 is an example of a magnetic rotor, such as magnetic rotors 224, 226 of Figure 2. Magnetic rotor 500 can include one or more magnetic sources 550. As seen in Figure 5, magnetic rotor 500 includes eight 550 magnetic sources that are permanent magnets. The magnets can be arranged in any suitable orientation. Magnetic sources 550 can be arranged so that adjacent permanent magnets provide different poles facing radially outward (eg, alternating N, S, N, S, N, S, N, S). Any suitable permanent magnet can be used, such as samarium-cobalt, neodymium or other magnets. In some cases, samarium-cobalt magnets may be desirable over neodymium magnets, as samarium-cobalt magnets may drop in magnetic field strength more slowly with greater heating. However, in some cases, neodymium magnets may be desirable over samarium-cobalt magnets, as neodymium magnets have stronger field strengths at lower temperatures.

[00119] The magnetic sources 550 may be enclosed by a housing 552. The housing 552 may be any suitable material capable of allowing magnetic flux to pass therethrough. In some cases, housing 552 may be made or may additionally include a non-metallic coating. In some cases, the 552 enclosure may include Kevlar® or a Kevlar® blend liner. In some cases, housing 552 may include portions designed to redirect flux so that permanent magnetic rotor 500 has an uneven magnetic flux profile along the length of the magnetic rotor.

[00120] In some cases, the magnetic rotor 500 may include a ferromagnetic core 554 having a central axis 556. The magnetic rotor 500 may include other suitable internal arrangements for supporting the magnetic sources 550. Any suitable variety of magnetic sources 550 may be used, however, it has been found that effective results can be obtained with an even number of magnetic sources 550, such as six or eight magnetic sources 550.

[00121] The magnetic sources 550 can be sized to cover any percentage of the circumference of the magnetic rotor 500. Effective results can be obtained with magnetic sources 550 sized to occupy approximately 40% to 95%, 50% to 90% or 70% to 80% of the circumference of the magnetic rotor 500.

[00122] The magnetic rotor 500 can be formed into any suitable size, however, it has been found that effective results can be obtained with a rotor with a diameter between 200 mm and 600 mm, at least 300 mm, at least 400 mm, at least 500 mm or about 600 mm.

[00123] The thickness of each magnetic source 550 can be any suitable thickness with the ability to fit the magnetic rotor 500, however, it has been found that effective results can be obtained with permanent magnet thicknesses of at least 15 mm, 15 to 100 mm 15 to 40 mm, 20 to 40 mm, 25 to 35 mm, 30 mm or 50 mm. Other thicknesses can be used.

[00124] Through testing and experimentation, it has been determined that highly effective heating power can be obtained with the use of six or eight magnets positioned around a single rotor, although other numbers of magnets may be used. When too many magnets are used, the heating power may drop. In some cases, the number of magnets can be selected to minimize installation and/or maintenance cost (for example, the number of magnets to be purchased). In some cases, the number of magnets can be selected to minimize voltage fluctuations that occur in the metallic strip due to the movement of magnets adjacent to the metallic strip. For example, fewer magnets can cause larger and/or longer voltage fluctuations, while more magnets can cause smaller and/or shorter voltage fluctuations. Through testing and experimentation, it has been determined that highly effective heating and/or levitating power can be obtained when the magnets occupy 40% to 95% of the rotor circumference, or more specifically, 50% to 90% or 70% at 80% of the rotor circumference. Through testing and experimentation, it has been determined that highly effective heating power can be obtained when the rotor diameter is large, such as 200, 300, 400, 500 or 600 mm or greater. Also, using larger rotors can help minimize magnet costs. In some cases, smaller rotors (e.g. 600, 500, 400, 300 or 200 mm in diameter or below) may be especially suitable for levitating the metallic article, while larger rotors may be especially suitable for heating the metallic article. .

[00125] As the rotor speed increases, the heating power tends to increase. However, in some cases, if the rotor speed reaches a threshold level, further increases in speed will negatively affect the heating efficiency due to the inherent inductance and resistivity characteristics of the metal strip. It has been determined that at or approximately 1800 revolutions per minute (e.g., within 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15% , or 20% of 1800 revolutions per minute) may be a desirable speed in part because of the simplicity of controlling rotor motors at the 60 Hz frequency found on the power grid in many locations. In some cases, other frequencies may be selected based on the rotor motor used and/or the electrical power supplied. It has been determined that while rotor speed can be a useful method of controlling the amount of thermal energy applied to the metallic strip, it can be advantageous to maintain a constant rotor speed and use the vertical aperture control and other controls to adjust the amount of thermal energy applied to the metal strip.

[00126] Through testing and experimentation, it was determined that highly effective heating power can be obtained when the thicknesses of the permanent magnets on the rotor are between 15 to 40 mm, 20 to 40 mm, or 25 to 35 mm, or approximately to 30 mm. Although strong heating power can be achieved with thicker magnets, using magnets within the above ranges can provide strong enough heating power while simultaneously keeping the installation/maintenance costs of the magnets low.

[00127] Figure 6 is a flowchart depicting a process 600 for continuously heat treating a metal strip in accordance with certain aspects of the present disclosure. Process 600 may be carried out using processing line 100 of Figure 1, or a similar processing line. In some cases, process 600 may include more or fewer elements than those depicted in Figure 6, as well as elements in different orders. In some cases, process 600 may include at least blocks 606, 608, and 610. In some cases, process 600 may additionally include at least block 614.

[00128] In block 602, a metallic strip can be uncoiled. In some cases, unwinding the metallic strip may include controlling the tension of the magnetic strip in block 604, such as through the use of magnetic rotors. At block 606, the metal strip can be heated, such as through the use of magnetic rotors. In some cases, heating the metallic strip in the 606 block may also include levitating the metallic strip using magnetic rotors.

[00129] In block 608, the metallic strip can be levitated in an embedding zone. In some cases, the metal strip can be levitated into an embedding zone using an array of magnetic rotors. While being levitated in the soaking zone, a temperature (e.g. peak metal temperature) of the metal strip can be maintained at or near the desired temperature (e.g. a solubilization temperature). In some cases, the metal strip can be levitated into the embedding zone in a gas-filled chamber. The gas-filled chamber can be filled with an inert gas, a minimally reactive gas, or a treatment gas.

[00130] At block 610, the metal strip may be directed into a quench zone where the metal strip is rapidly quenched, such as at a rate at or about 200 °C/sec. The metallic strip can be levitated, such as using a magnetic rotor arrangement. In some cases, quenching the metallic strip in block 610 may include flatness control via closed-loop feedback.

[00131] In block 612, the metallic strip can be leveled and/or microtextured by passing the metallic strip through leveling and/or microtexturing cylinders. In some cases, the metallic strip can be levitated by an arrangement of magnetic rotors in positions adjacent to the leveling and/or microtexturing cylinders. In some cases, levitating the metal strip at these locations may include controlling the tension of the metal strip as it passes through the leveling and/or microtexturing rollers.

[00132] In block 613, the metallic strip can be coated and/or lubricated. Coating and/or lubricating the metallic strip may include levitating the metallic strip using an array of magnetic rotors. Coating and/or lubricating the metal strip can include coating the metal strip with a fluid or solid material, including lubricants.

[00133] In block 614, the metal strip can be reheated. Reheating the metal strip can include passing the metal strip adjacent to an array of magnetic rotors. In some cases, the metal strip can be levitated by an array of magnetic rotors during reheating. In some cases, reheating the metallic strip at block 614 may include curing a coating on the metallic strip or facilitating the flow of a lubricant in the metallic strip.

[00134] In block 618, the metal strip can be wound. The metal strip can be wound onto a final coil as a heat-treated metal strip. In some cases, winding the metallic strip may include controlling the voltage of the magnetic strip at block 616, such as through the use of magnetic rotors.

[00135] Figure 7 is a flow chart depicting a process 700 for passing a metal strip through a continuous heat treatment line in accordance with certain aspects of the present disclosure. Process 700 can be used with processing line 100 of Figure 1 or a similar processing line. Process 700 can be enabled due to the use of magnetic rotors to levitate the metal strip at various positions along the processing line.

[00136] In the 702 block, one or more magnetic rotors can be rotated in a downstream direction. Any or all of the processing line's magnetic rotors can be turned in a downstream direction. In some cases, rotating a magnetic rotor in a downstream direction may include one or more upper magnetic rotors (for example, rotors located above the metal strip) at a greater speed than one or more lower magnetic rotors (for example, rotors located below of the metallic strip).

[00137] In block 704, a free end of the metal strip can be floated adjacent to the magnetic rotors. Rotation of the magnetic rotors in block 702 can facilitate floating the free end of the metal strip in block 704. In some cases, floating the free end of the metal strip can additionally include attaching the free end of the metal strip to a conveyor or other support. At block 706, the free end of the metal strip can be fed through the processing line. Feeding the free end of the metal strip through the processing line can include feeding the free end of the metal strip through one or more elements of the processing line. In some cases, feeding the free end of the metal strip through the processing line may include pushing the free end of the metal strip through the processing line using a conveyor.

[00138] In block 708, one or more of the magnetic rotors can be rotated in an upstream direction. The one or more magnetic rotors may include one or more magnetic rotors adjacent to an unwinder. Rotating the magnetic rotors in an upstream direction can occur after the metallic strip has been fully passed through the processing line.

[00139] Figure 8 is a schematic diagram depicting an initial stage of passing a metal strip 820 through a continuous heat treatment line in accordance with certain aspects of the present disclosure. In an initial passing phase, the magnetic rotors 824 can be rotated in a downstream direction 846. Rotation of the magnetic rotors 824 in a downstream direction 846 can facilitate the maintenance of a relatively high tension in the metal strip 820 upstream of the end free 859 of metallic strip. In some cases, an optional conveyor 858 can be detachably attached to the metal strip 820 to facilitate feeding the metal strip 820 through the processing line. Optional conveyor 858 can be lifted to move along the processing line, such as along one or more tracks.

[00140] Figure 9 is a schematic diagram depicting a secondary stage of passing a metal strip 920 in a continuous heat treatment line in accordance with certain aspects of the present disclosure. In a secondary passing stage, the magnetic rotors 924 can continue to rotate in a downstream direction 946. Rotation of the magnetic rotors 924 in a downstream direction 946 can continue to facilitate maintenance of a relatively high voltage in the metal strip 920 to amount of the free end 959 of the metal strip. In some cases, an optional conveyor 958 detachably coupled to the metal strip 920 can facilitate feeding the metal strip 920 through the processing line. Optional conveyor 958 can be lifted to move along the processing line, such as along one or more tracks. To feed the metal strip 920, the optional conveyor 958 can be directed in a downstream direction 946.

[00141] Figure 10 is a schematic diagram depicting a metal strip 1020 after being passed through a continuous heat treatment line in accordance with certain aspects of the present disclosure. After passing metal strip 1020 completely or at least substantially passing metal strip 1020 (e.g., at least 50% passed through the processing line), one or more magnetic rotors 1024 can be reversed to rotate in an opposite direction to downstream 1046. Rotation of the magnetic rotors in an upstream direction can facilitate maintaining a low voltage on the metal strip downstream of the magnetic rotors rotating in the upstream direction. In some cases, magnetic rotors that rotate in an upstream direction may be upstream of a heating zone so that the metallic strip 1020 is maintained at relatively low voltage while in the heating zone.

[00142] Figure 11 is a schematic top view diagram depicting a metallic strip 1120 and a subsequent metallic strip 1121 during a pre-soldering phase in accordance with certain aspects of the present disclosure. In the top view, metallic strip 1120 and subsequent metallic strip 1121 are shown levitated above an array of magnetic rotors 1124. The magnetic rotors 1124 depicted in Figure 11 may be magnetic rotors 1124 of a voltage adjustment zone or a voltage adjustment zone. of welding/joint, which can be located downstream of an uncoiler and upstream of a heating zone.

[00143] A longitudinally movable joint, such as a welder 1170, may be suspended above the metallic strip 1120 and the subsequent metallic strip 1121, although in other cases it may be suspended below. The mobile welding apparatus 1170 can move in a downstream direction 1146. The metallic strip 1120 and the subsequent metallic strip 1121 can also move in a downstream direction 1146. In some cases, the metallic strip 1120 and the subsequent metallic strip 1121 may move in a downstream direction 1146 at a speed below a normal operating speed for heat treating the metal strip. In the pre-welding phase, a front end 1178 (e.g., downstream end) of the subsequent metal strip 1121 can be moved toward a rear end 1180 (e.g., upstream end) of the metal strip 1120.

[00144] Figure 12 is a schematic top view diagram depicting a metal strip 1220 and a subsequent metal strip 1221 during a welding or joining stage in accordance with certain aspects of the present disclosure. In the top view, metallic strip 1220 and subsequent metallic strip 1221 are shown levitated above an array of magnetic rotors 1224. The magnetic rotors 1224 depicted in Figure 12 may be magnetic rotors 1224 of a voltage adjustment zone or a voltage adjustment zone. of welding/joint, which can be located downstream of an uncoiler and upstream of a heating zone.

[00145] In the welding or joining phase, the front end of the subsequent metal strip 1221 and the rear end of the metal strip 1220 can be brought together, such as in contiguity, to form a joint 1272. A movable joint, such as welding apparatus movable welder 1270, may be suspended above (or below) joint 1272 and moved in a downstream direction 1246 at the same or approximately the same speed as metallic strip 1220 and subsequent metallic strip 1221. In this way, movable welder 1270 may remain in a constant position with respect to joint 1272 during displacement of metal strip 1220. Mobile welding apparatus 1270 may weld or otherwise join metal strip 1220 to subsequent metal strip 1221 at joint 1272, such as through any proper technique.

[00146] Figure 13 is a schematic top view diagram depicting a metallic strip 1320 and a subsequent metallic strip 1321 during a post-soldering phase in accordance with certain aspects of the present disclosure. In the top view, metallic strip 1320 and subsequent metallic strip 1321 are shown levitated above an array of magnetic rotors 1324. The magnetic rotors 1324 depicted in Figure 13 may be magnetic rotors 1324 of a voltage adjustment zone or a voltage adjustment zone. of welding/joint, which can be located downstream of an uncoiler and upstream of a heating zone.

[00147] In the post-welding phase, the subsequent metal strip 1321 and the metal strip 1320 were welded or otherwise joined together at the joint, resulting in a weld 1374 between the subsequent metal strip 1321 and the metal strip 1320. mobile welder 1370 may stop moving in a downstream direction 1346, such as returning to a storage position. In the post-weld phase, the metallic strip 1320 and the subsequent metallic strip 1321 may start moving in the downstream direction 1346 at a higher speed than in the welding phase, such as a normal or near normal operating speed for the treatment. 1320 metallic strip thermal insulation.

[00148] Figure 14 is a flowchart depicting a process 1400 for joining a metallic strip to a subsequent metallic strip during travel of the metallic strip in accordance with certain aspects of the present disclosure. At block 1402, a metal strip can be moved in the downstream direction. Moving the metallic strip in a downstream direction may include levitating the metallic strip in an array of magnetic rotors. At block 1404, a leading end of a subsequent metallic strip may be moved toward a trailing end of the metallic strip until the ends adjoin to form a joint. The subsequent metal strip can begin unwinding at approximately the same time as the metal strip stops unwinding. At block 1406, a movable welding apparatus can be passed adjacent (e.g., above or below) the joint between the metallic strip and the subsequent metallic strip. The movable welding apparatus can be passed adjacent to the joint while the metallic strip moves in a downstream direction. Since the movable welding apparatus is adjacent to the joint, the movable welding apparatus can continue to move at the same speed as the joint (for example, the same speed as the metal strip). At block 1408, the movable welder can weld or otherwise join the joint while moving the metal strip.

[00149] Figure 15 is a schematic partial cut-away top view of a section of a processing line that depicts a metallic strip 1520 levitated over a set of magnetic rotors 1524 that have laterally separated magnetic sources 1576 according to certain aspects of the present revelation. Each of the magnetic rotors 1524 may include two or more magnetic sources 1576, such as permanent magnets, that are laterally separated (eg, along the length of the magnetic rotor 1524). Each of the magnetic sources 1576 depicted in Figure 15 may be an array of magnetic sources (eg, one or more magnetic sources). The laterally separated magnetic sources 1576 in a magnetic rotor 1524 may be displaced relative to the laterally separated magnetic sources 1576 in an immediately subsequent magnetic rotor 1524. The lateral and longitudinal spacing between magnetic sources 1567 within the array of magnetic rotors can facilitate the levitation of the metal strip 1520 without substantial heating of the metal strip. In some cases, the magnetic rotors 1524 of Figure 15 may be similar to the magnetic rotors 224 of Figure 2.

[00150] Figure 16 is a schematic partial cutaway top view of a section of a processing line that depicts a metallic strip 1620 levitated over a set of magnetic rotors 1626 that have magnetic sources close to the full width 1676 according to certain aspects of the present disclosure. Each of the magnetic rotors 1626 can be a magnetic source 1676 that extends at least across the full lateral width of the metallic strip 1520. In some cases, the magnetic source 1676 can extend along the entire length of the magnetic rotor 1626. Each of the magnetic sources 1676 depicted in Figure 16 may be an array of magnetic sources (eg, one or more magnetic sources). Magnetic rotors 1626 having full-width or nearly full-width magnetic sources 1676 can be especially useful for providing an amount of heating to metallic strip 1520 while simultaneously levitating metallic strip 1520. In some cases, magnetic rotors 1626 of Figure 16 can be similar to the magnetic rotors 226 of Figure 2.

[00151] The aforementioned description of the embodiments, including the illustrated embodiments, has been presented for purposes of illustration and description only and is not intended to be exhaustive or limiting of the precise forms disclosed. Various modifications, adaptations and uses thereof will be apparent to those skilled in the art.

[00152] As used below, any reference to a series of examples shall be understood to refer to each of those examples in a disjunctive manner (e.g., "Examples 1 to 4" shall be understood to mean "Examples 1, 2, 3, or 4").

[00153] Example 1 is a heat treatment line, comprising: a heating zone for accepting a metallic strip moving in a downstream direction, the heating zone comprising a plurality of magnetic rotors for inducing eddy currents in the strip metal for heating the metal strip to a metal peak temperature, wherein each of the plurality of magnetic rotors rotates around an axis of rotation perpendicular to the downstream direction and parallel to a lateral width of the metal strip; a soaking zone positioned downstream of the heating zone to accept the metallic strip and maintain the peak metal temperature for a period of time; and a quench zone positioned downstream of the soak zone for rapidly quenching the metal strip from the peak metal temperature.

[00154] Example 2 is the heat treatment line of Example 1, wherein the plurality of pairs of magnetic rotors, wherein each pair of magnetic rotors includes a bottom magnetic rotor positioned opposite the metal strip of a magnetic rotor top.

[00155] Example 3 is the heat treatment line of Examples 1 or 2, wherein each of the plurality of magnetic rotors comprises a plurality of permanent magnets positioned to rotate about the axis of rotation.

[00156] Example 4 is the heat treatment line of examples 1 to 3, in which the soaking zone includes an additional plurality of magnetic rotors for levitating the metallic strip, in which each of the additional plurality of magnetic rotors rotates in around a geometric axis of rotation perpendicular to the downstream direction and parallel to the lateral width of the metal strip.

[00157] Example 5 is the heat treatment line of example 4, wherein the soaking zone additionally comprises chamber walls positioned between the metallic strip and the additional plurality of magnetic rotors, wherein the chamber walls define a chamber for accept the metallic strip, in which the chamber is attachable to a gas supply.

[00158] Example 6 is the heat treatment line of examples 4 or 5, in which the soaking zone additionally comprises one or more sudden cooling devices to compensate for temperature increases induced in the metallic strip by rotation of the additional plurality of magnetic rotors .

[00159] Example 7 is the heat treatment line of examples 1 to 6, further comprising: an unwinder positioned upstream of the heating zone to supply the metallic strip to the heating zone from a coil; a leveling cylinder positioned downstream of the quench zone to control the leveling of the metal strip; and a reheat zone positioned downstream of the leveling cylinder for heating the metal strip, the reheat zone including one or more additional magnetic rotors.

[00160] Example 8 is the heat treatment line of examples 1 to 7, which further comprises a tension adjustment zone for adjusting the tension in the metal strip, wherein the tension adjustment zone comprises one or more magnetic rotors swivels around a geometric axis of rotation perpendicular to the downstream direction and parallel to the lateral width of the metal strip.

[00161] Example 9 is the heat treatment line of Examples 1 to 8, which further comprises an unwinder positioned upstream of the heating zone to supply the metallic strip to the heating zone from a starting coil and a rewinder positioned downstream of the quench zone to receive the metallic strip after the heat treatment and winding the metallic strip onto a final reel, in which a pass line is defined between the unwinder and the winder along which the metallic strip passes through the heating zone, soaking zone and sudden cooling zone without passing through an accumulator.

[00162] Example 10 is the heat treatment line of examples 1 to 9, which further comprises a movable welder positioned upstream of the heating zone to weld a metallic strip subsequent to the metallic strip during the course of the metallic strip.

[00163] Example 11 is a continuous heat treatment method, comprising: passing a metal strip adjacent to a plurality of magnetic rotors in the downstream direction; rotating the plurality of magnetic rotors, wherein rotating a magnetic rotor includes rotating the magnetic rotor about an axis of rotation perpendicular to the downstream direction and parallel to a lateral width of the metallic strip, and wherein rotating the plurality of magnetic rotors induce eddy currents in the metal strip to heat the metal strip to a metal peak temperature; passing the metal strip through a soak zone, wherein passing the metal strip through the soak zone comprises maintaining the peak metal temperature of the metal strip for a period of time; and quenching the metal strip from the peak metal temperature.

[00164] Example 12 is the method of Example 11, wherein the plurality of magnetic rotors includes a plurality of pairs of magnetic rotors, wherein each pair of magnetic rotors includes a bottom magnetic rotor and a top magnetic rotor separated by a gap, and wherein the metallic strip is adjacent to the plurality of rotors comprise passing the metallic strip through gaps of the plurality of pairs of magnetic rotors.

[00165] Example 13 is the method of Examples 11 or 12, wherein rotating a magnetic rotor of the plurality of magnetic rotors includes rotating a plurality of permanent magnets around the axis of rotation.

[00166] Example 14 is the method of Examples 11 to 13, wherein passing the metallic strip through the embedding zone comprises levitating the metallic strip, and wherein levitating the metallic strip comprises rotating an additional plurality of rotors magnetic elements adjacent to the metal strip.

[00167] Example 15 is the method of example 14, in which passing the metallic strip through the embedding zone comprises: passing the metallic strip through a chamber defined by the chamber walls positioned between the metallic strip and the additional plurality of magnetic rotors; and supplying the chamber with gas from a gas supply.

[00168] Example 16 is the method of Examples 14 or 15, wherein maintaining the metal peak temperature comprises applying a quench fluid to the metal strip to compensate for temperature increases induced in the metal strip by rotation of the additional plurality of magnetic rotors.

[00169] Example 17 is the method of examples 11 to 16, which further comprises: unwinding the metal strip from a starting coil; leveling the metal strip after tempering the metal strip; and reheating the metallic strip after leveling the metallic strip, wherein reheating the metallic strip comprises rotating one or more additional magnetic rotors adjacent the metallic strip.

[00170] Example 18 is the method of examples 11 to 17, which further comprises passing the metallic strip, wherein passing the metallic strip comprises: magnetic rotors rotating in a downstream direction, wherein the magnetic rotors are selected from the group consisting of the plurality of magnetic rotors and an additional set of magnetic rotors; passing one end of the metal strip through the magnetic rotors; and reversing rotation of the magnetic rotors to rotate the magnetic rotors in an upstream direction.

[00171] Example 19 is the method of Examples 11 to 18, further comprising: unwinding the metal strip from a starting coil before passing the metal strip adjacent to the plurality of magnetic rotors; backing up the metal strip into an ending coil after quenching the metal strip, wherein the metal strip on the final coil has been heat treated; and not passing the metallic strip through an accumulator between unwinding the metallic strip and rewinding the metallic strip.

[00172] Example 20 is the method of examples 11 to 19, which further comprises joining the metallic strip to a subsequent metallic strip, wherein joining the metallic strip comprises: placing the metallic strip and the subsequent metallic strip in contiguity with a joint during displacement of the metal strip; passing a mobile joint device over the joint during displacement of the metal strip; and join the gasket during the course of the metal strip.

[00173] Example 21 is the method of Examples 11 to 20, further comprising at least one of coating or lubricating the metallic strip and then heating the coated or lubricated metallic strip.

Claims (18)

1. Heat treatment line (100, 200, 300, 400), comprising: a heating zone (106, 206, 306, 406) for accepting a metal strip (120, 220, 320, 420) moving in a downstream direction (146, 246, 346, 446) and, heating the metal strip (120, 220, 320, 420) to a metal peak temperature; a soaking zone (108, 208, 308, 408) positioned downstream of the heating zone (106, 206, 306, 406) to accept the metal strip (120, 220, 320, 420) and maintain the peak temperature of metal for a period of time; and a quench zone (110, 210, 310, 410) positioned downstream of the soaking zone (108, 208, 308, 408) to quickly quench the metallic strip (120, 220, 320, 420) from the temperature of metal spike, characterized in that the heating zone (106, 206, 306, 406) comprises a plurality of magnetic rotors (226, 326, 426) for inducing eddy currents in the metal strip (108, 208, 308, 408 ) and the embedding zone (108, 208, 308, 408) comprises a further plurality of magnetic rotors (224, 324, 424, 1524) for levitating the metal strip (120, 220, 320, 420), each rotor magnet in the heating zone (106, 206, 306, 406) and in the soaking zone (108, 208, 308, 408) is configured to rotate about an axis of rotation that is perpendicular to the downstream direction (146, 246, 346, 446) and parallel to a lateral width of the metallic strip (120, 220, 320, 420), each magnetic rotor (1524) in the embedding zone (108, 208, 308, 408) comprising a plurality of magnetic sources (1576) laterally separated arranged in such a way that the lateral positions of the magnetic sources (1576) inside sequential magnetic rotors (1524) in the embedding zone (108, 208, 308, 408) are displaced from each other, resulting in an arrangement of magnetic fountains (1576). 2. Heat treatment line (100, 200, 300, 400) according to claim 1, characterized in that the plurality of magnetic rotors (226, 326, 426) comprises a plurality of pairs of magnetic rotors, wherein each pair of magnetic rotors comprises a bottom magnetic rotor positioned opposite the metal strip (120, 220, 320, 420) from a top magnetic rotor. 3. Heat treatment line (100, 200, 300, 400) according to claim 1, characterized in that each of the plurality of magnetic rotors (226, 326, 426, 500) comprises a plurality of permanent magnets (550) positioned to rotate about the axis of rotation (556). 4. Heat treatment line according to claim 1, characterized in that the soaking zone (308, 408) additionally comprises chamber walls (342, 344, 442, 444) positioned between the metal strip (320, 420 ) and the additional plurality of magnetic rotors (324, 424), wherein the chamber walls (342, 422, 442, 444) define a chamber for accepting the metal strip (3420, 420), wherein the chamber is attachable to a gas supply (368); or wherein the soaking zone (308, 408) additionally comprises one or more cooling devices to compensate for temperature increases induced in the metallic strip (320, 420) by rotation of the additional plurality of magnetic rotors (324, 424). 5. Heat treatment line (100, 200, 300) according to claim 1, characterized in that it additionally comprises: an unwinder (102, 202, 302) positioned upstream of the heating zone (106, 206, 306 ) for supplying the metallic strip (102, 220, 320) to the heating zone (106, 206, 306) from a coil; a leveling cylinder (238, 338) positioned downstream of the quench zone (110, 210, 310) to control flatness of the metal strip (120, 220, 320); and a reheat zone (114, 214, 314) positioned downstream of the leveling cylinder (238, 338) for heating the metal strip (120, 220, 320), wherein the reheat zone (114, 214, 314) includes one or more additional magnetic rotors (226, 326). 6. Heat treatment line (100, 200, 300) according to claim 1, characterized in that it additionally comprises a tension adjustment zone (104, 116, 204, 216, 304, 316) for adjusting the tension on the metal strip (120, 220, 320), wherein the tension adjustment zone (104, 116, 204, 216, 304, 316) comprises one or more magnetic rotors (226, 326) rotating around a geometric axis of rotation perpendicular to the downstream direction (146, 246, 346) and parallel to the lateral width of the metal strip (120, 220, 320). 7. Heat treatment line (100, 200, 300) according to claim 1, characterized in that it additionally comprises an unwinder (102, 202, 302) positioned upstream of the heating zone (106, 206, 306) to supply the metallic strip (120, 220, 320) to the heating zone (106, 206, 306) from a starting coil and a rewinder (118, 218, 318) positioned downstream of the quench zone ( 110, 210, 310) for receiving the metal strip (120, 220, 320) after heat treatment and winding the metal strip (120, 220, 320) onto a final coil, in which a passing line is defined between the unwinder (102, 202, 302) and the winder (118, 218, 318) along which the metallic strip (120, 220, 320) passes through the heating zone (106, 206, 306), the soaking (108, 208, 308) and the quench zone (110, 210, 310) without passing through an accumulator. 8. Heat treatment line (100) according to claim 1, characterized in that it additionally comprises a mobile welder (1170, 1270, 1370) positioned upstream of the heating zone (106, 206, 306, 406) to welding a subsequent metallic strip (1121, 1221, 1321) to the metallic strip (1120, 1220, 1320) during the stroke of the metallic strip (1120, 1220, 1320). 9. Method (600) of continuous heat treatment, comprising: passing (606) a metal strip (120, 220, 320, 420) through a heating zone (106, 206, 306, 406) in a downstream direction (146, 246, 346, 446), wherein the metal strip (120, 220, 320, 420) is heated to a peak metal temperature in the heating zone (106, 206, 306, 406); passing (608) the metal strip (120, 220, 320, 420) through an embedding zone (108, 208, 308, 408), where passing the metal strip (120, 220, 320, 420) through the zone soaking (108, 208, 308, 408) comprises maintaining the peak metal temperature of the metal strip (120, 220, 320, 420) for a period of time; and quenching (610) the metal strip (120, 220, 320, 420) from the metal peak temperature, characterized in that the heating zone (106, 206, 306, 406) comprises a plurality of magnetic rotors ( 226, 326, 426), and the embedding zone (108, 208, 308, 408) comprises a further plurality of magnetic rotors (226, 326, 426), each magnetic rotor (226, 326, 426) in the zone heating zone (106, 206, 306, 406) and soaking zone (108, 208, 308, 408) is configured to rotate around an axis of rotation that is perpendicular to the downstream direction (146, 246, 346, 446) and parallel to a lateral width of the metallic strip (120, 220, 320, 420); and wherein the method further comprises: rotating the plurality of magnetic rotors (226, 326, 426) about their respective axes of rotation, wherein rotation of the plurality of magnetic rotors (226, 326, 426) induces eddy currents on the metal strip (120, 220, 320, 420) to heat (606) the metal strip (120, 220, 320, 420) to the metal peak temperature; and levitating (608) the metallic strip (120, 220, 320, 420) passing through the embedding zone (108, 208, 308, 408), wherein levitating the metallic strip (120, 220, 320, 420) comprises the rotating the additional plurality of magnetic rotors (226, 326, 426) about their respective axes of rotation adjacent the metal strip (120, 220, 320, 420); each magnetic rotor (1524) in the embedding zone (108, 208, 308, 408) comprising a plurality of laterally spaced magnetic sources (1576) arranged such that the lateral positions of the magnetic sources (1576) within sequential magnetic rotors ( 1524) in the embedding zone (108, 208, 308, 408) are offset from each other, resulting in a staggered array of magnetic sources (1576). 10. Method according to claim 9, characterized in that the plurality of magnetic rotors (226, 326, 426) comprises a plurality of magnetic rotor pairs, wherein each of the plurality of magnetic rotor pairs comprises a bottom magnetic rotor and a top magnetic rotor separated by a gap, and wherein passing the metallic strip (220, 320, 420) adjacent to the plurality of magnetic rotors (226, 326, 426) comprises passing the metallic strip (220, 320 , 420) through gaps of the plurality of pairs of magnetic rotors. 11. Method according to claim 9, characterized in that the plurality of magnetic rotors (226, 326, 426, 500) comprise the rotation of a plurality of permanent magnets (550) around the geometric axis of rotation (556 ). 12. Method according to claim 9, characterized in that passing the metallic strip (320, 420) through the embedding zone (308, 408) comprises: passing the metallic strip (320, 420) through a defined chamber chamber walls (342, 344, 442, 444) positioned between the metal strip (320, 420) and the additional plurality of magnetic rotors (226, 326, 426); and supplying the chamber with gas from a gas supply (368). 13. Method according to claim 9, characterized in that maintaining the peak metal temperature comprises applying a quench fluid to the metal strip (120, 220, 320, 420) to compensate for temperature increases induced in the strip metal (120, 220, 320, 420) by rotating the additional plurality of magnetic rotors (226, 326, 426). 14. Method according to claim 9, characterized in that it additionally comprises: unwinding (602) the metal strip (120, 220, 320, 420) from a starting coil; leveling (612) the metallic strip (120, 220, 320) after sudden cooling (610) of the metallic strip (120, 220, 320); and reheating (614) the metal strip (120, 220, 320) after leveling (612) the metal strip (120, 220, 320), wherein reheating (614) the metal strip (120, 220, 320) comprises rotating one or more additional magnetic rotors (226, 326) adjacent the metal strip (120, 220, 320). 15. Method according to claim 9, characterized in that it further comprises passing the metallic strip, wherein passing (700) the metallic strip (820) comprises: rotating (702) magnetic rotors (824) in a downstream direction (846), wherein the magnetic rotors (824) are selected from the group consisting of the plurality of magnetic rotors and an additional set of magnetic rotors; passing (704, 706) one end of the metallic strip through the magnetic rotors (924); and reversing (708) rotation of the magnetic rotors (1024) to rotate the magnetic rotors (1024) in an upstream direction. 16. Method according to claim 9, characterized in that it additionally comprises: unwinding the metal strip (120, 220, 320) from a starting coil before passing the metal strip (120, 220, 320) adjacent to the plurality of magnetic rotors (226, 326); rewinding the metallic strip (120, 220, 320) onto a final reel after quenching the metallic strip (120, 220, 320), wherein the metallic strip (120, 220, 320) on the final reel has been heat treated; and not passing the metal strip (120, 220, 320) through an accumulator between unwinding the metal strip (120, 220, 320) and rewinding the metal strip (120, 220, 320). 17. Method according to claim 9, characterized in that it further comprises joining (1400) the metallic strip (1121, 1221, 1321) to a subsequent metallic strip (1120, 1220, 1320), in which the joining of the strip metal strip (1121, 1221, 1321) comprises: placing (1404) the metal strip (1221) and subsequent metal strip (1220) adjacent to a joint (1272) during displacement of the metal strip (1221); passing (1406) a movable joint device (1270, 1370) over the joint (1272) during displacement of the metal strip (1221); and joining (1408) the gasket (1272) during the path of the metal strip (1221). 18. Method according to claim 9, characterized in that it additionally comprises at least one of coating or lubricating the metallic strip and then heating the coated or lubricated metallic strip.