US20040007295A1 - Method of manufacturing aluminum alloy sheet - Google Patents

Method of manufacturing aluminum alloy sheet Download PDF

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US20040007295A1
US20040007295A1 US10/359,875 US35987503A US2004007295A1 US 20040007295 A1 US20040007295 A1 US 20040007295A1 US 35987503 A US35987503 A US 35987503A US 2004007295 A1 US2004007295 A1 US 2004007295A1
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Prior art keywords
feedstock
hot rolled
aluminum alloy
strip
hot
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Leland Lorentzen
David Peters
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NICHOLS ALUMINUM CASTING
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NICHOLS ALUMINUM CASTING
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Priority to US10/359,875 priority Critical patent/US20040007295A1/en
Assigned to NICHOLS ALUMINUM CASTING reassignment NICHOLS ALUMINUM CASTING ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PETERS, DAVID C., LORENTZEN, LELAND R.
Publication of US20040007295A1 publication Critical patent/US20040007295A1/en
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
    • B21B1/24—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length in a continuous or semi-continuous process
    • B21B1/26—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length in a continuous or semi-continuous process by hot-rolling, e.g. Steckel hot mill
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/38—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling sheets of limited length, e.g. folded sheets, superimposed sheets, pack rolling
    • B21B2001/383—Cladded or coated products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • B21B2003/001—Aluminium or its alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B15/00—Arrangements for performing additional metal-working operations specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
    • B21B15/0007—Cutting or shearing the product
    • B21B2015/0021—Cutting or shearing the product in the rolling direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B15/00—Arrangements for performing additional metal-working operations specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
    • B21B2015/0071—Levelling the rolled product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • B21B3/003—Rolling non-ferrous metals immediately subsequent to continuous casting, i.e. in-line rolling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B37/00—Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
    • B21B37/74—Temperature control, e.g. by cooling or heating the rolls or the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B38/00—Methods or devices for measuring, detecting or monitoring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B45/00—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
    • B21B45/004—Heating the product

Definitions

  • the present invention relates generally to casting of aluminum alloys and specifically to a continuous casting process for producing intermediate tempered aluminum alloy sheet.
  • the ingot While it is still hot, the ingot is subjected to breakdown hot rolling in a number of passes using reversing or non-reversing mill stands that serve to reduce the thickness of the ingot.
  • the ingot After breakdown hot rolling, the ingot is typically supplied to a tandem mill for hot finishing rolling, after which the sheet stock is coiled and the roll air cooled and stored. The roll is then typically batch annealed. The coiled stock is then finished reduced to final gauge by cold rolling using unwinders, rewinders and single and/or tandem rolling mills. After the coiled stock is at final gauge, the roll is back-annealed (also called stress-relieved or stabilized) in a batch process.
  • back-annealed also called stress-relieved or stabilized
  • Aluminum scrap is generated in most of the foregoing steps, in the form of scalping chips, end crops, edge trim, scrapped ingots and scrapped coils. Aggregate losses through such batch processes typically range from 25 to 40%. Reprocessing the scrap thus generated adds 25 to 40% to the labor and energy consumption costs of the overall manufacturing process.
  • the minimill process as described above requires about ten material handling operations to move ingots and coils between about nine process steps. Like other conventional processes described earlier, such operations are labor intensive, consume energy and frequently result in product damage. Scrap is generated in the rolling operations resulting in typical losses throughout the process of about 10 to 15%.
  • annealing is typically carried out in a batchwise fashion with the aluminum in coil form.
  • a common practice in producing aluminum alloy flat rolled products has been to employ slow air cooling of coils after hot rolling (because the hot rolling temperature is high enough to allow complete or near complete recrystallization of the hot coils before the aluminum cools down)
  • a furnace coil batch anneal must sometimes be used to effect complete or near complete recrystallization before cold rolling.
  • Batch coil annealing as typically employed in the prior art, requires several hours of uniform heating and soaking to achieve the anneal temperature.
  • prior art processes frequently employ an intermediate annealing operation prior to finish cold rolling to effect complete or near complete recrystallization.
  • the present invention is directed generally to the use of hot rolling and back annealing or in-line self-back-annealing during or after hot rolling to produce a desired intermediate temper aluminum alloy product.
  • the present invention provides a method for manufacturing of aluminum sheet stock.
  • the method includes the steps of:
  • finished gauge refers to the gauge selected for the aluminum alloy sheet product of the process
  • hot rolling refers to reducing the gauge of feedstock at a temperature of 400° F. or greater
  • cold rolling to reducing the gauge of feedstock at a temperature of less than 400° F.
  • back annealing to thermally induced softening of an aluminum alloy to produce at least substantially uniform, desired mechanical properties, typically meeting Aluminum Association limits.
  • An “intermediate temper” provides a metal with mechanical properties elevated from those typical at a dead soft temper, and includes all tempers in between O and Hx9.
  • back annealing examples include “stress-relieving” and “stabilizing”.
  • the back-annealed feedstock is immediately coiled and allowed cool to a temperature suitable for finishing operations such as leveling, slitting or painting.
  • the feedstock can be formed by any casting technique, such as continuous or direct chill casting.
  • continuous casting the feedstock is formed by depositing molten aluminum alloy on an endless belt formed of a heat conductive material. The molten metal solidifies to form a cast strip.
  • the feedstock is rolled to a finish gauge.
  • the hot rolled feedstock is free of cold rolling after the hot rolling step. No further reductions in gauge are generally required.
  • the hot rolling step typically reduces the thickness of the aluminum alloy feedstock by from about 40 to about 99%.
  • the aluminum alloy feedstock and/or hot rolled feedstock is preferably only partially recrystallized.
  • the back-annealing step is performed by in-line heating of the hot rolled feedstock.
  • back-annealing is performed during hot rolling.
  • Back-annealing times as referred to herein, define the total time required to heat up the material to a desired temperature and complete back-annealing.
  • the feedstock is preferably not fully annealed. In other words, the feedstock is not fully recrystallized. Typically, the degree of recrystallization of the feedstock is no more than about 60%. In many cases, the back annealed feedstock is free or substantially free (less than about 5% recrystallized) of recrystallization. To accomplish this result, back annealing is typically performed at a temperature within the range of about 700 to about 1000° F. This temperature range is generally at or above the exit temperature of the hot rolled feedstock from the hot rolling step.
  • the batch processing technique involves fourteen separate steps while the minimill prior art processing involves about nine separate steps, each with one or more handling operations in between.
  • the present invention differs from the prior art by virtue of in-line flow of product through the fabrication operations (thereby allowing fewer separate steps) and the metallurgical differences that the in-line method is capable of producing.
  • FIG. 1 is a comparative plot of in-process thickness versus time for a conventional minimill versus an in-line or continuous process embodiment of the present inventions
  • FIG. 2 is a comparative plot of temperature versus time for the in-line process embodiment of the present invention compared to two prior art processes
  • FIG. 3 is a plot of the in-process temperature for the in-line process embodiment of the present invention.
  • FIG. 4 is a flow chart of the in-line process embodiment of the present invention.
  • FIG. 5 is a schematic illustration of the in-line plant configuration according to the present invention with casting throughout finish rolling at the hot mill.
  • the various processes of the present invention (which are referred to collectively as the “megamill process”) hot roll to finish gauge and back anneal the fully hot rolled sheet, as necessary, to produce a desired intermediate temper.
  • a “back anneal” is conducted under conditions of time and temperature sufficient to soften, but not completely recrystallize, the hot rolled sheet to the desired temper.
  • the back anneal is typically conducted at a temperature that is less than the recrystallization temperature for the particular alloy being treated.
  • the sheet may be cast by any suitable technique, such as direct chill casting, electromagnetic casting, and continuous strip casting.
  • the back anneal can be batch or continuous, with a continuous (or in line) back anneal being preferred.
  • step 400 an aluminum-containing material is melted in a furnace (not shown) to form molten metal 500 .
  • the molten metal is transferred from the furnace to a metal degassing and filtering device (not shown) to reduce dissolved gases and particulate matter from the molten metal.
  • the degassed and filtered molten metal is cast to form cast feedstock 504 .
  • feedstock refers to any of a variety of aluminum alloys in the form of ingots, plates, slabs and strips, delivered to the hot rolling step 408 at a desired temperature.
  • An aluminum “ingot” typically has a thickness typically ranging from about 6 inches to about 36 inches.
  • An aluminum “plate,” on the other hand, herein typically refers to an aluminum alloy having a thickness from about 0.5 inches to about 6 inches.
  • a “strip” refers to an aluminum alloy having a thickness ranging from about 0.375 inches to about 3 inches (which range overlaps with an aluminum plate).
  • a “sheet” refers to an aluminum alloy in sheet form, typically having a thickness less than about 0.375 inches.
  • Ingots, slabs, plates, strips, and sheets are generally produced by direct chill casting, electromagnetic casting, or combinations thereof.
  • slabs and strips are produced by continuous casting techniques well known to those skilled in the art.
  • Continuous casting can be effected by any suitable continuous casting device, such as a twin belt caster like those described in U.S. Pat. Nos. 3,937,270; 5,363,902; 5,515,908; 5,564,491; and 6,102,102 (each of which is incorporated herein by reference), a drum caster like those described in U.S. Pat. Nos. 5,616,190 or 4,411,707 (each of which is incorporated herein by reference); or a block caster like those described in U.S. Pat. No. 5,469,912 (which is incorporated herein by reference).
  • a continuous strip casting technique which can be used in step 404 , is illustrated in FIG. 5.
  • the casting apparatus includes a pair of endless belts 508 a,b, carried by a pair of upper pulleys 512 a,b, and a pair of corresponding lower pulleys 516 a,b.
  • Each pulley 512 a,b and 516 a,b is mounted for rotation and is a suitable heat resistant pulley, Either or both of the upper pulleys 512 a,b are driven by suitable motor means or like driving means not illustrated in the drawing for purposes of simplicity, The same is true for the lower pulleys 516 a,b.
  • Each of the belts 508 a,b is an endless belt and is preferably formed of a metal that has low reactivity with the aluminum being cast. Stainless steel or copper is frequently preferred materials for use in the endless belts.
  • the pulleys 512 a,b and 516 a,b are positioned, as illustrated in FIG. 5, one above the other with a molding gap therebetween corresponding to the desired thickness of the aluminum strip 504 being cast.
  • Degassed and filtered Molten metal 500 to be cast is supplied to the molding gap through suitable metal supply means such as tundish 520 .
  • suitable metal supply means such as tundish 520 .
  • the inside of the tundish 520 corresponds substantially in width to the width of the belts 508 a,b and includes a metal supply delivery casting nozzle 524 to deliver molten metal 528 to the molding gap between the belts 508 a,b.
  • the casting apparatus also includes a pair of cooling devices 532 a - d positioned opposite that position of the endless belt in contact with the metal being cast in the molding gap between the belts.
  • the cooling devices 532 a - d cool the belts 508 a,b, respectively, while they are in contact with the molten metal.
  • the cooling devices 532 a - d are positioned as shown relative to the belts 508 a,b, respectively.
  • the cooling devices 532 a - d can be conventional cooling devices such as fluid nozzles positioned to spray a cooling fluid directly on the inside of belts 508 a,b to cool the belts through their thicknesses.
  • the feedstock 504 from between the belts 508 a,b is moved through optional pinch rolls 536 a,b into hot rolling stands 540 a - c, each including a pair of hot rolls 544 a,b, where the thickness of the feedstock is progressively decreased.
  • the feedstock After exiting from the caster and pinch rolls, the feedstock has a thickness typically ranging from about 0.5 to about 1.5 inches, more typically from about 0.6 to about 1 inch, and even more typically from about 0.65 to about 0.80 inches and a temperature above the solvus temperature and below the eutectic melting point and solidus temperature of the alloy, typically ranging from about 700 to about 1160° F., and even more typically ranging from about 750 to about 1050° F.
  • the cast feedstock 504 can be heated, preferably by a continuous or in line heater such as a solenoidal flux heater, after exit from the caster and before hot rolling as disclosed in U.S. Pat. Nos. 5,985,058, 5,993,573, 5,976,279, and 6,290,785, each of which is incorporated herein by this reference.
  • the cast feedstock 504 is reduced from the cast output gauge to a desired finish gauge.
  • the extent of the reductions in thickness effected by the hot rolling step 408 are subject to a wide variation, depending upon the types of alloys employed, their chemistry and the manner in which they are produced. For that reason, the percentage reduction in thickness of the hot rolling operation of the invention is not critical to the practice of the invention. However, for a specific product, known practices for reductions and temperatures must be used. Overall, the thickness of the cast feedstock is typically reduced by at least about 40%, more typically at least about 50%, and even more typically in the range of about 65% to about 99%.
  • the gauge of the hot rolled feedstock 548 output from the last hot rolling stand 540 c typically is no more than about 0.300 inches, more typically no more than about 0.200 inches, and even more typically ranges from about 0.180 to about 0.040 inches.
  • the thickness is preferably reduced by from about 30% to about 70% to produce an output gauge of from about 0.200 to about 0.400 inches
  • the thickness is preferably reduced by from about 30% to about 70% to produce an output gauge of from about 0.075 to about 0.250 inches
  • the third and final stand 540 c the thickness is preferably reduced by from about 30% to about 70% to produce the output gauge noted previously.
  • the output temperature of the (fully) hot rolled feedstock typically is at least about 250° F. and even more typically ranges from about 300 to about 1,000° F. It is to be understood that the number of hot rolling stands illustrated in FIG. 5 is not limiting. As will be appreciated, the number of hot mill stands used in hot rolling step 408 will vary depending on the input cast feedstock gauge and the output (fully) hot rolled feedstock gauge or finish gauge desired.
  • the hot rolled feedstock 548 exits the last hot rolling stand 540 c and is inputted into heater 552 for back annealing.
  • the heater 552 is any suitable heating device, such as a transflux induction heater, a gas fired heater, an oil fired heater, and an electric furnace, that has the capability of heating the hot rolled feedstock 548 to a temperature sufficient to back-anneal the feedstock 548 .
  • the heater can be batch or continuous, a continuous heater is preferred.
  • the feedstock 548 is immediately passed to the heater 552 for back-annealing while the feedstock 548 is still at or near the output temperature from the last hot rolling stand 540 c.
  • the average temperature of the hot rolled feedstock 548 when the feedstock is inputted into the heater is maintained preferably at a temperature of no less than about 50° F., more preferably no less than about 25° F., and even more preferably no less than about 0° F. less than the output temperature from the last hot rolling stand 540 c.
  • the average temperature of the hot rolled feedstock 548 when the feedstock is inputted into the heater is typically at least about 400° F., more typically at least about 425° F., and even more typically ranges from about 450 to about 550° F.
  • slow cooling following hot rolling is metallurgically desirable
  • the heating provided by heater 552 without intermediate cooling provides much improved metallurgical properties (grain size and formality) over conventional batch annealing and equal or better metallurgical properties compared to off-line flash annealing.
  • Table II provides a listing of specific alloys within the alloy families of Table I and provides, for each alloy and temper, the approximate feedstock thickness, the approximate ultimate tensile strength, the approximate yield strength, the approximate elongation percent (minimum in 2 inch or 4 inches in diameter), the approximate back anneal temperature range, and the approximate maximum percent recrystallization realized during back annealing.
  • the feedstock in a continuous back anneal preferably has a residence time of no more than about 120 seconds, more preferably no more than about 30 seconds, and even more preferably from about 1 to about 10 seconds and in a batch back anneal the feedstock has a residence time of more than about 8 hours, more preferably no more than about 5 hours, and even more preferably from about 1 to about 3 hours.
  • the back anneal temperature range is from about 600 to about 1,000° F., more generally from about 700 to about 950° F., and even more generally from about 700 to about 900° F.
  • the time and temperature of the anneal are selected such that the alloy is not completely recrystallized.
  • the maximum recrystallization is no more than about 60%.
  • the back anneal is conducted at a maximum temperature below the recrystallization temperature of the particular alloy.
  • the annealed feedstock 556 is coiled on a coiler 560 to form a roll.
  • back-annealing immediately follows hot rolling of the feedstock 504 to final thickness. “Immediately following” means that the time for a selected section of the feedstock to move from the last hot rolling stand 540 c to the opening of the heater 552 is no more than about 60 seconds, more preferably no more than about 15 seconds, and even more preferably no more than about 10 seconds.
  • the sequence and timing of process steps-in combination with, the back-annealing operation can provide equivalent or superior metallurgical characteristics in the final product.
  • the industry has normally employed slow air cooling after hot rolling. Only on some occasions are the hot rolling temperatures sufficient to allow annealing of the aluminum alloy before the metal cools down. It is common that the hot rolling temperature is not high enough to control back-annealing.
  • the prior art employed separate batch thermal steps before and/or after cold rolling in which the coil is placed in a furnace or heater maintained at a temperature sufficient to cause recrystallization or final mechanical properties.
  • the use of such furnace batch thermal operations represents a significant disadvantage. Such batch thermal operations require that the coil be heated for several hours at the correct temperature, after which such coils are typically cooled under ambient conditions.
  • the process of the present invention achieves final mechanical properties of the final product.
  • the use of the heater 552 allows the hot rolling temperature to be controlled independently from the back-annealing temperature. That in turn allows the use of hot rolling conditions that can maximize surface finish and texture (grain orientation).
  • the temperature of the feedstock 548 in the heater 552 can be elevated above the hot rolling temperature (or output temperature of the hot rolled feedstock 548 ) without the intermediate cooling suggested by the prior art. In that way mechanical properties can be effected rapidly, typically in less than about 30 seconds, and preferably in less than about 10 seconds for a continuous or in line back anneal.
  • the back-annealing operation consumes less energy since the alloy is already at an elevated temperature leaving the final hot rolling stand 540 c.
  • An advantage of the present invention arises from the fact that the preferred embodiment utilizes, as the finished gauge, a final hot rolling exit gauge rather than a cold rolling gauge as normally employed in the prior art.
  • the method of the invention obviates the need to employ breakdown cold rolling—prior to back-annealing.
  • the method of the present invention has, as a further advantage, the ability to produce a finished product where desired without the cold rolling step.
  • FIGS. 1 - 3 These advantages are illustrated graphically by FIGS. 1 - 3 .
  • FIG. 1 shows the thickness of intermediate and final feedstock (vertical axis) versus processing days (horizontal axis) during manufacture for both the minimill and the megamill processes.
  • the minimill process starts at about 0.75-inch thickness and takes 9 days.
  • the megamill process starts at about 0.750-inch thickness and takes 4 days (most of which is 1 day for the melting cycle and two days for coil cooling).
  • the individual vertical bars in FIG. 1 represent major processing and/or handling steps for the corresponding identified process.
  • FIG. 2 compares typical in-process feedstock temperatures (vertical axis) versus processing time (horizontal axis) for three methods of producing common alloy stock, namely a direct chill casting process, the minimill process, and the megamill process.
  • a direct chill casting process In the conventional ingot or DC casting process, there is a period for melting followed by a rapid cool during casting with a slow cool to room temperature thereafter.
  • the scalping process Once the scalping process is complete, the ingot is heated to a homogenization temperature before hot rolling. After hot rolling, the product is again cooled to room temperature. At this point, it is assumed in FIG. 2 that the hot rolling temperature and slow cool were sufficient to anneal the product. However, in some cases, a batch anneal step of about 600° F.
  • the in-line back-anneal step raises the temperature, and the hot rolled feedstock is immediately allowed to cool to room temperature.
  • the present invention differs substantially from the prior art in duration, frequency and rate of heating and cooling. As will be appreciated by those skilled in the art, these differences represent a significant departure from prior art practices for manufacturing aluminum common alloy sheet.
  • FIG. 3 plots feedstock temperature (vertical axis) against process step (vertical axis). The steps are melting, casting, hot rolling, back-annealing, and cooling. As can be seen from FIG. 3, the feedstock temperature only drops below about 400° F. after the back-annealing step. This figure shows the high degree of thermal efficiency of the megamill process.
  • the hot rolling temperature can be high enough to allow in-line self-back-annealing without the need for imparting additional heat to the hot rolled feedstock 548 by means of the heater 552 to raise the feedstock temperature.
  • the back-annealed feedstock can be subjected to further processing 412 , depending on the desired end product.
  • the feedstock can be subjected to leveling 416 , slitting 420 , painting 428 , or shearing to desired lengths.
  • the feedstock can be coiled and cooled to form coil sheet stock 424 .
  • other processing can be performed depending on the product.

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US38522702P 2002-05-31 2002-05-31
US42773202P 2002-11-19 2002-11-19
US43619402P 2002-12-23 2002-12-23
PCT/US2003/003754 WO2003066926A1 (fr) 2002-02-08 2003-02-07 Procede de realisation de feuille d'alliage d'aluminium
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Cited By (14)

* Cited by examiner, † Cited by third party
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US20050183801A1 (en) * 2004-02-19 2005-08-25 Ali Unal In-line method of making heat-treated and annealed aluminum alloy sheet
US20050186477A1 (en) * 2004-02-25 2005-08-25 Jae-Yul Ryu Current collector for a lithium secondary battery and a lithium secondary battery comprising the same
US20050189044A1 (en) * 2003-04-10 2005-09-01 Rinze Benedictus Al-Zn-Mg-Cu alloy with improved damage tolerance-strength combination properties
US20060032560A1 (en) * 2003-10-29 2006-02-16 Corus Aluminium Walzprodukte Gmbh Method for producing a high damage tolerant aluminium alloy
US20060174980A1 (en) * 2004-10-05 2006-08-10 Corus Aluminium Walzprodukte Gmbh High-strength, high toughness Al-Zn alloy product and method for producing such product
US20080173377A1 (en) * 2006-07-07 2008-07-24 Aleris Aluminum Koblenz Gmbh Aa7000-series aluminum alloy products and a method of manufacturing thereof
US20080251230A1 (en) * 2007-04-11 2008-10-16 Alcoa Inc. Strip Casting of Immiscible Metals
US20100119407A1 (en) * 2008-11-07 2010-05-13 Alcoa Inc. Corrosion resistant aluminum alloys having high amounts of magnesium and methods of making the same
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US8608876B2 (en) 2006-07-07 2013-12-17 Aleris Aluminum Koblenz Gmbh AA7000-series aluminum alloy products and a method of manufacturing thereof
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CN112207146A (zh) * 2020-10-29 2021-01-12 大力神铝业股份有限公司 铝合金板材的制备方法

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US10472707B2 (en) 2003-04-10 2019-11-12 Aleris Rolled Products Germany Gmbh Al—Zn—Mg—Cu alloy with improved damage tolerance-strength combination properties
US7666267B2 (en) 2003-04-10 2010-02-23 Aleris Aluminum Koblenz Gmbh Al-Zn-Mg-Cu alloy with improved damage tolerance-strength combination properties
US20050189044A1 (en) * 2003-04-10 2005-09-01 Rinze Benedictus Al-Zn-Mg-Cu alloy with improved damage tolerance-strength combination properties
US20060032560A1 (en) * 2003-10-29 2006-02-16 Corus Aluminium Walzprodukte Gmbh Method for producing a high damage tolerant aluminium alloy
US7182825B2 (en) * 2004-02-19 2007-02-27 Alcoa Inc. In-line method of making heat-treated and annealed aluminum alloy sheet
US20050183801A1 (en) * 2004-02-19 2005-08-25 Ali Unal In-line method of making heat-treated and annealed aluminum alloy sheet
US20050186477A1 (en) * 2004-02-25 2005-08-25 Jae-Yul Ryu Current collector for a lithium secondary battery and a lithium secondary battery comprising the same
US20060174980A1 (en) * 2004-10-05 2006-08-10 Corus Aluminium Walzprodukte Gmbh High-strength, high toughness Al-Zn alloy product and method for producing such product
US7883591B2 (en) 2004-10-05 2011-02-08 Aleris Aluminum Koblenz Gmbh High-strength, high toughness Al-Zn alloy product and method for producing such product
US20080173377A1 (en) * 2006-07-07 2008-07-24 Aleris Aluminum Koblenz Gmbh Aa7000-series aluminum alloy products and a method of manufacturing thereof
US20080210349A1 (en) * 2006-07-07 2008-09-04 Aleris Aluminum Koblenz Gmbh Aa2000-series aluminum alloy products and a method of manufacturing thereof
US8088234B2 (en) 2006-07-07 2012-01-03 Aleris Aluminum Koblenz Gmbh AA2000-series aluminum alloy products and a method of manufacturing thereof
US8608876B2 (en) 2006-07-07 2013-12-17 Aleris Aluminum Koblenz Gmbh AA7000-series aluminum alloy products and a method of manufacturing thereof
US8002913B2 (en) 2006-07-07 2011-08-23 Aleris Aluminum Koblenz Gmbh AA7000-series aluminum alloy products and a method of manufacturing thereof
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US8403027B2 (en) 2007-04-11 2013-03-26 Alcoa Inc. Strip casting of immiscible metals
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US8956472B2 (en) 2008-11-07 2015-02-17 Alcoa Inc. Corrosion resistant aluminum alloys having high amounts of magnesium and methods of making the same
WO2012125498A3 (fr) * 2011-03-11 2014-04-24 Fata Hunter, Inc. Laminoir de magnésium
US9248482B2 (en) 2011-03-11 2016-02-02 Fata Hunter, Inc. Magnesium roll mill
EA024683B1 (ru) * 2011-03-11 2016-10-31 Фата Хантер, Инк. Стан для прокатки магния
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CN112207146A (zh) * 2020-10-29 2021-01-12 大力神铝业股份有限公司 铝合金板材的制备方法

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