US20050166657A1 - Production of aluminum alloy sheet products in multi-product hot mills - Google Patents
Production of aluminum alloy sheet products in multi-product hot mills Download PDFInfo
- Publication number
- US20050166657A1 US20050166657A1 US10/768,210 US76821004A US2005166657A1 US 20050166657 A1 US20050166657 A1 US 20050166657A1 US 76821004 A US76821004 A US 76821004A US 2005166657 A1 US2005166657 A1 US 2005166657A1
- Authority
- US
- United States
- Prior art keywords
- rolls
- stock
- rolled
- sheet product
- critical quality
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 14
- 238000005096 rolling process Methods 0.000 claims abstract description 24
- 238000000034 method Methods 0.000 claims abstract description 22
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 20
- 239000000956 alloy Substances 0.000 claims abstract description 20
- 238000005098 hot rolling Methods 0.000 claims abstract description 11
- 238000000137 annealing Methods 0.000 claims abstract description 7
- 239000000203 mixture Substances 0.000 claims abstract 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 7
- 229910052749 magnesium Inorganic materials 0.000 claims description 7
- 239000011777 magnesium Substances 0.000 claims description 7
- 238000005219 brazing Methods 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 2
- 239000002184 metal Substances 0.000 claims description 2
- 239000000047 product Substances 0.000 description 18
- 239000000463 material Substances 0.000 description 9
- 239000002245 particle Substances 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 238000010409 ironing Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 238000012163 sequencing technique Methods 0.000 description 2
- KHOITXIGCFIULA-UHFFFAOYSA-N Alophen Chemical compound C1=CC(OC(=O)C)=CC=C1C(C=1N=CC=CC=1)C1=CC=C(OC(C)=O)C=C1 KHOITXIGCFIULA-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 235000013405 beer Nutrition 0.000 description 1
- 235000013361 beverage Nutrition 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000013507 mapping Methods 0.000 description 1
- 235000014214 soft drink Nutrition 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
Classifications
-
- 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
-
- 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
- B21B31/00—Rolling stand structures; Mounting, adjusting, or interchanging rolls, roll mountings, or stand frames
- B21B31/08—Interchanging rolls, roll mountings, or stand frames, e.g. using C-hooks; Replacing roll chocks on roll shafts
Definitions
- This invention relates to a method for improving the quality of rolled aluminum alloy sheet where sheet quality is very critical, e.g. can body stock produced in a multi-product hot rolling procedure.
- Modern metal cans as used for beverages such as soft drinks, beer and the like are commonly formed of a seamless one-piece body (which includes the bottom end and cylindrical sidewall of the can, and a top end bearing an opening).
- the body is produced from a blank of cold-rolled aluminum alloy sheet (can body stock) by a conventional forming technique known as drawing and ironing, which involves drawing the blank into a cup (cupping) and then passing it through a succession of dies to achieve the desired elongated cylindrical body configuration, with a sidewall of reduced thickness relative to the bottom.
- the sidewall may have a gauge of as little as 0.013-0.015 inch and as a consequence is very susceptible to failure if any kind of flaw or impurity exists in the can body stock. For example, the sidewall may split during the ironing process.
- Can body stock is typically formed from an AA 3XXX series alloy, e.g. AA 3104 alloy, which is direct-chill cast into large ingots which are scalped and homogenized, and successively hot rolled and cold rolled to the desired final gauge.
- AA 3XXX series alloy e.g. AA 3104 alloy
- the can body stock is typically rolled into sheet of a wide width of 60 inches or more in large centralized rolling mills.
- a rolling mill typically includes a series of roll stands which reduce the thickness of the ingot in stages by being compressed between rolls of successive stands, typically beginning with reversing rolls.
- These large rolling mills typically produce many products in addition to can body stock, and this necessitates the use of a flexible manufacturing procedure where different products are produced sequentially on the same mill.
- ingots of an aluminum alloy to be rolled are scalped and heated in a furnace to a required homogenizing temperature for several hours to ensure that the components of an alloy are uniformly distributed throughout the metallurgical structure. While still hot, the ingot is subjected to hot rolling in a number of passes using reversing or non-reversing mill stands which serve to reduce the thickness of the ingot. The slab thus formed is then fed to a tandem mill for hot finishing rolling, after which the sheet stock is coiled, air cooled and stored. The coiled sheet stock is subsequently cold rolled to final gauge.
- the patent provided a method for selecting setup parameters for rolling stands on a rolling mill by: (1) determining several web material classes according to similar hardness and rollability characteristics; (2) determining the thickness for web material of each class to have between rolling stands such that temperatures remain substantially constant; (3) selecting a product to produce from a particular web material; (4) determining which class includes web material of the product; (5) determining the exit thickness of the product; and (6) calculating the thickness including the entry thickness for the web material according to the class of the web material.
- the object of the present invention is to find a way of substantially preventing the transfer of small particles of iron/chrome material from the rolling mill rolls to highly critical sheet products during hot rolling.
- the rolling of highly critical sheet product is highly sensitive to how the rolls were used prior to rolling the particular stock.
- rolling of alloys having a high magnesium content e.g. an AA 5182 alloy
- These micro-annealed rolls were found to be a source of the very small particles embedded in the sheet products, such as can body stock. The problem, therefore, was how to avoid the small particles in the can body stock while continuing to use a rolling mill to process stocks other than can body stock, as well as can body stock, without the need to modify actual mill conditions.
- Rolls in a hot rolling mill are changed approximately twice during each week of production. It has been found that the problems that were occurring during the forming of aluminum alloy can sidewalls can be greatly decreased by hot rolling the can body stock within the first 72 hours of production time after the rolls have been changed and by selecting the order in which different products are produced such that products that generate sufficient heat during rolling to cause micro-annealing on the rolls are processed after the can body stock.
- the first 72 hours of production time includes normal times for minor maintenance as well as times for loading different process stocks, etc.
- actual stock rolling time during which the rolls are in contact with the stock is within about 32 hours.
- stocks that can affect the quality of the can body stock are run after the can body stock.
- These may include, in addition to alloys having a high concentration of magnesium, such materials as roll bite refusals and other mill upsets.
- Products such as cathode sheet, brazing sheet and anodize quality sheet may be rolled randomly with, i.e. before or after, the can body stock during the first production period, i.e. the first 72 hours, preferably 48 hours.
- the alloys having a high concentration of magnesium typically contain 4 to 5% by weight or more of magnesium. Examples of these alloys include AA5182, AA5086, AA5083, etc.
- cathode sheet alloys examples include AA1070 and AA1145, while an anodize quality sheet may, for example, be made of AA5005 alloy.
- the brazing sheet is typically a one- or two-sided sandwich or laminated construction formed of an AA3003 type core and a layer or layers of a 4XXX series alloy, such as AA4343, AA4045, AA4147.
- the 4XXX alloy typically comprises about 5 to 12% by weight of the brazing sheet.
- Micro-annealing of the surface of rolls typically occurs after the rolls reach a temperature of at least 575° F. During this micro-annealing, the surface of the rolls reach sufficient temperatures to soften the roll surface, which upon rolling of subsequent products can release the softened roll surface into the aluminum sheet. Avoiding the high temperature eliminates the risk of having the roll material released into the can stock sheet.
- the rolling of the can body stock was completed within about 30 hours after changing the rolls.
- the can stock contained no defects of the type that cause problems in a can plant during formation of can bodies.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Metal Rolling (AREA)
Abstract
Description
- This invention relates to a method for improving the quality of rolled aluminum alloy sheet where sheet quality is very critical, e.g. can body stock produced in a multi-product hot rolling procedure.
- Modern metal cans as used for beverages such as soft drinks, beer and the like are commonly formed of a seamless one-piece body (which includes the bottom end and cylindrical sidewall of the can, and a top end bearing an opening). The body is produced from a blank of cold-rolled aluminum alloy sheet (can body stock) by a conventional forming technique known as drawing and ironing, which involves drawing the blank into a cup (cupping) and then passing it through a succession of dies to achieve the desired elongated cylindrical body configuration, with a sidewall of reduced thickness relative to the bottom. The sidewall may have a gauge of as little as 0.013-0.015 inch and as a consequence is very susceptible to failure if any kind of flaw or impurity exists in the can body stock. For example, the sidewall may split during the ironing process.
- Can body stock is typically formed from an AA 3XXX series alloy, e.g. AA 3104 alloy, which is direct-chill cast into large ingots which are scalped and homogenized, and successively hot rolled and cold rolled to the desired final gauge.
- The can body stock is typically rolled into sheet of a wide width of 60 inches or more in large centralized rolling mills. Such a rolling mill typically includes a series of roll stands which reduce the thickness of the ingot in stages by being compressed between rolls of successive stands, typically beginning with reversing rolls. These large rolling mills typically produce many products in addition to can body stock, and this necessitates the use of a flexible manufacturing procedure where different products are produced sequentially on the same mill.
- In a typical operation, ingots of an aluminum alloy to be rolled are scalped and heated in a furnace to a required homogenizing temperature for several hours to ensure that the components of an alloy are uniformly distributed throughout the metallurgical structure. While still hot, the ingot is subjected to hot rolling in a number of passes using reversing or non-reversing mill stands which serve to reduce the thickness of the ingot. The slab thus formed is then fed to a tandem mill for hot finishing rolling, after which the sheet stock is coiled, air cooled and stored. The coiled sheet stock is subsequently cold rolled to final gauge.
- The production of can body stock is described in numerous U.S. patents such as U.S. Pat. Nos. 4,318,755, 4,614,224, 5,356,495, 5,470,405, etc.
- Ferreira and Horton, U.S. Pat. No. 5,609,053 looked at the problem of improving rolling mill efficiency when different products are sequentially being fed through a hot rolling mill. The patent provided a method for selecting setup parameters for rolling stands on a rolling mill by: (1) determining several web material classes according to similar hardness and rollability characteristics; (2) determining the thickness for web material of each class to have between rolling stands such that temperatures remain substantially constant; (3) selecting a product to produce from a particular web material; (4) determining which class includes web material of the product; (5) determining the exit thickness of the product; and (6) calculating the thickness including the entry thickness for the web material according to the class of the web material.
- A method of detecting surface flaws in rolled sheet is described in Smith et al, “The Use of an Electron Microprobe Mapping Technique to Improve Aluminum Hot Plate Surface Quality”, International Symposium on Aluminum Surface Science and Technology, Manchester, U.K., May 21-25, 2000. This attempted to detect surface flaws that could affect the final product.
- There has been an ongoing problem in can plants during the forming of the can bodies. Typically these have been cupper jams, tear offs in the body makers and split sidewalls during the ironing process. The historical interpretation of the defects has been linked to can plant tooling.
- It was eventually determined that the problem was being caused by very small particles embedded in the surface of the can body stock, as well as very small particles (10-100 μm) embodied within the sheet. These particles often fell out during the removal of a can from the can making press and because the particles are so small, accurate analysis of the specific alloy was challenging. It was eventually determined that the particles were iron/chrome based, but the source of these particles was not evident.
- Almost all rolls used in aluminum rolling mills are iron/chrome based and it was concluded that the rolling mill rolls must be the source of the problem.
- The object of the present invention is to find a way of substantially preventing the transfer of small particles of iron/chrome material from the rolling mill rolls to highly critical sheet products during hot rolling.
- According to the present invention, it has been found that the rolling of highly critical sheet product, such as can body stock, is highly sensitive to how the rolls were used prior to rolling the particular stock. For instance, rolling of alloys having a high magnesium content, e.g. an AA 5182 alloy, may cause elevated roll contact temperatures resulting in micro-annealing of the roll surfaces. These micro-annealed rolls were found to be a source of the very small particles embedded in the sheet products, such as can body stock. The problem, therefore, was how to avoid the small particles in the can body stock while continuing to use a rolling mill to process stocks other than can body stock, as well as can body stock, without the need to modify actual mill conditions.
- Rolls in a hot rolling mill are changed approximately twice during each week of production. It has been found that the problems that were occurring during the forming of aluminum alloy can sidewalls can be greatly decreased by hot rolling the can body stock within the first 72 hours of production time after the rolls have been changed and by selecting the order in which different products are produced such that products that generate sufficient heat during rolling to cause micro-annealing on the rolls are processed after the can body stock. The first 72 hours of production time includes normal times for minor maintenance as well as times for loading different process stocks, etc. Thus, actual stock rolling time during which the rolls are in contact with the stock is within about 32 hours.
- It is preferred to change the rolls about twice per week and to hot roll the can body stock within the first 48 hours of production time, with an actual contact of the rolls with the stock within about 21 hours.
- Thus, stocks that can affect the quality of the can body stock are run after the can body stock. These may include, in addition to alloys having a high concentration of magnesium, such materials as roll bite refusals and other mill upsets. Products such as cathode sheet, brazing sheet and anodize quality sheet may be rolled randomly with, i.e. before or after, the can body stock during the first production period, i.e. the first 72 hours, preferably 48 hours. The alloys having a high concentration of magnesium typically contain 4 to 5% by weight or more of magnesium. Examples of these alloys include AA5182, AA5086, AA5083, etc.
- Examples of cathode sheet alloys include AA1070 and AA1145, while an anodize quality sheet may, for example, be made of AA5005 alloy. The brazing sheet is typically a one- or two-sided sandwich or laminated construction formed of an AA3003 type core and a layer or layers of a 4XXX series alloy, such as AA4343, AA4045, AA4147. The 4XXX alloy typically comprises about 5 to 12% by weight of the brazing sheet.
- Micro-annealing of the surface of rolls typically occurs after the rolls reach a temperature of at least 575° F. During this micro-annealing, the surface of the rolls reach sufficient temperatures to soften the roll surface, which upon rolling of subsequent products can release the softened roll surface into the aluminum sheet. Avoiding the high temperature eliminates the risk of having the roll material released into the can stock sheet.
- It has been found that when the sequencing according to this invention such that the can body stock is processed at any time during a working cycle of a set of rolls, there were many occurrences of production problems in can plants using the can body stock. On the other hand, when the sequencing according to the invention is followed, production problems in can plants are almost totally eliminated.
- While the invention applies particularly to the production of can body stock, it can apply equally to any thin aluminum alloy sheet product wherein the quality of the sheet product is highly critical.
- A test was conducted on a commercial rolling mill with 120 inch rolls. The test was conducted over three days during which 434 coils aluminum alloy sheet were produced from ingots of 11 different alloys. These included 178 coils of can body stock from AA3104 aluminum alloy.
- The following product sequence was used:
Sequence Alloy No. of Coils 1 1100/1145 15 2 3003 59 3 3004 3 4 3104 178 5 5052 91 6 5182 17 7 5754 1 8 6061 1 9 6111 1 10 X308 22 11 29XX 14 - Following the can body stock (AA3104), the remaining products were run in the best available order based on delivery date, transitions and mill conditions.
- Within the above test, the rolling of the can body stock was completed within about 30 hours after changing the rolls. The can stock contained no defects of the type that cause problems in a can plant during formation of can bodies.
Claims (10)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002456243A CA2456243A1 (en) | 2004-01-28 | 2004-01-28 | Production of aluminum alloy sheet products in multi-product hot mills |
US10/768,210 US20050166657A1 (en) | 2004-01-28 | 2004-01-29 | Production of aluminum alloy sheet products in multi-product hot mills |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002456243A CA2456243A1 (en) | 2004-01-28 | 2004-01-28 | Production of aluminum alloy sheet products in multi-product hot mills |
US10/768,210 US20050166657A1 (en) | 2004-01-28 | 2004-01-29 | Production of aluminum alloy sheet products in multi-product hot mills |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050166657A1 true US20050166657A1 (en) | 2005-08-04 |
Family
ID=34912965
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/768,210 Abandoned US20050166657A1 (en) | 2004-01-28 | 2004-01-29 | Production of aluminum alloy sheet products in multi-product hot mills |
Country Status (2)
Country | Link |
---|---|
US (1) | US20050166657A1 (en) |
CA (1) | CA2456243A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100159275A1 (en) * | 2008-12-23 | 2010-06-24 | Jeffrey Edward Geho | Clad can stock |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4318755A (en) * | 1980-12-01 | 1982-03-09 | Alcan Research And Development Limited | Aluminum alloy can stock and method of making same |
US5356495A (en) * | 1992-06-23 | 1994-10-18 | Kaiser Aluminum & Chemical Corporation | Method of manufacturing can body sheet using two sequences of continuous, in-line operations |
US5470405A (en) * | 1992-06-23 | 1995-11-28 | Kaiser Aluminum & Chemical Corporation | Method of manufacturing can body sheet |
US5496423A (en) * | 1992-06-23 | 1996-03-05 | Kaiser Aluminum & Chemical Corporation | Method of manufacturing aluminum sheet stock using two sequences of continuous, in-line operations |
US5609053A (en) * | 1994-08-22 | 1997-03-11 | Alcan Aluminum Corporation | Constant reduction multi-stand hot rolling mill set-up method |
-
2004
- 2004-01-28 CA CA002456243A patent/CA2456243A1/en not_active Abandoned
- 2004-01-29 US US10/768,210 patent/US20050166657A1/en not_active Abandoned
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4318755A (en) * | 1980-12-01 | 1982-03-09 | Alcan Research And Development Limited | Aluminum alloy can stock and method of making same |
US5356495A (en) * | 1992-06-23 | 1994-10-18 | Kaiser Aluminum & Chemical Corporation | Method of manufacturing can body sheet using two sequences of continuous, in-line operations |
US5470405A (en) * | 1992-06-23 | 1995-11-28 | Kaiser Aluminum & Chemical Corporation | Method of manufacturing can body sheet |
US5496423A (en) * | 1992-06-23 | 1996-03-05 | Kaiser Aluminum & Chemical Corporation | Method of manufacturing aluminum sheet stock using two sequences of continuous, in-line operations |
US5609053A (en) * | 1994-08-22 | 1997-03-11 | Alcan Aluminum Corporation | Constant reduction multi-stand hot rolling mill set-up method |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100159275A1 (en) * | 2008-12-23 | 2010-06-24 | Jeffrey Edward Geho | Clad can stock |
WO2010071981A1 (en) * | 2008-12-23 | 2010-07-01 | Novelis Inc. | Clad can stock |
Also Published As
Publication number | Publication date |
---|---|
CA2456243A1 (en) | 2005-07-28 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: ALCAN INTERNATIONAL LIMITED, CANADA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:EPP, PHILIP J.;WOODLAND, RANDALL D.;SHUBER, JOHN A.;AND OTHERS;REEL/FRAME:015519/0091 Effective date: 20040315 |
|
AS | Assignment |
Owner name: CITICORP NORTH AMERICA, INC., NEW YORK Free format text: SECURITY INTEREST;ASSIGNORS:NOVELIS CORPORATION;NOVELIS INC.;REEL/FRAME:016369/0282 Effective date: 20050107 Owner name: CITICORP NORTH AMERICA, INC.,NEW YORK Free format text: SECURITY INTEREST;ASSIGNORS:NOVELIS CORPORATION;NOVELIS INC.;REEL/FRAME:016369/0282 Effective date: 20050107 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |
|
AS | Assignment |
Owner name: NOVELIS CORPORATION, OHIO Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:CITICORP NORTH AMERICA, INC.;REEL/FRAME:020487/0294 Effective date: 20080207 Owner name: NOVELIS INC., GEORGIA Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:CITICORP NORTH AMERICA, INC.;REEL/FRAME:020487/0294 Effective date: 20080207 Owner name: NOVELIS CORPORATION,OHIO Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:CITICORP NORTH AMERICA, INC.;REEL/FRAME:020487/0294 Effective date: 20080207 Owner name: NOVELIS INC.,GEORGIA Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:CITICORP NORTH AMERICA, INC.;REEL/FRAME:020487/0294 Effective date: 20080207 |