US20100034694A1 - Alloy - Google Patents

Alloy Download PDF

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Publication number
US20100034694A1
US20100034694A1 US12/489,908 US48990809A US2010034694A1 US 20100034694 A1 US20100034694 A1 US 20100034694A1 US 48990809 A US48990809 A US 48990809A US 2010034694 A1 US2010034694 A1 US 2010034694A1
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United States
Prior art keywords
alloy
electrograining
aluminium
strength
bend
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
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US12/489,908
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English (en)
Inventor
Glenn Crosbie Smith
Graham Alfred Flukes
Sarah Elizabeth Pickthall
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BRIDGNORTH ALUMINIUM Ltd
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BRIDGNORTH ALUMINIUM Ltd
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Assigned to BRIDGNORTH ALUMINIUM LTD. reassignment BRIDGNORTH ALUMINIUM LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Flukes, Graham Alfred, Smith, Glenn Crosbie, Pickthall, Sarah Elizabeth
Publication of US20100034694A1 publication Critical patent/US20100034694A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41N—PRINTING PLATES OR FOILS; MATERIALS FOR SURFACES USED IN PRINTING MACHINES FOR PRINTING, INKING, DAMPING, OR THE LIKE; PREPARING SUCH SURFACES FOR USE AND CONSERVING THEM
    • B41N1/00—Printing plates or foils; Materials therefor
    • B41N1/04—Printing plates or foils; Materials therefor metallic
    • B41N1/08—Printing plates or foils; Materials therefor metallic for lithographic printing
    • B41N1/083—Printing plates or foils; Materials therefor metallic for lithographic printing made of aluminium or aluminium alloys or having such surface layers
    • 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
    • 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

Definitions

  • This invention relates to an alloy suitable for processing into a lithographic sheet, to an alloy in the form of a thin rolled aluminium strip particularly for use by offset printing plate makers and to a method of processing such a lithographic sheet.
  • aluminium alloy in the form of a thin rolled aluminium strip is used by offset printing plate makers.
  • plate makers will initially degrease or etch the aluminium strip, typically in an alkaline solution. This process prepares the surface of the aluminium for graining, and evens out minor surface imperfections.
  • Electrograining is then carried out to create a surface topography with convoluted hemispherical pits. This is typically carried out in an electrolyte based on hydrochloric acid, or in one based on nitric acid.
  • Electrograining is carried out using an alternating current (AC) through an electrolytic cell containing the aluminium strip.
  • AC alternating current
  • the electrochemical reactions that take place on each half cycle effectively remove aluminium from the surface by dissolution.
  • the surface of the aluminium strip may be mechanically roughened, for example by brushing. This process is, however, less common.
  • the function of the pits formed in the surface of the aluminium strip is to increase the surface area of the aluminium strip, and to hold water. In other words, due to the presence of the pits, the aluminium strip becomes hydrophilic.
  • a desmutting step may then be carried out in order to remove aluminium hydroxide smut created during the electrograining process.
  • the aluminium strip is anodised. This results in the growth of a porous anodic oxide on the pitted surface of the aluminium strip.
  • This provides a hard wearing coating which enhances the longevity of print quality of a lithographic sheet formed from the aluminium strip. It also enables better adhesion of the light-sensitive coating and makes the plate more chemically inert, thus improving its shelf-life.
  • a photosensitive polymeric coating is then applied to the aluminium strip. This coating repels water, but attracts oil. It is required that the lithographic sheet attracts oil, since printing ink is oil-based.
  • the lithographic plate comprises a hydrophilic anodised aluminium layer covered by an oleophilic photosensitive layer.
  • an image is created by removing parts of the coating, for example by exposure to light.
  • the coating must also be hard-wearing in order to retain a well defined image during printing runs.
  • the aluminium strip used to form the lithographic sheet has sufficient strength and appropriate surface functionality.
  • surface functionality is used to describe the ability of a material to electrograin well in order to provide a uniform distribution in size of pits without any surface streakiness or directionality being formed. This is important for the quality of the resulting printed images.
  • the first alloy type is known as AA1050 and has the composition set out in Table 1 below. AA1050 exhibits good electrograining behaviour.
  • a material has “good electrograining behaviour” it means that the material has the ability to produce a uniformly pitted surface under a broad range of conditions. Such a material should also be capable of electrograining in either hydrochloric acid or nitric acid based electrolytes.
  • a second alloy type is known as AA3XXX and comprises AA3103 or AA3003 alloys having the compositions set out in Tables 2 and 3 below.
  • AA3XXX has improved strength when compared to the strength of AA1050.
  • the electrograining properties of AA3XXX are not as good as those of the AA1050 alloy type.
  • the AA1050 alloy type is traditionally used in the European, Asian and South American markets. This alloy type electrograins well in both HCl and HNO 3 based solutions, but has a lower strength compared to other alloys. This is thought to be a potential problem in situations where alloys are to be used to form a lithographic sheet for use in longer print runs.
  • the AA3XXX alloy type is traditionally used in North America. It is more difficult to electrograin this alloy type and therefore it is more often used when mechanical roughening processes may be applied.
  • AA3XXX alloys can be electrograined in HCl but the electrograining process may produce surface streakiness. These alloys, thus, have relatively poor electrograining behaviour, but have a high raw strength and high bake strength.
  • the wear resistance of the photosensitive coating is often improved by baking the lithographic plate. This process may, however, have an adverse effect on the strength of the aluminium substrate. This practice is more common in North America, and tends to explain the increased use of A3XXX.
  • the bake strength of an alloy is typically measured using a standard bake test.
  • the standard bake test involves heating the alloy for ten minutes at 240° C.
  • alloys to be used for processing into lithographic sheet do not soften significantly on baking, so that the strength of the alloy is not adversely affected.
  • Significant softening and the associated microstructural changes to the aluminium alloy substrate could also have a negative impact on the dimensional properties of the printing plate. This may be detrimental with respect to failure by fatigue.
  • an Al alloy suitable for processing into a lithographic sheet having a composition in weight % of:
  • the minimum aluminium content is 99.45 wt %. More preferably, the minimum aluminium content is 99.50 wt %.
  • the versatility of the alloy is further increased when recycling after use.
  • Magnesium is used to improve the graining performance of the alloy, but has a limited influence on the strength of the alloy. Magnesium does however improve the mechanical properties (such as the strength) of both the raw and baked alloy and therefore its presence in the alloy is important. However limiting the range of magnesium to 0.10 wt % is important insofar as it does not compromise the versatility of the alloy for recycling purposes.
  • An alloy according to the present invention may contain up to 0.099 wt % magnesium.
  • the magnesium content is within the range 0.02 to 0.05 wt %.
  • Zinc also improves the graining performance of the alloy but also has limited influence on the strength of the alloy. It has been found by the inventors that a weight percentage of up to 0.05 of zinc in the aluminium alloy can have beneficial effects in respect of the electrochemical properties of the alloy.
  • the minimum zinc content is 0.02 wt %.
  • the ratio of zinc to magnesium in the alloy may be substantially within the range 0.1 to 2.3.
  • the presence of iron in the aluminium alloy serves two purposes. The first is to ensure the formation of iron rich intermetallics which are essential for the development of a homogeneous pit structure during the electrograining (roughening) step of the plate making process. The second is to ensure that there is sufficient iron in the solid solution within the material which is beneficial for good temperature stability properties, and particularly to strength retention after plate baking.
  • An advantage of the alloy having a minimum iron content is that it ensures that a sufficient number of 2nd phase intermetallics are present in the structure of the alloy. This in turn can only be achieved when the level of iron solubility in aluminium is exceeded.
  • Increasing the iron content of the alloy is advantageous because iron provides a hardening effect in aluminium alloys, thus increasing the strength of the alloy.
  • titanium in an aluminium alloy is necessary to ensure adequate metallurgical grain size control.
  • too much titanium can have an adverse effect on the electrochemical performance of the alloy.
  • the inventors have found that if the weight percentage of titanium is no more than 0.015 the alloy can benefit from the grain size control effected by the titanium, but at the same time the adverse effects on the electrochemical performance are kept to a minimum.
  • An alloy according to the present invention may contain up to 0.049 wt % manganese.
  • the minimum manganese content is 0.005 wt %.
  • the presence of manganese in the alloy serves to increase both the raw and baked strength of the alloy.
  • the manganese may have a negative impact on the electrograining behaviour of the alloy and therefore the level of manganese in the alloy should not be too high.
  • the manganese content falls within the range 0.005 to 0.030 wt %.
  • the manganese to magnesium ratio is substantially within the range 0.08 to 1.63.
  • a lithographic sheet formed from an alloy according to the first aspect of the present invention.
  • a method for processing a lithographic sheet formed from an alloy according to the first aspect of the present invention is provided.
  • FIG. 1 is a graphical representation showing the ultimate tensile strength in the longitudinal direction of examples 1, 2, 3 and 4 identified above, in a raw, unbaked state and after having been baked at each of 200° C., 220° C., 240° C. and 260° C. for ten minutes, compared to known alloy groups AA3XXX and AA1050.
  • FIG. 2 is a graphical representation showing the proof stress (R p ) in the longitudinal direction of examples 1, 2, 3 and 4 identified above, in a raw, unbaked state and after having been baked at each of 200° C., 220° C., 240° C. and 260° C. for ten minutes, compared to known alloy group AA1050.
  • FIG. 3 is a graphical representation showing the ultimate tensile strength in the transverse direction of examples 1, 2, 3 and 4 identified above, in a raw, unbaked state and after having been baked at each of 200° C., 220° C., 240° C. and 260° C. for ten minutes, compared to known alloy group AA1050.
  • FIG. 4 is a graphical representation showing the proof stress (R p ) in the transverse direction of examples 1, 2, 3 and 4 identified above, in a raw, unbaked state and after having been baked at each of 200° C., 220° C., 240° C. and 260° C. for ten minutes, compared to known alloy group AA1050.
  • FIGS. 5 and 5 a are micrographs, each showing a cross section of a sample of an AA1050 alloy after undergoing a bend test.
  • FIG. 5 is at a magnification of ⁇ 200 and
  • FIG. 5 a is at a magnification of ⁇ 100.
  • FIGS. 6 and 6 a are micrographs, each showing a cross section of a sample of Example 1, identified above, after undergoing a bend test.
  • FIG. 6 is at a magnification of ⁇ 200 and
  • FIG. 6 a is at a magnification of ⁇ 100.
  • FIG. 7 is a micrograph showing the outer bend surface in more detail of the sample of AA1050 shown in FIG. 5 ; and is at a magnification of ⁇ 112.5.
  • FIG. 8 is a micrograph showing the outer bend surface in more detail of the sample of Example 1 shown in FIG. 6 .
  • FIG. 8 is at a magnification of ⁇ 112.5.
  • the tensile strength, or ultimate tensile strength/stress (UTS) is the highest load applied to a material in the course of a tensile test, divided by the original cross-sectional area of the material. In brittle or tough materials it coincides with the point of fracture, but usually extension continues under a decreasing stress after the UTS has been passed.
  • the proof stress (R p ) is the stress required to produce a certain amount of permanent set (plastic deformation) in metals that do not exhibit a distinct yield point.
  • proof stress is the stress producing a strain of 0.2% (R p 0.2).
  • the standard bake test is ten minutes at 240° C.
  • additional temperatures namely 200, 220 and 260° C., are also examined in order to show the behaviour of strength of each alloy, and how it reduces with different bake conditions.
  • each of Examples 1 to 4 has a higher ultimate tensile strength in the longitudinal direction, both in the raw unbaked state and at the identified temperatures, when compared to the AA1050 group of alloys.
  • the AA3XXX group of alloys does, however, have higher strength than the Examples 1 to 4.
  • FIG. 2 shows that each of the Examples 1 to 4 has a higher proof stress in the longitudinal direction, both in the raw unbaked state and at the identified temperatures, than the AA1050 group of alloys.
  • FIG. 3 shows that each of the Examples 1 to 4 has a higher ultimate tensile strength in the transverse direction, both in the raw unbaked state and at the indicated temperatures, than the AA1050 group of alloys.
  • FIG. 4 shows that each of the Examples 1 to 4 has a higher proof stress in the transverse direction than the AA1050 group of alloys, both in the raw state and at the temperatures indicated.
  • the bend test used is a static test based on making and examining a bend which is used to fix a lithographic plate onto a printing press.
  • a static test is deemed to be most appropriate, as the nature of the material (for example the alloy composition, the temper, and the method of processing the alloy) has a significant impact on the initial bend, yet a limited impact on fatigue. It is understood that failure by fatigue is mostly determined by the bend dimensions and the material gauge.
  • the thickness measurements of the samples were kept as constant as possible, ranging between 0.275 and 0.280 mm.
  • the inside bend radius and gauge largely determine the amount of strain on the outer surface of the bend. This can vary significantly with only a small change in set up parameters. Therefore, the inside bend radius is kept constant.
  • the aluminium litho plate would be bent using a plate bender.
  • a plate bender is associated with a printing press and is the piece of equipment that is used to form the bend.
  • a simple bend of 60° around a set radius was made to simulate the plate bender. 60° is in the region of typically used bend angles.
  • the tests were carried out in two directions, with the bend axis parallel to, and perpendicular to, the rolling direction of the plate.
  • the rolling direction is the direction in which the aluminium sheet is processed during rolling.
  • FIGS. 5 to 8 Micrographs showing bend test data for a sample of a AA1050 alloy and for a sample of Example 1 as identified above are shown in FIGS. 5 to 8 .
  • FIGS. 5 and 5 a are micrographs showing a cross section of the sample of the AA1050 alloy after undergoing a bend test, as described above. It can be seen from these figures that there is inward distortion on the inner surface of the alloy caused by compressive deformation of the inner bend surface. This distortion is in the encircled area identified by the reference numeral 1 . Compressive deformation can be gauged by the level of inward distortion.
  • FIGS. 6 and 6 a show a cross section of a sample of Example 1, as identified above, after undergoing a similar bend test. It can be seen from these figures that there is reduced inner bend deformation shown in area 3 , and the outer surface is smoother as shown in area 4 , when compared to the outer surface of the sample of AA1050 alloy shown in FIGS. 5 and 5 a.
  • FIGS. 7 and 8 show in more detail the outer bend surface of the sample of AA1050 alloy and a sample of Example 1, respectively. Again it can be seen from FIG. 7 , in the encircled areas labelled with the reference numeral 5 , that deep ridges exist in the sample of AA1050 alloy when compared to the sample of Example 1.
  • the “easy” laboratory condition is achieved by electrograining for 24 seconds.
  • the “intermediate” condition is achieved by electrograining for 9.5 seconds.
  • the “difficult” condition is achieved by electrograining for 6.5 seconds.
  • the present invention therefore provides an aluminium alloy having improved strength compared to the AA1050 alloy type, and improved electrograining behaviour compared to the AA3XXX alloy type.
  • a process for forming a lithographic sheet according to the present invention will now be briefly described.
  • the process may be viewed as three sub-processes; the production of alloy and slab casting; the production of thin rolled aluminium strip; and the production of a lithographic sheet. These processes will now be described in further detail.
  • Rolling sheet ingot is made by DC (direct chill) casting of molten aluminium.
  • the elemental composition of the metal is controlled to the described levels by appropriate additions.
  • the ingots are typically between 400-650 mm in thickness.
  • Scalping of the rolling sheet ingot is carried out to improve surface cleanliness and uniformity by removing the casting skin. Up to 25 mm in total is removed from both surfaces.
  • Pre-heating is carried out to achieve exit metal temperatures of 400-600° C. for hot rolling.
  • the ingot is hot rolled in multiple passes to a plate gauge of between 11-18 mm thick.
  • In-line quenching reduces the plate temperature to ⁇ 50° C.
  • the plate is then cold rolled to an intermediate gauge.
  • the target metal temperature is between 350-550° C.
  • the coil can then be leveled and degreased before supply for the production of lithographic sheet.
  • the surface is prepared for roughening by an alkaline-based etching process.
  • Roughening is preferably achieved by electrograining. This is carried out in an electrolyte based on hydrochloric acid, or an electrolyte based on nitric acid. An AC current is applied to the electrograining bath to achieve roughening.
  • the electrograined surface is anodised to improve wear resistance.
  • a photosensitive coating is applied.
  • the plate After the plate has been imaged, it can be baked to improve the wear resistance of the photosensitive coating.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Printing Plates And Materials Therefor (AREA)
  • Conductive Materials (AREA)
US12/489,908 2008-06-24 2009-06-23 Alloy Abandoned US20100034694A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0811534.7 2008-06-24
GB0811534A GB2461240A (en) 2008-06-24 2008-06-24 Aluminium alloy for lithographic sheet

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US (1) US20100034694A1 (de)
EP (1) EP2138592A3 (de)
JP (1) JP2010012779A (de)
CN (1) CN101613821A (de)
BR (1) BRPI0902046A2 (de)
GB (1) GB2461240A (de)
TW (1) TWI405856B (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015192448A1 (zh) * 2014-06-18 2015-12-23 厦门厦顺铝箔有限公司 铝合金制品及其制造方法

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Publication number Priority date Publication date Assignee Title
JP2013177685A (ja) * 2013-04-11 2013-09-09 Kobe Steel Ltd 自動製版印刷版用高強度アルミニウム合金板

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US726734A (en) * 1901-09-27 1903-04-28 Rowland Telegraphic Company Electric circuit.
US7267734B2 (en) * 1999-05-27 2007-09-11 Novelis Inc. Aluminum alloy sheet
US6447982B1 (en) * 1999-07-02 2002-09-10 Vaw Aluminium Ag Litho strip and method for its manufacture
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015192448A1 (zh) * 2014-06-18 2015-12-23 厦门厦顺铝箔有限公司 铝合金制品及其制造方法

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JP2010012779A (ja) 2010-01-21
GB2461240A9 (en) 2011-01-19
GB0811534D0 (en) 2008-07-30
CN101613821A (zh) 2009-12-30
BRPI0902046A2 (pt) 2010-04-20
EP2138592A3 (de) 2012-05-23
EP2138592A2 (de) 2009-12-30
TWI405856B (zh) 2013-08-21
GB2461240A (en) 2009-12-30
TW201012942A (en) 2010-04-01

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