US20190176224A1 - Apparatus for producing thin metal strip and method for producing thin metal strip using the same - Google Patents

Apparatus for producing thin metal strip and method for producing thin metal strip using the same Download PDF

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Publication number
US20190176224A1
US20190176224A1 US15/779,741 US201615779741A US2019176224A1 US 20190176224 A1 US20190176224 A1 US 20190176224A1 US 201615779741 A US201615779741 A US 201615779741A US 2019176224 A1 US2019176224 A1 US 2019176224A1
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Prior art keywords
molten metal
outer peripheral
peripheral surface
cooling roll
producing
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US15/779,741
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English (en)
Inventor
Tatsuo Nagata
Sukeyoshi Yamamoto
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Nippon Steel Corp
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Nippon Steel Corp
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Assigned to NIPPON STEEL CORPORATION reassignment NIPPON STEEL CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: NIPPON STEEL & SUMITOMO METAL CORPORATION
Publication of US20190176224A1 publication Critical patent/US20190176224A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0611—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by a single casting wheel, e.g. for casting amorphous metal strips or wires
    • B22D11/0614—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by a single casting wheel, e.g. for casting amorphous metal strips or wires the casting wheel being immersed in a molten metal bath, and drawing out upwardly the casting strip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0637—Accessories therefor
    • B22D11/064—Accessories therefor for supplying molten metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0634—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by a casting wheel and a co-operating shoe
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0637—Accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/10—Supplying or treating molten metal
    • B22D11/103—Distributing the molten metal, e.g. using runners, floats, distributors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/10—Supplying or treating molten metal
    • B22D11/11—Treating the molten metal
    • B22D11/112—Treating the molten metal by accelerated cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/003—Apparatus, e.g. furnaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
    • B22F2009/048—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by pulverising a quenched ribbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0425—Copper-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/18—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on silicides

Definitions

  • the present invention relates to an apparatus for producing a thin metal strip and a method for producing a thin metal strip using the apparatus.
  • rapid solidification process can provide metal materials with various properties.
  • the rapid solidification process refers to a process for solidifying molten metal at a certain cooling rate or higher.
  • the rapid solidification process enables, for example, refining crystal structures of a metal material, homogenizing a solute distribution, increasing a solid-solubility limit, producing amorphous layers (amorphous), and producing thermodynamic non-equilibrium phases.
  • known methods for producing a cast piece by the rapid solidification process include the strip casting process, the melt spinning process, the atomization process, the melt spinning process, and the like.
  • the melt spinning process is a method in which molten metal is jetted and rapidly cooled on a roll rotating at high speed to produce a ribbon-shaped thin metal strip in a flying manner.
  • a jet of a small amount of molten metal is supplied onto the roll. Therefore, the cooling rate is high.
  • the melt spinning process enables the production of a thin metal strip including fine grains.
  • a small amount of the molten metal is supplied onto the roll. Therefore, the melt spinning process has its limitation in production capability and has a difficulty of producing a thin metal strip in volume.
  • a method capable of producing a thin metal strip in volume is, for example, a single roll strip casting process.
  • the single roll strip casting process is a method for producing a thin metal strip by continuously supplying molten metal onto a rotating roll to rapidly cool the molten metal.
  • Methods for producing a cast piece using the strip casting process are, for example, described in Japanese Patent Application Publication No. 2011-206835 (Patent Literature 3) and Japanese Patent Application Publication No. 2001-291514 (Patent Literature 4).
  • the producing apparatus described in Japanese Patent Application Publication No. 2011-206835 is a producing apparatus for an aluminum clad plate.
  • This producing apparatus includes a first roll with a cooling capability and a first pool for storing first molten alloy.
  • the first pool is surrounded by a surface of the first roll, a first front plate, a rear member, and both-side members.
  • the first front plate lies forward of the first roll in a rotation direction.
  • the rear member lies rearward of the first roll in the rotation direction.
  • the first front plate includes a front edge portion and is movably provided such that the distance between the front edge portion and the surface of the first roll can vary.
  • the first roll cools the first molten alloy in the first pool to form a first metallic layer in a semi-solidified state or a solidified state on the surface of the first roll and rotates with the first metallic layer.
  • the first front plate is urged so that the front edge portion of the first front plate always abuts against a semi-solidified surface of the first metallic layer moving with the rotation of the first roll, at given force.
  • the strip casting process In the strip casting process, the amount of molten metal supplied onto a roll is large as compared with the melt spinning process. Therefore, the strip casting process enables the production of a thin metal strip in large volume. However, in the strip casting process, the cooling rate of the molten metal is low as compared with the melt spinning process. Therefore, the strip casting process has a difficulty of refining grains. For that reason, the strip casting process is requested to provide more refined grains.
  • Patent Literature 1 International Application Publication No. WO2012/099056
  • Patent Literature 2 Japanese Patent Application Publication No. 2013-161785
  • Patent Literature 4 Japanese Patent Application Publication No. 2001-291514
  • An objective of the present invention is to provide an apparatus for producing a thin metal strip that is capable of efficiently producing a thin metal strip including fine grains.
  • a producing apparatus is an apparatus for producing a thin metal strip by a single roll strip casting process.
  • the producing apparatus includes a cooling roll, a tundish, and a molten metal remover.
  • the cooling roll includes an outer peripheral surface and is configured to cool and solidify molten metal on the outer peripheral surface while rotating.
  • the tundish can accommodate the molten metal and is configured to supply the molten metal onto the outer peripheral surface of the cooling roll.
  • the molten metal remover is disposed downstream of the tundish in the rotating direction of the cooling roll with a gap provided between the molten metal remover and the outer peripheral surface of the cooling roll.
  • the molten metal remover is configured to remove a portion of a thickness of the molten metal on the outer peripheral surface of the cooling roll that is larger than the width of the gap described above. As a result, the thickness of the molten metal on the outer peripheral surface of the cooling roll is cut down to the width of the gap between the outer peripheral surface of the cooling roll and the molten metal remover.
  • a method for producing a thin metal strip according to the present embodiment is a method for producing a thin metal strip by a single roll strip casting process using the producing apparatus described above.
  • the producing method includes a supplying step, a rapid cooling step, and a thickness adjustment step.
  • the supplying step the molten metal in the tundish is supplied onto the outer peripheral surface of the cooling roll.
  • the rapid cooling step the molten metal on the outer peripheral surface is rapidly cooled with the cooling roll to be formed into the thin metal strip.
  • the thickness adjustment step a portion of a thickness of the molten metal on the outer peripheral surface of the cooling roll that is larger than the width of the gap described above is removed by the molten metal remover. As a result, the thickness of the molten metal on the outer peripheral surface is cut down to the width of the gap between the outer peripheral surface of the cooling roll and the molten metal remover.
  • Using the apparatus for producing a thin metal strip according to the present embodiment enables a thin metal strip including fine grains to be produced efficiently.
  • FIG. 1 is a cross-sectional view of an apparatus for producing a thin metal strip according to the present embodiment.
  • FIG. 2 is a cross-sectional view of the vicinity of a front edge of a molten metal remover of the producing apparatus in an enlarging manner.
  • FIG. 3 is a diagram illustrating an attachment angle of the molten metal remover.
  • FIG. 6 is a diagram illustrating the cross sectional shape of a molten metal remover.
  • FIG. 7 is a diagram illustrating the cross sectional shape of a molten metal remover different from that illustrated in FIG. 6 .
  • FIG. 8 is a diagram illustrating the cross sectional shape of a molten metal remover different from those illustrated in FIG. 6 and FIG. 7 .
  • FIG. 9 is a picture of a cross section of a thin metal strip produced by a production method according to the present embodiment, taken under an electron microscope (SEM).
  • FIG. 10 is a picture of a cross section of a thin metal strip produced without using the molten metal remover, taken under the electron microscope (SEM).
  • a producing apparatus is an apparatus for producing a thin metal strip by a single roll strip casting process.
  • the producing apparatus includes a cooling roll, a tundish, and a molten metal remover.
  • the cooling roll includes an outer peripheral surface and is configured to cool and solidify molten metal on the outer peripheral surface while rotating.
  • the tundish can accommodate the molten metal and is configured to supply the molten metal onto the outer peripheral surface of the cooling roll.
  • the molten metal remover is disposed downstream of the tundish in the rotating direction of the cooling roll with a gap provided between the molten metal remover and the outer peripheral surface of the cooling roll.
  • the molten metal remover is configured to remove a portion of a thickness of the molten metal that is larger than the width of the gap described above (hereafter, also referred to as a surface portion). As a result, the thickness of the molten metal on the outer peripheral surface of the cooling roll is cut down to the width of the gap between the outer peripheral surface of the cooling roll and the molten metal remover.
  • the producing apparatus includes a molten metal remover.
  • the molten metal remover is configured to be in contact with the molten metal when a free surface of the molten metal (a surface of the molten metal on a side on which the molten metal is not in contact with the cooling roll) in a liquid state or a semi-solidified state.
  • the molten metal remover is configured to remove the surface portion of the molten metal on the outer peripheral surface.
  • the thickness of the molten metal on the outer peripheral surface of the cooling roll is cut down to the width of the gap between the outer peripheral surface of the cooling roll and the molten metal remover.
  • the molten metal on the outer peripheral surface of the cooling roll becomes thin.
  • the cooling rate of the molten metal increases.
  • grains in the thin metal strip become small.
  • by using the strip casting it is possible to efficiently produce a thin metal strip including fine grains.
  • by cutting down the width of the thickness of the molten metal to the width of the gap as described above it is possible to perform rapid solidification without being affected not much by viscosity of the molten metal, wettability to the roll material, supply amount of the molten metal, and the like.
  • the width of a gap between the outer peripheral surface of the cooling roll and the molten metal remover is smaller than the thickness of the molten metal on the outer peripheral surface of the cooling roll on an upstream side of the molten metal remover in the rotating direction of the cooling roll.
  • the molten metal on the outer peripheral surface of the cooling roll becomes thinner. Therefore, the cooling rate of the molten metal becomes higher. As a result, the grains in the thin metal strip are more refined.
  • the tundish is disposed in the vicinity of the outer peripheral surface of the cooling roll and includes a supply end configured to guide the molten metal onto the outer peripheral surface of the cooling roll.
  • the molten metal remover is disposed above the supply end of the tundish.
  • the molten metal is cooled while being wound up by the cooling roll. Therefore, the time for which the molten metal is in contact with the outer peripheral surface of the cooling roll is long, and the cooling time of the molten metal is long. As a result, the grains in the thin metal strip are more refined.
  • molten metal remover is disposed opposite to the outer peripheral surface of the cooling roll and includes a heat dissipation surface configured to be in contact with the molten metal passing through the gap between the outer peripheral surface of the cooling roll and the molten metal remover.
  • the molten metal is subjected to heat dissipation from a surface in contact with the molten metal remover, as well as a surface in contact with the cooling roll (hereafter, also referred to as a solidified portion). Therefore, the cooling rate of the molten metal becomes high. As a result, the grains in the thin metal strip are more refined.
  • a method for producing a thin metal strip according to the present embodiment is a method for producing a thin metal strip by a single roll strip casting process using the producing apparatus described above.
  • the producing method includes a supplying step, a rapid cooling step, and a thickness adjustment step.
  • the supplying step the molten metal in the tundish is supplied onto the outer peripheral surface of the cooling roll.
  • the rapid cooling step the molten metal on the outer peripheral surface is rapidly cooled with the cooling roll to be formed into the thin metal strip.
  • the thickness adjustment step a portion of a thickness of the molten metal on the outer peripheral surface of the cooling roll that is larger than the width of the gap described above is removed by the molten metal remover. As a result, the thickness of the molten metal on the outer peripheral surface is cut down to the width of the gap between the outer peripheral surface of the cooling roll and the molten metal remover.
  • the producing method according to the present embodiment includes the thickness adjustment step.
  • the thickness adjustment step Through the thickness adjustment step, the molten metal on the outer peripheral surface of the cooling roll becomes thin. Therefore, the cooling rate of the molten metal becomes high. As a result, the grains in the thin metal strip are refined. In other words, by using the strip casting process, it is possible to efficiently produce a thin metal strip including fine grains.
  • the thin metal strip produced by the above production method of a thin metal strip may contain a chemical composition that includes Cu and Sn, and may contain a phase having D0 3 structure in the Strukturbericht notation.
  • the powder obtained by pulverizing this thin metal strip can be used as a negative electrode active material for a nonaqueous electrolyte secondary battery, such as a lithium ion secondary battery.
  • This negative electrode active material has excellent charge-discharge capacity and capacity retention characteristics.
  • a chemical composition of the above thin metal strip consists of, for example, 10 to 20 at % or 21 to 27 at % of Sn, with the balance being Cu and impurities.
  • the chemical composition of the above thin metal strip may further contain one or more selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Zn, Al, Si, B, and C in place of a part of Cu.
  • the ratio of the phase having D0 3 structure (hereinafter referred to as D0 3 phase) can be increased. Therefore, battery characteristics (capacity retention rate etc.) are increased.
  • FIG. 1 is a cross-sectional view of an example of an apparatus for producing a thin metal strip according to the present embodiment.
  • a producing apparatus 1 includes a cooling roll 2 , a tundish 4 , and a molten metal remover 5 .
  • the cooling roll 2 has an outer peripheral surface and is configured to cool and solidify molten metal 3 on the outer peripheral surface while rotating.
  • the cooling roll 2 includes a column-shaped barrel portion and a shaft portion not illustrated.
  • the barrel portion includes the outer peripheral surface described above.
  • the shaft portion is disposed at a central axis position of the barrel portion and attached to a driving source not illustrated.
  • the cooling roll 2 is configured to be rotated about a central axis 9 of the cooling roll 2 by the driving source.
  • the starting material of the cooling roll 2 is preferably a material having a high hardness and a high thermal conductivity.
  • the starting material of the cooling roll 2 is, for example, one selected from the group consisting of copper and copper alloys.
  • the starting material of the cooling roll 2 is preferably copper.
  • the cooling roll 2 may further include a coating on its surface. This inclusion of the coating increases the hardness of the cooling roll 2 . Therefore, it is advantageous, particularly in mass production.
  • the coating is, for example, one or two selected from the group consisting of plating coating and cermet coating.
  • the plating coating is, for example, one or two selected from the group consisting of chromium plating and nickel plating.
  • the cermet coating contains, for example, one, or two or more selected from the group consisting of tungsten (W), cobalt (Co), titanium (Ti), chromium (Cr), nickel (Ni), silicon (Si), aluminum (Al), boron (B), and carbides, nitrides, and carbo-nitrides of these elements. It is preferable that the outer layer of the cooling roll 2 is made of copper, and the cooling roll 2 further includes a chromium plating coating on its surface.
  • Reference character X illustrated in FIG. 1 denotes the rotating direction of the cooling roll 2 .
  • the cooling roll 2 rotates in a given direction X.
  • the molten metal 3 coming into contact with the cooling roll 2 is partially solidified on the outer peripheral surface of the cooling roll 2 and moves with the rotation of the cooling roll 2 .
  • the cooling roll 2 includes a cooling zone that lies downstream of the tundish 4 to be described later in the rotating direction of the cooling roll 2 but does not reach the molten metal remover 5 to be described later.
  • the molten metal 3 supplied onto the outer peripheral surface of the cooling roll 2 has a free surface. Therefore, rapid cooling is enabled. If the molten metal 3 has no free surface, that is, if a solidified portion of the molten metal 3 is covered with another portion of molten metal 3 , the solidified portion cannot be subjected to sufficient heat dissipation. This is because heat is continuously added to the solidified portion from the molten metal 3 lying on the solidified portion.
  • the molten metal 3 is made to have the free surface by being supplied onto the outer peripheral surface of the cooling roll 2 . Therefore, the solidified portion can be subjected to sufficient heat dissipation, which enables the rapid cooling. As a result, it is possible to obtain the thin metal strip 6 including more refined grains.
  • the roll peripheral speed of the cooling roll 2 is set as appropriate in consideration of the cooling rate and the efficiency of manufacturing of the molten metal 3 .
  • the upper limit of the roll peripheral speed is not particularly limited but, for example, 500 m/min in consideration of a plant capacity.
  • the roll peripheral speed can be determined from the diameter and the number of revolutions of the roll.
  • the inside of the cooling roll 2 may be filled with solvent for the heat dissipation. It is thereby possible to subject the molten metal 3 to the heat dissipation efficiently.
  • the solvent is, for example, one, or two or more selected from the group consisting of water, organic solvent, and oil.
  • the solvent may stay inside the cooling roll 2 or may be circulated through the outside.
  • the tundish 4 can accommodate the molten metal 3 and is configured to supply the molten metal 3 onto the outer peripheral surface of the cooling roll 2 .
  • the tundish 4 may always be heated. In this case, the melted state of the molten metal 3 having a high fusing point can be maintained. As a result, the molten metal 3 can be removed remaining in the melted state, with the molten metal remover 5 to be described later.
  • a heating temperature is not particularly limited as long as the heating temperature is equal to or higher than the liquidus temperature of a raw material. In a case of producing a Si alloy, the heating temperature is, for example, 1200° C. or more, and a more preferable heating temperature is 1500° C. or more. In a case of producing an alloy material for a magnet, the heating temperature is, for example, 1000° C. or more.
  • the shape of the tundish 4 is not particularly limited as long as the molten metal 3 can be supplied onto the outer peripheral surface of the cooling roll 2 . As shown in FIG. 1 , the shape of the tundish 4 may be a box-like shape with an open top, or may be other shapes.
  • the tundish 4 includes a supply end 7 for guiding the molten metal 3 on the outer peripheral surface of the cooling roll 2 .
  • the molten metal 3 is supplied from a crucible (not shown) to the tundish 4 , and then supplied to the outer peripheral surface of the cooling roll 2 through the supply end 7 .
  • the shape of the supply end 7 is not particularly limited.
  • the cross section of the supply end 7 may be rectangular as shown in FIG. 1 or it may be inclined. Alternatively, the supply end 7 may be in the form of a nozzle.
  • the tundish 4 is disposed in the vicinity of the outer peripheral surface of the cooling roll 2 .
  • the molten metal 3 can be stably supplied onto the outer peripheral surface of the cooling roll 2 .
  • the gap between the tundish 4 and the cooling roll 2 is appropriately set within a range where the molten metal 3 does not leak.
  • the material of the tundish 4 is preferably refractory.
  • the tundish 4 is made of, for example, one or more selected from the group consisting of aluminum oxide (Al 2 O 3 ), silicon monoxide (SiO), silicon dioxide (SiO 2 ), chromium oxide (Cr 2 O 3 ), magnesium oxide (MgO), titanium oxide (TiO 2 ), aluminum titanate (Al 2 TiO 5 ), And zirconium oxide (ZrO 2 ).
  • the molten metal remover 5 is a member that extends along the shaft direction of the cooling roll 2 .
  • An example of the molten metal remover 5 is a plate-shaped member that is disposed in parallel to the shaft direction of the cooling roll 2 , as illustrated in FIG. 1 .
  • the molten metal remover 5 is disposed downstream of the tundish 4 in the rotating direction of the cooling roll 2 with a gap provided between the molten metal remover 5 and the outer peripheral surface of the cooling roll 2 .
  • the molten metal remover 5 consists a main body 51 and a front edge portion 50 that is disposed opposite to the outer peripheral surface of the cooling roll 2 .
  • the shape of the front edge portion 50 is not particularly limited.
  • FIG. 2 is a cross-sectional view illustrating the vicinity of the front edge portion 50 of the molten metal remover 5 included in the producing apparatus 1 (a region surrounded by a broken line in FIG. 1 ) in an enlarging manner.
  • the molten metal remover 5 is disposed with a gap A between the molten metal remover 5 and the outer peripheral surface of the cooling roll 2 .
  • the molten metal remover 5 is configured to cut down the thickness of the molten metal 3 on the outer peripheral surface of the cooling roll 2 to the width of the gap A between the outer peripheral surface of the cooling roll 2 and the molten metal remover 5 .
  • the molten metal 3 lying upstream of the molten metal remover 5 in the rotating direction of the cooling roll 2 has a large thickness as compared with the width of the gap A.
  • an amount of molten metal 3 corresponding to a thickness by which the thickness of the molten metal 3 is more than the width of the gap A is removed by the molten metal remover 5 .
  • the thickness of the molten metal 3 is reduced to the width of the gap A.
  • the reduced thickness of the molten metal 3 makes the cooling rate of the molten metal 3 higher. As a result, the grains in the thin metal strip 6 are refined.
  • the width of the gap A is preferably smaller than a thickness B of the molten metal 3 on the outer peripheral surface on an upstream side of the molten metal remover 5 in the rotating direction of the cooling roll 2 .
  • the molten metal 3 on the outer peripheral surface of the cooling roll 2 becomes thinner. Therefore, the cooling rate of the molten metal 3 becomes higher. As a result, the grains in the thin metal strip 6 are more refined.
  • the width of the gap A between the outer peripheral surface of the cooling roll 2 and the molten metal remover 5 is a shortest distance between the molten metal remover 5 and the outer peripheral surface of the cooling roll 2 .
  • the width of the gap A is set as appropriate in accordance with a target cooling rate and a target efficiency of manufacturing. The smaller the width of the gap A, the thinner the molten metal 3 subjected to thickness adjustment. Therefore, the cooling rate of the molten metal 3 becomes higher. As a result, the grains in the thin metal strip 6 are more easily refined. Consequently, the upper limit of the gap A is preferably 400 more preferably 250 ⁇ m, still more preferably 100 ⁇ m, even still more preferably 50 ⁇ m, even still more preferably 30 ⁇ m.
  • the cooling rate is slow as compared with a case where the surface of the cooling roll 2 is made of copper. Therefore, in this case, the gap A is preferably narrowed.
  • the lower limit of the gap A is not particularly limited but, for example to, 10 ⁇ m.
  • the distance between a location where the molten metal 3 is supplied from the tundish 4 and a location where the molten metal remover 5 is disposed is set as appropriate.
  • the molten metal remover 5 may be disposed in a region where the free surface of the molten metal 3 (a surface of the molten metal 3 on a side on which the molten metal 3 is not in contact with the cooling roll 2 ) is in contact with the molten metal remover 5 in the liquid state or the semi-solidified state.
  • FIG. 3 is a diagram illustrating an attachment angle of the molten metal remover 5 .
  • the molten metal remover 5 is disposed such that an angle ⁇ formed by a plane PL 1 including the central axis 9 of the cooling roll 2 and a supply end 7 , and a plane PL 2 including the central axis 9 of the cooling roll 2 and the front edge portion 50 of the molten metal remover 5 is constant (Hereafter, this angle ⁇ will be referred to as an attachment angle ⁇ .).
  • the attachment angle ⁇ can be set as appropriate.
  • the upper limit of the attachment angle ⁇ is, for example, 45°.
  • the upper limit of the attachment angle ⁇ is preferably 30°.
  • the lower limit of the attachment angle ⁇ is not particularly limited but is preferably within such a range that does not cause the molten metal remover 5 not to directly come into contact with the molten metal 3 on the tundish 4 .
  • the molten metal remover 5 includes a heat dissipation surface 8 .
  • the heat dissipation surface 8 is disposed opposite to the outer peripheral surface of the cooling roll 2 .
  • the heat dissipation surface 8 is configured to come into contact with the molten metal 3 passing through a gap between the outer peripheral surface of the cooling roll 2 and the molten metal remover 5 .
  • the starting material of the molten metal remover 5 is preferably a refractory material.
  • the molten metal remover 5 contains, for example, one, or two or more selected from the group consisting of aluminum oxide (Al 2 O 3 ), silicon monoxide (SiO), silicon dioxide (SiO 2 ), chromium oxide (Cr 2 O 3 ), magnesium oxide (MgO), titanium oxide (TiO 2 ), aluminum titanate (Al 2 TiO 5 ), and zirconium oxide (ZrO 2 ).
  • the molten metal remover 5 contains one, or two or more selected from the group consisting of aluminum oxide (Al 2 O 3 ), silicon dioxide (SiO 2 ), aluminum titanate (Al 2 TiO 5 ), and magnesium oxide (MgO).
  • the molten metal remover 5 removes a surface portion of the molten metal 3 on the outer peripheral surface of the cooling roll 2 .
  • the surface portion of the molten metal 3 means a portion of a thickness of the molten metal 3 on the outer peripheral surface of the cooling roll 2 that is larger than the width of the gap A between the outer peripheral surface of the cooling roll 2 and the molten metal remover 5 .
  • the molten metal 3 on the outer peripheral surface of the cooling roll 2 becomes thin.
  • the reduction of the molten metal 3 in thickness makes the cooling rate of the molten metal 3 higher. Therefore, by producing a thin metal strip using the producing apparatus 1 , it is possible to obtain the thin metal strip 6 including more refined grains.
  • the apparatus for producing a thin metal strip according to the present embodiment is not limited to the producing apparatus 1 described above.
  • the molten metal 3 is supplied from a lateral side of the cooling roll 2 .
  • the molten metal 3 can be supplied above the cooling roll 2 .
  • FIG. 4 is a cross-sectional view of a producing apparatus 10 according to another embodiment, which is different from that illustrated in FIG. 1 to FIG. 3 .
  • the tundish 4 and the supply end 7 are disposed above the cooling roll 2 .
  • the molten metal remover 5 is disposed below the supply end 7 .
  • the rest of the configuration of the producing apparatus 10 is the same as that of the producing apparatus 1 .
  • the molten metal 3 is supplied from above the cooling roll 2 onto the outer peripheral surface of the cooling roll 2 .
  • the thickness of the molten metal 3 supplied onto the outer peripheral surface of the cooling roll 2 is cut down by the molten metal remover 5 as with the producing apparatus 1 .
  • the thickness of the molten metal 3 on the outer peripheral surface of the cooling roll 2 is reduced to the width of the gap A between the outer peripheral surface of the cooling roll 2 and the molten metal remover 5 .
  • the molten metal 3 is cooled while descending from the top of the cooling roll 2 along the outer peripheral surface of the cooling roll 2 .
  • the molten metal 3 is supplied from a lateral side of the cooling roll 2 in the same direction as the rotating direction of the cooling roll 2 .
  • the molten metal 3 is wound up by the cooling roll 2 to reach the top of the cooling roll 2 and then descends on the outer peripheral surface of the cooling roll 2 to be cooled. For that reason, in a case of using the producing apparatus 1 , the time for which the molten metal 3 is in contact with the outer peripheral surface of the cooling roll 2 is long as compared with the producing apparatus 10 .
  • the cooling time of the molten metal 3 is long.
  • the grains in the thin metal strip 6 are more refined. Consequently, the producing apparatus 1 illustrated in FIG. 1 , that is, disposing the molten metal remover 5 above the supply end 7 of the tundish 4 is preferable.
  • the number of molten metal removers 5 to be disposed may be one as illustrated in FIG. 1 to FIG. 4 , or a plurality of molten metal removers 5 may be disposed continuously in the rotating direction of the cooling roll 2 .
  • the molten metal remover(s) 5 disposed on a downstream side in the rotating direction of the cooling roll 2 are disposed to be closer to the cooling roll 2 than the molten metal remover(s) 5 disposed on an upstream side in the rotating direction of the cooling roll 2 .
  • a molten metal remover 5 at a most downstream position in the rotating direction of the cooling roll 2 is disposed such that a gap A between the molten metal remover 5 and the outer peripheral surface of the cooling roll 2 becomes the narrowest. Disposing a plurality of molten metal removers 5 enables stepwise removal of the molten metal 3 . In this case, a load applied to one molten metal remover 5 is lower. In this case, moreover, precise control of the thickness of the molten metal 3 is facilitated.
  • the molten metal remover 5 may be disposed in a direction along a normal line of the cooling roll 2 as illustrated in FIG. 1 to FIG. 4 or may be disposed in a direction different from a normal line of the cooling roll 2 as illustrated in FIG. 5 .
  • the molten metal remover 5 is disposed such as to incline from a normal direction of the cooling roll 2 toward the rotating direction of the cooling roll 2 .
  • it is easy to remove a portion of the molten metal 3 on the outer peripheral surface of the cooling roll 2 that is higher than the width of the gap A.
  • FIG. 5 the molten metal remover 5 is disposed such as to incline from a normal direction of the cooling roll 2 toward the rotating direction of the cooling roll 2 .
  • the molten metal remover 5 is configured to have a cross sectional shape different from that illustrated in FIG. 1 to FIG. 4 , which will be described later. In this case, the removal of the molten metal 3 can be performed even more efficiently.
  • the direction of the molten metal remover 5 is set as appropriate such that the cut-down of the thickness of the molten metal 3 is easy.
  • the cross sectional shape of the front edge portion 50 of the molten metal remover 5 (an edge of the molten metal remover 5 to be in contact with the molten metal 3 ) in a cross section perpendicular to the shaft of the roll may be a rectangle as illustrated in FIG. 1 to FIG. 4 or may be in another shape. Another shape may be, for example, a triangle as illustrated in FIG. 6 . Alternatively, as illustrated in FIG. 5 and FIG.
  • the front edge portion 50 of the molten metal remover 5 may be in a shape in which the width of a gap between the front edge portion 50 of the molten metal remover 5 on an entrance side for the molten metal 3 and the outer peripheral surface of the cooling roll 2 is different from the width of a gap between the front edge portion 50 of the molten metal remover 5 on an exit side for the molten metal 3 and the outer peripheral surface of the cooling roll 2 .
  • the cross sectional shape of the front edge portion 50 of the molten metal remover 5 is set as appropriate such that the thickness of the molten metal 3 is easily cut down.
  • a method for producing the thin metal strip 6 according to the present embodiment is a producing method using the producing apparatus 1 or 10 described above.
  • the producing method includes a supplying step, a rapid cooling step, and a thickness adjustment step.
  • the molten metal 3 is prepared.
  • the composition of the molten metal 3 is set as appropriate in accordance with an intended composition of the thin metal strip 6 .
  • the molten metal 3 contains, for example, one, or two or more selected from the group consisting of silicon (Si), titanium (Ti), chromium (Cr), vanadium (vanadium), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), zinc (Zn), aluminum (Al), copper (Cu), and tin (Sn), with the balance being impurities.
  • the molten metal 3 In the case of producing a metal ribbon for a negative electrode active material used in a lithium secondary battery or the like, it is preferable to produce the molten metal 3 so as to obtain a metal ribbon having the chemical composition described below.
  • the molten metal 3 consists, for example, neodymium (Nd), boron (B), and iron (Fe), with the balance being impurities.
  • the molten metal 3 is produced by heating a raw material having the chemical composition described above to the fusing point of the raw material or higher.
  • the molten metal 3 is produced.
  • the method of the heating include high-frequency induction heating, arc heating, plasma arc heating, electric resistance heating, and electron beam heating.
  • a heating temperature is not particularly limited as long as the heating temperature is equal to or higher than the liquidus temperature of the raw material.
  • the heating temperature is, for example, 1200° C. or more, more preferably 1500° C. or more.
  • the heating temperature is, for example, 1000° C. or more.
  • the molten metal 3 in the tundish 4 is supplied onto the outer peripheral surface of the cooling roll 2 .
  • the molten metal 3 is supplied from the crucible to the tundish 4 .
  • the supply of the molten metal 3 from the crucible to the tundish 4 may be made by tilting the crucible to pour the molten metal 3 directly.
  • a nozzle or the like may be used to supply the molten metal 3 from the crucible to the tundish 4 .
  • the molten metal 3 is supplied onto the outer peripheral surface of the cooling roll 2 .
  • the cooling roll 2 rotates, as described above, about the central axis 9 of the cooling roll 2 at a given speed.
  • the molten metal 3 supplied from the tundish 4 comes into contact with the outer peripheral surface of the cooling roll 2 , the molten metal 3 is partially solidified to be transferred to the cooling roll 2 .
  • the molten metal 3 moves with the rotation of the cooling roll 2 .
  • a surface of the molten metal 3 not in contact with the outer peripheral surface of the cooling roll 2 (free surface) is in a liquid state or a semi-solidified state.
  • the tundish 4 may always be heated. In this case, the melted state of the molten metal 3 having a high fusing point can be maintained. Therefore, the molten metal 3 can be removed by the molten metal remover 5 while being in the melted state.
  • a heating temperature is not particularly limited as long as the heating temperature is equal to or higher than the liquidus temperature of the raw material. In a case of producing a Si alloy, the heating temperature is, for example, 1200° C. or more, and a more preferable heating temperature is 1500° C. or more. In a case of producing an alloy material for a magnet, the heating temperature is, for example, 1000° C. or more.
  • the molten metal 3 on the outer peripheral surface is rapidly cooled with the cooling roll 2 to be formed into the thin metal strip 6 .
  • the rapid cooling step is started when the molten metal 3 is supplied onto the outer peripheral surface of the cooling roll 2 in the supplying step described above. In the rapid cooling process, the molten metal 3 is cooled from a solidified portion.
  • the cooling roll 2 includes a cooling zone that lies downstream of the tundish 4 in the rotating direction of the cooling roll 2 but does not reach the molten metal remover 5 .
  • the molten metal 3 supplied onto the outer peripheral surface of the cooling roll 2 includes a free surface. Therefore, rapid cooling is enabled. If the molten metal 3 has no free surface, that is, if the solidified portion is covered with another portion of molten metal 3 , the solidified portion cannot be subjected to sufficient heat dissipation. This is because heat is continuously added to the solidified portion from the molten metal 3 lying on the solidified portion.
  • the molten metal 3 is made to have the free surface by being supplied onto the outer peripheral surface of the cooling roll 2 . Therefore, the solidified portion can be subjected to sufficient heat dissipation, which enables the rapid cooling. As a result, the thin metal strip 6 including more refined grains can be produced.
  • the thickness of the molten metal 3 on the outer peripheral surface of the cooling roll 2 is cut down by the molten metal remover 5 , in the middle of the rapid cooling step, to the width of the gap A between the outer peripheral surface of the cooling roll 2 and the molten metal remover 5 .
  • the molten metal 3 is not solidified as a whole but gradually solidified from a solidified portion.
  • the free surface of the molten metal 3 comes into contact with the molten metal remover 5 , in a liquid state or a semi-solidified state.
  • the hardness of the molten metal 3 in the liquid state or the semi-solidified state is low.
  • the thickness of the molten metal 3 is larger than the width of the gap A, the free surface of the molten metal 3 in the liquid state or the semi-solidified state is blocked or removed.
  • the molten metal 3 thereby becomes thin.
  • the cooling rate of the molten metal 3 increases.
  • the thin metal strip 6 including more refined grains can be produced.
  • the disposition of the heat dissipation surface 8 enables the molten metal 3 to be subjected to heat dissipation from the heat dissipation surface 8 as well as the solidified portion. In this case, the cooling rate of the molten metal 3 becomes high.
  • the area and shape of the heat dissipation surface 8 are set as appropriate. For example, as illustrated in FIG. 8 , by forming the front edge portion 50 of the molten metal remover 5 into an L shape, the area of the heat dissipation surface 8 can be increased. In this case, the cooling rate of the molten metal 3 can be made higher.
  • the molten metal 3 reduced in thickness through the thickness adjustment step is subsequently cooled on the cooling roll 2 .
  • the molten metal 3 is thin. Therefore, the cooling rate is remarkably high. As a result, grains in the thin metal strip 6 are fine.
  • the entire molten metal 3 is solidified into the thin metal strip 6 .
  • the thin metal strip 6 is separated from the outer peripheral surface of the cooling roll 2 and collected.
  • the ratio of a phase having D0 3 structure in Strukturbericht notation (hereinafter also referred to as D0 3 phase) is large.
  • the D0 3 phase acts as a host for occlusion and release a lithium. Therefore, the greater the ratio of D0 3 phase in the metal strip is, the better the electric capacity and the cycle life of a battery are.
  • a preferable chemical composition of the thin metal strip as a negative electrode active material is Sn, with the balance being Cu and impurities. More preferably, the chemical composition of the thin metal strip contains 10 to 20 at % or 21 to 27 at % of Sn, with the balance being Cu and impurities. In the chemical composition of the thin metal strip, the more preferable Sn content is 13 to 16 at %, 18.5 to 20 at %, or 21 to 27 at %.
  • the chemical composition may contain 10 to 20 at % or 21 to 27 at % of Sn, and one or more selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Zn, Al, Si, B, and C, with the balance being Cu and impurities.
  • the above chemical composition may contain: Sn: 10 to 20 at % or 21 to 27 at % of Sn, and one or more selected from the group consisting of Ti: 9.0 at % or less, V: 49.0 at % or less, Cr: 49.0 at % or less, Mn: 9.0 at % or less, Fe: 49.0 at % or less, Co: 49.0 at % or less, Ni: 9.0 at % or less, Zn: 29.0 at % or less, Al: 49.0 at % or less, Si: 49.0 at % or less, B: 5.0 at % or less, and C: 5.0 at % or less, with the balance being Cu and impurities.
  • a raw material contained nickel (Ni), titanium (Ti), and silicon (Si).
  • One kilogram of the raw material in a mixed state was heated to 1450° C. to be produced into molten metal.
  • the molten metal was supplied from the tundish onto the cooling roll.
  • the cooling roll was one the outer peripheral surface of which is covered with copper and the inside of which is cooled by water.
  • the cooling roll had a diameter of 20 cm and a width of 18 cm.
  • the peripheral speed of the roll was 120 m/min.
  • the thin metal strips made of Si alloy obtained in Example 1 to Example 3 were cut, and cross sections were observed under a scanning electron microscope (SEM).
  • Example 1 the producing apparatus according to the present embodiment was used to produce a thin metal strip made of Si alloy.
  • the thin metal strip made of Si alloy was produced using the molten metal remover.
  • the molten metal remover was a flat alumina plate having a thickness of 3 mm.
  • the width of the gap between the molten metal remover and the outer peripheral surface of the cooling roll was 80 ⁇ m.
  • Example 2 a thin metal strip made of Si alloy was produced using the producing apparatus according to the present embodiment from which the molten metal remover was detached. In other words, the thin metal strip made of Si alloy was produced without using the molten metal remover.
  • Example 3 a thin metal strip made of Si alloy was produced under the same conditions as those of Example 1 except that a producing apparatus with no cooling zone on the cooling roll in a region between the tundish and the molten metal remover was used. In other words, without the free surface, the molten metal was supplied to the molten metal remover.
  • FIG. 9 is a picture of a cross section of the thin metal strip produced by the producing method according to the present embodiment (with the molten metal remover), taken under the electron microscope (SEM).
  • the thin metal strip produced by the method according to the present embodiment had an average coating thickness of 80 ⁇ m.
  • the size of a grain in a Si phase of the thin metal strip produced by the method according to the present embodiment was not more than 2 ⁇ m.
  • FIG. 10 is a picture of a cross section of the thin metal strip produced by a conventional method (without the molten metal remover), taken under the electron microscope (SEM).
  • the thin metal strip produced by the conventional method had an average coating thickness of 440 ⁇ m.
  • the size of a grain in a Si phase of the thin metal strip produced by the conventional method was 20 to 30 ⁇ m.
  • Example 3 in which the production was made by removing the molten metal without the free surface with the molten metal remover, the size of a grain in a Si phase of the thin metal strip was 10 to 15 ⁇ m.
  • the method according to the present embodiment provides a thin metal strip with finer crystal grain than the conventional method.
  • Each of the thin metal strip had a chemical composition, containing 20.0 at % of Sn and 8.0 at % of Si, with the balance being Cu and impurities.
  • the ratio (mass %) of D0 3 phase (phase having D0 3 structure) in the produced thin metal strip was determined.
  • test numbers 1 to 3 and 5 to 8 thin metal strips were produced by the production method (with a blade member) of this embodiment.
  • test number 4 a thin metal strip was produced by a conventional manufacturing method (without a blade member).
  • molten metal of each test number was provided onto the cooling roll from the tundish.
  • the composition of the coating film on the surface of the cooling roll used was as shown in Table 1. That is, in test numbers. 1 and 2, the surface of the cooling roll was Cu, and in test numbers 3 and 4, the surface of the cooling roll was a Cr plating film.
  • the interior of the cooling roll was cooled with water. The diameter of the cooling roll was 20 cm, and the width was 18 cm.
  • the ratio occupied by D0 3 phase in the produced thin metal strips of each test numbers 1 to 8 was determined by the following method.
  • X-ray diffraction measurement was conducted on the thin metal strips and measurement data of the X-ray diffraction profile was obtained. Specifically, an X-ray diffraction profile of the thin metal strip was obtained, using a SmartLab (rotor target maximum output 9 KW; 45 kV-200 mA) manufactured by Rigaku Corporation. Based on the obtained X-ray diffraction profile (measured data), the crystal structure in the thin metal strip was analyzed by the Rietveld method. The X-ray diffraction apparatus and measurement conditions are described below.
  • the crystal structure of D0 3 phase is cubic, and in terms of classification of a space group, No. 225(Fm-3m) of International Table (Volume-A).
  • a calculated value of diffraction profile (hereinafter, referred to as a calculated profile) of each thin metal strip was found by Rietveld method.
  • Rietan-2000 program name
  • the ratio of D0 3 phase is shown in Table 1. Referring to Table 1, the ratio of D0 3 phase in the thin metal strips of test numbers 1 to 3 and 5 to 8 produced by the product method (with a blade member) of the present embodiment was higher than the ration of D0 3 phase in the thin metal strip of test number 4 produced by the conventional production method).

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