WO2024178495A1

WO2024178495A1 - Casting process for aluminum alloys, looped belt for a belt caster, and belt caster including same

Info

Publication number: WO2024178495A1
Application number: PCT/CA2024/050202
Authority: WO
Inventors: Willard Mark Truman Gallerneault; Andrew David Howells
Original assignee: Hazelett Castechnology Ulc
Priority date: 2023-02-28
Filing date: 2024-02-20
Publication date: 2024-09-06

Abstract

A process for manufacturing aluminum-based alloy thin sheets of a selected shape, looped belts for a belt caster and the belt caster including the looped belts are described. In a continuous belt caster, and from molten aluminum-based alloy, an aluminum-based alloy thin strip having a thickness of about 1 mm to about 5 mm is continuously cast and simultaneously cooled by at least one looped belt comprising at least one score line defined therein. The aluminum-based alloy strip is conveyed away from the thin-gauge belt caster. A line of weakness is formed at a location where the aluminum based-alloy thin strip contacted the at least one score line and the aluminum-based alloy thin strip is breakable along the line of weakness by application of a force to form an aluminum-based alloy thin sheet.

Description

CASTING PROCESS FOR ALUMINUM ALLOYS, LOOPED BELT FOR A BELT CASTER, AND BELT CASTER INCLUDING SAME

TECHNICAL FIELD

[0001] The present disclosure relates to a casting process for manufacturing aluminum-based alloy sheets from a molten aluminum-based alloy fed to a belt caster. It also relates to a looped belt for a belt caster and to the belt caster including same.

BACKGROUND

[0002] Some existing processes are known for manufacturing aluminum-based alloy strips with an altered casting surface by producing a mark onto a continuously cast strip. The mark can be a trademark or a trade name, a product designation, a casting direction, or any desired pattern. The mark can also be used to cut the continuously cast strip into predetermined length strips as disclosed in US patent No. 4,658,885. However, the existing processes do not employ equipment widely used in industry such as a belt caster, wherein, for example, a pair of looped belts is cooled by a cooling system allowing the production of very thin aluminum-based alloy sheets. There is indeed a need for systems providing substantially thin aluminum-based alloy sheets of a selected shape using equipment still operated as of today, such as belt casters in order to eliminate a subsequent cutting step.

SUMMARY

[0003] In accordance with an aspect, there is provided a process for manufacturing aluminum-based alloy thin sheets of a selected shape. The process comprises continuously casting and simultaneously cooling an aluminum-based alloy thin strip having a thickness of about 1 mm to about 5 mm by feeding molten aluminum-based alloy to a thin-gauge belt caster operating at a belt caster speed, the thin-gauge belt caster comprising at least one looped belt having at least one score line defined therein; and conveying the aluminum-based alloy thin strip away from the thin-gauge belt caster. A line of weakness is formed at a location where the aluminum based-alloy thin strip contacts the at least one score line and the aluminum-based alloy thin strip is breakable along the line of weakness by application of a force to form an aluminum-based alloy thin sheet.

[0004] In some implementations, the thin-gauge belt caster imparts a cast strip speed at an exit of the thin-gauge belt caster and the aluminum-based alloy thin strip is conveyed away from the thin-gauge belt caster using an exit conveyor, the exit conveyor operating at a conveyor speed faster than the cast strip speed. For instance, the conveyor speed can be at least 1% faster than the cast strip speed. The conveyor speed can be about 1 to 2% faster than the cast strip speed.

[0005] In some implementations, the at least one score line extends across a width of the at least one looped belt and the line of weakness is a separation line along which the aluminum-based alloy thin strip breaks. The force to break the aluminum-based alloy thin strip can be a pulling force applied by the exit conveyor operating at the conveyor speed faster than the cast strip speed and the aluminum-based alloy thin strip breaks along the separation line when conveyed by the exit conveyor.

[0006] In some implementations, the at least one score line has a closed figure shape and defines closed figure pattern subject to slower heat transfer when the aluminum- based alloy thin strip is cooled in the thin-gauge belt caster. The process can further comprise applying at least one of : a transversal force inside the closed figure pattern, vibrations to the aluminum-based alloy thin strip, a magnetic force to the closed figure pattern, and a flexion force to the aluminum-based alloy thin strip at the exit of the thin- gauge belt caster to break the aluminum-based alloy thin strip and separate aluminum- based alloy thin sheet from a remainder of the aluminum-based alloy thin strip.

[0007] In some implementations, the at least one looped belt is one looped belt, and the thin-gauge belt caster further comprises a roll counter-rotating relatively to the looped belt.

[0008] In some implementations, the at least one looped belt is two looped belts counter-rotating relatively to one another.

[0009] In some implementations, the thickness of the aluminum-based alloy thin strip is less than about 3.5 mm. [0010] In some implementations, a depth of the at least one score line is at least about 5 microns and less than about 20 microns.

[0011] In some implementations, the depth of the at least one score line is between about 8 microns and about 12 microns.

[0012] In some implementations, the depth of the at least one score line is at least 0.03% of the thickness of the aluminum-based alloy thin strip.

[0013] In some implementations, a width of the at least one score line is sufficiently narrow to prevent the molten aluminum-based alloy from flowing thereinto.

[0014] In some implementations, the width of the at least one score line is about 15 microns to about 80 microns.

[0015] In some implementations, the width of the at least one score line is between about 45 microns and about 55 microns.

[0016] In some implementations, the belt caster speed is between about 10 m/min and about 100 m/min and, in other implementations, the belt caster speed is between about 30 m/min and about 100 m/min.

[0017] In some implementations, the exit conveyor is a roller table or a belt conveyor.

[0018] In some implementations, the at least one score line is substantially uniform in at least one of depth and width across the at least one looped belt.

[0019] In some implementations, the at least one score line comprises a plurality of score line segments defining non-void angles between adjacent ones of the score line segments.

[0020] In some implementations, the at least one score line defines a zig-zag pattern.

[0021] In some implementations, the at least one score line defines a curvilinear pattern. [0022] In some implementations, a width of the at least one score line is shorter than a solidification zone inside the thin-gauge belt caster.

[0023] In some implementations, along the line of weakness, at the breakage of the aluminum-based alloy thin strip, the aluminum-based alloy strip comprises more liquid state aluminum than in adjacent sections of the aluminum-based alloy thin strip.

[0024] According to another aspect, there is provided an aluminum-based alloy thin sheet manufactured using the process described above.

[0025] According to still another aspect, there is provided a use of the aluminum-based alloy thin sheet as an anode in battery industry applications.

[0026] According to another aspect, there is provided a looped belt for a thin-gauge belt caster, the looped belt comprising a belt body having an external surface and at least one score line defined therein and extending inwardly from the external surface. In an embodiment, the at least one score line extends across a width of the belt body.

[0027] In some implementations of the looped belt, a depth of the at least one score line is at least about 5 microns and less than about 20 microns.

[0028] In some implementations of the looped belt, the depth of the at least one score line is between about 8 microns and about 12 microns.

[0029] In some implementations of the looped belt, a width of the at least one score line is about 15 microns to about 80 microns.

[0030] In some implementations of the looped belt, the width of the at least one score line is between about 45 microns and about 55 microns.

[0031] In some implementations of the looped belt, the at least one score line is substantially uniform in at least one of depth and width.

[0032] In some implementations of the looped belt, the at least one score line comprises a plurality of score line segments defining non-void angles between adjacent ones of the segments. [0033] In some implementations of the looped belt, wherein the at least one score line defines a zig-zag pattern.

[0034] In some implementations of the looped belt, wherein the at least one score line has a closed figure shape.

[0035] In some implementations of the looped belt, the at least one score line defines a curvilinear pattern.

[0036] In another aspect, there is provided a thin-gauge belt caster comprising at least one of the looped belt as described above.

[0037] While the present techniques will be described in conjunction with example embodiments, it will be understood that it is not intended to limit the scope of the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included as defined by the present description. The objects, advantages and other features of the present techniques will become more apparent and be better understood upon reading of the following non-restrictive description of the invention, given with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Other objects, advantages and features will become more apparent upon reading the following non-restrictive description of embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings in which:

[0039] Figure 1 shows a thin sheet casting production line for aluminum-based alloys comprising a belt caster, in accordance with an embodiment.

[0040] Figure 1 A is a side elevation view, enlarged, of a portion a belt of the belt caster having a score line defined therein.

[0041] Figure 2 includes Figures 2a, 2b, 2c, 2d, 2e, and 2f, which are top plan views of non-limitative embodiments of leading edges of aluminum-based alloy sheets manufactured with corresponding score line patterns extending across a width of a belt of the belt caster.

[0042] Figure 3 includes Figures 3a, 3b, 3c, 3d, 3e, and 3f, which are top plan views of non-limitative embodiments of aluminum-based alloy sheets having leading and trailing edges manufactured with corresponding score line patterns.

[0043] Figure 4 is a top plan view of a belt of the belt caster, in accordance with an embodiment, wherein the belt has a plurality of score line patterns, each one defining a closed figure of a circular shape.

[0044] Figure 5 is a schematic cross sectional view the belt having a score line defined therein with an aluminum-based alloy thin strip superposed thereto.

DETAILED DESCRIPTION

[0045] In accordance with a non-limitative embodiment, referring to Figure 1 , the process comprises several steps that are carried out either simultaneously and/or continuously. At least some of these steps are carried out in-line, without interruption between the consecutive steps. First, an aluminum-based alloy thin strip 48 is produced by continuously casting and simultaneously cooling an aluminum-based alloy with a thin- gauge belt caster 34. The cast aluminum-based alloy strip 48 is characterized as being thin since it has a thickness between about 1 mm and about 5 mm. In some non-limitative implementations, the thickness of the aluminum-based alloy thin strip is less than about 3.5 mm. In an in-line process, the cast aluminum-based alloy strip 48 is conveyed away from the thin-gauge belt caster by an exit conveyor 66 mounted downstream to the thin- gauge belt caster 34, along a production line 68. The exit conveyor 66 can be, for example, a roller table or a belt conveyor.

[0046] In a non-limitative embodiment shown, the thin-gauge belt caster 34 includes two looped belts 36, 38, counter- rotating with respect to one another. However, it is appreciated that, in an alternative embodiment, the belt caster 34 can include only one looped belt 36, counter- rotating with a casting roll (not shown). At least one of the looped belts 36, 38 (if the belt caster 34 includes two looped belts) or the looped belt (if the belt caster 34 includes only one looped belt) has at least one score line 64 defined therein. More particularly, each one of the looped belts 36, 38 has a belt body and the belt body of at least one of the looped belt 36, 38 has the score line(s) 64 being defined therein and extending inwardly from an external surface 70 thereof, i.e. , the surface in contact with the aluminum alloy. The score line 64 can be engraved in the belt body and extends along at least a portion of a width of the belt body of the looped belt(s) 36, 38. In a non-limitative embodiment, the score line 64 extends across an entire width of the belt body of the looped belt(s) 36, 38, i.e., from one of the longitudinal edges of the belt to other longitudinal edges or along a transversal axis of the belt. In another embodiment, the score line 64 has a closed figure shape, i.e. a shape where there are no open endings. In a more mathematical sense, it can be defined as a shape or curve where the line segments are connected and have the same starting and ending point.

[0047] For instance, and without being limitative, the continuously casting and simultaneously cooling an aluminum-based alloy thin strip can be carried out with a twinbelt caster, such as the one described in US patent no. 11 ,000,893 or Hazelett 2.0 thin- gauge belt caster (available from Hazelett Strip Casting Corporation, Colchester, VT, USA).

[0048] The thin-gauge belt caster 34 is operated at a belt caster speed (v_caster) and imparts a cast strip speed to the aluminum-based alloy thin strip 48 at an exit thereof, i.e., adjacent to an entry of the exit conveyor 66. In some implementations, the cast strip speed is not equal to the belt caster speed, with the cast strip speed being slightly slower. The exit conveyor 66 is operated at a conveyor speed (v_COnveyor), which can be faster than the cast strip speed in some implementations. For instance, and without being limitative, the conveyor speed can be at least 1% faster than the cast strip speed. In some implementations, the conveyor speed is about 1% to 2% faster than the cast strip speed. Therefore, when the cast strip 48 contacts the exit conveyor 66, the latter exerts a pulling force of the strip 48.

[0049] For instance, and without being limitative, the belt caster speed can range between about 10 m/min and about 100 m/min and, in some implementations, between about 30 m/min and about 100 m/min.

[0050] In the non-limitative embodiment shown in Figure 1 , the upper looped belt 36 includes only one score line 64 extending transversally. However, it is appreciated that, in an alternative embodiment, the looped belt (either the upper belt 36, the lower belt 38 or both belts 36, 38) can have more than one score line defined therein from the external surface 70, as shown for instance in Figure 4. The score line(s) 64 contact the aluminum alloy at least in a solidification zone 62 of the belt caster 34. The solidification zone 62 corresponds to regions II and III of Figure 1. When contacting the aluminum alloy, the score line(s) form a line of weakness (or a separation line) along which the aluminum- based alloy thin strip 48 will break when pulled by the exit conveyor 66, to form an aluminum-based alloy thin sheet 72. The aluminum-based alloy thin sheet 72 can be characterized as being “of a selected shape” since its shape substantially conform/corresponds to the shape of the respective score line(s) 64, as will be described in more details below. For instance, for score lines 64 extending across the width of one of the belts 36, 38, the aluminum-based alloy thin sheet 72 has a shape that conform to the shape of the score lines 64 at least along its leading edge 74 and its trailing edge 76.

[0051] Breaking of the aluminum-based alloy thin strip 48 occurs along the line of weakness when the cast strip 48 exits the belt caster 34. In some implementations, a force is applied to the aluminum-based alloy thin strip to break same along the line of weakness to form the aluminum-based alloy thin sheet 72.

[0052] The force to break the aluminum-based alloy thin strip 48 can be a pulling force applied by the exit conveyor 66 operating at the conveyor speed (v_COnveyor) faster than the cast strip speed (v_caster). In the embodiment wherein the score line(s) 64 extend across the width of one of the belts 36, 38, the aluminum-based alloy thin strip 48 breaks along the separation/line of weakness when conveyed by the exit conveyor 66.

[0053] In another embodiment, the force can be a transversal force applied to the aluminum-based alloy thin strip 48 downstream the belt caster 34, i.e. a force applied transversally to the strip 48, normal to the solidification/casting direction and the casting surface, to break the aluminum-based alloy thin strip 48 and define at least one sheet 72. In still other embodiments, the force can be a magnetic force, vibrations or a flexion force (i.e. bending of the aluminum-based alloy thin strip 48) to break the strip 48 into one or more sheet 72.

[0054] In the embodiment wherein the score line(s) 64 have a closed figure shape, they define weakness/separation lines having a corresponding shape and, upon application of the force, the thin sheet(s) 72 separate from a remainder of the aluminum- based alloy thin strip 48.

[0055] The weakness/separation line extends along a portion of the strip 48 which has been in contact with a respective one of the one score line(s) 64, during the continuously casting and simultaneously cooling step, i.e., in the belt caster 34. More particularly, the contact between the strip 48 and the score line 64 occurs during solidification of the aluminum-based melt, i.e., in the solidification zone 62 of the belt caster 34, wherein the aluminum in liquid state is contained inside a solid aluminum shell. Being in contact with the score line 64, this portion of the aluminum strip 48 cools at a different (slower) heat transfer rate than the adjacent portions of the aluminum-based alloy thin strip 48, which are directly in contact with the looped belts 36, 38. More particularly, the adjacent portions of the aluminum-based alloy thin strip 48, which are directly in contact with the looped belts 36, 38, are the first portions to solidify, pulling liquid metal away from the portion in contact with the score line 64 due to solidification shrinkage (about 6% in aluminum) and leaving the portion in contact with the score line 64 thinner and weaker. The score line 64 creates an air gap between the cast aluminum-based alloy thin strip 48 and the looped belt 36, as shown in Figure 5, reducing the heat transfer rate and consequently, the cooling/solidification rate of the aluminum melt along the separation line. Therefore, along the separation line, a greater portion of the aluminum-based alloy remains in a substantially liquid (i.e., semi-solid) state for a longer time period than the alloy in contact with the looped belt 36. Accordingly, when exiting the belt caster 34 and entering the exit conveyor 66, the aluminum-based alloy along the separation line can comprise more of liquid state aluminum than adjacent sections of the aluminum-based alloy thin strip (or at least a different microstructure) and defining the line of weakness. When a force is applied normal to the solidification direction and within the boundary defined by the closed figure pattern, the aluminum-based alloy thin strip 48 breaks along the weakness/separation line(s) to define the aluminum-based alloy thin sheet(s) 72. For instance, if the score line(s) 64 extend across a width of the belt 36, 38, when pulled by the exit conveyor 66, which operates at a greater speed than the cast strip speed at the belt caster output, the aluminum-based alloy thin strip 48 breaks along the separation line(s) to define the aluminum-based alloy thin sheet(s) 72.

[0056] Referring to Figure 1 , the score line 64 contacts the aluminum-based alloy thin strip 48 in regions II and/or III of molds 58 or 60. The regions II and III represent a space of a selected volume. The molten metal flows between the molds 58 and 60 and the thickness of the resulting aluminum-based alloy thin strip 48 is determined by the distance between (i) the scored looped belt 36, and (ii) a roll, or a second belt (belt 38 on Figure 1) that can counter rotate relative to the scored looped belt 36.

[0057] As mentioned above, to manufacture aluminum-based alloy thin sheets 72 of a selected shape, at least one of the looped belt(s) 36, 38 comprise at least one score line 64 defined therein and extending inwardly from the external surface. In some implementations, the score line(s) 64 extend across the width of the belt body. In some implementations, the score line(s) 64 have a closed figure shape. Even though the looped belt(s) 36, 38 can include more than one score line, the following paragraphs will refer to one score line. The score line 64 can be of a depth of at least about 5 microns and less than about 20 microns. In some implementations, the depth of the score line 64 is between 8 microns and about 12 microns. The depth of the score line 64 formed in the body of the looped belt 36 can depend on the thickness of the aluminum-based alloy thin strip 48 being cast. More particularly, in a non-limitative embodiment, the depth of the score line 64 can be determined in manner such that the portion of the aluminum strip 48 along the separation line contains a sufficient quantity of liquid aluminum-based alloy when a force is applied thereon (for instance, when pulled by the exit conveyor 66) to ensure breakage. Accordingly, in a non-limitative embodiment, the depth of the scored line 64 can be at least 0.03% of the thickness of the aluminum-based alloy thin strip 48.

[0058] Moreover, the score line 64 can have a width “W_s” (extending between the two score line edges or extending normal to the width (or transversal axis) of the belt 36, if extending across the belt 36, 38), which is sufficiently narrow to prevent the molten aluminum-based alloy from flowing thereinto and therefore, contact the external surface 70 of the looped belt 36. In a non-limitative embodiment, the width “W_s” of the score line 64 can be between about 15 microns and about 80 microns and, in another embodiment, between about 45 microns and about 55 microns. In a non-limitative embodiment, the width “W_s” and/or the depth “D” of the score line 64 can be substantially uniform across the width of the looped belt 36.

[0059] Referring now to Figures 2 and 3, non-limitative embodiments of the possible and selected shapes for the aluminum-based alloy thin sheets 72 for score line(s) extending across the width of the belt 36, 38. The shape of the sheets 72 along their transversal edges depends on the shape (or patterns) of the score line(s) 64 engraved in the looped belt(s) 36, 38. The transversal edges of the sheet 72 can be defined as a leading edge 74 and a trailing edge 76.

[0060] Figure 2 shows alternative and non-limitative embodiments for the shape of the leading edge 74 of the sheets 72, while Figure 3 shows alternative and non-limitative embodiments for both the shape of the leading and trailing edges 74, 76 of the sheets 72. It is appreciated that the shape of the leading edge 74 of one sheet 72 corresponds to the shape of the trailing edge 76 of a previously-manufactured sheet. Therefore, the shapes shown for the leading edges 74 can be shapes for the trailing edges and vice-versa. Furthermore, one looped belt 36, 38 can include more than one score line 64 with at least two of the score lines 64 having a different shape (or pattern). It is appreciated that, in some implementations, wherein the shape of the trailing edge of a previously- manufactured sheet does not correspond to the desired shaped of the following sheet, a waste sheet can be manufactured between two sheets having a selected shape (depending upon geometric nesting).

[0061] In non-limitative embodiments, the score line(s) 64 defined in the body of the looped belt 36, 38 can be substantially straight, extending either normal to a longitudinal axis of the production line 68 (not shown) (or parallel to the transversal axis of the belt 36, 38) or at an oblique angle therewith (Figure 2b). In another embodiment, the score line(s) 64 can be arcuate/curvilinear, either a concave arc of a circle (not shown) or a convex arc of a circle (Figure 2a). It can define a curvilinear pattern, such as the non-limitative embodiment shown in Figure 2c.

[0062] In some implementations, such as the ones shown in Figures 2d, 2e, and 2f, the score line 64 can include a plurality of score line segments, either straight or curvilinear segments, defining non-void angles between adjacent ones of the segments. In one embodiment, the score line 64 can include a plurality of angled score line segments defining a zig-zag pattern on the body of the looped belt 36, 38. In still other implementations, the score line(s) 64 can be a mixture of curvilinear line segments and straight-line segments as shown in Figure 2f. [0063] In an embodiment, the score line 64 extends continuously along the width of the looped belt 36, 38, i.e., there is no score line discontinuity or portion of the looped belt width without being engraved by the score line 64.

[0064] In an embodiment, the score line 64 has a pattern width “w”, extending from its leading point (or segment) to its trailing point (or segment). It is understood that, if the looped belt 36,38 comprises two or more score lines 64, each one of the score lines has its own pattern width “w” with its leading point (or segment) and its trailing point (or segment). In an embodiment, the pattern width “w” is equal to or shorter than a length of the solidification zone 62 and/or a length of the molds 58 or 60 of the thin-gauge belt caster 34 and/or the length of the regions II and III in Figure 1.

[0065] In some implementations, the shape of the score line 64 is non-reentrant, i.e., the same score line does not have two segments that are at a same position along a transversal axis of the belt (along the belt width).

[0066] The shape of the score lines 64 defined in the body of the looped belts 36, 38 can be selected to manufacture sheets 72 having selected leading and trailing edges 74,76. For instance, aluminum-based alloy thin sheet 72 can be manufactured to have a shape corresponding to the aluminum sheets used in the anodes for battery industry applications.

[0067] Referring now to Figure 4, there is shown an embodiment wherein the belt 36, 38 includes a plurality of score lines 64, each one having a closed figure shape and more particularly a circular shape. It is appreciated that the shape of the score lines can vary from the embodiment shown. The belts 36, 38 can have a plurality of shapes engraved therein, producing sheets 72 of corresponding shape.

[0068] Each one of the score lines 64 defines a closed figure pattern subject to slower heat transfer, when the aluminum-based alloy thin strip 48 is cooled in the belt caster 34. Downstream the belt caster 34, when a force is applied to the aluminum strip 48, normal to the solidification direction and within the boundary defined by the closed figure pattern, the latter breaks along the score lines 64. As mentioned above, the force can be: a transversal force applied inside the closed figure pattern of the strip 48, vibrations applied to the thin strip 48, a magnetic force applied to the closed figure pattern, and/or a flexion force applied to the thin strip 48. In some embodiments, the transversal force can be applied by a low force punch, knock-out process or a bolster system, which can be synchronized with the production line speed or via a vision system. Therefore, aluminum- based alloy thin sheets 72 of variable shapes can be manufactured continuously downstream of the belt caster 34.

[0069] T urning back to Figure 1 , there is shown that, following the breaking of the strip 48 into sheets, the sheets 72 can be transferred to a quenching apparatus 78 (optional) to lower the sheet temperature to a temperature suitable for handling and, then to a slab stacker unit 80.

[0070] Several alternative implementations and examples have been described and illustrated herein. The implementations of the technology described above are intended to be exemplary only. A person of ordinary skill in the art would appreciate the features of the individual implementations, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the implementations could be provided in any combination with the other implementations disclosed herein. It is understood that the technology may be embodied in other specific forms without departing from the central characteristics thereof. The present implementations and examples, therefore, are to be considered in all respects as illustrative and not restrictive, and the technology is not to be limited to the details given herein. Accordingly, while the specific implementations have been illustrated and described, numerous modifications come to mind.

Claims

1. A process for manufacturing aluminum-based alloy thin sheets of a selected shape, the process comprising: continuously casting and simultaneously cooling an aluminum-based alloy thin strip having a thickness of about 1 mm to about 5 mm by feeding molten aluminum-based alloy to a thin-gauge belt caster operating at a belt caster speed, the thin-gauge belt caster comprising at least one looped belt having at least one score line defined therein; and conveying the aluminum-based alloy thin strip away from the thin-gauge belt caster, wherein a line of weakness is formed at a location where the aluminum based-alloy thin strip contacts the at least one score line and the aluminum- based alloy thin strip is breakable along the line of weakness by application of a force to form an aluminum-based alloy thin sheet.

2. The process of claim 1 , wherein the thin-gauge belt caster imparts a cast strip speed at an exit of the thin-gauge belt caster and the aluminum-based alloy thin strip is conveyed away from the thin-gauge belt caster using an exit conveyor, the exit conveyor operating at a conveyor speed faster than the cast strip speed.

3. The process of claim 2, wherein the conveyor speed is at least 1% faster than the cast strip speed.

4. The process of claim 2, wherein the conveyor speed is about 1 to 2% faster than the cast strip speed.

5. The process of any one of claims 2 to 4, wherein the at least one score line extends across a width of the at least one looped belt and the line of weakness is a separation line along which the aluminum-based alloy thin strip breaks.

6. The process of claim 5, wherein the force to break the aluminum-based alloy thin strip is a pulling force applied by the exit conveyor operating at the conveyor speed faster than the cast strip speed and the aluminum-based alloy thin strip breaks along the separation line when conveyed by the exit conveyor.

7. The process of any one of claims 1 to 4, wherein the at least one score line has a closed figure shape and defines closed figure pattern subject to slower heat transfer when the aluminum-based alloy thin strip is cooled in the thin-gauge belt caster, and the process further comprises applying at least one of : a transversal force inside the closed figure pattern, vibrations to the aluminum-based alloy thin strip, a magnetic force to the closed figure pattern, and a flexion force to the aluminum-based alloy thin strip at the exit of the thin-gauge belt caster to break the aluminum-based alloy thin strip and separate aluminum-based alloy thin sheet from a remainder of the aluminum-based alloy thin strip.

8. The process of any one of claims 1 to 7, wherein the at least one looped belt is one looped belt, and the thin-gauge belt caster further comprises a roll counter-rotating relatively to the looped belt.

9. The process of any one of claims 1 to 7, wherein the at least one looped belt is two looped belts counter-rotating relatively to one another.

10. The process of any one of claims 1 to 9, wherein the thickness of the aluminum- based alloy thin strip is less than about 3.5 mm.

11. The process of any one of claims 1 to 10, wherein a depth of the at least one score line is at least about 5 microns and less than about 20 microns.

12. The process of any one of claims 1 to 10, wherein the depth of the at least one score line is between about 8 microns and about 12 microns.

13. The process of any one of claims 1 to 10, wherein the depth of the at least one score line is at least 0.03% of the thickness of the aluminum-based alloy thin strip.

14. The process of any one of claims 1 to 13, wherein a width of the at least one score line is sufficiently narrow to prevent the molten aluminum-based alloy from flowing thereinto.

15. The process of any one of claims 1 to 13, wherein the width of the at least one score line is about 15 microns to about 80 microns.

16. The process of any one of claims 1 to 13, wherein the width of the at least one score line is between about 45 microns and about 55 microns.

17. The process of any one of claims 1 to 16, wherein the belt caster speed is between about 10 m/min and about 100 m/min.

18. The process of any one of claims 2 to 6, wherein the exit conveyor is a roller table or a belt conveyor.

19. The process of any one of claims 1 to 18, wherein the at least one score line is substantially uniform in at least one of depth and width inside the at least one looped belt.

20. The process of one of claims 5 and 6, wherein the at least one score line comprises a plurality of score line segments defining non-void angles between adjacent ones of the score line segments.

21. The process of claim 20, wherein the at least one score line defines a zig-zag pattern.

22. The process of any one of claims 1 to 19, wherein the at least one score line defines a curvilinear pattern.

23. The process of any one of claims 1 to 22, wherein a width of the at least one score line is shorter than a solidification zone inside the thin-gauge belt caster.

24. The process of any one of claims 1 to 21 , wherein along the line of weakness, at the breakage of the aluminum-based alloy thin strip, the aluminum-based alloy strip comprises more liquid state aluminum than in adjacent sections of the aluminum- based alloy thin strip.

25. An aluminum-based alloy thin sheet manufactured using the process of any one of claims 1 to 24.

26. Use of the aluminum-based alloy thin sheet of claim 25 as an anode in battery industry applications.

27. A looped belt for a thin-gauge belt caster, the looped belt comprising a belt body having an external surface and at least one score line defined therein and extending inwardly from the external surface.

28. The looped belt of claim 27, wherein the at least one score line extends across a width of the belt body.

29. The looped belt of claim 28, wherein the at least one score line comprises a plurality of score line segments defining non-void angles between adjacent ones of the segments.

30. The looped belt of claim 29, wherein the at least one score line defines a zig-zag pattern.

31. The looped belt of claim 27, wherein the at least one score line has a closed figure shape.

32. The looped belt of any one of claims 27 to 31 , wherein a depth of the at least one score line is at least about 5 microns and less than about 20 microns.

33. The looped belt of any one of claims 27 to 31 , wherein the depth of the at least one score line is between about 8 microns and about 12 microns.

34. The looped belt of any one of claims 27 to 33, wherein a width of the at least one score line is about 15 microns to about 80 microns.

35. The looped belt of any one of claims 27 to 33, wherein the width of the at least one score line is between about 45 microns and about 55 microns.

36. The looped belt of any one of claims 27 to 35, wherein the at least one score line is substantially uniform in at least one of depth and width.

37. The looped belt of any one of claims 27 to 29 and 32 to 36, wherein the at least one score line defines a curvilinear pattern.

38. A thin-gauge belt caster comprising at least one of the looped belt of any one of claims 27 to 37.