Simultaneous multi-alloy casting

Abstract

A method of casting a multi-layered metal ingot including the steps of delivering a metallic divider member into a direct chill mold, pouring a first molten metal into the mold on one side of the divider member, and pouring a second molten metal into the mold on the other side of the divider member, and allowing the first molten metal and the second molten metal solidify to form a metal ingot which includes the divider metal layer disposed there between.

1 . A multi-layered metal product comprising:
 a layer of a divider metal; and   a first metal layer direct chill cast onto one side of said divider metal layer.   
   
   
       2 . The metal product of  claim 1  further comprising a second metal layer direct chill cast onto the other side of said divider metal layer. 
   
   
       3 . The metal product of  claim 1 , wherein said divider metal comprises an alloy containing at least about 97% aluminum. 
   
   
       4 . The metal product of  claim 2 , wherein said first metal layer and said second metal layer each are an alloy of an Aluminum Association series selected from the group consisting of 1000, 2000, 3000, 4000, 5000, 6000, 7000 and 8000. 
   
   
       5 . The metal product of  claim 1 , wherein the thickness of said layer of divider metal is about 0.5 to about 6% of the thickness of said metal product. 
   
   
       6 . The metal product of  claim 1 , wherein the thickness of said layer of divider metal is about 1 to about 3% of the thickness of said metal product. 
   
   
       7 . The metal product of  claim 1 , wherein said metal product is an ingot or a billet. 
   
   
       8 . The metal product of  claim 7 , wherein said layer of a divider metal is about 0.07 to about 0.25 inch thick. 
   
   
       9 . The metal product of  claim 7 , wherein said layer of a divider metal is over about 0.25 to about 6 inches thick. 
   
   
       10 . The metal product of  claim 2 , wherein said metal product is a plate, a sheet or foil. 
   
   
       11 . The metal product of  claim 10  further comprising an outer metal layer roll bonded to one of said first metal layer and said second metal layer. 
   
   
       12 . The metal product of  claim 10  further comprising a pair of outer metal layers, each said outer metal layers being roll bonded to one of said first metal layer and said second metal layer. 
   
   
       13 . The metal product of  claim 11 , wherein said outer metal layer comprises a pair of metal layers direct chill cast onto opposing sides of a divider metal layer. 
   
   
       14 . The metal product of  claim 2  further comprising at least one other layer of divider metal and at least one other metal layer direct chill cast onto one side of said other layer of divider metal and one of the first or second metals is direct chill cast onto the other side of the other layer of divider metal. 
   
   
       15 . The metal product of  claim 2  wherein the melting point of the divider metal is at least about 5° C. greater than the melting points of each of the first metal and the second metal. 
   
   
       16 . A multi-layered metal ingot comprising:
 a layer of a divider metal;   a first metal layer bonded to one side of said divider metal layer; and   a second metal layer bonded to another side of said divider metal layer, wherein the thickness of said layer of divider metal comprises no more than about 3% of the thickness of said ingot.   
   
   
       17 . The ingot of  claim 16 , wherein said first metal layer and said second metal layer are each direct chill cast onto said divider metal layer. 
   
   
       18 . The ingot of  claim 16 , wherein said divider metal comprises an alloy containing at least about 97% aluminum. 
   
   
       19 . The ingot of  claim 16 , wherein said first metal layer and said second metal layer each are an alloy of an Aluminum Association series selected from the group consisting of 1000, 2000, 3000, 4000, 5000, 6000, 7000 and 8000. 
   
   
       20 . The ingot of  claim 16 , wherein said layer of a divider metal is about 0.07 to about 0.25 inch thick. 
   
   
       21 . The ingot of  claim 16 , wherein said layer of a divider metal is over about 0.25 to about 6 inches thick. 
   
   
       22 . The ingot of  claim 16 , further comprising an outer metal layer roll bonded to one of said first metal layer and said second metal layer. 
   
   
       23 . The ingot of  claim 22 , wherein said outer metal layer comprises a pair of metal layers direct chill cast onto opposing sides of a divider metal layer. 
   
   
       24 . The ingot of  claim 16  further comprising a pair of outer metal layers, each said outer metal layers being roll bonded to one of said first metal layer and said second metal layer. 
   
   
       25 . The ingot of  claim 16  further comprising at least one other layer of divider metal and at least one other metal direct chill cast onto one side of said other layer of divider metal with one of the first or second metals direct chill cast onto the other side of the other layer of divider metal. 
   
   
       26 . The ingot of  claim 25 , wherein said first metal, said second metal, and said at least one other metal are each an alloy of an Aluminum Association series selected from the group consisting of 1000, 2000, 3000, 4000, 5000, 6000, 7000 and 8000.