Casting process for aluminium alloys

Abstract

A process for manufacturing an aluminum-based alloy sheet directly from a molten aluminum-based alloy is described. In a continuous caster, such as a belt-caster, and directly from the molten aluminum-based alloy, a substantially solid and substantially thin aluminum-based alloy strip, thinner than about 10 mm, is continuously cast and simultaneously cooled with a compression force on the solidifying aluminum-based alloy in a range of about 2 to about 3000 pounds per linear inch of alloy strip width. The substantially solid aluminum-based alloy strip can then be rolled, so as to obtain the aluminum-based alloy sheet. The process can include pulse heating the aluminum-based allowed sheet.

1 . A process for manufacturing an aluminum-based alloy sheet from a molten aluminum-based alloy, the process comprising:
 continuously casting and simultaneously cooling an aluminum-based alloy strip thinner than about 10 mm by feeding a belt caster with the molten aluminum-based alloy, with a compression force on the aluminum-based alloy strip, during its solidification, in a range of about 2 to about 3000 pounds per linear inch of alloy strip width to obtain the aluminum-based alloy strip in a substantially solid state.   
     
     
         2 . A process for manufacturing an aluminum-based alloy sheet from a molten aluminum-based alloy, the process comprising, in a continuous in-line sequence:
 continuously casting and simultaneously cooling the molten aluminum-based alloy to obtain an aluminum-based alloy strip thinner than about 10 mm, while applying a compression force on the aluminum-based alloy strip, during its solidification, in a range of about 2 to about 3000 pounds per linear inch of alloy strip width to obtain the aluminum-based alloy strip in a substantially solid state.   
     
     
         3 . The process of  claim 1 , further comprising rolling the substantially solid aluminum-based alloy strip following the simultaneous casting and cooling to obtain the aluminum-based alloy sheet. 
     
     
         4 . The process of  claim 1 , wherein the compression force applied on the solidifying aluminum-based alloy strip ranges between about 10 to about 150 pounds per linear inch of alloy strip width. 
     
     
         5 - 7 . (canceled) 
     
     
         8 . The process of  claim 1 , wherein the simultaneous casting and cooling is carried out with a belt caster. 
     
     
         9 . The process of  claim 3 , further comprising quenching the substantially solid aluminum-based alloy strip following the simultaneous casting and cooling and prior to the rolling. 
     
     
         10 . The process of  claim 9 , wherein the process is free of heat treatment step following the simultaneous casting and cooling and prior to the rolling. 
     
     
         11 . The process of  claim 3 , wherein the process is free of quenching and heat treatment steps following the simultaneous casting and cooling and prior to the rolling, to obtain the aluminum-based alloy sheet. 
     
     
         12 . The process of  claim 3 , further comprising quenching the aluminum-based alloy sheet following the rolling. 
     
     
         13 . The process of  claim 12 , further comprising artificially ageing the aluminum-based alloy sheet following the quench. 
     
     
         14 . The process of  claim 3 , further comprising artificially ageing the aluminum-based alloy sheet following the rolling. 
     
     
         15 . The process of  claim 1 , wherein the simultaneously cooling is performed at a cooling rate of between about 100 K/s and about 1500 K/s. 
     
     
         16 . The process of  claim 3 , wherein the rolling comprises cold-rolling at a temperature in a range of about room temperature to about 150° C. 
     
     
         17 . (canceled) 
     
     
         18 . The process of  claim 3 , further comprising coiling the aluminum-based alloy strip following the simultaneously casting and cooling and uncoiling the coiled aluminum-based alloy strip before rolling the aluminum-based alloy strip. 
     
     
         19 - 46 . (canceled) 
     
     
         47 . The process of  claim 1 , further comprising pulse heating the aluminum-based alloy strip at a temperature range of about 400° C. to about 570° C. for a time period in a range of about 2 seconds to about 10 seconds. 
     
     
         48 - 56 . (canceled) 
     
     
         57 . An aluminum-based alloy sheet manufactured using the process of  claim 1 , having a yield strength of between about 200 MPa and about 500 MPa, an ultimate tensile strength of between about 220 MPa and about 520 Mpa, and an elongation of between about 1% and about 12%. 
     
     
         58 - 61 . (canceled) 
     
     
         62 . The process of  claim 2 , further comprising rolling the substantially solid aluminum-based alloy strip following the simultaneous casting and cooling to obtain the aluminum-based alloy sheet. 
     
     
         63 . The process of  claim 2 , wherein the compression force applied on the solidifying aluminum-based alloy strip ranges between about 10 to about 150 pounds per linear inch of alloy strip width. 
     
     
         64 . The process of  claim 2 , wherein the simultaneous casting and cooling is carried out with a belt caster and the rolling comprises cold-rolling performed at a temperature in a range of about room temperature to about 150° C. 
     
     
         65 . The process of  claim 2 , wherein the simultaneously cooling is performed at a cooling rate of between about 100 K/s and about 1500 K/s. 
     
     
         66 . The process of  claim 2 , further comprising pulse heating the aluminum-based alloy strip at a temperature range of about 400° C. to about 570° C. and for a time period in a range of about 2 seconds to about 10 seconds. 
     
     
         67 . An aluminum-based alloy sheet manufactured using the process of  claim 2 , having a yield strength of between about 200 MPa and about 500 MPa, an ultimate tensile strength of between about 220 MPa and about 520 Mpa, and an elongation of between about 1% and about 12%.