Metal casting and rolling line

Abstract

A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.

What is claimed is: 
     
         1 . An intermediate metal product, comprising:
 a primary phase of solid aluminum formed by cooling liquid metal in a continuous casting device at a strip thickness of 7 mm-50 mm; and   a secondary phase including an alloying element, wherein the secondary phase is spheroidized by hot or warm working the primary phase and secondary phase at a reduction of section of approximately 10% to 80%.   
     
     
         2 . The intermediate metal product of  claim 1 , wherein hot or warm working includes hot or warm rolling, and the reduction of section is a reduction of thickness. 
     
     
         3 . The intermediate metal product of  claim 1 , wherein the reduction of section is approximately 30% to 80%. 
     
     
         4 . The intermediate metal product of  claim 1 , wherein the reduction of section is approximately 50% to 70%. 
     
     
         5 . The intermediate metal product of  claim 1 , wherein the metal product is formed in the shape of a metal strip coiled into a coil. 
     
     
         6 . The intermediate metal product of  claim 1 , wherein the secondary phase is further spheroidized by sustaining a peak metal temperature in the primary phase and the secondary phase that is approximately 15° C.-45° C. below a solidus temperature of the metal product, wherein the peak metal temperature is sustained for a duration of less than or equal to 10 minutes prior to the hot or warm working. 
     
     
         7 . The intermediate metal product of  claim 6 , wherein the peak metal temperature is sustained for a duration of approximately 1-10 minutes. 
     
     
         8 . The intermediate metal product of  claim 6 , wherein the peak metal temperature is sustained for a duration of approximately 1-3 minutes. 
     
     
         9 . The intermediate metal product of  claim 1 , wherein the secondary phase is further spheroidized by sustaining a peak metal temperature of approximately 450° C. to 580° C. in the primary phase and secondary phase for a duration of less than or equal to 10 minutes prior to the hot or warm working. 
     
     
         10 . The intermediate metal product of  claim 9 , wherein the duration is approximately 1-3 minutes prior to the hot or warm working. 
     
     
         11 . The intermediate metal product of  claim 1 , wherein the secondary phase is further spheroidized by sustaining a peak metal temperature of approximately 450° C. to 580° C. in the primary phase and secondary phase for a duration of less than or equal to 6 hours prior to the hot or warm working. 
     
     
         12 . The intermediate metal product of  claim 11 , wherein the duration is at or less than 2 hours. 
     
     
         13 . The intermediate metal product of  claim 11 , wherein the duration is at or less than 1 hour. 
     
     
         14 . An intermediate metal product, comprising:
 a primary phase of solid aluminum formed by cooling liquid metal in a continuous casting device at a strip thickness of 7 mm-50 mm; and   a secondary phase including an alloying element, wherein the alloying element is supersaturated in the primary phase by fast cooling freshly-solidified metal to a temperature below a solutionizing temperature.   
     
     
         15 . An aluminum metal product, comprising:
 a continuously cast aluminum alloy reduced in thickness to a thickness of at or less than approximately 35 mm, wherein the continuously cast aluminum alloy contains iron present in amounts of at least 0.2% by weight, wherein a median equivalent circle diameter for iron-based intermetallic particles is less than approximately 0.8 μm.