Note: Descriptions are shown in the official language in which they were submitted.
HIGH ZINC ALUMINUM ALLOY PRODUCTS
[0001]
BACKGROUND OF INVENTION
[0002] Casting aluminum alloys to fonn cast aluminum alloy products is
known.
TECHNICAL FIELD
[0003] The present invention relates to cast aluminum alloy products, and
products
derived therefrom.
BRIEF SUMMARY OF INVENTION
[0004] In one or more embodiments detailed herein, the present invention
is a cast
product comprising an aluminum alloy strip; wherein the aluminum alloy strip
comprises: 4 wt.
% to 28 wt. % zinc; and wherein a variation of a weight percent of the zinc is
15% or less
between a surface and a thickness center of the aluminum alloy strip.
[0005] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
6 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy strip
comprises 8 wt. % to 28 wt. % zinc. In one or more embodiments detailed
herein, the aluminum
alloy strip comprises 10 wt. % to 28 wt. % zinc. In one or more embodiments
detailed herein, the
aluminum alloy strip comprises 4 wt. % to 15 wt. % zinc. In one or more
embodiments detailed
herein, the aluminum alloy strip comprises 6 wt. % to 12 wt. % zinc. In one or
more
embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 10
wt. % zinc. In
one or more embodiments detailed herein, the aluminum alloy strip comprises 4
wt. % to 8 wt. %
zinc.
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[0006] In one or more embodiments detailed herein, the variation of the
zinc weight
percent is 12% or less between the surface and the thickness center of the
aluminum alloy strip.
[0007] In one or more embodiments detailed herein, the present invention is
a cast
product comprising an aluminum alloy strip; wherein the aluminum alloy strip
comprises: (i) 4
wt. % to 28 wt. % zinc; (ii) 1 wt. A) to 3 wt. % copper; and (iii) 1 wt. % to
3 wt. % magnesium;
and wherein a variation of a weight percent of the zinc is 15% or less between
a surface and a
thickness center of the aluminum alloy strip.
[0008] In one or more embodiments detailed herein, the aluminum alloy strip
comprises
4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy strip
comprises 4 wt. % to 12 wt. % zinc. In one or more embodiments detailed
herein, the aluminum
alloy strip comprises 4 wt. % to 10 wt. % zinc.
[0009] In one or more embodiments detailed herein, the aluminum alloy strip
comprises
1 wt. % to 2.5 wt. % copper. In one or more embodiments detailed herein, the
aluminum alloy
strip comprises 1 wt. % to 2.0 wt. % copper. In one or more embodiments
detailed herein, the
aluminum alloy strip comprises 1 wt. % to 1.5 wt. % copper.
[00010] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
1 wt. % to 2.5 wt. % magnesium. In one or more embodiments detailed herein,
the aluminum
alloy strip comprises 1 wt. ,4) to 2.0 wt. A) magnesium. In one or more
embodiments detailed
herein, the aluminum alloy strip comprises 1 wt. % to 1.5 wt. % magnesium.
[00011] In one or more embodiments detailed herein, the cast product
comprises an
aluminum alloy strip; wherein the aluminum alloy strip comprises: 4 wt. % to
28 wt. % zinc and
1 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, a
variation of a weight
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percent of the zinc is 15% or less between a surface and a thickness center of
the aluminum alloy
strip.
BRIEF DESCRIPTION OF THE DRAWINGS
[00012] FIG. 1 is a schematic of a non-limiting method of making the cast
product;
[00013] FIG. 2 is an enlarged cross-sectional schematic of the molten metal
delivery tip
and rolls shown in FIG. 1;
[00014] FIG. 3 shows the variation in zinc weight percentage from surface
to a thickness
depth of 3,000 micrometers in a cast product;
[00015] FIG. 4 shows the variation in zinc weight percentage from surface
to a thickness
depth of 3,000 micrometers in a cast product;
[00016] FIG. 5 shows the variation in zinc weight percentage from surface
to a thickness
depth of 3,000 micrometers in a cast product;
[00017] FIG. 6 shows the variation in zinc weight percentage from surface
to a thickness
depth of 3,000 micrometers in a cast product;
[00018] FIG. 7 shows the variation in zinc weight percentage from surface
to a thickness
depth of 3,000 micrometers in a cast product;
[00019] FIG. 8 shows the variation in zinc weight percentage from surface
to a thickness
depth of 3,000 micrometers in a cast product;
[00020] FIG. 9 shows the variation in zinc weight percentage from surface
to a thickness
depth of 3,000 micrometers in a cast product;
[00021] FIG. 10 shows the variation in zinc weight percentage from surface
to a thickness
depth of 3,000 micrometers in a cast product;
3
[00022] FIG. 11 shows the variation in zinc weight percentage through depth
of a prior art
ingot cast by direct chill casting;
[00023] FIG. 12 shows the variation in zinc weight percentage through depth
of a prior art
cast product;
[00024] FIG. 13 shows the weight percentages of zinc, magnesium and copper
across
grains from the surface to 200 micrometers thickness depth in a cast product
according to an
embodiment of the present invention.
[00025] FIG. 14 shows the weight percentages of the zinc, magnesium and
copper across
grains through thickness depth for a direct chill cast prior art product;
[00026] FIG. 15 shows the structure of a cast product according to an
embodiment of the
present invention;
[00027] FIG. 16 shows the structure of a cast product according to an
embodiment of the
present invention; and
[00028] FIG. 17 shows the structure of a cast product according to an
embodiment of the
present invention.
[00029] The figures include illustrative embodiments of the present
invention and
illustrate various objects and features thereof. Further, the figures are not
necessarily to scale,
some features may be exaggerated to show details of particular components. In
addition, any
measurements, specifications and the like shown in the figures are intended to
be illustrative, and
not restrictive. Therefore, specific structural and functional details
disclosed herein are not to be
interpreted as limiting, but merely as a representative basis for teaching one
skilled in the art to
variously employ the present invention.
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[00030] The present invention will be further explained with reference to
the attached
drawings, wherein like structures arc referred to by like numerals throughout
the several views.
The drawings shown are not necessarily to scale, with emphasis instead
generally being placed
upon illustrating the principles of the present invention. Further, some
features may be
exaggerated to show details of particular components.
DETAILED DESCRIPTION OF THE INVENTION
[00031] Among those benefits and improvements that have been disclosed,
other objects
and advantages of this invention will become apparent from the following
description taken in
conjunction with the accompanying figures. Detailed embodiments of the present
invention are
disclosed herein; however, it is to be understood that the disclosed
embodiments are merely
illustrative of the invention that may be embodied in various forms. In
addition, each of the
examples given in connection with the various embodiments of the invention
which are intended
to be illustrative, and not restrictive.
[00032] Throughout the specification and claims, the following terms take
the meanings
explicitly associated herein, unless the context clearly dictates otherwise.
The phrases "in one
embodiment" and "in some embodiments" as used herein do not necessarily refer
to the same
embodiment(s), though they may. Furthermore, the phrases "in another
embodiment" and "in
some other embodiments" as used herein do not necessarily refer to a different
embodiment,
although they may. Thus, as described below, various embodiments of the
invention may be
readily combined, without departing from the scope or spirit of the invention.
[00033] In addition, as used herein, the term "or" is an inclusive "or"
operator, and is
equivalent to the term "and/or," unless the context clearly dictates
otherwise. The term "based
on" is not exclusive and allows for being based on additional factors not
described, unless the
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context clearly dictates otherwise. In addition, throughout the specification,
the meaning of "a,"
"an," and "the" include plural references. The meaning of "in" includes "in"
and "on."
[00034] As used herein, the term "at least one of A, B, or C" and the like,
means "only A",
"only B", "only C", or "any combination of A, B, and C."
[00035] In one or more embodiments detailed herein, the present invention
is a cast
product comprising an aluminum alloy strip; wherein the aluminum alloy strip
comprises: 4 wt.
% to 28 wt. % zinc; and wherein a variation of a weight percent of the zinc is
15% or less
between a surface and a thickness center of the aluminum alloy strip.
[00036] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
6 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy strip
comprises 8 wt. % to 28 wt. % zinc. In one or more embodiments detailed
herein, the aluminum
alloy strip comprises 10 wt. % to 28 wt. % zinc. In one or more embodiments
detailed herein, the
aluminum alloy strip comprises 4 wt. % to 15 wt. ')/0 zinc. In one or more
embodiments detailed
herein, the aluminum alloy strip comprises 6 wt. % to 12 wt. % zinc. In one or
more
embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 10
wt. ()/0 zinc. In
one or more embodiments detailed herein, the aluminum alloy strip comprises 4
wt. % to 8 wt. %
zinc.
[00037] In one or more embodiments detailed herein, the variation of the
zinc weight
percent is 12% or less between the surface and the thickness center of the
aluminum alloy strip.
[00038] In one or more embodiments detailed herein, the present invention
is a cast
product comprising an aluminum alloy strip; wherein the aluminum alloy strip
comprises: (i) 4
wt. % to 28 wt. % zinc; (ii) 1 wt. % to 3 wt. % copper; and (iii) 1 wt. % to 3
wt. % magnesium;
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and wherein a variation of a weight percent of the zinc is 15% or less between
a surface and a
thickness center of the aluminum alloy strip.
[00039] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy strip
comprises 4 wt. % to 12 wt. % zinc. In one or more embodiments detailed
herein, the aluminum
alloy strip comprises 4 wt. % to 10 wt. % zinc.
[00040] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
1 wt. % to 2.5 wt. % copper. In one or more embodiments detailed herein, the
aluminum alloy
strip comprises 1 wt. % to 2.0 wt. % copper. In one or more embodiments
detailed herein, the
aluminum alloy strip comprises 1 wt. % to 1.5 wt. % copper.
[00041] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
1 wt. % to 2.5 wt. '?/o magnesium. In one or more embodiments detailed herein,
the aluminum
alloy strip comprises 1 wt. % to 2.0 wt. ,/c. magnesium. In one or more
embodiments detailed
herein, the aluminum alloy strip comprises 1 wt. % to 1.5 wt. % magnesium.
[00042] In one or more embodiments detailed herein, the cast product
comprises an
aluminum alloy strip; wherein the aluminum alloy strip comprises: 4 wt. % to
28 wt. % zinc and
1 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, a
variation of a weight
percent of the zinc is 15% or less between a surface and a thickness center of
the aluminum alloy
strip.
[00043] In one or more embodiments detailed herein, the present invention
is a cast
product comprising an aluminum alloy strip; wherein the aluminum alloy strip
comprises: 4 wt.
% to 25 wt. % zinc; and wherein a variation of a weight percent of the zinc is
15% or less
between a surface and a thickness depth of 3,000 micrometers in the aluminum
alloy strip.
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[00044] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
6 wt. % to 25 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy strip
comprises 8 wt. % to 25 wt. % zinc. In one or more embodiments detailed
herein, the aluminum
alloy strip comprises 10 wt. % to 25 wt. % zinc. In one or more embodiments
detailed herein, the
aluminum alloy strip comprises 4 wt. % to 15 wt. % zinc. In one or more
embodiments detailed
herein, the aluminum alloy strip comprises 4 wt. % to 12 wt. % zinc. In one or
more
embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 10
wt. % zinc. In
one or more embodiments detailed herein, the aluminum alloy strip comprises 4
wt. % to 8 wt. (Yo
zinc.
[00045] In one or more embodiments detailed herein, the variation of the
zinc weight
percent is 12% or less between the surface and the thickness depth of 3,000
micrometers in the
aluminum alloy strip.
[00046] In one or more embodiments detailed herein, the present invention
is a cast
product comprising an aluminum alloy strip; wherein the aluminum alloy strip
comprises: (i) 4
wt. % to 25 wt. % zinc; (ii) 1 wt. % to 3 wt. % copper; and (iii) 1 wt. % to 3
wt. % magnesium;
and wherein a variation of a weight percent of the zinc is 15% or less between
a surface and a
thickness depth of 3,000 micrometers in the aluminum alloy strip.
[00047] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy strip
comprises 4 wt. % to 12 wt. % zinc. In one or more embodiments detailed
herein, the aluminum
alloy strip comprises 4 wt. % to 10 wt. % zinc.
[00048] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
1 wt. (?4 to 2.5 wt. % copper. In one or more embodiments detailed herein, the
aluminum alloy
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strip comprises 1 wt. % to 2.0 wt. % copper. In one or more embodiments
detailed herein, the
aluminum alloy strip comprises 1 wt. % to 1.5 wt. % copper.
[00049] In one or more embodiments detailed herein, the aluminum alloy
strip comprises
1 wt. % to 2.5 wt. % magnesium. In one or more embodiments detailed herein,
the aluminum
alloy strip comprises 1 wt. % to 2.0 wt. % magnesium. In one or more
embodiments detailed
herein, the aluminum alloy strip comprises 1 wt. % to 1.5 wt. % magnesium.
[00050] As used herein, the term "aluminum alloy" means an aluminum metal
with
soluble elements either in the aluminum lattice or in a phase within aluminum.
Elements may
include aluminum, copper, iron, magnesium, nickel, silicon, zinc, chromium,
manganese,
titanium, vanadium, zirconium, tin, scandium, lithium. Elements are added to
influence physical
properties of the aluminum alloy and performance characteristics.
[00051] As used herein, the phrase "7xxx aluminum alloys" and the like
means an
aluminum alloy selected from 7xxx aluminum alloys registered with the Aluminum
Association
and unregistered variants of the same.
[00052] As used herein, the term "cast product" means a product that has
been produced
by a casting method such as continuous casting as detailed in U.S. Patent Nos.
6,672,368 and
7,125,612. In one or more embodiments detailed herein, the term "cast product"
includes a
product produced from the "cast product". In one or more embodiments, the term
"cast product"
includes a rolled product produced from the "cast product".
[00053] As used herein, the term "variation" of the weight percent of an
alloying element
in a specified thickness depth has units of "%" and is calculated according to
the following
equation:
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[00054] (maximum weight percent of alloying element in the specified
thickness depth ¨
minimum weight percent of the alloying element in the specified thickness
depth) / (average
weight percent of the alloying element in the specified thickness depth)*100.
[00055] As used herein, the term "centerline segregation" means the
enrichment or
depletion of alloying elements in a central portion of an aluminum alloy
strip. In embodiments,
centerline segregation is determined based on a variation of the weight
percent of an alloying
element in a specified thickness depth of an aluminum alloy strip. In one or
more embodiments
detailed herein, centerline segregation is determined based on a variation of
weight percent of an
alloying element of greater than 15% between a surface and a thickness depth
of 3,000
micrometers. In one or more embodiments detailed herein, centerline
segregation is determined
based on a variation of weight percent of an alloying element of greater than
15% between a
surface and a thickness center of the aluminum alloy strip.
[00056] As used herein, the "weight percent of an alloying element" in a
specified
thickness depth is determined using the "macro-segregation procedure" detailed
herein.
[00057] As used herein, the term "strip" may be of any suitable thickness,
and is generally
of sheet gauge (0.006 inch to 0.249 inch) or thin-plate gauge (0.250 inch to
0.400 inch), i.e., has
a thickness in the range of from 0.006 inch to 0.400 inch. In one embodiment,
the strip has a
thickness of at least 0.040 inch. In one embodiment, the strip has a thickness
of less than 0.320
inch. In one or more embodiments detailed herein, the strip has a thickness of
from 0.0070 to
0.18 inches. In one or more embodiments detailed herein, the strip has a
thickness of from 0.08
to 0.2 inches.
[00058] As used herein, "surface" means a top surface or a bottom surface
of the cast
product.
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[00059] As used herein, "thickness center" means a depth of half the total
thickness of the
cast product or half thickness (t/2).
[00060] In one or more embodiments detailed herein, the aluminum alloy
strip may
include any aluminum alloy haying 4 wt. % to 28 wt. % zinc. In one or more
embodiments
detailed herein, the aluminum alloy strip may include at least one of 1 wt. %
to 3 wt. c)/0 copper
and 1 wt. % to 3 wt. % magnesium. In one or more embodiments detailed herein,
the aluminum
alloy may include 7xxx (zinc based) aluminum alloys.
[00061] In one or more embodiments detailed herein, the aluminum alloy
strip has 4 wt. %
to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum
alloy strip has 4
wt. % to 27 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy strip
has 4 wt. % to 25 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy
strip has 4 wt. % to 22 wt. % zinc. In one or more embodiments detailed
herein, the aluminum
alloy strip has 4 wt. % to 20 wt. % zinc. In one or more embodiments detailed
herein, the
aluminum alloy strip has 4 wt. % to 18 wt. % zinc. In one or more embodiments
detailed herein,
the aluminum alloy strip has 4 wt. % to 15 wt. % zinc. In one or more
embodiments detailed
herein, the aluminum alloy strip has 4 wt. % to 13 wt. % zinc. In one or more
embodiments
detailed herein, the aluminum alloy strip has 4 wt. % to 11 wt. % zinc. In one
or more
embodiments detailed herein, the aluminum alloy strip has 4 wt. O/0 to 10 wt.
% zinc. In one or
more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 9
wt. % zinc. In one
or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 8
wt. % zinc. In
one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. %
to 7 wt. % zinc.
In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt.
% to 6 wt. ')/0
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zinc. In one or more embodiments detailed herein, the aluminum alloy strip has
4 wt. % to 5 wt.
% zinc.
[00062] In one or more embodiments detailed herein, the aluminum alloy
strip has 5 wt. ')/0
to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum
alloy strip has 6
wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy strip
has 7 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy
strip has 8 wt. % to 28 wt. % zinc. In one or more embodiments detailed
herein, the aluminum
alloy strip has 9 wt. % to 28 wt. % zinc. In one or more embodiments detailed
herein, the
aluminum alloy strip has 10 wt. % to 28 wt. % zinc. In one or more embodiments
detailed
herein, the aluminum alloy strip has 11 wt. % to 28 wt. % zinc. In one or more
embodiments
detailed herein, the aluminum alloy strip has 13 wt. % to 28 wt. % zinc. In
one or more
embodiments detailed herein, the aluminum alloy strip has 15 wt. % to 28 wt. %
zinc. In one or
more embodiments detailed herein, the aluminum alloy strip has 18 wt. % to 28
wt. % zinc. In
one or more embodiments detailed herein, the aluminum alloy strip has 20 wt. %
to 28 wt. %
zinc. In one or more embodiments detailed herein, the aluminum alloy strip has
22 wt. % to 28
wt. % zinc.
[00063] In one or more embodiments detailed herein, the aluminum alloy
strip has 5 wt. %
to 27 wt. % zinc. In one or more embodiments detailed herein, the aluminum
alloy strip has 7
wt. % to 25 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy strip
has 8 wt. % to 23 wt. % zinc. In one or more embodiments detailed herein, the
aluminum alloy
strip has 9 wt. % to 20 wt. % zinc. In one or more embodiments detailed
herein, the aluminum
alloy strip has 10 wt. % to 18 wt. % zinc. In one or more embodiments detailed
herein, the
aluminum alloy strip has 12 wt. % to 15 wt. % zinc.
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[00064] In one or more embodiments detailed herein, the aluminum alloy
strip has 1 wt. %
to 2.8 wt. % copper. In one or more embodiments detailed herein, the aluminum
alloy strip has 1
wt. % to 2.6 wt. % copper. In one or more embodiments detailed herein, the
aluminum alloy
strip has 1 wt. % to 2.4 wt. % copper. In one or more embodiments detailed
herein, the
aluminum alloy strip has 1 wt. 'Yu to 2.2 wt. % copper. In one or more
embodiments detailed
herein, the aluminum alloy strip has 1 wt. % to 2.0 wt. % copper. In one or
more embodiments
detailed herein, the aluminum alloy strip has 1 wt. % to 1.8 wt. % copper. In
one or more
embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 1.6 wt. %
copper. In one
or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to
1.4 wt. % copper.
In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt.
% to 1.2 wt. %
copper.
[00065] In one or more embodiments detailed herein, the aluminum alloy
strip has 1.2 wt.
% to 3 wt. % copper. In one or more embodiments detailed herein, the aluminum
alloy strip has
1.4 wt. ')/0 to 3 wt. % copper. In one or more embodiments detailed herein,
the aluminum alloy
strip has 1.6 wt. % to 3 wt. % copper. In one or more embodiments detailed
herein, the
aluminum alloy strip has 1.8 wt. % to 3 wt. % copper. In one or more
embodiments detailed
herein, the aluminum alloy strip has 2.0 wt. % to 3 wt. % copper. In one or
more embodiments
detailed herein, the aluminum alloy strip has 2.2 wt. % to 3 wt. % copper. In
one or more
embodiments detailed herein, the aluminum alloy strip has 2.4 wt. % to 3 wt. %
copper. In one
or more embodiments detailed herein, the aluminum alloy strip has 2.6 wt. % to
3 wt. % copper.
In one or more embodiments detailed herein, the aluminum alloy strip has 2.8
wt. ,10 to 3 wt. %
copper.
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[00066] In one or more embodiments detailed herein, the aluminum alloy
strip has 1.2 wt.
% to 2.8 wt. % copper. In one or more embodiments detailed herein, the
aluminum alloy strip
has 1.4 wt. A to 2.6 wt. % copper. In one or more embodiments detailed
herein, the aluminum
alloy strip has 1.6 wt. % to 2.4 wt. % copper. In one or more embodiments
detailed herein, the
aluminum alloy strip has 1.8 wt. % to 2.2 wt. % copper.
[00067] In one or more embodiments detailed herein, the aluminum alloy
strip has 1 wt. %
to 2.8 wt. % magnesium. In one or more embodiments detailed herein, the
aluminum alloy strip
has 1 wt. % to 2.6 wt. ()/0 magnesium. In one or more embodiments detailed
herein, the
aluminum alloy strip has 1 wt. % to 2.4 wt. % magnesium. In one or more
embodiments detailed
herein, the aluminum alloy strip has 1 wt. % to 2.2 wt. (?/0 magnesium. In one
or more
embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 2.0 wt. %
magnesium. In
one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. %
to 1.8 wt. %
magnesium. In one or more embodiments detailed herein, the aluminum alloy
strip has 1 wt. %
to 1.6 wt. % magnesium. In one or more embodiments detailed herein, the
aluminum alloy strip
has 1 wt. % to 1.4 wt. ()/0 magnesium. In one or more embodiments detailed
herein, the
aluminum alloy strip has 1 wt % to 1.2 wt. % magnesium.
[00068] In one or more embodiments detailed herein, the aluminum alloy
strip has 1.2 wt.
% to 3 wt. % magnesium. In one or more embodiments detailed herein, the
aluminum alloy strip
has 1.4 wt. % to 3 wt. % magnesium. In one or more embodiments detailed
herein, the
aluminum alloy strip has 1.6 wt. % to 3 wt. % magnesium. In one or more
embodiments detailed
herein, the aluminum alloy strip has 1.8 wt. % to 3 wt. % magnesium. In one or
more
embodiments detailed herein, the aluminum alloy strip has 2.0 wt. % to 3 wt. %
magnesium. In
one or more embodiments detailed herein, the aluminum alloy strip has 2.2 wt.
% to 3 wt. %
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magnesium. In one or more embodiments detailed herein, the aluminum alloy
strip has 2.4 wt.
% to 3 wt. % magnesium. In one or more embodiments detailed herein, the
aluminum alloy strip
has 2.6 wt. % to 3 wt. % magnesium. In one or more embodiments detailed
herein, the
aluminum alloy strip has 2.8 wt. % to 3 wt. ')/0 magnesium.
[00069] In one or more embodiments detailed herein, the aluminum alloy
strip has 1.2 wt.
% to 2.8 wt. % magnesium. In one or more embodiments detailed herein, the
aluminum alloy
strip has 1.4 wt. % to 2.6 wt. % magnesium. In one or more embodiments
detailed herein, the
aluminum alloy strip has 1.6 wt. % to 2.4 wt. % magnesium. In one or more
embodiments
detailed herein, the aluminum alloy strip has 1.8 wt. % to 2.2 wt. %
magnesium.
[00070] In one or more embodiments detailed herein, the aluminum alloy
strip has 0.1 wt.
% to 1.0 wt. % manganese. In one or more embodiments detailed herein, the
aluminum alloy
strip has 0.2 wt. % to 1.0 wt. % manganese. In one or more embodiments
detailed herein, the
aluminum alloy strip has 0.4 wt. % to 1.0 wt. % manganese. In one or more
embodiments
detailed herein, the aluminum alloy strip has 0.6 wt. % to 1.0 wt. %
manganese. In one or more
embodiments detailed herein, the aluminum alloy strip has 0.8 wt. % to 1.0 wt.
% manganese.
[00071] In one or more embodiments detailed herein, the aluminum alloy
strip has 0.1 wt.
% to 0.8 wt. % manganese. In one or more embodiments detailed herein, the
aluminum alloy
strip has 0.1 wt. % to 0.9 wt. % manganese. In one or more embodiments
detailed herein, the
aluminum alloy strip has 0.1 wt. % to 0.7 wt. % manganese. In one or more
embodiments
detailed herein, the aluminum alloy strip has 0.1 wt. % to 0.5 wt. %
manganese. In one or more
embodiments detailed herein, the aluminum alloy strip has 0.1 wt. % to 0.3 wt.
% manganese.
[00072] In one or more embodiments detailed herein, the aluminum alloy
strip has 0.05
wt. % to 0.3 wt. % chromium. In one or more embodiments detailed herein, the
aluminum alloy
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strip has 0.1 wt. % to 0.3 wt. % chromium. In one or more embodiments detailed
herein, the
aluminum alloy strip has 0.15 wt. % to 0.3 wt. % chromium. In one or more
embodiments
detailed herein, the aluminum alloy strip has 0.2 wt. % to 0.3 wt. % chromium.
In one or more
embodiments detailed herein, the aluminum alloy strip has 0.25 wt. % to 0.3
wt. % chromium.
[00073] In one or more embodiments detailed herein, the aluminum alloy
strip has 0.05
wt. % to 0.25 wt. % chromium. In one or more embodiments detailed herein, the
aluminum
alloy strip has 0.05 wt. % to 0.2 wt. % chromium. In one or more embodiments
detailed herein,
the aluminum alloy strip has 0.05 wt. % to 0.15 wt. % chromium. In one or more
embodiments
detailed herein, the aluminum alloy strip has 0.05 wt. % to 0.1 wt. %
chromium. In one or more
embodiments detailed herein, the aluminum alloy strip has 0.15 wt. ')/0 to
0.25 wt. % chromium.
[00074] In one or more embodiments detailed herein, the aluminum alloy
strip has 0.04
wt. % to 0.25 wt. % zirconium. In one or more embodiments detailed herein, the
aluminum alloy
strip has 0.04 wt. % to 0.2 wt. % zirconium. In one or more embodiments
detailed herein, the
aluminum alloy strip has 0.04 wt. % to 0.18 wt. % zirconium. In one or more
embodiments
detailed herein, the aluminum alloy strip has 0.04 wt. % to 0.15 wt. %
zirconium. In one or more
embodiments detailed herein, the aluminum alloy strip has 0.04 wt. ')/0 to 0.1
wt. % zirconium.
[00075] In one or more embodiments detailed herein, the aluminum alloy
strip has 0.1 wt.
% to 0.25 wt. % zirconium. In one or more embodiments detailed herein, the
aluminum alloy
strip has 0.15 wt. % to 0.25 wt. % zirconium. In one or more embodiments
detailed herein, the
aluminum alloy strip has 0.2 wt. % to 0.25 wt. % zirconium.
[00076] In one or more embodiments detailed herein, the aluminum alloy
strip has 0.07
wt. % to 0.14 wt. % zirconium.
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[00077] In one or more embodiments detailed herein, the aluminum alloy
strip includes at
least one of zinc, copper, magnesium, manganese, chromium, or zirconium. In
one or more
embodiments detailed herein, the aluminum alloy strip is free of at least one
of copper,
magnesium, manganese, chromium, or zirconium.
[00078] In one or more embodiments detailed herein, the aluminum alloy
strip may
contain secondary elements and/or other elements. As used herein, "secondary
elements" are Fe,
Si, and/or Ti. As used herein, "other elements" includes any elements of the
periodic table other
than aluminum (Al), Zn, Cu, Mn, Cr, Zr, Mg, Fe, Si, and/or Ti.
[00079] In one or more embodiments detailed herein, a variation of the zinc
weight
percent between a surface and a thickness center of the aluminum alloy strip
is 15% or less. In
one or more embodiments detailed herein, a variation of the zinc weight
percent between a
surface and a thickness center of the aluminum alloy strip is 14% or less. In
one or more
embodiments detailed herein, a variation of the zinc weight percent between a
surface and a
thickness center of the aluminum alloy strip is 13% or less. In one or more
embodiments
detailed herein, a variation of the zinc weight percent between a surface and
a thickness center of
the aluminum alloy strip is 12% or less. In one or more embodiments detailed
herein, a variation
of the zinc weight percent between a surface and a thickness center of the
aluminum alloy strip is
11 4) or less. In one or more embodiments detailed herein, a variation of the
zinc weight percent
between a surface and a thickness center of the aluminum alloy strip is 10% or
less. In one or
more embodiments detailed herein, a variation of the zinc weight percent
between a surface and
a thickness center of the aluminum alloy strip is 9% or less. In one or more
embodiments
detailed herein, a variation of the zinc weight percent between a surface and
a thickness center of
the aluminum alloy strip is 8% or less. In one or more embodiments detailed
herein, a variation
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of the zinc weight percent between a surface and a thickness center of the
aluminum alloy strip is
7% or less. In one or more embodiments detailed herein, a variation of the
zinc weight percent
between a surface and a thickness center of the aluminum alloy strip is 6% or
less. In one or
more embodiments detailed herein, a variation of the zinc weight percent
between a surface and
a thickness center of the aluminum alloy strip is 5% or less. In one or more
embodiments
detailed herein, a variation of the zinc weight percent between a surface and
a thickness center of
the aluminum alloy strip is 4% or less. In one or more embodiments detailed
herein, a variation
of the zinc weight percent between a surface and a thickness center of the
aluminum alloy strip is
3% or less. In one or more embodiments detailed herein, a variation of the
zinc weight percent
between a surface and a thickness center of the aluminum alloy strip is 2% or
less.
[00080] In one or more embodiments detailed herein, a variation of the zinc
weight
percent between a surface and a thickness center of the aluminum alloy strip
is 0.1% to 15%. In
one or more embodiments detailed herein, a variation of the zinc weight
percent between a
surface and a thickness center of the aluminum alloy strip is 0.1% to 14%. In
one or more
embodiments detailed herein, a variation of the zinc weight percent between a
surface and a
thickness center of the aluminum alloy strip is 0.1% to 13%. In one or more
embodiments
detailed herein, a variation of the zinc weight percent between a surface and
a thickness center of
the aluminum alloy strip is 0.1% to 12%. In one or more embodiments detailed
herein, a
variation of the zinc weight percent between a surface and a thickness center
of the aluminum
alloy strip is 0.1% to 11%. In one or more embodiments detailed herein, a
variation of the zinc
weight percent between a surface and a thickness center of the aluminum alloy
strip is 0.1% to
10%. In one or more embodiments detailed herein, a variation of the zinc
weight percent
between a surface and a thickness center of the aluminum alloy strip is 0.1%
to 9%. In one or
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more embodiments detailed herein, a variation of the zinc weight percent
between a surface and
a thickness center of the aluminum alloy strip is 0.10/o to 8%. In one or more
embodiments
detailed herein, a variation of the zinc weight percent between a surface and
a thickness center of
the aluminum alloy strip is 0.1% to 7%. In one or more embodiments detailed
herein, a variation
of the zinc weight percent between a surface and a thickness center of the
aluminum alloy strip is
0.1% to 6%. In one or more embodiments detailed herein, a variation of the
zinc weight percent
between a surface and a thickness center of the aluminum alloy strip is 0.1%
to 5%. In one or
more embodiments detailed herein, a variation of the zinc weight percent is
0.1% to 4% between
a surface and a thickness center of the aluminum alloy strip.
[00081] In one or more embodiments detailed herein, a variation of the zinc
weight
percent between a surface and a thickness center of the aluminum alloy strip
is 1% to 15%. In
one or more embodiments detailed herein, a variation of the zinc weight
percent between a
surface and a thickness center of the aluminum alloy strip is 2% to 15%. In
one or more
embodiments detailed herein, a variation of the zinc weight percent between a
surface and a
thickness center of the aluminum alloy strip is 3% to 15%. In one or more
embodiments detailed
herein, a variation of the zinc weight percent between a surface and a
thickness center of the
aluminum alloy strip is 4% to 15%. In one or more embodiments detailed herein,
a variation of
the zinc weight percent between a surface and a thickness center of the
aluminum alloy strip is
5% to 15%. In one or more embodiments detailed herein, a variation of the zinc
weight percent
between a surface and a thickness center of the aluminum alloy strip is 6% to
15%. In one or
more embodiments detailed herein, a variation of the zinc weight percent
between a surface and
a thickness center of the aluminum alloy strip is 7% to 15%. In one or more
embodiments
detailed herein, a variation of the zinc weight percent between a surface and
a thickness center of
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the aluminum alloy strip is 8% to 15/o. In one or more embodiments detailed
herein, a variation
of the zinc weight percent between a surface and a thickness center of the
aluminum alloy strip is
9% to 15%. In one or more embodiments detailed herein, a variation of the zinc
weight percent
between a surface and a thickness center of the aluminum alloy strip is 10% to
15%. In one or
more embodiments detailed herein, a variation of the zinc weight percent
between a surface and
a thickness center of the aluminum alloy strip is 11% to 15%. In one or more
embodiments
detailed herein, a variation of the zinc weight percent between a surface and
a thickness center of
the aluminum alloy strip is 12% to 15%.
[00082] In one or more embodiments detailed herein, a variation of the zinc
weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 15% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 14% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 13% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 12% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 11% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 10% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 9% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
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percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 8% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 7% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 6% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 5% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 4% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 3% or less. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 2% or less.
[00083] In one or more embodiments detailed herein, a variation of the zinc
weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 15%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 14%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 13%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 12%. In one or more embodiments detailed herein, a variation
of the zinc weight
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percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 11%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 10%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 9%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 8%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 7%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 6%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 0.1% to 5%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent is 0.1% to 4% between a surface and a thickness depth of 3,000
micrometers in the
aluminum alloy strip.
[00084] In one or more embodiments detailed herein, a variation of the zinc
weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 1% to 15%. In one or more embodiments detailed herein, a variation of
the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 2% to 15%. In one or more embodiments detailed herein, a variation of
the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 3% to 15%. In one or more embodiments detailed herein, a variation of
the zinc weight
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percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 4% to 15%. In one or more embodiments detailed herein, a variation of
the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 5% to 15%. In one or more embodiments detailed herein, a variation of
the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 6% to 15%. In one or more embodiments detailed herein, a variation of
the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 7% to 15%. In one or more embodiments detailed herein, a variation of
the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 8% to 15%. In one or more embodiments detailed herein, a variation of
the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 9% to 15%. In one or more embodiments detailed herein, a variation of
the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 10% to 15%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 11% to 15%. In one or more embodiments detailed herein, a variation
of the zinc weight
percent between a surface and a thickness depth of 3,000 micrometers in the
aluminum alloy
strip is 12% to 15%.
[00085] In one or more embodiments detailed herein, the aluminum alloy has
a zinc
weight percent of 4% to 28% or any other weight percent range detailed herein
and does not
exhibit centerline segregation.
[00086] Non-Limiting Method For Producing Aluminum Alloy Strip
23
[00087] In embodiments, the casting of the aluminum alloy strip detailed
herein may be
accomplished via a continuous casting apparatus capable of producing
continuously cast
products that are solidified at high solidification rates. One example of a
continuous casting
apparatus capable of achieving the above-described solidification rates is the
apparatus described
in U.S. Patent Nos. 6,672,368 and 7,125,612. In one or more embodiments
detailed herein, the
aluminum alloy strip is continuously cast using the Micromill process
described in U.S. Patent
Nos. 6,672,368 and 7,125,612.
[00088] In embodiments, as illustrated in Figures 1-2, a molten aluminum
alloy metal M
may be stored in a hopper H (or tundish) and delivered through a feed tip T,
in a direction B, to a
pair of rolls Ri and Rz, having respective roll surfaces Di and Dz, which are
each rotated in
respective directions Ai and Az, to produce a solid cast product S. In one or
more embodiments
detailed herein, gaps Gi and Gz may be maintained between the feed tip T and
respective rolls Ri
and Rz as small as possible to prevent molten metal from leaking out, and to
minimize the
exposure of the molten metal to the atmosphere, while maintaining a separation
between the feed
tip T and rolls Ri and Rz. A plane L through the centerline of the rolls Ri
and Rz passes through
a region of minimum clearance between the rolls Ri and Rz referred to as the
roll nip N.
[00089] In one or more embodiments detailed herein, during casting, the
molten metal M
directly contacts the cooled rolls Ri and Rz at regions 2 and 4, respectively.
Upon contact with
the rolls Ri and Rz, the metal M begins to cool and solidify. The cooling
metal produces an upper
shell 6 of solidified metal adjacent the roll Ri and a lower shell 8 of
solidified metal adjacent to
the roll Rz. The thickness of the shells 6 and 8 increases as the metal M
advances towards the nip
N. Large dendrites 10 of solidified metal (not shown to scale) may be produced
at the interfaces
between each of the upper and lower shells 6 and 8 and the molten metal M. The
large dendrites
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may be broken and dragged into a center portion 12 of the slower moving flow
of the molten
metal M and may be carried in the direction of arrows C1 and C2. The dragging
action of the flow
can cause the large dendrites 10 to be broken further into smaller dendrites
14 (not shown to
scale). In the central portion 12 upstream of the nip N referred to as a
region 16, the metal M is
semi-solid and may include a solid component (the solidified small dendrites
14) and a molten
metal component. The metal M in the region 16 may have a mushy consistency due
in part to the
dispersion of the small dendrites 14 therein. At the location of the nip N,
some of the molten
metal may be squeezed backwards in a direction opposite to the arrows C1 and
C2. The forward
rotation of the rolls R1 and R2 at the nip N advances substantially only the
solid portion of the
metal (the upper and lower shells 6 and 8 and the small dendrites 14 in the
central portion 12)
while forcing molten metal in the central portion 12 upstream from the nip N
such that the metal
may be completely solid as it leaves the point of the nip N. In this manner
and in one or more
embodiments detailed herein, a freeze front of metal may be formed at the nip
N. Downstream
of the nip N, the central portion 12 may be a solid central portion, 18
containing the small
dendrites 14 sandwiched between the upper shell 6 and the lower shell 8. In
the central portion,
18, the small dendrites 14 may be 20 microns to 50 microns in size and have a
generally globular
shape. The three portions, of the upper and lower shells 6 and 8 and the
solidified central portion
18, constitute a single, solid cast product (S in Figure 1 and element 20 in
Figure 2). Thus, the
aluminum alloy cast product 20 may include a first portion of an aluminum
alloy and a second
portion of the aluminum alloy (corresponding to the shells 6 and 8) with an
intermediate portion
(the solidified central portion18) therebetween. The solid central portion 18
may constitute 20
percent to 30 percent of the total thickness of the cast product 20.
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[00090] The rolls R1 and R2 may serve as heat sinks for the heat of the
molten metal M. In
one embodiment, heat may be transferred from the molten metal M to the rolls
R1 and R, in a
uniform manner to ensure uniformity in the surface of the cast product 20.
Surfaces DI and D2 of
the respective rolls R1 and R2 may be made from steel, copper, nickel, or
other suitable material
and may be textured and may include surface irregularities (not shown) which
may contact the
molten metal M.
[00091] The control, maintenance and selection of the appropriate speed of
the rolls Rt
and R2 may impact the ability to continuously cast products. The roll speed
determines the speed
that the molten metal M advances towards the nip N. If the speed is too slow,
the large dendrites
will not experience sufficient forces to become entrained in the central
portion 12 and break
into the small dendrites 14. In one or more embodiments detailed herein, the
roll speed may be
selected such that a freeze front, or point of complete solidification, of the
molten metal M may
form at the nip N. Accordingly, the present casting apparatus and methods may
be suited for
operation at high speeds such as those ranging from 25 to 500 feet per minute;
alternatively from
40 to 500 feet per minute; alternatively from 40 to 400 feet per minute;
alternatively from 100 to
400 feet per minute; and alternatively from 150 to 300 feet per minute. The
linear rate per unit
area that molten aluminum is delivered to the rolls R1 and R2 may be less than
the speed of the
rolls R1 and R, or about one quarter of the roll speed.
[00092] Continuous casting of aluminum alloys according to the present
disclosure may
be achieved by initially selecting the desired dimension of the nip N
corresponding to the desired
gauge of the cast product S. The speed of the rolls Ri and R, may be increased
to a desired
production rate or to a speed which is less than the speed which causes the
roll separating force
increases to a level which indicates that rolling is occurring between the
rolls R1 and R2. Casting
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at the rates contemplated by an embodiment of the present invention (i.e. 25
to 400 feet per
minute) solidifies the aluminum alloy cast product about 1000 times faster
than aluminum alloy
cast as an ingot cast and improves the properties of the cast product over
aluminum alloys cast as
an ingot. The rate at which the molten metal is cooled may be selected to
achieve rapid
solidification of the outer regions of the metal. Indeed, the cooling of the
outer regions of metal
may occur at a rate of at least 1000 degrees Celsius per second.
[00093] The continuous cast strip may be of any suitable thickness, and is
generally of
sheet gauge (0.006 inch to 0.249 inch) or thin-plate gauge (0.250 inch to
0.400 inch), i.e., has a
thickness in the range of from 0.006 inch to 0.400 inch. In one embodiment,
the strip has a
thickness of at least 0.040 inch. In one embodiment, the strip has a thickness
of less than 0.320
inch.
[00094] Macro-Segregation Procedure
[00095] Samples are first mounted and polished in Lucite using standard
metallographic
preparation techniques for aluminum. An Electron Probe Micro Analyzer ("EPMA")
is used to
profile the distribution of the alloying elements across a thickness to show
the macro-segregation
of the alloying elements.
[00096] EPMA line scans are set with an initial spot of 100 micrometers
diameter about
50 micrometers from the sample surface moving in the thickness direction until
the other surface
is reached. The defocused beam spots are calculated to maintain a 50
micrometer separation to
provide 50% overlap between points.
[00097] A JEOL JXA 8530F Field Emission Electron Probe Microanalyzer
Hyperprobe
with 4 Wave dispersive spectrometers and JEOL SDD-EDS are used to gather the
data. The
operating conditions are:
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[00098] Accelerating Voltage: 15kV
[00099] Beam Intensity: 100nA
[000100] Defocus electron beam: 100 m
[000101] Line scan profile step 50 um
[000102] Analyzed elements may include: Ti, Zr, Mg, Si, Mn, Fe, Cu, Zn and
Al
[000103] The wave dispersive spectrometer (WDS) crystal and spectrometers
are used as
detailed in the Table 1.
Table 1
Spectrometer Diffracting Crystal Counter Element
1 PETJ Gas Flow (P-10) Ti, Zr
2 TAP Gas Flow (P-10) Mg, Si
3 LIFH Sealed Xe gas Mn, Fe
4 LIFL Sealed Xe gas Cu, Zn
SDD-EDS Al
The counting time is 10 seconds for all elements
[000104] A background measurement is collected every 50 spots for 5 seconds
on positive
and negative background locations. Elements measured are quantitatively
analyzed using the
JEOL quant ZAF analysis package for metals with atomic number correction by
Philibert-Tixier
method and flourescence excitation correction by Reed method.
[000105] Alternately, the concentration of alloying elements through depth
of a sample was
determined using a quantometer consistent with the method used to analyze the
samples from
U.S. Patent No. 6,672,368.
[000106] Micro-Segregation Procedure
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[000107] Samples are first mounted and polished in Lucite using standard
metallographic
preparation techniques for aluminum. An EPMA is used to profile the
distribution of the alloying
elements across a thickness to show the micro-segregation of the alloying
elements.
[000108] EPMA line scans are set with a focused spot moving with a 1
micrometer step
across several grains to provide overlapping points through multiple grains.
[000109] A JEOL JXA 8530F Field Emission Electron Probe Microanalyzer
Hyperprobe
with 4 Wave dispersive spectrometers and JEOL SDD-EDS are used to gather the
data. The
operating conditions are:
[000110] Accelerating Voltage: 15kV
[000111] Beam Intensity: 100nA
[000112] Focused electron beam
[000113] Line scan profile step 1 p.m
[000114] Analyzed elements may include: Ti, Zr, Mg, Si, Mn, Fe, Cu, Zn and
Al
[000115] The WDS crystal and spectrometers are used as detailed in Table 1.
[000116] A background measurement is collected every 50 spots for 5 seconds
on positive
and negative background locations. Elements measured are quantitatively
analyzed using the
JEOL quant ZAF analysis package for metals with atomic number correction by
Philibert-Tixier
method and flourescence excitation correction by Reed method.
[000117] NON-LIMITING EXAMPLES
[000118] Aluminum alloy samples were cast using the apparatus detailed in
U.S. Patent No.
6,672,368 at a speed of 55 feet per minute to 85 feet per minute and had a
final thickness detailed
in the tables below. The average weight percentages of the zinc, magnesium and
copper from
the surface to 3,000 micrometers thickness depth in each sample was determined
using either the
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"macro-segregation" procedure detailed herein or via quantometer. Table 2
below shows the
average weight percentages of zinc, copper and magnesium from surface to a
thickness depth of
3,000 micrometers in each of the cast samples and the method used to determine
the weight
percentages in each sample:
Table 2
Sample Thickness Avg. Zn Avg. Mg Avg. Cu Method
(mm) wt.?/ wt.% wt.%
1 3.5 4.26 1.50 1.59 macro-segregation
procedure
2 3.3 5.60 1.85 2.28 quantometer
3 3.9 6.38 1.47 1.53 macro-segregation
procedure
4 3.4 7.34 2.13 1.90 quantometer
3.4 7.56 1.94 2.42 quantometer
6 4.1 8.71 1.68 1.43 macro-segregation
procedure
7 3.9 15.98 1.21 1.53 macro-segregation
procedure
8 3.6 27.46 0.97 1.64 macro-segregation
procedure
[000119] Table 3 below shows the variation of zinc weight percentages in
each of the
samples from surface to a thickness depth of 3,000 micrometers:
Table 3
Sample Min. Zn wt.% Max. Zn wt.% Avg. Zn wt.% Variation (%)
1 3.91 4.52 4.26 14.40
2 5.40 5.75 5.60 6.25
3 6.17 6.66 6.38 7.68
4 7.11 7.54 7.34 5.86
5 6.95 7.71 7.56 10.05
6 8.34 8.96 8.71 7.12
7 15.10 17.09 15.98 12.45
8 25.53 29.70 27.46 15.19
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[000120] The average weight percentages of the zinc, magnesium and copper
from the
surface to the thickness center in each sample were determined using either
the "macro-
segregation" procedure detailed herein or via quantometer. Table 4 below shows
the average
weight percentages of zinc, copper and magnesium from surface to a thickness
center in each of
the cast samples and the method used to determine the weight percentages in
each sample:
Table 4
Sample Thickness (mm) Avg. Zn Avg. Mg Avg. Cu Method
wt.% wt.% wt.%
1 3.5 4.27 1.50 1.61 macro-segregation
procedure
2 3.3 5.64 1.86 2.28 quantometer
3 3.9 6.36 1.47 1.52 macro-segregation
procedure
4 3.4 7.33 2.12 1.88 quantometer
3.4 7.54 1.93 2.42 quantometer
6 4.1 8.71 1.70 1.42 macro-segregation
procedure
7 3.9 15.97 1.21 1.52 macro-segregation
procedure
8 3.6 27.54 0.99 1.70 macro-segregation
procedure
[000121] Table 5 below shows the variation of zinc weight percentages in
each of the
samples from surface to a thickness center in each sample:
Table 5
Sample Min. Zn wt.% Max. Zn wt.% Avg. Zn wt.% Variation (%)
1 3.91 4.52 4.27 14.29
2 5.48 5.75 5.64 4.79
3 6.17 6.57 6.36 6.29
4 7.11 7.54 7.33 5.87
5 6.95 7.71 7.54 10.08
6 8.44 8.96 8.71 5.97
7 15.10 17.09 15.97 12.46
8 25.96 29.70 27.54 13.58
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[000122] The data generated for each sample is plotted in Figures 3-10. A
comparison the
weight percentages of the zinc, magnesium and copper through thickness of a
direct chill cast
prior art product and a continuously cast prior art product of U.S. Patent No.
6,672,368 are also
included as Figures 11-12 for comparison.
[000123] As shown in Figures 3-10 and the tables above, the inventors
surprisingly found
that the variation of the zinc weight percent between a surface and a
thickness depth of 3,000
micrometers in samples 1-7 according to the present invention is less than
15%. Moreover, the
variation of the zinc weight percent between a surface and a thickness depth
of 3,000
micrometers of sample 8 is greater than 15%. Similarly, based on visual
inspection of Figures
11-12, the variation of the zinc weight percent between a surface and a
thickness depth of 3,000
micrometers in the direct chill cast prior art product and the continuously
cast prior art product is
greater than 15%.
[000124] As shown in Figures 3-10 and the tables above, the inventors
surprisingly found
that the variation of the zinc weight percent between a surface and a
thickness center in samples
1-8 according to the present invention is less than 15%. Moreover, based on
visual inspection of
Figures 11-12, the variation of the zinc weight percent between a surface and
a thickness center
of the direct chill cast prior art product and the continuously cast prior art
product is greater than
15%.
[000125] The weight percentages of the zinc, magnesium and copper across
grains from the
surface to 200 micrometers thickness depth in sample 6 was determined using
the "micro-
segregation" procedure detailed herein. The data is presented in Figure 13.
For comparison, the
weight percentages of the zinc, magnesium and copper across grains through
thickness for a
32
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direct chill cast prior art product are shown in Figure 14. As shown in Figure
13, the inventors
surprisingly found that the weight percent of the primary alloying elements
Zn, Cu and Mg were
substantially uniform across the grains within the matrix with an increase in
the weight percent
of the alloying elements at the positions of second phase particles at grain
boundaries and within
the grains.
[000126] Figure 15 shows the structure of sample 6. The structure of
samples of aluminum
alloys having average zinc contents of 16% and 25% cast using the apparatus
detailed in U.S.
Patent No. 6,672,368 at a speed of 55 feet per minute are shown in Figures 16
and 17,
respectively. Figures 15-17 show products of the present invention have a
globular grain
structure and are substantially free of micro-segregation. Moreover, as
illustrated in Figures 15-
17, the products of the present invention may be substantially free of
dendrites and consist
primarily of globular non-dendritic grains ¨ i.e., a globular grain structure.
Also, as shown by the
absence of shading within the grains of Figures 15-17 when the samples are
observed in
polarized light, the products are substantially free of micro-segregation
effects.
[000127] While a number of embodiments of the present invention have been
described, it
is understood that these embodiments are illustrative only, and not
restrictive, and that many
modifications may become apparent to those of ordinary skill in the art.
Further still, the various
steps may be carried out in any desired order (and any desired steps may be
added and/or any
desired steps may be eliminated).
33
