Method for casting composite ingot

a composite metal and ingot technology, applied in the direction of thin material handling, transportation and packaging, etc., can solve the problems of difficult roll difficulty in controlling the method, and difficulty in rolling-bonding of aa5000 series alloys to other alloys, so as to facilitate metallurgical bonding and better control
US20060185816A1Inactive Publication Date: 2006-08-24NOVELIS INC
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Patent Information

Authority / Receiving Office
US Ā· United States
Patent Type
Applications(United States)
Current Assignee / Owner
NOVELIS INC
Publication Date
2006-08-24
Estimated Expiration
Not applicable Ā· inactive patent

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Abstract

A method and apparatus for the casting of a composite metal ingot comprising at least two separately formed layers of one or more alloys. An open ended annular mould has a feed end and an exit end and divider wall for dividing the feed end into at least two separate feed chambers, where each feed chamber is adjacent at least one other feed chamber. For each pair of adjacent feed chambers a first alloy stream is fed through one of the pair of feed chambers into the mould and a second alloy stream is fed through another of the feed chambers. A self-supporting surface is generated on the surface of the first alloy stream and the second alloy stream is contacted with the first stream such that the upper surface of the second alloy stream is maintained at a position such that it first contacts the self-supporting surface where the self-supporting surface temperature is between the liquidus and solidus temperatures of the first alloy or it first contacts the self-supporting surface where the self-supporting surface temperature is below the solidus temperatures of the first alloy but the interface between the two alloys is then reheated to between the liquidus and solidus temperatures, whereby the two alloy streams are joined as two layers. The joined alloy layers are then cooled to form a composite ingot. This composite ingot has a substantially continuous metallurgical bond between alloy layers with dispersed particles of one or more intermetallic compositions of the first alloy in a region of the second alloy adjacent the interface. The combination of an alloy of high strength bonded to a surface layer of higher ductility gives a sheet of improved bendability compared to the high strength alloy used alone.
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Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation-in-part of our prior U.S. application Ser. No. 10 / 875,978 filed Jun. 23, 2004 which claims the benefit of U.S. Provisional Application Ser. No. 60 / 482,229, filed Jun. 24, 2003, both of which are incorporated herein by this reference.FIELD OF THE INVENTION

[0002] This invention relates to a method and apparatus for casting composite metal ingots, as well as novel composite metal ingots thus obtained. BACKGROUND OF THE INVENTION

[0003] For many years metal ingots, particularly aluminum or aluminum alloy ingots, have been produced by a semi-continuous casting process known as direct chill casting. In this procedure molten metal has been poured into the top of an open ended mould and a coolant, typically water, has been applied directly to the solidifying surface of the metal as it emerges from the mould.

[0004] Such a system is commonly used to produce large rectangular-section ingots for the production of...

Claims

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