Aluminum automotive heat shields

Abstract

Disclosed is a method for producing aluminum automotive heat shields or panels such as from scrap derived molten aluminum alloy using a continuous caster to cast the alloy into a slab. The method comprises providing a molten aluminum alloy consisting essentially of 0.1 to 0.7 wt. % Si, 0.2 to 0.9 wt. % Fe, 0.05 to 0.5 wt. % Cu, 0.05 to 1.3 wt. % Mn, 0.2 to 2.8 wt. % Mg, 0.3 wt. % max. Cr, 0.3 wt. % max. Zn, 0.2 wt. % max. Ti, the remainder aluminum, incidental elements and impurities and providing a continuous caster such as a belt caster, block caster or roll caster for continuously casting the molten aluminum alloy. The molten aluminum alloy is cast into a slab which is rolled into a sheet product and then annealed. Thereafter, the sheet product is formed into the automotive heat shield or panel with strength and formability as required by the automotive industry.

Description

BACKGROUND OF THE INVENTION[0001]This invention relates to aluminum alloy vehicular heat shields or panels made from scrap aluminum and more particularly, it relates to a method of melting scrap aluminum and casting it into sheet having good forming characteristics and to forming the sheet into vehicular heat shields or panels.[0002]In many instances, continuous casting of molten aluminum into slab utilizing twin belt, twin roll or block casters is favored over DC casting because continuous casting can result in substantial energy savings and total conversion cost savings compared to the DC cast method. In the continuous casting process, molten metal is continuously introduced to an advancing mold and a slab is produced which may be continuously formed into a sheet product which is collected or wound into a coil. However, the continuous casting is not without problems. For example, it has been discovered that the alloy composition and the processing steps must be carefully controlle...

AI Technical Summary

Benefits of technology

The invention is a process for producing aluminum sheet product with consistent levels of formability using low-cost methods. The process involves continuously casting a slab from molten aluminum scrap and rolling it into a sheet product suitable for use in producing vehicular parts such as heat shields. The process also includes annealing the sheet product for forming into heat shields or panels. The invention provides an improved process for producing aluminum sheet product that meets the forming requirements of heat shields and other automotive parts. The process also involves using a continuous caster to cast the alloy and a continuous rolling operation to produce the sheet product. The resulting sheet product has good levels of formability and can be formed into heat shields or panels for automotive applications.

Problems solved by technology

However, the continuous casting is not without problems.

If the alloy and processing steps are not controlled, then in the forming steps, fracture can occur and the formed parts have to be scrapped.

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