Copper Sleeves for Aluminium Strip Casting

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Copper Sleeves for Aluminium Strip Casting

- Table of contents -

Introduction Manufacturing of Cu sleeves Copper alloys for Cu sleeves

Aluminium strip casting with Cu sleeves

Summary and outlook

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Copper Sleeves for Aluminium Strip Casting

- Introduction -

The application of copper sleeves for aluminium strip casting has been discussed in various papers in the recent years. Although significant advantages in casting speed can be expected copper sleeves are not applied in strip casting today. Due to the limited hardness, ductility and especially strength at higher temperatures of the available copper alloys the attempts made to apply copper sleeves in strip casting have not been successful. Therefore KME started in 1998 the development of copper alloys / sleeves for aluminium strip casting. Nowadays KME has the knowledge and the possibilities for the manufacturing of copper alloys as well as sleeves for this application.

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Copper Sleeves for Aluminium Strip Casting

- Objectives of the development -

While maintaining the proven strip casting technology the customer is enabled by the application of copper sleeves to: realise high casting speeds extent the production capacity decrease casting costs per ton Aluminium

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Copper Sleeves for Aluminium Strip Casting

- Table of contents -

Introduction Manufacturing of Cu sleeves Copper alloys for Cu sleeves

Aluminium strip casting with Cu sleeves

Summary and outlook

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Copper Sleeves for Aluminium Strip Casting

- Steps of manufacturing casting sleeves Melting & Casting Hot & Cold Forging Heat treatment
Copper alloy foundry Billet sizes: 720, 820 or 1020 mm Forging of cast billet to the dimensions of sleeves in strip casting & heat treatment

Machining

CNC-turning lathe with driven tools, Vertical CNC-turning mill CNC-milling machines CNC-gun drilling Ultrasonic tests, Dye penetration tests, X-Ray, Roughness measurements Control of dimensions Shrink fitted Mechanically fitted Hot isostatic pressed (HIP) final turning process, grinding, crowning, texturing coating

Quality Control
Assembling

Final Machining
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Copper Sleeves for Aluminium Strip Casting

- Final machining of copper sleeves -

Assembled and machined copper sleeves

Final machining on turning lathe

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Copper Sleeves for Aluminium Strip Casting

- Typical equivalent stress (Von Mises) after shrink fitting View on outer surface View on plane of symmetry

SEQV [N/mm]

Boundary conditions for non linear calculation: Material of copper shell: Wall thickness: Inside diameter of copper shell:
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Elbrodur B95 83 mm 672 mm

* For reasons of the overview the steel core (without cooling slots) is blanked out

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Copper Sleeves for Aluminium Strip Casting

- Assembling: Shrinkage process of copper sleeves (Example 1) -

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Copper Sleeves for Aluminium Strip Casting

- Assembling: Shrinkage process of copper sleeves (Example 2) -

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Copper Sleeves for Aluminium Strip Casting

- Table of contents -

Introduction Manufacturing of Cu sleeves Copper alloys for Cu sleeves

Aluminium strip casting with Cu sleeves

Summary and outlook

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Copper Sleeves for Aluminium Strip Casting

- KME - AMM Advanced Mold Materials Material Properties
Chem. Composition (without Cu) Phys. Properties Electrical Conductivity Thermal Conductivity Recrystall. Temperatur Softening Temperatur Modulus of Elasticity Mech. Properties 0.2 % Proof Stress Rp0.2 20 C / 68 F C 20 200 350 500 20 200 350 500 20 200 350 500 / / / / / / / / / / / / / F 68 392 662 932 68 392 662 932 68 392 662 932 MPa 270 255 230 (200) 390 340 290 (230) 25 24 22 (20) 125 300 280 250 (220) 410 360 310 (250) 21 20 19 (16) 130 490 470 450 (405) 630 590 550 (445) 18 14 (9) (3) 200 510 500 495 (440) 630 580 540 (465) 14 12 (10) (3) 200 20 C / 68 F 20 C / 68 F Sm/mm % IACS W/(mK) C C GPa 48 84 350 (700) 590 128 48 83 350 (700) 590 128 33 57 240 (700) 590 128 40 69 290 (700) 590 128

Temperature

Units

Elbrodur G

Elbrodur GP

Elbrodur B95

Elbrodur NIB

0.65 Cr 0.1 Zr

0.65 Cr 0.1 Zr

1.0 Co 0.1 Be

1.5 Ni 0.2 Be

Tensile Strength Rm

MPa

Elongation A5

Hardness HBS
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20 / 68

2.5/62.5

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Copper Sleeves for Aluminium Strip Casting

- Equivalent stresses (Von Mises) during casting operation View on outer surface View on plane of symmetry

SEQV [N/mm]

Boundary conditions for non linear calculation: Material of copper shell: Wall thickness: Inside diameter of copper shell:
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Elbrodur B95 83 mm 672 mm

* For reasons of the overview the steel core (without cooling slots) is blanked out

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Copper Sleeves for Aluminium Strip Casting

- Thermal conductivity of Cu alloys versus strength -

CuAg

350

Elbrodur G

Thermal conductivity [W/mK]

Elbrodur GF

250

Elbrodur NIB
300 400 600

150

Osnisil G

Elbrodur B95

700

Tensile Strenght [MPa]

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Copper Sleeves for Aluminium Strip Casting

- Proof stress of Elbrodur G, NIB, B95 at 20 C / 200 C / 350 C 600 20 C 500 200 C 350 C 400

0.2 % Proof Stress [MPa]

300

200

100

0 Elbrodur G Elbrodur NIB Elbrodur B95

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Copper Sleeves for Aluminium Strip Casting

- Table of contents -

Introduction Manufacturing of Cu sleeves Copper alloys for Cu sleeves

Aluminium strip casting with Cu sleeves

Summary and outlook

SEe / Kol

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Copper Sleeves for Aluminium Strip Casting

- Typical casting parameters with steel sleeves F = 4.3 MN (max. 8.5 MN) F = 4.3 MN (max. 8.5 MN)

Cooling water: Inlet 34C Outlet 38C

Life time: 8 - 10.000 to Aluminium per pair of sleeves at max. casting width

Productivity: 10 - 12.000 jato Aluminium

Machining of sleeves: pre-turned and crowned (0,3 mm) ground to Ra = 0,6 - 0,8 m
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Copper Sleeves for Aluminium Strip Casting

- Productivity increase with Copper sleeves 395
3003 with steel sleeve

380 365

1100 with steel sleeve

Strip temperature at roll exit [C]

350 335 320 305 290 275 260 245 230 215 200 0,9 1,05 1,2 1,35 1,5 1,65 1,8 1,95 2,1 2,25 2,4 2,55 2,7 2,85 3
Based on results from casting trials 1100 cast with combination of steel and copper sleeve

3003 with copper sleeve

Productivity [t / h / m strip width]

* source: P.A.E.
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Copper Sleeves for Aluminium Strip Casting

- Principal of casting trial with Cu sleeves -

T ~ 90 C

vsleev
e

T ~ 110 C T ~ 400 - 450 C vstrip

Aluminium coil

vsleev
e

rolling forces

During the casting of aluminium strips the copper sleeves are loaded with high temperatures and forces inducing high levels of stress in the shell
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Copper Sleeves for Aluminium Strip Casting

- FEM-Calculation: Temperature distribution during startup -

T [C]

View on outer surface Time [s]

View on plane of symmetry

Temperature [C]

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Copper Sleeves for Aluminium Strip Casting

- Casting process - Trial with customer -

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Copper Sleeves for Aluminium Strip Casting

- Casted coil - Trial with customer -

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Copper Sleeves for Aluminium Strip Casting

- Productivity Range Strip Thickness [mm] St / St Shell
Roll Casting

Productivity [t / (m h)] 0.5 - 1.5

Cooling Rate [C / s]

St / Cu Shell Cu / Cu Shell
LGS Casting

10 - 5

1.6 - 2.1 1.8 - 2.8 1.5 - 1.8

102 - 103

St / St Shell

103 - 104 104 - 105 105 - 106

4-2
Cu / Cu Shell
Melt Spinning

3.0 - 7.0 0.3 - 0.08 90

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Copper Sleeves for Aluminium Strip Casting

- Capacities and Costs in Strip Casting ( I ) -

Shell

Roll diameter [mm]

Alloy

Gauge [mm]

Width [mm]

Operating costs [ / t]

Production Capacity [tpy]

CMYV MO22 CMYV / Cu Cu MO22 / Cu CMYV MO22 CMYV / Cu MO22 / Cu Cu

840

1100

1700

120 116 120 129 119 130 127 124 123 130

17500 16700 26600 35500 25000 14400 13500 23700 22400 33000

840
840 / 870 870 840 / 870 840 840 840 / 870 840 / 870 870

1100
1100 1100 1100 3003 3003 3003 3003 3003

6
6 8 8 6 6 6 8 8

1700
1700 1700 1700 1700 1700 1700 1700 1700

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Copper Sleeves for Aluminium Strip Casting

- Capacities and Costs in Strip Casting ( II ) Fundamentals of the calculation: Sleeve wear: 1 mm reduction in diameter per 27 tons of cast output of the sleeves
actual: - average 1. set: - actual average set no. 3: ~ 34 t / mm ~ 44 t / mm

Costs represent casting cost including labour, energy, remachining and maintenance. Cost level representing European labour. Depreciation not included

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Copper Sleeves for Aluminium Strip Casting

- Average Productivity for different Alloys * -

Alloy

Composition

St / St [ t / (mh) ]

St / Cu [ t / (mh) ]

St / St ( 960 mm) [ t / (mh) ]

1100

Al 0.5 Fe 0.1 Cu Al 0.2 Si 0.4 Fe Al 1.0 Mn Al 1.0 Mg

1.23

1.8

1.34

1235

1.25

1.7

1.4

3003

1.03

1.75

1.08

5005

0.9

1.65

0.9

* based on the actual results of casting trials; shell diameter 840 mm

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Copper Sleeves for Aluminium Strip Casting

- Comparison of shell life St - Sleeve: 840 mm x 1700 mm casting width
100 mm 115 t / mm / m 11500 x 1.7

remachining allowance: shell wear: shell wear x casting width:

= 11500 t = 19500 t

Cu - Sleeve:

870 mm x 1700 mm casting width

135 mm 40 t / mm / m 5400 x 1.7

remachining allowance: shell wear: shell wear x casting width:

= 5400 t = 9180 t

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Copper Sleeves for Aluminium Strip Casting

- Barker etching - Micrograph in polarised light AlMn1

Sampling point: Edge

Magnification 25 : 1

Sampling point: Centre

Magnification 25 : 1

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Copper Sleeves for Aluminium Strip Casting

- Barker etching - Micrograph in polarised light AlMn1

Sampling point: Edge

Magnification 100 : 1

Sampling point: Centre

Magnification 100 : 1

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Copper Sleeves for Aluminium Strip Casting

- Casted coil - Trial with customer -

Edge of Aluminium strip

Microstructure of casted strip

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Copper Sleeves for Aluminium Strip Casting

- Table of contents -

Introduction Manufacturing of Cu sleeves Copper alloys for Cu sleeves

Aluminium strip casting with Cu sleeves

Summary and outlook

SEe / Kol

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Copper Sleeves for Aluminium Strip Casting

- Summary Copper sleeves have proven to be capable of increasing casting speed in strip casting thereby offering a potential to increase production capacity and decrease production costs

No modifications necessary on the casting machine, cooling system or steel cores

Maintenance and re-machining is done similar to steel sleeves

Copper sleeves are able to form a stable Al-layer (AlCu) on the surface that prevents the pollution of Al strips with Be and Co.

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Copper Sleeves for Aluminium Strip Casting

- References Casting wheels for non-ferrous alloys Casting rolls for thin strip casting of steel and copper
Geie Myosotis Ugine (France) BHP (Australia) <-> Castrip (USA) RIST (Korea) VAI-CSM / AST Pilot Caster VASTRIP (Italy) Krupp Thyssen Nirosta (Germany) Norddeutsche Affinerie NA (Germany) RWTH Aachen (Germany)

Casting rolls for special applications (amorphous alloys)

VAC (Germany) Honeywell (USA)

Casting sleeves for thin strip casting of aluminium:

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Castal (Greece), customer not known Choil (Korea) Eurofoil (Luxembourg) MAL (Hungary) Hydro Inasa (Spain) Teknik Alminyum Sanayi (Turkey)

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Copper Sleeves for Aluminium Strip Casting

- Scale of KMEs activities Melting & Casting & Forming Copper alloys with high strength requirements at increased temperatures Wide range of different dimensions Close coordination between casting process and subsequent forming process to ensure optimal material properties and tight tolerances CNC-controlled milling and turning machines Assembling of copper sleeves and steel cores Final machining (grinding, crowning) Pressure test up to 2 MPa Quality control

Machining & Assembling

Engineering

Detail design engineering (3D, 2D) FEM calculations (thermal & structural) Material development Failure examination and analysis
SEM & EDX Micrographs / polished sections Tensile, fatigue & bending tests

Research & Development

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