Evaluation and Characterization of In-Line Annealed Continuous Cast Aluminum Sheet
This R&D program will develop optimized, energy-efficient thermo-mechanical processing procedures for in-line annealing of continuously cast hot bands of two 5000 series aluminum alloys (5754 and 5052). The implementation of the R&D will result in the production of sheet with improved formability at high levels of productivity consistency and quality. The proposed R&D involves the following efforts: (1) Design and build continuous in-line annealing equipment for plant-scale trials; (2) Carry out plant-scale trials at Commonwealth Aluminum Corp.'s (CAC) plant in Carson; (3) Optimize the processing variables utilizing a metallurgical model for the kinetics of microstructure and texture evolution during thermo-mechanical processing; (4) Determine the effects of processing variables on the microstructure, texture, mechanical properties, and formability of aluminum sheet; (5) Develop design parameters for commercial implementation; and (6) Conduct techno-economic studies of the recommended process equipment to identify impacts on production costs. The research and development is appropriate for the domestic industry as it will result in improved aluminum processing capabilities and thus lead to greater application of aluminum in various industries including the automotive market. A teaming approach is critical to the success of this effort as no single company alone possesses the breadth of technical and financial resources for successfully carrying out the effort. This program will enable more energy efficient aluminum sheet production technology, produce consistent high quality product, and have The proposal addresses the needs of the aluminum industry as stated in the aluminum industry roadmap by developing new and improved aluminum processes utilizing energy efficient techniques. The effort is primarily related to the subsection on Rolling and Extrusion with the R&D to address energy and environmental efficiencies in aluminum manufacturing and will provide significant energy, environmental and economic benefits thus benefiting a broad cross-section of the aluminum industry. The results from this project will have a positive impact on improving efficiencies in other areas of aluminum processing including Casting and in the Finished Products Sector of the roadmap Continuous casting (CC) leads to 25% energy savings in the production of aluminum sheet products compared to conventional DC casting as it does away with the intermediate steps of DC cast ingots and homogenization of the ingots and substituting it with a continuous casting process which goes directly into the hot rolling mill. The results of the proposed research will enable further applications of continuous casting technology. The aim here is to develop a continuous in line anneal process that will replace the existing batch type techniques thereby resulting in a continuous uni-directional movement of material from cast to final product. The goal of this multi-partner R&D project is to develop energy-efficient and optimized thermomechanical processing for the production of continuous cast 5000 series aluminum sheet alloys. Full scale implementation of the proposed effort by the year 2015 could lead to yearly energy savings of 23 trillion Btu and related energy cost savings of $96 million per year for the U. S. aluminum rolled products industry. The major achievements of this project based on the goals and objectives of the project are given.
- Research Organization:
- Secat, Inc.
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- FC36-01ID14024
- OSTI ID:
- 862312
- Report Number(s):
- DOE/ID14024; TRN: US200712%%79
- Country of Publication:
- United States
- Language:
- English
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