Twin-roll Casting Research Articles

Microstructure and mechanical properties of high-strength Al-Zn-Mg-Ni alloys with excellent twin-roll castability

This paper proposes a new high-strength Al-Zn-Mg-Ni alloy with excellent twin-roll castability compared with conventional Al-Zn-Mg-Cu alloys. Thermodynamic calculations were carried out to identify the solidification range and amount of residual liquid phase in the Al-Zn-Mg-(Cu, Ni) alloys, which are factors exerting significant influence on the formation of defects in the final strips. The designed Al-Zn-Mg-Ni alloys exhibited a narrower solidification range and smaller amount of residual liquid at the final solidification temperature, resulting in excellent surface quality after twin-roll casting compared with Al-Zn-Mg-Cu alloys. A series of rolling and heat treatment processes was performed on the Al-Zn-Mg-Ni alloy strips, and the mechanical properties of the final sheets were evaluated. The results showed that the yield and tensile strength were increased without affecting the elongation up to approximately 1.0wt.% Ni addition. Additionally, compared with conventional Al-Zn-Mg-Cu alloys, equivalent or higher tensile properties were achieved after T6 tempering. In conclusion, the Al-Zn-Mg-Ni alloy exhibits high-strength with excellent twin-roll castability.

Formation of the primary structure of cast slabs from aluminum alloys during their twin-roll casting

Formation of the primary structure of cast slabs from aluminum alloys during their twin-roll casting

Production of AZ80 magnesium alloy wires: influence of heat treatment on microstructure and properties after twin-roll casting

AbstractTwin-roll casting (TRC) of magnesium sheets has already been analysed in numerous ways. The installation of a pilot plant for the twin-roll casting of magnesium wire at the Institute of Metal Forming, TU Bergakademie Freiberg, has opened up a further area for research. The principle of twin-roll casting of wire is comparable, although the microstructure development is different because of the resulting process-specific solidification and forming conditions. In this work, wire was produced for the first time from the magnesium alloy AZ80 using the TRC process. The microstructure consists of dendritic areas, twins, deformed areas and recrystallised grains. A non-basal texture with low intensity is developed, which is retained even after heat treatment. A temperature of 450 °C and a holding time of 1 h have been shown to be favourable for heat treatment to achieve a uniform grain structure. On the basis of the microstructure and texture analysis, the responsible recrystallisation mechanisms were discussed. Finally, mechanical properties at room temperature were presented and compared with extruded and cast material from the literature.

Reduction of Elongation Anisotropy of Roll-Cast Strips by Cold Rolling and Annealing

Roll-cast strips are usually cold-rolled and annealed before forming. The elongation of these strips is known to be different between the casting and lateral directions after thinning by cold rolling. Whether cold rolling is the main factor determining the anisotropy of the elongation is not clear. Likewise, it is not clear whether the elongation anisotropy can be reduced by conventional cold rolling. Roll-cast strips have centerline segregation, forming a so-called band area. The relationship between the anisotropy of the elongation and these defects is not clear. A strip cast using an unequal-diameter twin-roll caster also has a band area but a strip cast using a single-roll caster equipped with a scraper has no centerline segregation or band area. Strips made this way were cold-rolled in the casting and lateral directions, and tensile testing was conducted on the cold-rolled and annealed strips. In this study, the ability of conventional cold rolling and one-time annealing to reduce the elongation anisotropy of a cast strip was clarified. Moreover, the influence of the band area and Fe impurities on the elongation anisotropy was determined.

A multi-field couped model for controlling segregation in twin-roll casting

So-called center and edge segregation are formed during twin-roll casting, which cannot be effectively eliminated in subsequent rolling and heat treatment, thus significantly diminishing the quality of final product. Numerous studies have been conducted on such segregations so far, unfortunately, without fully considering conservation of mass, momentum, energy and solute throughout the process, as well as synergy of thermodynamics and kinetics for interfacial migration. Accordingly, a two-phase Eulerian-Eulerian volume-averaged model is herein established to predict the segregation upon twin-roll casting for Al–Si alloys, which, for the first time, addresses effects due to the interfacial migration and the solute diffusion on the solute transfer process, and so-called correlation between thermodynamics and kinetics (i.e., thermo-kinetic correlation). On this basis, the model accurately predicts the flow field upon twin-roll casting, where, the increased casting speed leads to the descended kissing point, thus gradually causing the decreased vortex area and the increased cooling rate. Whereas, the increased heat transfer coefficient leads to the ascended kissing point, thus gradually causing the increased vortex area and the decreased cooling rate. In the modeling, the increased thermodynamic driving force for interfacial migration is always accompanied by the decreased kinetic energy barrier, and vice versa. Furthermore, the model also accurately predicts the segregation upon twin-roll casting, where, the thermodynamic driving force increases with the casting speed, thus decreasing the central segregation, whereas, the heat transfer coefficient increases, thus enhancing the generalized stability and in turn, effectively suppressing the edge segregation. By employing a strategy involving high driving force in the early stage and high generalized stability in the late stage, it was determined that the anticipated center and edge segregation could be effectively suppressed.

Sub-rapid solidification microstructure characteristics and control mechanisms of twin-roll cast aluminum alloys: A review

Rapid growth in industrial sectors such as automotive and shipbuilding has highlighted the significance of strip casting technology to produce lightweight alloys, particularly aluminum alloys widely used in both industrial production and daily life. Twin-roll casting (TRC), as an economically and environmentally friendly method for slab/strip production and processing, has attracted significant interest from researchers. However, the development of TRC aluminum alloys faces many challenges due to limited understanding of microstructural characteristics and control mechanisms. To further enhance comprehension of TRC aluminum alloys, this article reviews the influencing parameters, control methods, and existing issues related to TRC sub-rapid solidification (SRS) microstructure. It firstly summarizes TRC equipment types and their solidification characteristics, followed by a detailed analysis on key parameters affecting the evolution of TRC microstructure including rolling speed, roll separation force (RSF), and heat transfer coefficient (HTC). Finally, solutions to TRC defects are summarized and evaluated alongside their underlying mechanisms. This article provides a comprehensive review of the characteristics and control mechanisms of TRC microstructure while offering valuable insights for the future production of high-quality TRC aluminum strips.

Research on temperature field and thermal deformation characteristics of casting rollers in twin-roll casting process

The twin-roll casting (TRC) process is considered a revolutionary technology in the metallurgical field and has garnered significant attention and research in recent years. The casting rollers used in the TRC process are crucial for achieving the desired shape of the casting strip. This study investigates the temperature distribution and thermal deformation of casting rollers in the TRC process using numerical simulation. A novel model for predicting the thermal resistance distribution at the circumferential interface between the casting roller and the molten pool has been introduced. The study examined the effects of various factors including casting roller diameter, water channel position, number, and diameter on temperature, thermal deformation, and heat flux. The findings reveal that increasing the casting roller diameter from 460 mm to 500 mm or augmenting the distance from the water channel to the casting roller surface from 35 mm to 55 mm resulted in a 37 % and 30 % increase in the maximum surface temperature of the casting roller, respectively. Additionally, an increase in the number of water channels from 30 to 50 and a growth in their diameter from 20 mm to 28 mm resulted in the average heat flux of the casting roller remaining stable, with fluctuations less than 1 MW/m2. Leveraging the insights gained from the thermal deformation behavior of the casting roller and the ideal shape of the casting strip, a comprehensive control approach for the casting roller profile was developed. The outcomes of this research provide a valuable theoretical framework for enhancing the design of casting roller structures in the TRC process.

Inline Hot Rolling of Al-5%Mg Strip Cast Using an Unequal Diameter Twin-Roll Caster.

One advantage of twin-roll casting for aluminum alloys is that hot rolling can be omitted, thus shortening the process. The effect of inline hot rolling on the anisotropy of the mechanical properties, especially the elongation, of the roll-cast strip has not been investigated. In a high-speed twin-roll caster, inline hot rolling forms the metal shape before the temperature of the cast strip decreases below the temperature needed for hot rolling. In this study, inline hot rolling of Al-5%Mg strips cast using an unequal diameter twin-roll caster was performed to validate the technique and evaluate its ability to reduce surface cracking and improve the elongation anisotropy. A rolling speed of 30 m/min was used, and the effects of temperature and thickness reduction during inline hot rolling on the surface and mechanical properties were investigated. Inline hot rolling was found to effectively reduce the formation of surface cracks and the anisotropy of the mechanical properties.

Hot Deformation Behavior of Free-Al 2.43 wt.% Si Electrical Steel Strip Produced by Twin-Roll Strip Casting and Its Effect on Microstructure and Texture.

Twin-roll strip casting (TRSC) technology has unique advantages in the production of non-oriented electrical steel. However, the hot deformation behavior of high-grade electrical steel produced by TRSC has hardly been reported. This work systematically studied the hot deformation behavior of free-Al 2.43 wt.% Si electrical steel strip produced by twin-roll strip casting. During the simulated hot rolling test, deformation reduction was set as 30%, and the ranges of deformation temperature and strain rate were 750~950 °C and 0.01~5 s-1, respectively. The obtained true stress-strain curves show that the peak true stress decreased with an increase in the deformation temperature and with a decrease in the strain rate. Then, the effect of hot deformation parameters on microstructure and texture was analyzed using optical microstructure observation, X-ray diffraction, and electron backscattered diffraction examination. In addition, based on the obtained true stress-strain curves of the strip cast during hot deformation, the constitutive equation for the studied silicon steel strip was established, from which it can be found that the deformation activation energy of the studied steel strip is 83.367 kJ/mol. Finally, the kinetics model of dynamic recrystallization for predicting the recrystallization volume percent was established and was verified by a hot rolling experiment conducted on a rolling mill.

Mitigating segregation and synergistically improving corrosion resistance via Ca-Y microalloying in twin-roll cast Mg-Al-Mn dilute alloys

This study investigates Ca-Y microalloying to address macro-segregation and enhance corrosion resistance in twin-roll cast Mg-Al-Mn alloys. Ca-Y microalloying alleviates macro-segregation by transforming Al-Al pairs into Al-Ca pairs and refines eutectic Al2Ca via heterogeneous nucleation. In 3.5 wt% NaCl solution, Ca-Y microalloying promotes the formation of protective Al2O3, Y2O3, and Ca-oxides on the eutectic Al2Ca, thus reducing pitting corrosion. More importantly, Ca-Y microalloying prevents the formation of Al-poor regions, which are prone to micro-galvanic corrosion and oxide film degradation. Overall, Ca-Y microalloying significantly improves corrosion resistance via a synergistic effect in refining the eutectic Al2Ca phase and decreasing Al-solute segregation.

Research on flow, heat transfer, and solidification characteristics of flow distribution process in the twin-roll casting

Twin-roll casting (TRC) has seen a significant interest in recent years due to its short process, low energy consumption, and low emission. The research included both numerical simulation and experimental validation to examine the flow and temperature field distribution of the TRC process. The “U-shaped” buffer groove is identified as beneficial for maintaining a stable liquid level distribution in the molten pool through comparison with various flow distributor structures. The solidified billet shell dispersion around the casting roller in the molten pool is observed to undergo three distinct stages: stable growth, thickness fluctuation, and rapid growth. The inclusion of two circular side outlets, each with a diameter ranging from 8 to 10 mm, proves advantageous in maintaining a stable distribution of the liquid level within the molten pool. The edge outlet size ranges from 7 to 9 mm, and ensuring a U-shaped buffer groove width/flow distribution of 1.25–1.58 aids in enhancing casting stability.

Numerical Analysis of Temperature and Stress Field of Side Dam on the Twin‐Roll Strip Casting

Side sealing technology is crucial in the twin‐roll casting process. The performance of side dam materials directly determines twin‐roll casting (TRC) process stability and safety. An orthogonal test is conducted to study the effects of thermal conductivity, linear expansion coefficient, and elastic modulus on the maximum thermal stress of side dams. The elastic modulus and linear expansion coefficient are identified as key factors affecting the maximum thermal stress of the side dam. The fluctuation of maximum thermal stress under different elastic modulus and linear expansion coefficients is 79.7 and 75.8 MPa, respectively, whereas it is only 11.2 MPa under different thermal conductivity. A side dam with heterogeneous material along height and thickness gradient is designed. The results indicate that the maximum thermal stress in the contact area between the side dam and the molten metal decreases to 31.2 MPa, representing a reduction of more than 30 MPa compared to the homogeneous side dam with optimal performance. The results provide important guidance in improving the stability of the TRC process.

Effect of Sc addition on downstream processing of twin-roll cast Al−Cu−Li−Mg−Zr-based alloys

A processing scheme for preparing strips of Al−Cu−Li−Mg−Zr-based alloys microalloyed with Sc was proposed. This scheme includes a twin-roll casting of strips with a near-net-shaped 3 mm-thick gauge and a homogenization/solution treatment processing step. Two twin-roll cast Al−Cu−Li−Mg−Zr-based alloys were studied, one with an addition of 0.17 wt.% Sc, and the other without addition of Sc. Both alloys were annealed at 300 °C for 30 min, 450 °C for 30 min, and 530 °C for 30 min and quenched into room temperature water. The first two annealing steps provide a fine dispersion of Al3Zr/Al3(Sc,Zr) particles. The final annealing step serves as homogenization/solution treatment. A fine crystallization structure of the twin-roll cast materials enables the dissolution of primary particles containing the main alloying elements during a relatively short annealing time. Shorter soaking duration limits the depletion of surface layers from Li and significant coarsening of Al3Zr/Al3(Sc,Zr) dispersoids. The Sc-containing material has significantly finer grains already in the as-cast state. The Al3(Sc,Zr) dispersoids formed during the homogenization/solution treatment step prevent grain coarsening at high temperatures. Strengthening θ′(Al2Cu), T1(Al2CuLi), and rare S’(Al2CuMg) phases are formed during subsequent artificial aging at 180 °C. The increase in yield strength was 200 MPa in the peak-aged conditions. This value is comparable to the ones reported in similar direct-chill cast materials, thus validating the proposed processing scheme.

The comprehensive study on texture evolution and recrystallization behavior of twin-roll strip casting Fe-50 %Co alloy

The iron-cobalt soft magnetic alloy exhibits excellent properties such as high saturation magnetic induction, high magnetic permeability, and high Curie temperature, making it widely used in areas like aviation generators and electric motors. However, traditional iron-cobalt alloy strip materials often suffer from a high magnetic anisotropy constant, which hinders their performance in practical applications. In this study, twin-roll strip casting was employed to produce Fe-50Co soft magnetic alloy cold-rolled strip materials. The research findings reveal that the initial microstructure of the Fe-50Co alloy strip prepared through twin-roll strip casting is primarily composed of coarse columnar grains and equiaxed grains, with a strong {001} orientation for the columnar grains. Notably, a significant number of Σ3 grain boundaries are present within the cast strip. These grain boundaries effectively reduce dislocation accumulation during the cold rolling process and subsequently minimize the nucleation sites for γ-texture during subsequent annealing. Furthermore, a strong {001}<uv0> texture is formed in the finished strip material after cold rolling and annealing, resulting in superior magnetic properties. The alloy exhibited excellent magnetic properties after annealing at 900 ℃ for 5 h followed by furnace cooling to 750 ℃ with the cooling rate of 50 ℃/h and then to 300 ℃ with the cooling rate of 180 ℃/h, the B5000 was ∼ 2.417 T, P1.5/400 was ∼22.651 W/kg and P2/1000 was 183.51 W/kg. These findings provide valuable insights for the development of Fe-50Co alloys with excellent magnetic properties.

Influence of pre-stretching and annealing on microstructure and mechanical properties evolution of twin-roll cast Mg-2Al-1Zn-1Ca (wt.%) plates

Pre-stretching and annealing treatments were conducted on twin roll cast Mg-2Al-1Zn-1Ca (AZX211, in wt.%) plates with a rare earth-like texture. Varying amounts of deformation were applied along the rolling direction (RD) and transverse direction (TD) of AZX211 alloy in order to modify its mechanical properties at room temperature. The results demonstrate that pre-stretching treatment effectively enhances the yield strength (YS), especially along the RD. The strengthening mechanism is attributed to the production of a large number of dislocations and sub-grain boundaries, but the work-hardening ability of the plate will be greatly weakened. Additionally, annealing treatment substantially improves the plasticity and in-plane anisotropy and restores the work-hardening ability. The notable distinction in the pre-stretching process between different directions lies in the underlying deformation mechanism. In case of RD, deformation is predominantly governed by the slip mechanism of {0002} 〈11−20〉 basal slip and {10−10} 〈11−20〉 prismatic slip, while along the TD, deformation is primarily controlled by {0002} 〈11−20〉 basal slip without significant twinning deformation. When a 6 % pre-stretching is conducted, the initial rare earth-like texture of the sample transforms into a symmetrically distributed double-peak basal texture, accompanied by grain refinement. This texture transformation is chiefly due to the dominance of {0002} 〈11−20〉 basal slip-driven deformation. Moreover, the annealed sample maintains a strong basal texture, owing to strain-induced recrystallization.

Annealing temperature effects on microstructure and magnetic properties of Fe-6.5wt. %Si alloy strips prepared by TSTRC process

The Fe-6.5wt.%Si alloy exhibits remarkable soft magnetic characteristics, such as high magnetic permeability, low coercivity, high resistivity, and nearly zero magnetostriction. These attributes establish it as an ideal material for low-power, low-noise electric motors and transformers. This investigation aimed to assess the impact of annealing temperature (ranging from 800 to 1200 °C for 1 h) on the microstructure, texture, and magnetic properties of a 0.15 mm thick Fe-6.5wt.%Si alloy sheet, which was obtained by subjecting the strips produced through the top side-pouring twin-roll casting (TSTRC) process to multi-pass warm rolling in the temperature range of 600 ∼ 800 °C, avoiding hot rolling. Additionally, the recrystallization mechanism of the annealed sheet at 1100 °C for 1 h was explored. The findings indicate that enhancing the annealing temperature corresponded to a reduction in magnetic induction (B8 and B50) as well as iron losses (P10/50, P10/400, and P2/1000). The annealed sheet at 1200 °C for 1 h demonstrated the most favorable magnetic properties, displaying iron losses of 0.486 W/kg, 6.895 W/kg, and 1.232 W/kg for P10/50, P10/400, and P2/1000, respectively. These results illustrate excellent overall magnetic characteristics. The coercivity (Hc) of both B8 and B50 decreased as the annealing temperature increased in the hysteresis loop measurements. Specifically, for B8, it decreased from 62.84 A/m to 24.50 A/m, and for B50, it decreased from 78.10 A/m to 35.50 A/m. The average grain size of the samples gradually increased as the annealing temperature ranged from 800 to 1200 °C. The dominant texture observed was {111}, and the volume fraction of {111} texture increased while the volume fractions of {100} and {110} textures decreased. Upon annealing at 1100 °C for 8 s, the elongated and flattened deformed structures were mainly replaced by equiaxed grains, indicating the completion of the recrystallization process. However, there was a noticeable distinction in the coarsening degree of equiaxed grains based on their orientations. The presence of λ-oriented grains was less prominent, while α-oriented and γ-oriented grains were relatively more abundant. As the annealing time increased from 8 s to 1 h, there was a decrease in the presence of λ-oriented and α-oriented grains, while the presence of γ-oriented grains significantly increased.

Investigation of segregation behaviour in 2060 aluminium-lithium alloy during twin-roll casting

The utilization of the twin-roll casting process to fabricate aluminium (Al) - lithium (Li) alloys is regarded as an efficient and energy-saving strategy to meet the aerospace industry’s demands for reducing processing steps, cost-effectiveness, and corrosion resistance. This study successfully achieved the preparation of Al-Li alloy twin-roll cast slabs across various processing ranges to investigate the corrosion resistance differences in different processing conditions. Remarkable macro segregation phenomena were observed in the fabrication under high twin-roll casting speeds for TRC-3. By combining temperature and flow rate calculations, we comprehensively analysed the results of this segregation mechanism. The segregation is inherited into the final T6 state microstructure, exacerbating the precipitation of the T1 phases and deteriorating the ultimate corrosion resistance performance. We delved into a profound discussion regarding the mechanistic impact of segregation on corrosion behaviour. Ultimately, this study postulates a process parameter range for twin-roll casting of Al-Li alloys, aimed at attaining minimal segregation and maximal corrosion resistance.

Generalized stability criterion for columnar to equiaxed grain transition during solidification upon vertical twin roll casting

To promote the columnar to equiaxed grain transition (CET) to obtain uniform equiaxed grain, most of the available theoretical works mainly focus on the growth but ignore the nucleation. Regarding it, a systematical framework integrating nucleation catalyzed by refiners with dendritic growth, was constructed, where, a new conception of generalized stability (GS), considering evolving thermodynamic driving force (ΔG) and kinetic energy barrier (Q) upon solidification of VTC, was adopted to study the CET position, the grain radius and the mechanical properties. By adding the refiners, especially the Al–5Ti–1B refiner, the larger thickness of 5–6 mm for equiaxed grain and finer grain radius of 19 μm are exhibited by increasing the ΔG for nucleation and the GS for growth, possessing simultaneously improved strength and plasticity. Following a criterion of high ΔG–high GS, the refiner diameter is optimized to be 0.3 μm.

Improving long-term thermal stability in twin-roll cast Al-Mg-Si-Cu alloys by optimizing Mg/Si ratios

Achieving high thermal stability in the 6xxx series alloys remains a challenging task, which limits their engineering application. Herein, Al-Mg-Si-Cu alloys with various Mg/Si ratios (0.5, 1, 2, and 4) were fabricated by twin-roll casting (TRC), and the microstructure evolution and mechanical properties during long-term thermal exposure of 150 °C/1000 h were studied. The results disclosed that alloys with a high Mg/Si ratio exhibited better thermal stability. The alloys with the Mg/Si ratio of 2 (Mg/Si∼2) achieved a stable high yield strength of ∼330 MPa and meanwhile maintained a satisfactory fracture elongation (> 10 %) throughout the thermal exposure process. This excellent thermal stability can be attributed to the microstructure consisting of high-density L phases and fine α-AlFeSi phases, which was related to the optimized Mg/Si ratio. Specifically, L phases were dominated in peak-aged Mg/Si∼2 alloys, while the counterparts in alloys with the Mg/Si ratio of 1 (Mg/Si∼1) were β'' and Q' phases. During the thermal exposure process, the L phases remained stable without coarsening, which was mainly due to the high coherence and low interfacial energy of the L-matrix interface. Meanwhile, the main Fe-containing phases in Mg/Si∼2 and Mg/Si∼1 alloys were fine near-spheroidal α-AlFeSi and large-size needle-like β-AlFeSi, respectively, which lead to a better ductility of Mg/Si∼2 alloys. This work may provide a strategy for the preparation of 6xxx series alloys with high thermal stability.

Tuning heterogeneous microstructure and improving mechanical properties of twin-roll strip cast low carbon steels by on-line heat treatments

Coarse austenite grains are unavoidable in the low carbon steels processed by twin-roll strip casting. Unfortunately, the polygonal ferrite (PF) grains cannot be refined by conventional on-line cooling process, resulting in low strength. In this work, an on-line heat treatment including reaustenitizing and subsequent controlled cooling was performed in laboratory to form heterogeneous microstructures composed of PF and acicular ferrite (AF). It has been founded that increased prior austenite grain size and the cooling rate led to more AF laths, which inhibited the growth of PF grains. When the prior austenite grain size is less than 60 μm, the formation of AF is suppressed. The tensile tests indicate that the heterostructured steels exhibited higher yield strength than the samples without AF. The improvement of yield strength can be attributed to the grain boundary strengthening, dislocation strengthening and back stress strengthening. The higher AF volume fraction leads to higher dislocation density in PF grains, and more AF/PF interfaces may increase the amount of accumulated geometrically necessary dislocations. Therefore, the contributions of dislocation and back stress strengthening increase with the increase of AF volume fractions. High dislocation density and the generation of back stress contribute a high strain hardening rate to delay the necking and sustain good plasticity. Moreover, the heterostructured steels exhibit the two-stage work hardening behavior during tensile test, which indicates that plastic deformation starts in PF grains while the AF laths remain in elastic state, and then plastic deformation occurs in both strain hardened PF grains and AF laths.