camisa cu 02

Special Products SEe / Kol

Copper Sleeves

for

Aluminium Strip Casting


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


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.


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



Introduction




Summary and outlook


Copper Sleeves for Aluminium Strip Casting - Steps of manufacturing casting sleeves -

Melting & Casting

Hot & Cold Forging

Heat treatment

Machining

Quality Control

Assembling

Final Machining

• Copper alloy foundry

• Billet sizes: ø 720, 820 or 1020 mm

• Forging of cast billet to the dimensions of sleeves in strip

casting & heat treatment

• 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


Copper Sleeves for Aluminium Strip Casting - Final machining of copper sleeves -

Assembled and machined copper sleeves

Final machining on turning lathe


SEQV [N/mm²]

Boundary conditions for non linear calculation:

• Material of copper shell: Elbrodur® B95

• Wall thickness: 83 mm

• Inside diameter of copper shell: 672 mm * For reasons of the overview the steel core

(without cooling slots) is blanked out

View on plane of symmetry View on outer surface

Copper Sleeves for Aluminium Strip Casting - Typical equivalent stress (Von Mises) after shrink fitting -


Copper Sleeves for Aluminium Strip Casting - Assembling: Shrinkage process of copper sleeves (Example 1) -


Copper Sleeves for Aluminium Strip Casting - Assembling: Shrinkage process of copper sleeves (Example 2) -



Introduction




Summary and outlook


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

Hardness HBS

Tensile Strength Rm

Elongation A5

Units

%

Sm/mm²

% IACS

W/(m•K)

°C

°C

GPa

MPa

2.5/62.5

MPa

%

Elbrodur® NIB

1.5 Ni

0.2 Be

290

40

69

(700)

590

128

510

500

495

(440)

200

630

580

540

(465)

14

12

(10)

(3)

Elbrodur® G

0.65 Cr

0.1 Zr

350

48

84

(700)

590

128

125

270

255

230

(200)

390

340

290

(230)

25

24

22

(20)

Elbrodur® GP

0.65 Cr

0.1 Zr

350

48

83

(700)

590

128

130

300

280

250

(220)

410

360

310

(250)

21

20

19

(16)

Temperature

20 °C / 68 °F

20 °C / 68 °F

20 °C / 68 °F

°C / °F

20 / 68

200 / 392

350 / 662

500 / 932

20 / 68

20 / 68

200 / 392

350 / 662

500 / 932

20 / 68

200 / 392

350 / 662

500 / 932

Elbrodur® B95

1.0 Co

0.1 Be

240

33

57

(700)

590

128

490

470

450

(405)

200

630

590

550

(445)

18

14

(9)

(3)

Copper Sleeves for Aluminium Strip Casting - KME - AMM® Advanced Mold Materials -


Copper Sleeves for Aluminium Strip Casting - Equivalent stresses (Von Mises) during casting operation -

SEQV [N/mm²]

Boundary conditions for non linear calculation:

• Material of copper shell: Elbrodur® B95

• Wall thickness: 83 mm

• Inside diameter of copper shell: 672 mm * For reasons of the overview the steel core

(without cooling slots) is blanked out

View on plane of symmetry View on outer surface


Copper Sleeves for Aluminium Strip Casting - Thermal conductivity of Cu alloys versus strength -

Tensile Strenght [MPa]

Th

erm

al c

on

du

cti

vit

y [

W/m

•K]

350

150

300 400 700 600

250

Cu

Ag

Elb

rod

ur®

G

Elb

rod

ur®

G

F

Elb

rod

ur®

N

IB

Osn

isil®

G

Elb

rod

ur®

B

95


Copper Sleeves for Aluminium Strip Casting - Proof stress of Elbrodur® G, NIB, B95 at 20 °C / 200 °C / 350 °C -

0

100

200

300

400

500

600

Elbrodur G Elbrodur NIB Elbrodur B95

0.2

% P

roo

f S

tre

ss

[M

Pa

]

20 °C

200 °C

350 °C



Introduction




Summary and outlook


F = 4.3 MN

(max. 8.5 MN)

F = 4.3 MN

(max. 8.5 MN)

Cooling water:

Inlet 34°C

Outlet 38°C

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

Copper Sleeves for Aluminium Strip Casting - Typical casting parameters with steel sleeves -


200

215

230

245

260

275

290

305

320

335

350

365

380

395

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

Productivity [t / h / m strip width]

Str

ip te

mp

era

ture

at ro

ll e

xit [

°C]

3003 with steel sleeve

Based on results from casting

trials

1100 with

steel sleeve

1100 cast with

combination of steel and

copper sleeve 3003 with copper sleeve

Copper Sleeves for Aluminium Strip Casting - Productivity increase with Copper sleeves -

* source: P.A.E.


rolling forces

vsleev

e

vsleev

e

vstrip

Aluminium

coil

T ~ 400 - 450 °C

T ~ 110 °C

T ~ 90 °C

Copper Sleeves for Aluminium Strip Casting - Principal of casting trial with Cu sleeves -

During the casting of aluminium strips the copper sleeves are

loaded with high temperatures and forces inducing high levels

of stress in the shell


Time [s] T

emper

ature

[°C

]

T [°C]

View on outer surface

View on plane of symmetry

Copper Sleeves for Aluminium Strip Casting - FEM-Calculation: Temperature distribution during startup -


Copper Sleeves for Aluminium Strip Casting - Casting process - Trial with customer -


Copper Sleeves for Aluminium Strip Casting - Casted coil - Trial with customer -


Copper Sleeves for Aluminium Strip Casting - Productivity Range -

Strip Thickness Productivity Cooling Rate

[mm] [t / (m • h)] [°C / s]

10 - 5

0.5 - 1.5

102 - 103 1.6 - 2.1

1.8 - 2.8

4 - 2

1.5 - 1.8 103 - 104

St / St Shell

St / Cu Shell

Cu / Cu Shell

3.0 - 7.0 104 - 105

0.3 - 0.08 90 105 - 106

St / St Shell

Cu / Cu Shell

LGS Casting

Roll Casting

Melt Spinning


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 840 1100 6 1700 120 17500

MO22 840 1100 6 1700 116 16700

CMYV / Cu 840 / 870 1100 6 1700 120 26600

Cu 870 1100 8 1700 129 35500

MO22 / Cu 840 / 870 1100 8 1700 119 25000

CMYV

MO22

CMYV / Cu

MO22 / Cu

Cu

840

840

840 / 870

840 / 870

870

3003

3003

3003

3003

3003

6

6

6

8

8

1700

1700

1700

1700

1700

130

127

124

123

130

14400

13500

23700

22400

33000


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: ~ 34 t / mm

- actual average set no. 3: ~ 44 t / mm

• Costs represent casting cost including labour, energy,

remachining and maintenance. Cost level representing

European labour.

• Depreciation not included


Copper Sleeves for Aluminium Strip Casting - Average Productivity for different Alloys * -

Alloy

Composition

St / St

[ t / (m•h) ]

St / Cu

[ t / (m•h) ]

St / St (ø 960 mm)

[ t / (m•h) ]

1100 Al

0.5 Fe 0.1 Cu 1.23 1.8 1.34

1235 Al

0.2 Si 0.4 Fe 1.25 1.7 1.4

3003 Al

1.0 Mn 1.03 1.75 1.08

5005 Al

1.0 Mg 0.9 1.65 0.9

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


Copper Sleeves for Aluminium Strip Casting - Comparison of shell life -

St - Sleeve: ø 840 mm x 1700 mm casting width

• remachining allowance: 100 mm

• shell wear: 115 t / mm / m = 11500 t

• shell wear x casting width: 11500 x 1.7 = 19500 t

Cu - Sleeve: ø 870 mm x 1700 mm casting width

• remachining allowance: 135 mm

• shell wear: 40 t / mm / m = 5400 t

• shell wear x casting width: 5400 x 1.7 = 9180 t


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


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


Copper Sleeves for Aluminium Strip Casting - Casted coil - Trial with customer -

Microstructure of casted strip Edge of Aluminium strip



Introduction




Summary and outlook


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.


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:

• Castal (Greece), customer not known

• Choil (Korea)

• Eurofoil (Luxembourg)

• MAL (Hungary)

• Hydro Inasa (Spain)

• Teknik Alüminyum Sanayi (Turkey)


Copper Sleeves for Aluminium Strip Casting - Scale of KME’s 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

Machining & Assembling • 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

Engineering • Detail design engineering (3D, 2D)

• FEM calculations (thermal & structural)

Research & Development • Material development

• Failure examination and analysis • SEM & EDX

• Micrographs / polished sections

• Tensile, fatigue & bending tests

camisa cu 02

Documents

application of copper

manufacturing casting

aluminium strip casting

aluminium strip casting

aluminium strip casting

dimensions of sleeves

cu sleeves summary

casting costs