Continuous Casting

We know all about the world class application of Twin Roll Casting (TRC) and Twin Belt Casting (TBC)

Continuous casting processes have developed into mature technologies for manufacturing aluminium products and, in many cases, can provide alternative production routes to conventional hot mill processesing with significant advantages. Continuous casting benefits from reduced Capex and a smaller footprint and, as a result, can be the perfect choice for staggered investment plans or for creating capacity for new markets.

From the initial phases of a new continuous casting project it is necessary to understand clearly the advantages and limitations of the technology. This is to ensure you target the right markets and determine the necessary process steps and equipment to minimise the investment risk. Our consultants have hands-on manufacturing experience when it comes to selecting the best processes to achieve world class quality products. We understand what can be achieved with the cast strip in terms of productivity, metallurgical quality and surface quality.

Do you want to know what products can be made using TRC and TBC?

We can tell you the benefits and drawbacks of these process routes for particular products, and we can help you set up your continuous casting process. Our consultants have created and run stable processes for all continuous casting applications.

We’re actively involved in new developments in TRC and TBC technologies for both automotive sheet and electronic packaging.

We offer support in new product development using these technologies

This covers everything from alloy selection to the processing conditions necessary to obtain the desired product requirements. You can try out your ideas using small scale simulation as we have access to both TRC and TBC off-line process routes.

If you’re using continuous casting technology already but struggling to meet the product requirements, we can help

Contact one of our consultants with details of your problem and we will try to help you. We have a lot of experience, both in plants and through government-funded research programmes, of continuous casting technology.

A word on automotive

Continuous casting can be used to produce both conventional AA6xxx series automotive closure sheet and AA5xxx series automotive sheet for structural purposes. When compared to the hot rolling route, the twin roll cast route is relatively shorter with less working of the metal, thereby reducing the possibilities for microstructural control. However, despite this, it is possible to develop rolling and annealing practices which produce sheet with both the essential microstructural features and sufficient formability.

It has been shown that the grain size of twin roll cast product at the final gauge is finer than that of DC-cast alloys, with a much finer dispersion of intermetallic particles. This means that twin roll casting is a particulalry good route fror increasing the end of life scrap recycled content of automotive alloys. Twin roll cast AA5xxx alloys have demonstrated good strength, elongation and forming indices, giving mechanical characteristics equal to or better than those of DC-cast alloys. The corrosion properties of twin roll-cast alloys can be much better than those of DC-cast alloys due to the refinement of iron-bearing intermetallic phases, and twin roll-cast AA6xxx sheet is not susceptible to roping.

 

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Speak to our expert

Vicente Martin

Vicente is one of our Process Improvement consultants and an expert in aluminium foil rolling. A metallurgist with 25 years’ experience, he has a wealth of both product and process knowledge.

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