Novelis Fusion™, A Novel Process for the Future

Bischoff, Todd F.; Hudson, Lawrence G.; Wagstaff, Robert B.

doi:10.1007/978-3-319-48228-6_77

Cited by 3 publications

(4 citation statements)

References 2 publications

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“…To produce LMC by casting, two methods are mostly used. Using the so-called 'Novelis Fusion' method, different aluminum alloys can be combined by a modified direct chill ingot casting process [135]. The second method is a roll casting process, where the melt is poured onto a sheet and is then rolled by two rollers.…”

Section: Manufacturing Of Layered Metal Compositesmentioning

confidence: 99%

Cladded steel for clutch disc carriers

Lührs¹,

Sittig²,

Niendorf

2019

Forsch Ingenieurwes

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Bei einer zunehmenden Verbreitung elektronischer Medien kommt dem gedruckten Fachbericht auch weiterhin eine große Bedeutung zu. In der vorliegenden Reihe werden deshalb wichtige Forschungsarbeiten präsentiert, die am Institut für Werkstofftechnik -Metallische Werkstoffe der Universität Kassel gewonnen wurden. Das Institut kommt damit auch -neben der Publikationstätigkeit in Fachzeitschriften -seiner Verpflichtung nach, über seine Forschungsaktivitäten Rechenschaft abzulegen und die Resultate der interessierten Öffentlichkeit kenntlich und nutzbar zu machen.Allen Institutionen, die durch Sach-und Personalmittel die durchgeführten Forschungsarbeiten unterstützen, sei an dieser Stelle verbindlich gedankt.

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Section: Manufacturing Of Layered Metal Compositesmentioning

confidence: 99%

Cladded steel for clutch disc carriers

Lührs¹,

Sittig²,

Niendorf

2019

Forsch Ingenieurwes

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“…Technical challenges associated with the widespread use of Fusionä casting for clad aluminum applications include (i) slower casting speeds, (ii) higher labor requirements during Fusionä casting, (iii) lower yield due to product quality inconsistencies, and (iv) heat treatment and rolling of composite ingots. Specific to the low product yields are problems with oxide entrainment near the core/clad interface, [2] as well as inconsistent clad thickness. [3] Although these interface quality problems have been solved by developing empirical operating ranges for the Fusionä casting of specific alloy combinations, a general lack of understanding of the interface formation process will inhibit future development of the process for casting of different core/clad alloy combinations for new applications.…”

Section: Introductionmentioning

confidence: 99%

“…In another section of the patent, they suggest that if the metal level of the 'second' alloy is kept a few millimeters above the bottom of the metal chill bar (i.e., dividing wall), then this may prevent oxides formed on the surface of the 'second' alloy from being entrained at the bond interface. In a follow-up patent to the original Fusionä patent, [2] it is suggested that surface oxides may be deleterious to obtaining a good interface during casting. As such, this patent describes a system where an 'oxide-skimmer' or 'wiper' is placed on the top surface of the liquid metal sumps, in close proximity to the chill bar.…”

Section: Introductionmentioning

confidence: 99%

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Interface Formation During Fusion™ Casting of AA3003/AA4045 Aluminum Alloy Ingots

Ciano

Caron

Weckman

et al. 2015

Metall Mater Trans B

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Fusionä casting is a unique Direct Chill continuous casting process whereby two different alloys can be cast simultaneously, producing a laminated ingot for rolling into clad sheet metal such as AA3003/AA4045 brazing sheet. Better understanding of the wetting and interface formation process during Fusionä casting is required to further improve process yields and also explore use of other alloy systems for new applications. In this research, AA3003-core/AA4045-clad ingots were cast using a well-instrumented lab-scale Fusionä casting system. As-cast Fusionä interfaces were examined metallurgically and by mechanical testing. Computational fluid dynamic analyses of the Fusion TM casts were also performed. It was shown that the liquid AA4045-clad alloy was able to successfully wet and create an oxide-free, metallurgical, and mechanically sound interface with the lightly oxidized AA3003-core shell material. Based on the results of this study, it is proposed that the bond formation process at the alloys interface during casting is a result of discrete penetration of AA4045 liquid at defects in the preexisting AA3003 oxide, dissolution of underlying AA3003 by liquid AA4045, and subsequent bridging between penetration sites. Spot exudation on the AA3003 chill cast surface due to remelting and inverse segregation may also improve the wetting and bonding process.

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