Abstract: A thin-walled metal container is formed with a bottom wall which is substantially flat and connected to a container side wall through a curved wall portion located at the periphery of the flat bottom wall. A stacking support member is attached to the lower surface of the bottom wall to define a rest surface for supporting the container on a horizontal surface, The stacking support member is made of foam material to prevent `sweating` of the container on a table surface while also minimizing scratching, Other non-metallic materials may function as the stacking support member.

Abstract: A flanging apparatus includes a flanging head assembly having a cluster of freely rotatable spin flanging rollers and a stop ring against which the flange hits during the final flange forming stages to limit the flange to a specific diameter. To prevent the flange from entering the crack formed between the rotating roller and the stationary stop ring, there is provided a step spacing the stop ring surface from the roller forming surface. The forming process occurs as a result of spring biased relative axial movement of the can open end toward the forming surfaces, caused by contact between the can bottom with a base pad movable in a working stroke toward the flanging rollers with a cam controlled spindle. A spring extends between the base pad and a base pad spring collar attached to the spindle to create a predetermined spring force which is normally applied throughout the flange forming process.

Abstract: A method for making aluminum foil comprises providing an aluminum-based alloy composition consisting essentially of about 0.05 to 0.20 weight percent silicon, about 0.02 to 0.50 weight percent iron, about 0.05 to 0.30 weight percent copper and balance aluminum and inevitable impurities and grain refining elements, wherein the ratio of iron to silicon ranges between about 2:1 and 4:1. The aluminum-alloy composition is continuously cast using a unitary and chilled casting wheel to form a cast strip product of desired width and gauge. The cast strip product is then homogenized, cold rolled and recrystallized annealed into an aluminum foil product. The aluminum-based alloy composition produces a single roll cast product having minimum microshrinkage porosity on the air surface thereof. Reducing or eliminating the microshrinkage porosity in the cast product results in an aluminum foil product having a minimum of pinholes in the final foil product.

Abstract: A thin-walled metal container is formed with a bottom wall having a substantially flat central panel connected to a curved wall portion through an annular, inclined flat or frustum wall portion. The curved wall portion joins the container side wall and is defined by the base radius. The inclined or frustum connecting wall portion acts as a hinge which enables the central panel to move between an upper, non-tensioned position and a lower, tensioned position. In the upper position, the annular downward facing surface of the curved wall located at the radially outermost periphery of the bottom wall defines a support surface which supports the container against necking, seaming, and filling column loads. After displacement of the central panel to the lower, tensioned position, which may occur after filling as a result of carbonation pressure, the container rests on a series of circumferentially spaced feet.

Abstract: A method and apparatus for spin flow necking-in a D&I can is disclosed wherein an externally located free spinning form roll is moved radially inward and axially against the outside wall of the open end of a trimmed can. A spring loaded interior support slide roll moves under the forming force of the form roll as the latter slides along a conical forming surface of a second free roll mounted axially inwardly adjacent the slide roll. To minimize the plug diameter variation between successively necked cans, the axial retracting movement of the slide roll is halted at a predetermined location via contact with a spacer to prevent further radial inward movement of the form roll which would otherwise occur as a result of only cam controlled form roll movement.

Abstract: A container is formed with a bottom wall comprising a central panel and a resting radius formed from an annular wall depending downwardly from the central panel periphery and then outwardly and upwardly to join the container side wall. A method is disclosed which reduces the resting radius by tightening the curvature thereof through deformation of the outer annular wall so that the resting radius is better able to resist eversion under the influence of pressure within the container. The outer wall is deformed by radially inward flexing of plural fingers which are cammed radially inwardly into contact with it through a cam follower arrangement which also controls a can support member to (1) locate the bottom wall in a first position between the reforming fingers and supporting anvil, and (2) in a second, elevated stripping position where the container is removed from the apparatus. The container bottom wall is preferably reformed during necking-in of the container open end.

Abstract: A method and apparatus for trimming edge scrap from continuously cast metal strip includes an edge trimming device in combination with a drag casting apparatus for producing aluminum or aluminum alloy cast strip. The edge trimming device includes a tool which marks the casting surface of the casting wheel to disruption the solidification rate during casting of the molten aluminum. Disruption of the solidification rate forms a longitudinal split in the strip being cast resulting in formation of a high quality cast strip product acceptable for further processing and edge trim scrap. The edge trim scrap may be recovered and recycled for further use. The edge trimming device includes adjustable features to permit varying the location of the longitudinal split along the width of the strip being cast in response to casting parameters such as excess gauge variation, surface defects or changing of the cast strip width prior to or during the continuous casting operation.

Abstract: Method and apparatus for forming can ends is disclosed wherein ends are blank from sheet material and formed in a die in which the completed end is formed and removed from the die at a vertical position below the blanking position. Formation and removal of the end beneath the cut line enables better control of the ends after forming, Vacuum is applied to the end underside to positively seat the end against lower die forming elements as the lower elements raise the end to the level of an ejection slot where pressurized air blows the air from between the dies. An automatic lubrication circuit for properly lubricating seal members forming pneumatic cushions for resiliently biasing the various die members is also disclosed.

Abstract: A method of die-necking the open end of a can body to form a reduced diameter neck having a smooth profile comprising first forming a reduced diameter control neck at the open end of the sidewall of the can body, and then totally reforming the control neck and the adjacent portion of the sidewall to form a second reduced diameter neck. The diameter of the second neck is less than the diameter of the control neck, and the axial length of the second neck is substantially greater than the axial length of the control neck.

Abstract: A start-up method and apparatus for continuous casting of molten metal into a cast strip product includes initially casting a start-up alloy having sufficient strength, flexibility and casting surface release properties to achieve steady state casting conditions. A target alloy follows the start-up alloy being cast to produce a cast strip product of the target alloy composition. A start-up alloying vessel is disposed between the source of the target alloy and the casting apparatus to facilitate introduction of a start-up alloy into the casting process or formulation of a particular start-up alloy for initiation of the continuous casting operation.

Abstract: An expandable structural member comprises two outer skin members, a plastically deformable reinforcing layer arranged between the two outer skin members, and a foamable polymer composition coated on at least one of each adjacent surface of the reinforcing layer and the respective outer skin member. Each adjacent surface of the reinforcing layer and the respective outer skin member contact one another and are intermittently bonded to one another, with the intermittent bonds on one surface of the reinforcing layer being non-aligned with the intermittent bonds on the other surface of the reinforcing layer. Additionally, the foamable polymer composition is foamable by application of heat to the structural member, whereby the foamed polymer resulting from application of heat to the structural member expands the outer skin members from contact with the reinforcing layer at non-bonded areas and plastically deforms the reinforcing layer into a three-dimensional reinforcing configuration.

Abstract: A multi-station machine for necking-in the open end of a metal container body includes a plurality of necking spindle assemblies mounted at circumferentially spaced locations on a tooling disc turret in coaxial alignment with corresponding base pad spindle assemblies mounted to a base pad turret. The turrets are co-rotatable with a main turret shaft. Cam controlled tooling activating assemblies are mounted on the tooling disc turret to control the necking-in movement of an eccentric roll and an external forming roll in each necking spindle in synchronism with the delivery of vacuum suction through the base pad spindles which clamps the container bottom walls to the respective base pads. A sequential latching arrangement associated with the tooling activating assemblies prevents tool-to-tool contact between the outer forming rolls with the eccentric rolls in the absence of container bodies on station.

Abstract: Method and apparatus for forming can ends is disclosed wherein ends are blank from sheet material and formed in a die in which the completed end is formed and removed from the die at a vertical position below the blanking position. Formation and removal of the end beneath the cut line enables better control of the ends after forming. Vacuum is applied to the end underside to positively seat the end against lower die forming elements as the lower elements raise the end to the level of an ejection slot where pressurized air blows the air from between the dies. An automatic lubrication circuit for properly lubricating seal members forming pneumatic cushions for resiliently biasing the various die members is also disclosed.

Abstract: A method and apparatus for continuously casting metal includes a tundish having edge seals and risers positioned at an outlet portion thereof . The edge seals and risers are configured to reduce the depth of molten metal adjacent the tundish sidewalls such that a lesser volume of molten metal contacts a driven casting surface to permit rapid solidification of edge portions of a cast strip. The edge seals and risers also are configured to form a meniscus between the seals and casting surface to effectively seal a gap between the tundish sidewall and continuous casting surface to prevent molten metal leakage therethrough. Preventing molten metal flow through the gap between the casting surface and sidewalls eliminates the requirement for a mechanical seal during continuous casting of molten metals.

Abstract: A method and machine for forming can necks in metal container bodies is disclosed. The machine comprises a pilot assembly coaxially situated and longitudinally movable with respect to and within a necking die member having an annular static die forming surface longitudinally advanced into contact with the can side wall defining the open end. Prior to necking, the pilot assembly is inserted into the open end and then stopped. Continued forward movement of the necking die member opens a valve between the pilot assembly and die member to flow pressurized fluid from a reservoir in the pilot to pressurize the can. This prevents crushing of the can under necking loads. The reservoir is located entirely within the pilot shaft and has a dimensional volume greater than the can body interior volume. This results in rapid delivery of pressurized fluid into the can before the greatest necking loads are applied to the side wall.

Abstract: A method and apparatus for spin flow necking-in a D&I can is disclosed wherein an externally located free spinning form roll is moved radially inward and axially against the outside wall of the open end of a trimmed can. A spring-loaded interior support slide roll moves under the forming force of the form roll as the latter slides along a conical forming surface of a second free roll mounted axially inwardly adjacent the slide roll. To prevent damage to the metal caused by excessive pressure contact between the form and slide rolls, the slide roll is axially retracted via a cam ring which initially contacts the form roll during radially inward necking movement.

Abstract: An adjustable flow control device for use in a metal strip continuous casting apparatus comprises a tundish for directing molten metal onto a moving chill surface and a plurality of individually and vertically adjustable flow control plates which extend across the width of the tundish. Each of the individual and vertically adjustable flow control plates define a flow passageway between the plate bottom edge and the tundish floor for controlling molten metal flow in the tundish. By providing individually adjustable flow control plates, flow of molten metal can be controlled in discrete width portions of the tundish to improve cast strip thickness and cross-sectional profile. The adjustable flow control device may be responsive to sensed casting parameters to permit automatic and precise control over cast strip thickness and cross-sectional profile during continuous casting of metal, in particular, aluminum alloys.

Abstract: A flanging head assembly having a cluster of freely rotatable spin flanging rollers includes a stop ring against which the flange hits during the final flange forming stages to limit the flange to a specific diameter. To prevent the flange from entering the crack formed between the rotating roller and the stationary stop ring, there is provided a step spacing the stop ring surface from the roller forming surface. In this manner, as the terminal edge of the flange slides around the flanging roller during final forming, it will pass over the crack and across the step to lodge in a corner formed between the step and stop ring surface. In a preferred embodiment, the step is a conical surface extending from the stop ring surface in a direction away from the can bottom. This conical surface extends radially inwardly a sufficient distance to contact unsupported flange portions between the flanging rollers to limit the degree of elastic sagging of these portions.