Abstract: The present invention discloses a product comprising a 1xxx, 3xxx and 8xxx series aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product. The product has an O-temper tensile strength, O-temper elongation, and O-temper Mullen pressure that are at least 10% greater compared to the average values of the same alloy in O-temper cast using a slab or roll-casting process. The product is substantially free of pinholes caused by centerline segregation of intermetallic particles. In another embodiment, the present invention discloses a 8111 or 8921 aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product.

Abstract: The present invention discloses an aluminum alloy product having a first outer layer, a central layer, and a second outer layer. The central layer of the aluminum alloy product has a higher concentration of particulate matter than said first or second outer layers. The particular matter has a size of at least about 30 microns. And, the aluminum alloy product has a thickness ranging from between about 0.004 inches to about 0.25 inches.

Abstract: The present invention discloses a method of strip casting an aluminum alloy from immiscible liquids that yields a highly uniform structure of fine second phase particles. The results of the present invention are achieved by using a known casting process to cast the alloy into a thin strip at high speeds. In the method of the present invention, the casting speed is preferably in the region of about 50-300 feet per minute (fpm) and the thickness of the strip preferably smaller than 0.08-0.25 inches. Under these conditions, favorable results are achieved when droplets of the immiscible liquid phase nucleate in the liquid ahead of the solidification front established in the casting process. The droplets of the immiscible phase are engulfed by the rapidly moving freeze front into the space between the Secondary Dendrite Arms (SDA).

Abstract: A method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter, the particulate matter having a size of at least about 30 microns. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product including a central layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces.

Abstract: The present invention discloses a method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter, the particular matter having a size of at least about 30 microns. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a product comprising a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product comprised of a central layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces.

Abstract: The present invention discloses an aluminum alloy product having a first outer layer, a central layer, and a second outer layer. The central layer of the aluminum alloy product has a higher concentration of particulate matter than said first or second outer layers. The particular matter has a size of at least about 30 microns. And, the aluminum alloy product has a thickness ranging from between about 0.004 inches to about 0.25 inches.

Abstract: The present invention discloses a method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a product comprising a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product comprised of an inner layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces. The method yields an MMC having a central layer enriched with particulate matter and sandwiched between metallic outer layers.

Abstract: The present invention discloses a product comprising a 1xxx, 3xxx and 8xxx series aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product. The product has an O-temper tensile strength, O-temper elongation, and O-temper Mullen pressure that are at least 10% greater compared to the average values of the same alloy in O-temper cast using a slab or roll-casting process. The product is substantially free of pinholes caused by centerline segregation of intermetallic particles. In another embodiment, the present invention discloses a 8111 or 8921 aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product.

Abstract: The present invention discloses a method of strip casting an aluminum alloy from immiscible liquids that yields a highly uniform structure of fine second phase particles. The results of the present invention are achieved by using a known casting process to cast the alloy into a thin strip at high speeds. In the method of the present invention, the casting speed is preferably in the region of about 50-300 feet per minute (fpm) and the thickness of the strip preferably smaller than 0.08-0.25 inches. Under these conditions, favorable results are achieved when droplets of the immiscible liquid phase nucleate in the liquid ahead of the solidification front established in the casting process. The droplets of the immiscible phase are engulfed by the rapidly moving freeze front into the space between the Secondary Dendrite Arms (SDA).

Abstract: The present invention discloses a method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a product comprising a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product comprised of an inner layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces. The method yields an MMC having a central layer enriched with particulate matter and sandwiched between metallic outer layers.