Abstract: A method of imparting a non-stick coating to a surface of an aluminum foil sheet, and the resulting foil sheet. The method involves coating at least part (preferably at least 40%) of an area of a surface of a metal sheet article (preferably an aluminum foil sheet) with a substantially solvent-free silicone oil at an average coating application rate in a range of 1.5 to 10 mg/ft2 of the coated surface area. The coated sheet article is then preferably coiled. The coated sheet article is then heated in the presence of air or oxygen at a temperature of 250° C. or higher for a period of time of at least 10 minutes. The treated surface is both non-stick and food-friendly.

Abstract: A method is described for making an aluminum alloy foil suitable for application to fins used in heat exchangers. The method comprises providing an aluminum alloy composition containing about 0.27% to about 0.55% by weight of iron, about 0.06% to about 0.55% by weight of silicon and optionally up to about 0.20% by weight of copper; continuously casting a coiled strip from the molten aluminum alloy; cold rolling the continuously cast coil to a final gauge of about 0.076 mm to about 0.152 mm and partially annealing the aluminum alloy sheet at a temperature below about 260° C., with a maximum overheat of about 10° C. to anneal the aluminum alloy foil substantially without any recrystallization.

Abstract: A method of treating a surface of a metal foil or sheet to make the surface wettable. The method comprises obtaining a metal foil or sheet having an oil-coated surface to be treated, applying a solution of phosphoric acid in a polar, non-aqueous, water-free solvent evenly to the surface at a rate of application in a range of at least 10 mg/ft2, the phosphoric acid being contained in the solution at a concentration such that the phosphoric acid contacts the surface in an amount of 0.5 to 2.0 mg/ft2; and removing the solvent by either drying the surface or heating the foil or sheet at an elevated temperature above ambient to evaporate the oil from the surface to be treated with the proviso that the elevated temperature does not fall in the range between 130 to 240° C. The resulting foil has a wettable surface and can be used, for example, for coating with a layer of another material (e.g. polymer or adhesive) and achieve high peel strength.

Abstract: A method of imparting a non-stick coating to a surface of an aluminum foil sheet, and the resulting foil sheet. The method involves coating at least part (preferably at least 40%) of an area of a surface of a metal sheet article (preferably an aluminum foil sheet) with a substantially solvent-free silicone oil at an average coating application rate in a range of 1.5 to 10 mg/ft2 of the coated surface area. The coated sheet article is then preferably coiled. The coated sheet article is then heated in the presence of air or oxygen at a temperature of 250° C. or higher for a period of time of at least 10 minutes. The treated surface is both non-stick and food-friendly.

Abstract: The present invention provides an aluminum alloy foil for fins used in heat exchangers. The aluminum alloy composition consists essentially of about 0.25% to about 0.6% by weight of Si; about 0.15% to about 0.50% by weight of Fe; about 0.20% to about 0.70% by weight of Mn; less than about 0.05% Cu; and less than about 0.05% Mg, with the balance aluminum including unavoidable impurities. The alloy composition may also contain less than 0.10% Zn or 0.50-2.00% Zn. The invention also provides a method for making an aluminum alloy wherein during cold rolling interanneal is carried out at a gauge such that the cold work after internanneal is between about 30-70%.

Abstract: A method is described for making an aluminum alloy foil suitable for application to fins used in heat exchangers. The method comprises providing an aluminum alloy composition containing about 0.27% to about 0.55% by weight of iron, about 0.06% to about 0.55% by weight of silicon and optionally up to about 0.20% by weight of copper; continuously casting a coiled strip from the molten aluminum alloy; cold rolling the continuously cast coil to a final gauge of about 0.076 mm to about 0.152 mm and partially annealing the aluminum alloy sheet at a temperature below about 260° C., with a maximum overheat of about 10° C. to anneal the aluminum alloy foil substantially without any recrystallization.

Abstract: The present invention provides an aluminum alloy foil for fins used in heat exchangers. The aluminum alloy composition consists essentially of about 0.25% to about 0.6% by weight of Si; about 0.15% to about 0.50% by weight of Fe; about 0.20% to about 0.70% by weight of Mn; less than about 0.05% Cu; and less than about 0.05% Mg, with the balance aluminum including unavoidable impurities. The alloy composition may also contain less than 0.10% Zn or 0.50-2.00% Zn. The invention also provides a method for making an aluminum alloy wherein during cold rolling interanneal is carried out at a gauge such that the cold work after internanneal is between about 30-70%.

Abstract: High strength foil having dead fold foil characteristics is produced without the rolling and other production problems encountered with prior high strength foils by controlling manganese content, interannealing temperatures and, optionally, final annealing temperatures. The alloy contains 0.05 to 0.15 %, preferably 0.095 to 0.125%, manganese by weight. Cold worked sheet is interannealed at a temperature of about 200° C. to about 260° C., preferably 230° to 250 ° C., to produce substantially fully recrystallized sheet while maintaining most of the manganese in solid solution. The interannealed sheet is rolled to final gauge and finally annealed, preferably at a temperature of about 250° C. to about 325° C., more preferably about 260° C. to about 325° C., to produce dead fold aluminum foil with a yield strength of at least 89.6 MPa (13 ksi), and ultimate tensile strength of at least 103.4 MPa (15 ksi) and a Mullen rating of at least 89.6 kPa (13 psi) at a gauge of 0.0015 cm (0.

Abstract: The invention relates to a recyclable aluminum foil. The foil is made of an alloy containing 0.2%-0.5% Si, 0.4%-0.8% Fe, 0.1%-0.3% Cu, and 0.05%-0.3% Mn by weight. with the balance aluminum and incidental impurities. The foil contains at least about 2% by weight of strengthening particulates and has at least about 0.1% by weight of the copper and/or manganese retained in solid solution. The invention also relates to a method of manufacturing a sheet of aluminum based on an alloy which involves continuously casting an alloy of the above composition to form a sheet of alloy, coiling said sheet of alloy, cold rolling the sheet of alloy, interannealing the alloy after a first pass of the cold rolling; and further cold rolling the alloy to a final desired gauge. The foil, which is suitable for household use, has improved strength due to a larger quantity of dispersoids fortified by elements in solid solution, and can be recycled with other alloy scrap.

Abstract: A new aluminum based alloy having properties which mimic homogenized DC cast 3003 alloy and a low-cost method for manufacturing it are described. The alloy contains 0.40% to 0.70% Fe, 0.10% to less than 0.30% Mn, more than 0.10% to 0.25% Cu, less than 0.10% Si, optionally up to 0.10% Ti and the balance Al and incidental impurities. The alloy achieves properties similar to homogenized DC cast 3003 when continuously cast followed by cold rolling and if desired annealing at final gauge. Suprisingly no other heat treatments are required.

Abstract: A process for forming silicon nitride containing little or no silicon carbide. The process involves producing a uniform dispersion of finely divided silica particles in a polymer, heating the polymer/silica dispersion in a non-oxidizing atmosphere to carbonize the polymer, and heating the resulting carbonized product to a temperature in the range of 1300.degree.-1800.degree. C. in a non-oxidizing nitrogen-containing atmosphere. This latter heating step is carried out in the presence of a metal oxide (preferably alumina which is capable, in the reaction conditions, of reducing the amount of silicon carbide formed as an undesired by-product.

Abstract: A process for forming carbides of silicon or metals in fine powder or whisker form. The process comprises forming a substantially uniform and non-agglomerated dispersion of a microfine powder of an oxide of silicon or a carbide-forming metal within a matrix of a polymer, carbonizing the oxide-containing polymer in an inert atmosphere and heating the carbonized product at high temperature to cause the oxide to react with carbon to form a carbide. The polymer must have a molecular weight of at least 10,000, a high carbon yield of at least 30% by weight, and a chemical structure which is infusible or capable of being rendered infusible. The preferred polymers are polyacrylonitrile, cellulose and polyvinyl alcohol, but other polymers with similar characteristics can be employed. The process is relatively inexpensive and gives an extremely finely divided product of high purity.

Abstract: A process of forming hollow microspheres containing carbon or a polymer which is a carbon precursor. The process comprises forming a solution in a liquid solvent of a polymer having the following properties (a) a molecular weight of at least 10,000 and a long chain structure; (b) an ability to be coagulated by or precipitated from the solution by a non-solvent for the polymer; (c) an ability to form a continuous stretchable film when coagulated or precipitated from solution; (d) a chemical structure which is infusible or capable of being rendered infusible, and (e) a high carbon yield of at least 30% by weight upon being carbonized in a non-reactive atmosphere. An insoluble particulate blowing agent is incorporated into the solution and the solution is then divided into droplets and the droplets are introduced into a liquid bath containing a suitable non-solvent for the polymer.

Abstract: A cement for bonding carbon blocks, particularly the cathode blocks of electrolytic cells, e.g. Hall-Heroult cells used for the production of aluminum. The cement comprises a carbonaceous aggregate of particle size smaller than 48 Tyler mesh, a curable water-soluble liquid polymeric resin (preferably a phenol-formaldehyde resin), water and normally a curing agent for the resin. The water is used in such an amount that the proportion of the resin can be reduced without adversely affecting the viscosity of the cement at ambient temperature. The cement carbonizes when the carbon blocks are subjected to high temperatures and has a linear shrinkage of less than 5%, which reduces the tendency of the carbonized cement to crack.

Abstract: A process for forming hollow microspheres containing carbon or a polymer which is a carbon precursor. The process comprises forming a solution in a liquid solvent of a polymer having the following properties (a) a molecular weight of at least 10,000 and a long chain structure; (b) an ability to be coagulated by or precipitated from the solution by a non-solvent for the polymer; (c) an ability to form a continuous stretchable film when coagulated or precipitated from solution; (d) a chemical structure which is infusible or capable of being rendered infusible, and (e) a high carbon yield of at least 30% by weight upon being carbonized in a non-reactive atmosphere. An insoluble particulate blowing agent is incorporated into the solution and the solution is then divided into droplets and the droplets are introduced into a liquid bath containing a suitable non-solvent for the polymer.