Patents Assigned to Novelis Inc.
  • Publication number: 20200049407
    Abstract: Disclosed are adjustable kiln flights for rotary kilns and associated methods. The kiln flight includes a base configured to be secured to a rotary kiln surface of a rotary kiln. In some aspects, the kiln flight includes a flight body rotatably supported on the base such that an angular orientation of the flight body is adjustable. In various examples, the kiln flight includes a height adjuster movably supported relative to the base such that a height of the kiln flight is adjustable. A method of controlling a rotary kiln with the adjustable kiln flight includes supporting a kiln flight on a base that is secured to an inner kiln surface of a rotary kiln, and adjusting at least one of the angular orientation of the kiln flight or the height of the kiln flight.
    Type: Application
    Filed: August 6, 2019
    Publication date: February 13, 2020
    Applicant: Novelis, Inc.
    Inventors: JungYoung SON, Cameron Koentopp
  • Publication number: 20200024713
    Abstract: Provided herein are highly formable aluminum alloys and methods of making the same. The highly formable aluminum alloys described herein can be prepared from recycled materials without significant addition of primary aluminum alloy material. The aluminum alloys are prepared by casting an aluminum alloy that can include such recycled materials and processing the resulting cast aluminum alloy article. Also described herein are methods of using the aluminum alloys and alloy products.
    Type: Application
    Filed: July 22, 2019
    Publication date: January 23, 2020
    Applicant: Novelis Inc.
    Inventors: Sazol Kumar Das, Matthew Heyen, Peter Evans, Martin Beech, ChangOok Son, Mark Marsh, Rajeev G. Kamat, Rainer Kossak, David Fryatt, David Scott Fisher, Guillaume Florey, Cyrille Bezencon, Juergen Timm
  • Publication number: 20200023417
    Abstract: Provided herein are highly-formable aluminum alloys and methods of making such alloys. The method of preparing aluminum alloys described herein can include a low final cold reduction step and/or an optional inter-annealing step to produce randomly distributed crystallographic texture components that produce an isotropic aluminum alloy product exhibiting improved formability and deep drawability. The methods described herein result in aluminum alloy microstructures having a balance of alpha fibers and beta fibers that promote improved formability of aluminum alloy sheets. The resulting improvements in quality allow for shaping processes with reduced rates of spoilage.
    Type: Application
    Filed: July 22, 2019
    Publication date: January 23, 2020
    Applicant: Novelis Inc.
    Inventors: Sazol Kumar Das, Matthew Josef Heyen, ChangOok Son, Rashmi Ranjan Mohanty, Guillaume Florey
  • Patent number: 10538833
    Abstract: Disclosed are alloys for anodized-quality aluminum sheets with improved surface quality, and methods for making these sheets. The alloys are designed to minimize the formation of cathodic intermetallic particles that result in surface streaks of anodized sheet products formed from the alloys. Further, the alloys allow the incorporation of recycled scrap aluminum in anodized-quality sheets.
    Type: Grant
    Filed: June 27, 2017
    Date of Patent: January 21, 2020
    Assignee: NOVELIS INC.
    Inventors: Daehoon Kang, Wei Wen, Devesh Mathur
  • Patent number: 10538834
    Abstract: Disclosed are high-strength aluminum alloys and methods of making and processing such alloys. More particularly, disclosed is a 6XXX series aluminum alloy exhibiting improved mechanical strength, formability, corrosion resistance, and anodized qualities. An exemplary method includes homogenizing, hot rolling, solutionizing, and quenching. In some cases, the processing steps can further include annealing and/or cold rolling.
    Type: Grant
    Filed: December 16, 2016
    Date of Patent: January 21, 2020
    Assignee: NOVELIS INC.
    Inventors: Wei Wen, Hany Ahmed, Rajeev Kamat, Corrado Bassi, Guillaume Florey, Cyrille Bezencon, Juergen Timm, David Leyvraz, Aude Despois, Sazol Kumar Das
  • Publication number: 20200010278
    Abstract: A conveying system, such as a conveying system for material including non-ferrous metals, includes a conveying belt and a stabilizer. The conveying belt includes a conveying surface and is adapted to convey the material on the conveying surface. The stabilizer is configured to apply a stabilizing force onto the material on the conveyor belt such that the material is stabilized while being conveyed. A method of stabilizing material on a conveyor belt includes receiving the material on the conveying surface of the conveyor belt, conveying the material at a conveying speed with the conveyor belt, and applying the stabilizing force onto the material with a stabilizer such that vertical displacement of at least some of the material is dampened and/or minimized at the conveying speed.
    Type: Application
    Filed: July 8, 2019
    Publication date: January 9, 2020
    Applicant: Novelis Inc.
    Inventors: Michael R. Kosmicki, Adwait A. Thakur
  • Publication number: 20200010941
    Abstract: Described are metal products having spatially non-uniform strength and formability profiles. The spatial non-uniformity of these properties may be achieved by heat-treating the metal product in a spatially non-uniform fashion, such that different portions of the metal product exhibit different strength and formability characteristics. The metal products may be formed into stamped products, with strength and formability characteristics customized to allow for suitable drawing during the stamping process.
    Type: Application
    Filed: July 5, 2019
    Publication date: January 9, 2020
    Applicant: Novelis Inc.
    Inventors: Peter Lloyd Redmond, Rajeev G. Kamat, Aude Celine Despois, Sazol Kumar Das, Richard Burrows
  • Publication number: 20200009576
    Abstract: Disclosed are systems and methods for sorting material on a conveyor of a conveyor system, such as a conveyor system for material including non-ferrous metals. The conveyor system includes a conveyor belt and a separator system. The conveyor belt is adapted to convey the material. The separator system includes a separator below the conveyor belt and is configured to selectively apply a separating force onto the material on the conveyor belt such that at least one piece of the material is lifted off of the conveyor belt. A method of sorting material on a conveyor belt includes receiving the material on the conveyor belt, conveying the material with the conveyor belt, and applying the separating force onto the material with the separator such that at least one piece of the material is lifted off of the conveyor belt.
    Type: Application
    Filed: July 8, 2019
    Publication date: January 9, 2020
    Applicant: Novelis Inc.
    Inventors: Adwait A. Thakur, Michael R. Kosmicki
  • Patent number: 10527280
    Abstract: A high organic concurrent decoating kiln includes a low-oxygen zone and a high-oxygen zone. The disclosed kiln allows a gas low in free oxygen to be used in the initial stages of decoating, while a gas higher in free oxygen can be used in the final stages. The total amount of free oxygen used throughout the kiln, in particular at the upstream portion of the kiln, is kept low. Exhaust gas can be recirculated for use in a burner-fired chamber that provides the initial low-oxygen gas to the kiln.
    Type: Grant
    Filed: May 22, 2015
    Date of Patent: January 7, 2020
    Assignee: NOVELIS INC.
    Inventor: Edwin L. Rauch
  • Patent number: 10513766
    Abstract: Provided are new high strength 6xxx aluminum alloys and methods of making aluminum sheets thereof. These aluminum sheets may be used to fabricate components which may replace steel in a variety of applications including the transportation industry. In some examples, the disclosed high strength 6xxx alloys can replace high strength steels with aluminum. In one example, steels having a yield strength below 340 MPa may be replaced with the disclosed 6xxx aluminum alloys without the need for major design modifications.
    Type: Grant
    Filed: December 16, 2016
    Date of Patent: December 24, 2019
    Assignee: NOVELIS INC.
    Inventors: Hany Ahmed, Wei Wen, Corrado Bassi, Aude Despois, Guillaume Florey, Xavier Varone
  • Publication number: 20190381549
    Abstract: Systems and methods of quenching a metal substrate include cooling a top surface and a bottom surface of the metal substrate until a strip temperature is cooled to an intermediate temperature. Cooling of the top surface of the metal substrate is discontinued when the strip temperature reaches the intermediate temperature, and cooling of the bottom surface of the metal substrate continues until the metal substrate reaches a target temperature, where the target temperature is less than the intermediate temperature.
    Type: Application
    Filed: June 13, 2019
    Publication date: December 19, 2019
    Applicant: Novelis Inc.
    Inventors: David Anthony Gaensbauer, Andrew James Hobbis
  • Publication number: 20190381551
    Abstract: Provided herein are systems and methods for removing a viscous material from a material article. In particular, a viscous material removal system can include a seal and a biasing mechanism. The viscous material removal system can also serve as a viscous material containment system. The systems can provide viscous material removal from planar and non-planar articles, as well as articles having surface irregularities or a topography including ridges and valleys. A method for removing viscous materials can include contacting the seal to the material article, maintaining contact of the seal across a width of the material article via the biasing mechanism, and passing the material article over the seal, thus removing the viscous material from the material article.
    Type: Application
    Filed: June 13, 2019
    Publication date: December 19, 2019
    Applicant: Novelis Inc.
    Inventors: Heinz Werner Becker, Rejean Lemay, Andrew James Hobbis, David Anthony Gaensbauer
  • Publication number: 20190381552
    Abstract: Provided herein are systems and methods for containing a viscous material, such as a coolant, on a roll and/or a roll processed engineering material (e.g., a metal strip). In particular, a viscous material containment system can include a movable seal and a gas delivery device. A method for cooling a roll can include applying a viscous material, such as a coolant, to the roll and containing the viscous material on the roll using the viscous material containment system. In some cases, the viscous material containment system can be used to facilitate removal of the viscous material from the roll and/or the roll processed engineering material.
    Type: Application
    Filed: June 13, 2019
    Publication date: December 19, 2019
    Applicant: Novelis Inc.
    Inventors: Renato Rufino Xavier, David Skingley Wright, Michael Kosmicki, Carlos Eboli, Timothy F. Stanistreet, Young Taeg Park
  • Publication number: 20190381562
    Abstract: Systems and methods are disclosed for using magnetic fields (e.g., changing magnetic fields) to control metal flow conditions during casting (e.g., casting of an ingot, billet, or slab). The magnetic fields can be introduced using rotating permanent magnets or electromagnets. The magnetic fields can be used to induce movement of the molten metal in a desired direction, such as in a rotating pattern around the surface of the molten sump. The magnetic fields can be used to induce metal flow conditions in the molten sump to increase homogeneity in the molten sump and resultant ingot.
    Type: Application
    Filed: August 30, 2019
    Publication date: December 19, 2019
    Applicant: Novelis Inc.
    Inventors: Samuel R. Wagstaff, Wayne J. Fenton, Robert B. Wagstaff, Milan Felberbaum, Todd F. Bischoff, Tina J. Kosmicki
  • Publication number: 20190381550
    Abstract: A hybrid rolling mill includes at least one work stand and a lubrication system. The at least one work stand includes an upper work roll and a lower work roll. The lubrication system includes a first lubricant applicator and a second lubricant applicator. The first lubricant applicator is configured to supply a first lubricant at an entry side of the work stand in a first rolling mode. The second lubricant applicator is configured to supply a second lubricant at the entry side of the work stand in a second rolling mode.
    Type: Application
    Filed: June 13, 2019
    Publication date: December 19, 2019
    Applicant: Novelis Inc.
    Inventors: David Anthony Gaensbauer, David Edward Gantzer
  • Publication number: 20190381546
    Abstract: Provided herein are systems and methods for containing a viscous material, such as coolant, applied to cool a roll or a roll processed engineering material such as a metal strip. In particular, a viscous material containment system can include a housing, a viscous material delivery system, a plurality of movable seals and a plurality of gas delivery devices. A method for cooling a roll can include applying a vicious material, such as coolant, to the roll and containing the viscous material on the roll using the viscous material containment system. In some cases, the viscous material containment system can be used to facilitate removal of the viscous material from the roll.
    Type: Application
    Filed: June 13, 2019
    Publication date: December 19, 2019
    Applicant: Novelis Inc.
    Inventors: David Edward Gantzer, Timothy F. Stanistreet, Robert William Mallory, Renato Rufino Xavier, James Charles Riggs, Frank Su, David Skingley Wright
  • Patent number: 10508328
    Abstract: Systems and methods of hot forming a metal blank include receiving the metal blank at a heater and positioning the blank adjacent a magnetic rotor of the heater. The systems and methods also include heating the metal blank through the magnetic rotor by rotating the magnetic rotor. Rotating the magnetic rotor induces a magnetic field into the metal blank such that the metal blank is heated.
    Type: Grant
    Filed: September 27, 2017
    Date of Patent: December 17, 2019
    Assignee: NOVELIS INC.
    Inventors: Julio Malpica, Cedric Wu, Rahul Vilas Kulkarni, Rodger Brown, Duane E. Bendzinski
  • Publication number: 20190376165
    Abstract: Provided herein are novel aluminum alloy compositions and methods of making and processing the same. The alloys described herein can be used in bottle making applications and exhibit enhanced runnability, formability, and appearance. The methods of producing an aluminum alloy sheet described herein can include casting an aluminum alloy to form an ingot, homogenizing the ingot, hot rolling the ingot to produce a hot band, and cold rolling the hot band to an aluminum alloy sheet of final gauge.
    Type: Application
    Filed: June 7, 2019
    Publication date: December 12, 2019
    Applicant: Novelis Inc.
    Inventors: Wei Wen, Yi Wang, Richard Hamerton, Adriano Manuel Povoa Ferreira, Babak Raeisinia, Zhuoru Wu, Sebastijan Jurendic, Vishwanath Hegadekatte, Carlos Nobrega
  • Patent number: 10493508
    Abstract: Metal work rolls texturized with engineered textures can impart desired impression patterns on metal strips. Engineered textures can be controlled with particularity to achieve desired surface characteristics (e.g., lubricant trapping, coefficient of friction, or surface reflectivity) on work rolls and metal strips, and to allow for impression patterns to be imparted on metal strips during high percentages of reduction of thickness (e.g., greater than about 5% or greater than about 15%, such as around 30%-55%). Engineered textures can be applied by focusing energy beams at specific points of an outer surface of a work roll to impart texture elements on the work roll. In some cases, an engineered texture element that can be used to generate a generally circular impression element can be generally elliptical in shape, having a length that is shorter than its width by a factor dependent on the reduction of thickness percentage.
    Type: Grant
    Filed: October 13, 2016
    Date of Patent: December 3, 2019
    Assignee: NOVELIS INC.
    Inventors: Corrado Bassi, Joerg Mathieu, Susanne Glock, Daniel Winkler
  • Publication number: 20190360082
    Abstract: Provided are new high strength 6xxx aluminum alloys and methods of making aluminum sheets thereof. These aluminum sheets may be used to fabricate components which may replace steel in a variety of applications including the transportation industry. In some examples, the disclosed high strength 6xxx alloys can replace high strength steels with aluminum. In one example, steels having a yield strength below 340 MPa may be replaced with the disclosed 6xxx aluminum alloys without the need for major design modifications.
    Type: Application
    Filed: August 7, 2019
    Publication date: November 28, 2019
    Applicant: Novelis Inc.
    Inventors: Hany AHMED, Wei WEN, Corrado BASSI, Aude DESPOIS, Guillaume FLOREY, Xavier VARONE