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.

Abstract: The present invention provides an apparatus for strip casting of molten metal including a pair of casting rollers adapted to receive molten metal along a horizontal axis, wherein a vertical distance separating the pair of casting rollers defines a molding zone; and an electromagnetic edge containment apparatus positioned on each side of the molding zone having an induction coil wound about a portion of a magnetic member to generate magnetic lines of force upon application of a current, wherein the poles of the magnetic member are positioned distal from to aligned to the planar sidewall of the casting rollers and the current provides magnetic lines of force perpendicular to said horizontal axis that contain the molten metal in contact to the casting rollers without substantially increasing the temperature of the molten metal.

Abstract: A method of making aluminum alloy sheet in a continuous in-line process is provided. A continuously-cast aluminum alloy strip is optionally quenched, hot or warm rolled, annealed or heat-treated in-line, optionally quenched, and preferably coiled, with additional hot, warm or cold rolling steps as needed to reach the desired gauge. The process can be used to make aluminum alloy sheet of T or O temper having the desired properties, in a much shorter processing time. The T or O temper may be selected by annealing the strip to achieve an O temper or solution heat treating the strip to achieve a T temper, and, if a T temper is desired, quenching the strip subsequent to the solution heat treating. The invention further provides a hot or warm rolling step wherein the strip is substantially reduces to a final thickness about 10-65% from a casting thickness.

Abstract: A method of making aluminum alloy sheet in a continuous in-line process is provided. A continuously-cast aluminum alloy strip is optionally quenched, hot or warm rolled, annealed or heat-treated in-line, optionally quenched, and preferably coiled, with additional hot, warm or cold rolling steps as needed to reach the desired gauge. The process can be used to make aluminum alloy sheet of T or O temper having the desired properties, in a much shorter processing time.

Abstract: A monolithic container having a bottom wall, a sidewall interconnected to the bottom wall and extending upwardly and outwardly therefrom to define an open end of the monolithic container at an upper edge of the sidewall, the sidewall having a peripheral flange extending outwardly from the upper edge. The monolithic container formed from an aluminum alloy feedstock comprising: from about 0.05 to 0.55% by weight silicon, from 0.10 to about 0.50% by weight iron, from less than about 0.60% by weight copper, from about less than about 0.4% by weight manganese, from about 0.9 to about 1.8% by weight magnesium, with the balance being aluminum and impurities.

Abstract: An aluminum alloy sheet and a method for producing an aluminum alloy sheet. The aluminum alloy sheet is useful for forming into drawn and ironed container bodies. The sheet preferably has an after-bake yield strength of at least about 37 ksi and an elongation of at least about 2 percent. Preferably the sheet also has earing of less than about 2 percent.