Abstract: Disclosed herein are systems and method for forming a final hollow body from a metal strip. A forming system may include a forming station, a joining station, an inline heater, and a hydroforming station. Forming the final hollow body from the metal strip may include receiving the metal strip at the forming station and bending the metal strip to a desired cross-section with the forming station and such that longitudinal edges of the metal strip are abutting. In some aspects, the forming station includes at least one roller. The method may include welding the abutting longitudinal edges together as a seam region via the joining station and to form an intermediate hollow body. The method may include heating the seam region of the intermediate hollow body with the inline heater and hydroforming the intermediate hollow body to the final hollow body with the hydroforming station.

Abstract: Described herein are methods of processing heat treatable aluminum alloys using an accelerated aging step, along with aluminum alloy products prepared according to the methods. The methods of processing the heat treatable alloys described herein provide a more efficient method for producing aluminum alloy products having the desired strength and formability properties. For example, conventional methods of processing alloys can require 24 hours of aging. The methods described herein, however, substantially reduce the aging time, often requiring eight hours or less of aging time.

Abstract: Provided herein are systems and methods for producing thick gauge aluminum alloy articles such as plates, shates, slabs, sheet plates or the like. A method for producing thick gauge aluminum alloy articles can include continuously casting an aluminum alloy article and hot or warm rolling the aluminum alloy article. Also provided herein is a continuous casting system for producing thick gauge aluminum alloy articles. The disclosed thick gauge aluminum alloy articles can be provided in any suitable temper.

Abstract: Provided herein are ultra-high strength aluminum alloys and products prepared therefrom, along with methods of processing the ultra-high strength aluminum alloys. The aluminum alloys described herein are high solute alloys, including significant amounts of zinc (Zn), magnesium (Mg), copper (Cu), and other elements in addition to aluminum. The aluminum alloys described herein are amenable to post-aging processing without cracking.

Abstract: A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.

Abstract: Systems and methods are described for roll-forming metal substrates. The metal substrates are subjected to induction heating during the roll-forming process by exposure to time-varying magnetic fields, such as by exposure to a rotating permanent magnet, or exposure to laser radiation from a laser source. Heating of the metal substrates allows improved formability or plasticity of the substrate in order to reduce or eliminate damage to the substrate during roll-forming to low bending radius to thickness ratios. Heating of the high-strength metal substrates can also function to temper the substrates and/or improve surface corrosion resistance and form high-strength end products with desirable properties.

Abstract: Described herein are 7xxx series aluminum alloys with unexpected properties and novel methods of producing such aluminum alloys. The aluminum alloys exhibit high strength and are highly formable. The alloys are produced by continuous casting and can be hot rolled to a final gauge and/or a final temper. The alloys can be used in automotive, transportation, industrial, and electronics applications, just to name a few.

Abstract: A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.

Abstract: Described herein are formable, high strength aluminum alloy products and methods of preparing and processing the same. The methods of preparing and processing the aluminum alloy products include casting an aluminum alloy and performing tailored rolling and downstream thermal processing steps. The resulting aluminum alloy products possess high strength and formability properties.

Abstract: A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.

Abstract: A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.

Abstract: Provided herein are ultra-high strength aluminum alloys and products prepared therefrom, along with methods of processing the ultra-high strength aluminum alloys. The aluminum alloys described herein are high solute alloys, including significant amounts of zinc (Zn), magnesium (Mg), copper (Cu), and other elements in addition to aluminum. The aluminum alloys described herein are amenable to post-aging processing without cracking.

Abstract: Described herein are methods of processing heat treatable aluminum alloys using an accelerated aging step, along with aluminum alloy products prepared according to the methods. The methods of processing the heat treatable alloys described herein provide a more efficient method for producing aluminum alloy products having the desired strength and formability properties. For example, conventional methods of processing alloys can require 24 hours of aging. The methods described herein, however, substantially reduce the aging time, often requiring eight hours or less of aging time.

Abstract: Described herein are formable, high strength aluminum alloy products and methods of preparing and processing the same. The methods of preparing and processing the aluminum alloy products include casting an aluminum alloy and performing tailored rolling and downstream thermal processing steps. The resulting aluminum alloy products possess high strength and formability properties.

Abstract: Provided herein are continuously cast aluminum alloy products exhibiting uniform surface characteristics. The aluminum alloy products have a first surface comprising a width, wherein the first surface comprises an average of 50 exudates or less per square centimeter across the width of the first surface. Also provided herein are methods of making aluminum alloy products having improved surface characteristics. Further provided are methods and systems for manufacturing aluminum alloy products, such as sheets, having reduced surface defects.

Abstract: The present disclosure generally provides 7xxx series aluminum alloy products in a stable T4 temper. The disclosure also provides methods of making such products, for example, using processes that include a combination of casting, rolling, solutionizing, quenching, reheating, and slow cooling. The disclosure also provides various end uses of such products, such as in automotive, transportation, electronics, and industrial applications.

Abstract: Disclosed herein are methods of processing 7xxx aluminum alloys using a rapid pre-aging step, along with alloys prepared according to the methods. The aluminum alloy products described herein have high strength when subjected to a rapid pre-aging step, as described above, and subsequent thermal treatment, such as paint baking or coating. The alloys prepared and processed according to the methods described herein can be used, for example, in automotive, transportation, electronics, and industrial applications.

Abstract: A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.

Abstract: Described herein are 7xxx series aluminum alloys with unexpected properties and novel methods of producing such aluminum alloys. The aluminum alloys exhibit high strength and are highly formable. The alloys are produced by continuous casting and can be hot rolled to a final gauge and/or a final temper. The alloys can be used in automotive, transportation, industrial, and electronics applications, just to name a few.

Abstract: Provided herein are systems and methods for producing thick gauge aluminum alloy articles such as plates, shates, slabs, sheet plates or the like. A method for producing thick gauge aluminum alloy articles can include continuously casting an aluminum alloy article and hot or warm rolling the aluminum alloy article. Also provided herein is a continuous casting system for producing thick gauge aluminum alloy articles. The disclosed thick gauge aluminum alloy articles can be provided in any suitable temper.