METHOD OF PRODUCING ALUMINUM PRODUCTS
Methods of producing pack rolled aluminum products by contacting bright finishes of two strips with each other, contacting matte finishes of each strip to a pair of work rolls, and rolling the strips through a sheet and foil rolling mill are disclosed. Concomitant to the contacting step is lubricating at least one of the bright finishes of the two strips. Each strip can achieve a reduction in thickness of at least about 65% after the rolling step.
Aluminum foil can be produced by rolling sheet ingots cast from molten aluminum, then re-rolling on sheet and foil rolling to the desired thickness, or by continuously casting and cold rolling. To maintain constant thickness in aluminum foil production, when the foil has become too thin, the rollers can apply less pressure thereby increasing film thickness. Alternatively, when the foil has become too thick, the rollers can apply more pressure thereby causing the foil to be made thinner. In these rolling modes, the actual reduction in thickness may be dependent on the lubricating regime of a rolling oil and the ability to maintain a stable oil film within the roll gap.
SUMMARYMethods of increasing the reduction of foil thicknesses to minimize the number of passes through a sheet and foil rolling mill are disclosed. One embodiment discloses a method comprising: (a) producing a first pack rolled aluminum product having a first side and a second side and a first thickness; (b) separating the first pack rolled aluminum product into a first strip and a second strip, wherein the first strip is associated with the first side and a third side, and wherein the second strip is associated with the second side and a fourth side; and (c) rolling the first strip and the second strip into a second pack rolled aluminum product, wherein the rolling comprises: (i) contacting the first side of the first strip with the second side of the second strip; (ii) contacting the third side of the first strip with a first work roll; (iii) contacting the fourth side of the second strip with a second work roll; and wherein after the rolling step (c), the thickness of the second pack rolled aluminum product is at least about 65% less than the first thickness of the first pack rolled aluminum product. In one embodiment, the rolling step (c) comprises: concomitant to the contacting step (c)(i), lubricating at least one of the first side of the first strip and the second side of the second strip with a lubricant.
In one embodiment, the method further comprises: (d) separating, after the rolling step (c), the second pack rolled aluminum product into the first strip and the second strip, wherein the separating step (d) occurs in the absence of welding between the first strip and the second strip. The aluminum products produced by the presently disclosed embodiments include aluminum foils and aluminum sheets. In one embodiment, before the rolling step (c), the first side and the second side have bright finishes and the third side and the fourth side have matte finishes. In one embodiment, the thickness of the first pack rolled aluminum product is not greater than about 0.2 mm, wherein after the rolling step (c), the thickness of the second pack rolled aluminum product is equal to or at least about 65% less than the thickness of the first pack rolled aluminum product.
One embodiment discloses a method comprising: (a) producing a first strip having a first embossed side and a third side; (b) producing a second strip having a second embossed side and a fourth side; (c) rolling the first strip and the second strip into a pack rolled aluminum product, wherein the rolling comprises: (i) contacting the third side of the first strip with the fourth side of the second strip; (ii) contacting the first embossed side of the first strip with a first work roll; (iii) contacting the second embossed side of the second strip with a second work roll; and (d) separating the pack rolled aluminum product into the first strip and the second strip; wherein the thicknesses of the first and second strips after the rolling step (c) are at least about 65% less than the thicknesses of the first and second strips before the rolling step (c), respectively. In one embodiment, the rolling step (c) comprises: concomitant to the contacting step (c)(i), lubricating at least one of the third side of the first strip and the fourth side of the second strip with a lubricant. In one embodiment, the separating step (d) occurs in the absence of welding between the first strip and the second strip. The aluminum products produced by the presently disclosed embodiments include aluminum foils or aluminum sheets. In one embodiment, before the rolling step (c), the third and fourth sides can have bright or matte finishes.
One embodiment discloses a method comprising: (a) producing a first pack rolled aluminum product having a first side and a second side and a first thickness; (b) separating the first pack rolled aluminum product into a first strip and a second strip, wherein the first strip is associated with the first side and a third side, and wherein the second strip is associated with the second side and a fourth side; and (c) rolling the first strip and the second strip into a second pack rolled aluminum product, wherein the rolling comprises: (i) contacting the first side of the first strip with the second side of the second strip; (ii) contacting the third side of the first strip with a first work roll; (iii) contacting the fourth side of the second strip with a second work roll; and (d) separating the second pack rolled aluminum product into the first strip and the second strip in the absence of welding, wherein the thicknesses of the first and second strips after the rolling step (c) are at least about 65% less than the thicknesses of the first and second strips before the rolling step (c), respectively. In one embodiment, the rolling step (c) comprises: concomitant to the contacting step (c)(i), lubricating at least one of the first side of the first strip and the second side of the second strip with a lubricant. Any of the above embodiments may comprise producing aluminum foils or aluminum sheets.
In one embodiment, the lubricant comprises a rolling oil, wherein the rolling oil includes C10 to C16 paraffin and kerosene. In other embodiments, the lubricant includes an additive, and wherein the additive is at least one of a fatty acid, alcohol, and an ester, and wherein: the fatty acid includes C12 to C18 oleic, stearic and isostearic compounds; the alcohol includes C12 to C16 compounds; and the ester includes methyl laurate, butyl ester and TMP ester.
Other variations, embodiments and features of the present methods will become evident from the following detailed description, drawings and claims.
It will be appreciated by those of ordinary skill in the art that the presently disclosed methods can be embodied in other specific forms without departing from the spirit or essential character thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive.
The reduction of the sheet or foil may be controlled by adjusting the meters per minute (mpm) of the rolls 12, 13 and the viscosity (the resistance to flow), quantity, and temperature of the rolling lubricants, which may be added to facilitate the rolling process. The lubricants may be applied to the rolls 12, 13 by spraying nozzles 15(a) disposed substantially adjacent the rolls 12,13. In some embodiments, lubricants may be applied to the sheet or foil using sprayers or applicators 15(b) disposed substantially adjacent a coil of sheet or foil 16(a) as it unrolls and is about to enter the rolling mill 10. In some embodiments, the lubricant may be applied concomitantly to the sheet or foil prior to entering 16(a) the rolling process or after exiting 16(b) the rolling mill 10. As used herein, “lubricant” and the like means a substance (often a liquid) introduced between two moving surfaces to reduce friction. For example, a lubricant may be used to mitigate or even restrict or eliminate the welding of two strips of sheet or foil 16 during a rolling step. In one embodiment, the lubricant includes a rolling oil, wherein the rolling oil includes C10 to C16 paraffin and/or kerosene.
The gap and pressure between the work rolls 12 at least assist in determining the thickness and/or length of the sheet or foil leaving 16(b) the mill 10. This gap can be adjusted by raising or lowering one or both of the work rolls 12. In one embodiment, under contacting rolling mode, the work rolls 12 may be touching the outside or width of a rolled product and pressure may be maintained therewith. As used herein, a “bright finish” is produced when the sheet or foil 16(a) comes in contact with the surface of the work roll 12 while a “matte finish” is produced when two sheets or foils 16(a) are packed together and rolled simultaneously. Generally, after a rolling step, the sides that are touching each other end up with matte finishes while the sides that are touching the surfaces of the work roll 12 end up with bright finishes. This will become more apparent in subsequent figures and discussion.
A “bright finish” may result in partial duplication of the work roll surface morphology. In addition, the bright finish may contain microscopic channels that facilitate lubricant flow backward. A “matte finish” may result in an isotropic surface morphology, and may be configured to trap lubricant during the foil rolling process. “Isotropic” and the like means the same or similar characteristics or uniformity in most or all directions. “Work roll surface” and the like means a surface that has been ground with an abrasive wheel or rotary abrasive belt or other suitable abrasive material so as to produce an elongated surface with elongated scratches, as opposed to a textured surface composed of isotropic pits. For example, a work roll surface can be conventional (un-textured), embossed or textured (e.g., depressions, craters, and other surface morphologies formed by rolling, grinding, polishing and sand blasting).
The presently disclosed methods can be carried out on rolls having surface roughness Ra of about 0.08 to about 0.29 micron. In two examples, the double-rolling method can be carried out on rolls having surface roughness Ra of about 0.09 micron and 0.14 micron. In one embodiment, the methods can be carried out on rolls having surface roughness Ra less than about 0.08 micron or greater than about 0.29 micron. Rougher rolls may be less efficient during the rolling process while the smoother rolls may be more efficient. In other words, a roll with a higher surface roughness Ra may have lower percentage of reduction compared to another roll of similar thickness but with lower surface roughness Ra. Accordingly, the amount of reduction may be a combination of several factors including mill speed, surface roughness, and initial thickness of the film, to name a few.
The sheet and foil rolling mill 10 further includes a gauge meter 17 for measuring the thickness of the sheet or foil 16(b). As used herein, “thickness” relative to an aluminum product (e.g., pack rolled aluminum product or strip) and the like means the thickness of an aluminum product as measured by a micrometer or digital caliper in accordance with techniques used by the National Institute of Standards and Technology. In some embodiments, the aluminum products include aluminum foils and aluminum sheets, the aluminum products composed of aluminum or aluminum alloy of 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx and 8xxx series. In one embodiment, other types of aluminum alloys may also be incorporated. As used herein, “aluminum foil” means an aluminum product having a thickness of not greater than about 200 microns, and “aluminum sheet” means an aluminum product having a thickness of at least about 201 microns and not greater than about 0.249 inches (about 6324 microns).
The sheet and foil rolling mill 10 may also include a flatness roll 18 for measuring the flatness of the product or making the sheet or foil 16(b) more uniform when it exits the rolls 12, and an ironing roll 19 for smoothing or uniformly coiling the sheet or foil 16(b). As shown, the aluminum sheet or foil 16(b) can be wounded into coil form. In one embodiment, the aluminum sheet or foil 16(b) exiting the rolling mill 10 need not be wounded into a coil.
A reduction in film thickness can be accomplished by means of rolling from continuous cast or hot rolled aluminum coils with initial foil gauges of from about 2 mm to about 10 mm down to final foil gauges of from about 0.006 mm to about 0.2 mm. In one embodiment, different passes can be made in heavy gauge cold rolling mills 10 to provide cold rolled foil stock coils. The coils can subsequently be transferred to foil mills 10 at thicknesses of from about 0.2 mm to about 1 mm and continued rolling to final foil gauges. As used herein, “continuous cast” means a fabrication process produced by rolling sheet ingots cast from molten aluminum and then re-rolling on sheet and foil rolling mills to the desired thickness. “Hot rolling” or “hot rolled” and the like means a fabrication process in which the aluminum product is heated above its recrystallization temperature and then deformed between rollers to form thinner cross sections. “Cold rolling” or “cold rolled” and the like means a fabrication process produced in which the aluminum product is deformed by passing it through rollers at a temperature below its recrystallization temperature.
In one embodiment, the first side 22 of the first strip 32 and the second side 24 of the second strip 34 have bright finishes while the third side 42 of the first strip 32 and the fourth side 44 of the second strip 34 have matte finishes. In other embodiments, there can be a mixture of finishes. For example, both the first and second sides 22, 24 can have matte finishes, or one side can be bright and the other side can be matte. Likewise, both the third and fourth sides 42, 44 can have bright finishes, or one side can be bright and the other can be matte. In one embodiment, the thickness t1 of the first pack rolled aluminum product 20 is not greater than about 0.2 mm, wherein after the rolling step of
In one embodiment, the first pack rolled aluminum product 20 starts with a thickness t1 of about 40 microns with each strip 32, 34 of the first pack rolled aluminum product 20 having a thickness of about 20 microns after the separation step. After the rolling step, the resulting second pack rolled aluminum product 30 may have a thickness t2 of not greater than about 12 microns or a reduction in thickness of at least about 70%. The second pack rolled aluminum product 30 can be further separated by the methods previously described into two strips 52, 54 as shown in
In one embodiment, the second separating step as shown in
After the strips have been separated 63, they may again be subjected to a second double roll step to produce a second pack rolled product 65. In one embodiment, the matte side of the strips are making contact with the work rolls. For example, a first matte side of a first strip may contact a first work roll while a second matte side of a second strip may contact a second work roll. The sides opposite the matte finishes of each strip may have bright finishes, and would be making contact with each other. In other words, a first bright side of a first strip may contact a second bright side of a second strip. Lubricants 64 similar to those described above may be dispensed concomitantly on the strips of foil or sheet. In one embodiment, the lubricant may be applied 64 while or after the first pack rolled aluminum product is being separated into two strips 63. In one embodiment, the lubricant may be applied 64 prior to the bright sides of each strip making contact with each other and the matte sides making contact with the work rolls to produce a second pack rolled product 65. The reduction in thickness of each strip of the second pack rolled product may be at least about 65%. In one embodiment, the reduction in thickness can range from about 65% to about 80%.
In one embodiment, the lubricant may bring about an absence of welding between the strips. In one embodiment, the lubricant includes an additive. In one embodiment, the additive is at least one of a fatty acid, alcohol, and an ester. In one embodiment, the fatty acid includes C12 to C18 oleic, stearic and isostearic compounds. In one embodiment, the alcohol includes C12 to C16 compounds. In one embodiment, the ester includes methyl laurate, butyl ester and TMP ester.
The second pack rolled product may subsequently be separated into two strips, applied with additional lubricant, and rolled through a third set of work rolls to produce a third pack rolled product (not shown). In other words, the rolling processes may be repeated as many times as necessary to achieve additional thickness reductions.
In one embodiment, work rolls may be textured or embossed to produce similar lubricant retaining effect as that of the strips having matte finishes, or embossed or textured finishes. In one embodiment, skin pass texturing can be carried out on the work rolls including lamination to produce textured or embossed work rolls.
In one embodiment, texture can be applied to both surfaces of a single sheet or foil (not shown) that may subsequently be rolled without doubling and with a reduction in thickness of at least about 65%. In other words, the rolling need not be carried out on two or more strips of sheet or foil but a single sheet or foil may be rolled through the work rolls and achieve at least about 65% of reduction in thickness.
After the two strips have been produced 66, the product may be rolled through a rolling mill in a first rolling pass 67. In one embodiment, the first rolling step 67 may produce a first pack rolled aluminum product, the aluminum product being aluminum foil or aluminum sheet. In one embodiment, the first rolling step 67 involves contacting the embossed side of the first strip with a first work roll, contacting the embossed side of the second strip with a second work roll, and contacting the surfaces opposite the embossed sides with each other. In one embodiment, the sides opposite the embossment may have bright finishes and be in contact with the work rolls. In one embodiment, alternating surfaces may make contact with the work rolls. In other words, an embossed finish of a first strip can contact a first work roll, while a matte finish of a second strip can contact a second work roll, or a bright finish of a first strip can contact a first work roll, while an embossed finish of a second strip can contact a second work roll. In some embodiments, various configurations of surfaces touching work rolls and each other are possible.
After the first rolling step 67, the product may be separated into two strips 68. In one embodiment, each strip may have a textured side. The reduction in thickness of each of the separated strips can range from about 65% to about 80%. The separated strips may subsequently be rolled through a rolling mill in a second rolling pass 70. The reduction in thickness through the second rolling pass 70 can also range from about 65% to about 80%. The second rolling pass 70 may be carried out with the textured finishes touching the work rolls and the opposite sides touching each other. Lubricants similar to those discussed above may be applied 69 concomitantly to the separating step 68. In one embodiment, the lubricant may be applied 69 to the textured sides of the separated strips. In one embodiment, the lubricant may be applied 69 to the side opposite the textured sides of the separated strips. In one embodiment, the lubricant comprises a rolling oil, wherein the rolling oil includes C10 to C16 paraffin and kerosene. In some embodiments, the lubricant comprises an additive, wherein the additive is at least one of a fatty acid, alcohol and an ester. In one embodiment, the fatty acid includes C12 to C18 oleic, stearic and isostearic compounds. In one embodiment, the alcohol includes C12 to C16 compounds. In one embodiment, the ester includes methyl laurate, butyl ester and TMP ester.
In some embodiments, the method may consist of one or more of the steps described above.
The test results of
Other test runs are illustrated in
Although not shown, mill speeds in excess of up to 1000 meters per minute, or 1200 meters per minute, or 1500 meters per minute, or 2000 meters per minute, may result in thickness reductions of at least about 65%.
In terms of length efficiencies, each block of rolled length corresponds to the thickness blocks. For example, a reduction of about 205 microns to about 96 microns translates to increased coil length from about 6.1 kilometers to about 13.2 kilometers, a reduction of about 96 microns to about 44 microns translates to increased coil length from about 13.2 kilometers to about 28.8 kilometers, and so forth. The longer the coils, the longer the time it takes to process through the rolling mill or doubling machine. To achieve a final length of about 70.4 kilometers of final thickness coil requires passing through the rolling mill at least about 181.9 kilometers length of coil using the traditional method, the 181.9 kilometers representing the sum of all lengths of coils being passed through the rolling mills in the five passes (6.1 km+13.2 km+28.8 km+63.4 km+70.4 km=181.9 km). In contrast, utilizing the presently disclosed methods, about 117.5 kilometers of coil are passed through the rolling mills to achieve the final length of about 70.4 kilometers (7.9 km+18.1 km+21.1 km+70.4 km=117.5 km). In one embodiment, this may translate to an improvement in mill productivity of about 40%.
Although the presently disclosed methods have been described in detail with reference to several embodiments, additional variations and modifications exist within the scope and spirit of the disclosure as described and defined in the following claims.
Claims
1. A method comprising:
- (a) producing a first pack rolled aluminum product having a first side and a second side and a first thickness;
- (b) separating the first pack rolled aluminum product into a first strip and a second strip, wherein the first strip is associated with the first side and a third side, and wherein the second strip is associated with the second side and a fourth side; and
- (c) rolling the first strip and the second strip into a second pack rolled aluminum product, wherein the rolling comprises: (i) contacting the first side of the first strip with the second side of the second strip; (ii) contacting the third side of the first strip with a first work roll; (iii) contacting the fourth side of the second strip with a second work roll; and
- wherein after the rolling step (c), the thickness of the second pack rolled aluminum product is at least about 65% less than the first thickness of the first pack rolled aluminum product.
2. The method of claim 1, wherein the rolling step (c) comprises:
- concomitant to the contacting step (c)(i), lubricating at least one of the first side of the first strip and the second side of the second strip with a lubricant.
3. The method of claim 2, further comprising:
- (d) separating, after the rolling step (c), the second pack rolled aluminum product into the first strip and the second strip.
4. The method of claim 3, wherein the separating step (d) occurs in the absence of welding between the first strip and the second strip.
5. The method of claim 1, wherein the produced aluminum products include aluminum foils and aluminum sheets.
6. The method of claim 1, wherein before the rolling step (c), the first side and the second side have bright finishes and the third side and the fourth side have matte finishes.
7. The method of claim 1, wherein the thickness of the first pack rolled aluminum product is not greater than about 0.2 mm, wherein after the rolling step (c), the thickness of the second pack rolled aluminum product is equal to or at least about 65% less than the thickness of the first pack rolled aluminum product.
8. The method of claim 2, wherein the lubricant comprises a rolling oil, wherein the rolling oil includes C10 to C16 paraffin and kerosene.
9. The method of claim 2, wherein the lubricant includes an additive, and wherein the additive is at least one of a fatty acid, alcohol, and an ester, and wherein:
- the fatty acid includes C12 to C18 oleic, stearic and isostearic compounds;
- the alcohol includes C12 to C16 compounds; and
- the ester includes methyl laurate, butyl ester and TMP ester.
10. A method comprising:
- (a) producing a first strip having a first embossed side and a third side;
- (b) producing a second strip having a second embossed side and a fourth side;
- (c) rolling the first strip and the second strip into a pack rolled aluminum product, wherein the rolling comprises: (i) contacting the third side of the first strip with the fourth side of the second strip; (ii) contacting the first embossed side of the first strip with a first work roll; (iii) contacting the second embossed side of the second strip with a second work roll; and
- (d) separating the pack rolled aluminum product into the first strip and the second strip; wherein the thicknesses of the first and second strips after the rolling step (c) are at least about 65% less than the thicknesses of the first and second strips before the rolling step (c), respectively.
11. The method of claim 10, wherein the rolling step (c) comprises:
- concomitant to the contacting step (c)(i), lubricating at least one of the third side of the first strip and the fourth side of the second strip with a lubricant.
12. The method of claim 10, wherein the separating step (d) occurs in the absence of welding between the first strip and the second strip.
13. The method of claim 10, wherein the produced aluminum products include aluminum foils and aluminum sheets.
14. The method of claim 10, wherein before the rolling step (c), the third and fourth sides can have bright or matte finishes.
15. The method of claim 11, wherein the lubricant comprises a rolling oil, wherein the rolling oil includes C10 to C16 paraffin and kerosene.
16. The method of claim 11, wherein the lubricant includes an additive, and wherein the additive is at least one of a fatty acid, alcohol, and an ester, and wherein:
- the fatty acid includes C12 to C18 oleic, stearic and isostearic compounds;
- the alcohol includes C12 to C16 compounds; and
- the ester includes methyl laurate, butyl ester and TMP ester.
17. A method comprising:
- (a) producing a first pack rolled aluminum product having a first side and a second side and a first thickness;
- (b) separating the first pack rolled aluminum product into a first strip and a second strip, wherein the first strip is associated with the first side and a third side, and wherein the second strip is associated with the second side and a fourth side; and
- (c) rolling the first strip and the second strip into a second pack rolled aluminum product, wherein the rolling comprises: (i) contacting the first side of the first strip with the second side of the second strip; (ii) contacting the third side of the first strip with a first work roll; (iii) contacting the fourth side of the second strip with a second work roll; and
- (d) separating the second pack rolled aluminum product into the first strip and the second strip in the absence of welding, wherein the thicknesses of the first and second strips after the rolling step (c) are at least about 65% less than the thicknesses of the first and second strips before the rolling step (c), respectively.
18. The method of claim 17, wherein the rolling step (c) comprises:
- concomitant to the contacting step (c)(i), lubricating at least one of the first side of the first strip and the second side of the second strip with a lubricant.
19. The method of claim 17, wherein the produced aluminum products include aluminum foils and aluminum sheets.
20. The method of claim 18, wherein the lubricant includes an additive, and wherein the additive is at least one of a fatty acid, alcohol, and an ester, and wherein:
- the fatty acid includes C12 to C18 oleic, stearic and isostearic compounds;
- the alcohol includes C12 to C16 compounds; and
- the ester includes methyl laurate, butyl ester and TMP ester.
Type: Application
Filed: Mar 24, 2009
Publication Date: Sep 30, 2010
Inventor: Vicente Martin SAENZ de MIERA (Jaca)
Application Number: 12/409,635
International Classification: B21H 8/00 (20060101);