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Special Products SEe / Kol
Copper Sleeves
for
Aluminium Strip Casting
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Table of contents -
Introduction
Manufacturing of Cu sleeves
Copper alloys for Cu sleeves
Aluminium strip casting with Cu sleeves
Summary and outlook
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Introduction -
• The application of copper sleeves for aluminium strip casting
has been discussed in various papers in the recent years.
Although significant advantages in casting speed can be
expected copper sleeves are not applied in strip casting today.
Due to the limited hardness, ductility and especially strength at
higher temperatures of the available copper alloys the attempts
made to apply copper sleeves in strip casting have not been
successful.
• Therefore KME started in 1998 the development of copper
alloys / sleeves for aluminium strip casting. Nowadays KME has
the knowledge and the possibilities for the manufacturing of
copper alloys as well as sleeves for this application.
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Objectives of the development -
While maintaining the proven strip casting technology the customer
is enabled by the application of copper sleeves to:
• realise high casting speeds
• extent the production capacity
• decrease casting costs per ton Aluminium
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Table of contents -
Introduction
Manufacturing of Cu sleeves
Copper alloys for Cu sleeves
Aluminium strip casting with Cu sleeves
Summary and outlook
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Steps of manufacturing casting sleeves -
Melting & Casting
Hot & Cold Forging
Heat treatment
Machining
Quality Control
Assembling
Final Machining
• Copper alloy foundry
• Billet sizes: ø 720, 820 or 1020 mm
• Forging of cast billet to the dimensions of sleeves in strip
casting & heat treatment
• CNC-turning lathe with driven tools, Vertical CNC-turning
mill
• CNC-milling machines
• CNC-gun drilling
• Ultrasonic tests, Dye penetration tests, X-Ray, Roughness
measurements
• Control of dimensions
• Shrink fitted
• Mechanically fitted
• Hot isostatic pressed (HIP)
• final turning process, grinding, crowning, texturing
• coating
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Copper Sleeves for Aluminium Strip Casting - Final machining of copper sleeves -
Assembled and machined copper sleeves
Final machining on turning lathe
Special Products SEe / Kol
SEQV [N/mm²]
Boundary conditions for non linear calculation:
• Material of copper shell: Elbrodur® B95
• Wall thickness: 83 mm
• Inside diameter of copper shell: 672 mm * For reasons of the overview the steel core
(without cooling slots) is blanked out
View on plane of symmetry View on outer surface
Copper Sleeves for Aluminium Strip Casting - Typical equivalent stress (Von Mises) after shrink fitting -
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Assembling: Shrinkage process of copper sleeves (Example 1) -
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Assembling: Shrinkage process of copper sleeves (Example 2) -
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Table of contents -
Introduction
Manufacturing of Cu sleeves
Copper alloys for Cu sleeves
Aluminium strip casting with Cu sleeves
Summary and outlook
Special Products SEe / Kol
Material
Properties
Chem. Composition
(without Cu)
Phys. Properties
Electrical Conductivity
Thermal
Conductivity
Recrystall. Temperatur
Softening Temperatur
Modulus of Elasticity
Mech. Properties
0.2 % Proof Stress Rp0.2
Hardness HBS
Tensile Strength Rm
Elongation A5
Units
%
Sm/mm²
% IACS
W/(m•K)
°C
°C
GPa
MPa
2.5/62.5
MPa
%
Elbrodur® NIB
1.5 Ni
0.2 Be
290
40
69
(700)
590
128
510
500
495
(440)
200
630
580
540
(465)
14
12
(10)
(3)
Elbrodur® G
0.65 Cr
0.1 Zr
350
48
84
(700)
590
128
125
270
255
230
(200)
390
340
290
(230)
25
24
22
(20)
Elbrodur® GP
0.65 Cr
0.1 Zr
350
48
83
(700)
590
128
130
300
280
250
(220)
410
360
310
(250)
21
20
19
(16)
Temperature
20 °C / 68 °F
20 °C / 68 °F
20 °C / 68 °F
°C / °F
20 / 68
200 / 392
350 / 662
500 / 932
20 / 68
20 / 68
200 / 392
350 / 662
500 / 932
20 / 68
200 / 392
350 / 662
500 / 932
Elbrodur® B95
1.0 Co
0.1 Be
240
33
57
(700)
590
128
490
470
450
(405)
200
630
590
550
(445)
18
14
(9)
(3)
Copper Sleeves for Aluminium Strip Casting - KME - AMM® Advanced Mold Materials -
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Equivalent stresses (Von Mises) during casting operation -
SEQV [N/mm²]
Boundary conditions for non linear calculation:
• Material of copper shell: Elbrodur® B95
• Wall thickness: 83 mm
• Inside diameter of copper shell: 672 mm * For reasons of the overview the steel core
(without cooling slots) is blanked out
View on plane of symmetry View on outer surface
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Thermal conductivity of Cu alloys versus strength -
Tensile Strenght [MPa]
Th
erm
al c
on
du
cti
vit
y [
W/m
•K]
350
150
300 400 700 600
250
Cu
Ag
Elb
rod
ur®
G
Elb
rod
ur®
G
F
Elb
rod
ur®
N
IB
Osn
isil®
G
Elb
rod
ur®
B
95
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Proof stress of Elbrodur® G, NIB, B95 at 20 °C / 200 °C / 350 °C -
0
100
200
300
400
500
600
Elbrodur G Elbrodur NIB Elbrodur B95
0.2
% P
roo
f S
tre
ss
[M
Pa
]
20 °C
200 °C
350 °C
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Table of contents -
Introduction
Manufacturing of Cu sleeves
Copper alloys for Cu sleeves
Aluminium strip casting with Cu sleeves
Summary and outlook
Special Products SEe / Kol
F = 4.3 MN
(max. 8.5 MN)
F = 4.3 MN
(max. 8.5 MN)
Cooling water:
Inlet 34°C
Outlet 38°C
Life time: 8 - 10.000 to Aluminium
per pair of sleeves at max. casting width
Productivity: 10 - 12.000 jato Aluminium
Machining of sleeves:
• pre-turned and crowned (0,3 mm)
• ground to Ra = 0,6 - 0,8 m
Copper Sleeves for Aluminium Strip Casting - Typical casting parameters with steel sleeves -
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200
215
230
245
260
275
290
305
320
335
350
365
380
395
0,9 1,05 1,2 1,35 1,5 1,65 1,8 1,95 2,1 2,25 2,4 2,55 2,7 2,85 3
Productivity [t / h / m strip width]
Str
ip te
mp
era
ture
at ro
ll e
xit [
°C]
3003 with steel sleeve
Based on results from casting
trials
1100 with
steel sleeve
1100 cast with
combination of steel and
copper sleeve 3003 with copper sleeve
Copper Sleeves for Aluminium Strip Casting - Productivity increase with Copper sleeves -
* source: P.A.E.
Special Products SEe / Kol
rolling forces
vsleev
e
vsleev
e
vstrip
Aluminium
coil
T ~ 400 - 450 °C
T ~ 110 °C
T ~ 90 °C
Copper Sleeves for Aluminium Strip Casting - Principal of casting trial with Cu sleeves -
During the casting of aluminium strips the copper sleeves are
loaded with high temperatures and forces inducing high levels
of stress in the shell
Special Products SEe / Kol
Time [s] T
emper
ature
[°C
]
T [°C]
View on outer surface
View on plane of symmetry
Copper Sleeves for Aluminium Strip Casting - FEM-Calculation: Temperature distribution during startup -
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Casting process - Trial with customer -
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Copper Sleeves for Aluminium Strip Casting - Casted coil - Trial with customer -
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Copper Sleeves for Aluminium Strip Casting - Productivity Range -
Strip Thickness Productivity Cooling Rate
[mm] [t / (m • h)] [°C / s]
10 - 5
0.5 - 1.5
102 - 103 1.6 - 2.1
1.8 - 2.8
4 - 2
1.5 - 1.8 103 - 104
St / St Shell
St / Cu Shell
Cu / Cu Shell
3.0 - 7.0 104 - 105
0.3 - 0.08 90 105 - 106
St / St Shell
Cu / Cu Shell
LGS Casting
Roll Casting
Melt Spinning
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Capacities and Costs in Strip Casting ( I ) -
Shell
Roll diameter
[mm]
Alloy
Gauge
[mm]
Width
[mm]
Operating
costs
[€ / t]
Production
Capacity
[tpy]
CMYV 840 1100 6 1700 120 17500
MO22 840 1100 6 1700 116 16700
CMYV / Cu 840 / 870 1100 6 1700 120 26600
Cu 870 1100 8 1700 129 35500
MO22 / Cu 840 / 870 1100 8 1700 119 25000
CMYV
MO22
CMYV / Cu
MO22 / Cu
Cu
840
840
840 / 870
840 / 870
870
3003
3003
3003
3003
3003
6
6
6
8
8
1700
1700
1700
1700
1700
130
127
124
123
130
14400
13500
23700
22400
33000
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Capacities and Costs in Strip Casting ( II ) -
Fundamentals of the calculation:
• Sleeve wear: 1 mm reduction in diameter per 27 tons of cast
output of the sleeves
actual: - average 1. set: ~ 34 t / mm
- actual average set no. 3: ~ 44 t / mm
• Costs represent casting cost including labour, energy,
remachining and maintenance. Cost level representing
European labour.
• Depreciation not included
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Copper Sleeves for Aluminium Strip Casting - Average Productivity for different Alloys * -
Alloy
Composition
St / St
[ t / (m•h) ]
St / Cu
[ t / (m•h) ]
St / St (ø 960 mm)
[ t / (m•h) ]
1100 Al
0.5 Fe 0.1 Cu 1.23 1.8 1.34
1235 Al
0.2 Si 0.4 Fe 1.25 1.7 1.4
3003 Al
1.0 Mn 1.03 1.75 1.08
5005 Al
1.0 Mg 0.9 1.65 0.9
* based on the actual results of casting trials; shell diameter 840 mm
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Comparison of shell life -
St - Sleeve: ø 840 mm x 1700 mm casting width
• remachining allowance: 100 mm
• shell wear: 115 t / mm / m = 11500 t
• shell wear x casting width: 11500 x 1.7 = 19500 t
Cu - Sleeve: ø 870 mm x 1700 mm casting width
• remachining allowance: 135 mm
• shell wear: 40 t / mm / m = 5400 t
• shell wear x casting width: 5400 x 1.7 = 9180 t
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Copper Sleeves for Aluminium Strip Casting - Barker etching - Micrograph in polarised light -
AlMn1
Sampling point: Edge Magnification 25 : 1 Sampling point: Centre Magnification 25 : 1
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Barker etching - Micrograph in polarised light -
AlMn1
Sampling point: Edge Magnification 100 : 1 Sampling point: Centre Magnification 100 : 1
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Casted coil - Trial with customer -
Microstructure of casted strip Edge of Aluminium strip
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Table of contents -
Introduction
Manufacturing of Cu sleeves
Copper alloys for Cu sleeves
Aluminium strip casting with Cu sleeves
Summary and outlook
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Summary -
• Copper sleeves have proven to be capable of increasing casting speed in strip
casting thereby offering a potential to increase production capacity and decrease
production costs
• No modifications necessary on the casting machine, cooling system or steel cores
• Maintenance and re-machining is done similar to steel sleeves
• Copper sleeves are able to form a stable Al-layer (AlCu) on the surface that
prevents the pollution of Al strips with Be and Co.
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - References -
• Casting wheels for non-ferrous alloys
• Casting rolls for thin strip casting of steel and copper
• Geie Myosotis Ugine (France)
• BHP (Australia) <-> Castrip (USA)
• RIST (Korea)
• VAI-CSM / AST Pilot Caster VASTRIP (Italy)
• Krupp Thyssen Nirosta (Germany)
• Norddeutsche Affinerie NA (Germany)
• RWTH Aachen (Germany)
• Casting rolls for special applications (amorphous alloys)
• VAC (Germany)
• Honeywell (USA)
• Casting sleeves for thin strip casting of aluminium:
• Castal (Greece), customer not known
• Choil (Korea)
• Eurofoil (Luxembourg)
• MAL (Hungary)
• Hydro Inasa (Spain)
• Teknik Alüminyum Sanayi (Turkey)
Special Products SEe / Kol
Copper Sleeves for Aluminium Strip Casting - Scale of KME’s activities -
Melting & Casting & Forming • Copper alloys with high strength requirements at
increased temperatures
• Wide range of different dimensions
• Close coordination between casting process and
subsequent forming process to ensure optimal material
properties and tight tolerances
Machining & Assembling • CNC-controlled milling and turning machines
• Assembling of copper sleeves and steel cores
• Final machining (grinding, crowning)
• Pressure test up to 2 MPa
• Quality control
Engineering • Detail design engineering (3D, 2D)
• FEM calculations (thermal & structural)
Research & Development • Material development
• Failure examination and analysis • SEM & EDX
• Micrographs / polished sections
• Tensile, fatigue & bending tests