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Direct strip casting of metals and alloys

M Ferry, University of New South Wales, Australia

Woodhead Publishing Series in Metals and Surface Engineering No. 17

 - first book to review the implications of strip technology for a range of alloys
 - essential book on a technology destined to have a profound impact on the manufacturing landscape of the twenty-first century

Direct strip casting is a continuous casting process for producing metallic sheet directly from the molten state that minimises the need for substantial secondary processing. This important book is the first to review the implications of strip casting technology for a range of alloys, including carbon and stainless steel, aluminium, magnesium, titanium, copper and other non-ferrous alloys.

The book is divided into six chapters, with the first two describing the physical metallurgy of candidate alloys for direct strip casting and the development of microstructure during solidification. Chapter 3 describes the principles of continuous casting processes and the evolution of direct strip casting. It provides the foundation for the following two chapters which describe process variables and their impact on microstructure and strip quality. The final chapter describes possible techniques in secondary processing and fabrication of the as-cast strip. Two appendices discuss simulation and modelling issues, and the measurement and representation of textures in metal strip.

Direct strip casting of metals and alloys is a standard reference on a technology destined to have a profound impact on the manufacturing landscape of the twenty-first century.

ISBN 1 84569 049 4
ISBN-13: 978 1 84569 049 6
March 2006
296 pages  234 x 156mm  hardback  
£145.00 / US$245.00 / €175.00

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About the author

Professor Michael Ferry MIMMM, CEng, MIEAust, CPEng is in the School of Materials Science and Engineering in the University of New South Wales, Australia.

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Contents

Metallurgy of alloys suitable for direct strip casting
 - Introduction
 - Metallurgy of ferrous alloys: Phase stability; Alloying elements in iron; Phase transformations and key DSC steel grades
 - Metallurgy of non-ferrous alloys: Aluminium alloys; Magnesium alloys; Titanium alloys; Copper alloys; Other non-ferrous alloys

Overview of solidification processing
 - Introduction
 - Development of solidification microstructure: Nucleation from the melt; Crystal growth beyond the nucleation stage
 - Effect of processing variables on cast structure: Possible grain structures; Mould properties, melt superheat and cooling rate; Fluid flow during casting
 - Typical casting defects: Segregation of alloying elements; Other casting defects
 - Macroscopic heat flow in solidification

Continuous casting processes and the emergence of DSC
 - Types of continuous casting processes: Casting of ingots, billets and slabs; Thin slab casting; Direct strip casting; Melt quenching processes
 - The emergence of direct strip casting: General evolution of the process; The revival of strip casting of iron alloys; Current status of direct strip casting
 - Comparison between DSC and other continuous casting processes: Process characteristics and advantages of strip casting; Economic viability of strip casting; Energy and environmental considerations

DSC process variables and cast strip quality
 - Introduction
 - Overview of process control in strip casting
 - Important process variables in DSC: Melt management; Mould characteristic and molten metal delivery; Secondary processes and processing
 - Strip formation during DSC: Single roll/belt casters; Twin roll casters; Twin belt/block casters; Influence of casting speed on strip characteristics; Some factors affecting as-cast strip thickness
 - Heat transfer in strip casting: Principal modes of heat transfer; Variation of heat transfer in strip casting; Factors influencing heat transfer in strip casting
 - Cast strip quality: Control of internal defects; Surface condition of as-cast strip; Mechanical and other properties

As-cast microstructure, texture and properties
 - Introduction
 - General features of strip-cast microstructures: Dendritic growth in a flowing melt; Secondary dendrite arm spacing
 - Strip-cast ferrous alloys: Low carbon steels; Austenitic stainless steels; Ferritic stainless steels; Other ferrous alloys
 - Strip-cast non-ferrous alloys: Aluminium alloys; Magnesium alloys; Copper alloys; Other non-ferrous alloys

Secondary processing and fabrication
 - Introduction
 - Scope of secondary processing
 - Control of thermal path after strip casting: Direct cooling and coiling; Direct heat treatment processes
 - Hot rolling processes: Conventional hot rolling; In-line rolling; Ferrite grain refinement by controlled rolling
 - Low temperature rolling processes: Microstructural development during cold rolling; Rolling textures; Warm rolling of strip-cast low carbon steel
 - Static annealing processes: Annealing methods; Quantifying recrystallization; Recrystallization behaviour of strip-cast metals
 - Final fabrication methods: Forming and formability; Surface treatments and coatings

Appendix A: Simulation and modelling of direct strip casting
 - Introduction
 - Experimental techniques
 - Mathematical techniques

Appendix B: Representation of textures and their interpretation
 - Introduction
 - Measurement of textures
 - Representation of orientations and textures: Pole figures; Inverse pole figures; Orientation distribution function
 - Typical textures in metal strip: Solidification textures; Texture development during secondary processing

References