Fe was added to Al-4.7%Mg to make model alloys of recycled Al-Mg alloy. The effect of Fe addition on the mechanical properties of the Al-4.7%Mg strip cast using a single-roll caster equipped with a scraper was investigated. The added Fe content was 0.2, 0.4, 0.6, and 0.8%. The as-cast strip cast at 30 m/min was cold rolled down to a thickness of 1 mm thick annealed to conduct a tensile test and a cup test. The as-cast strip could be cold rolled without cracking. The tensile stress and the 0.2% proof stress were only slightly affected by the addition of Fe. The elongation gradually decreased as the Fe content increased. When the Fe content was 0.8%, the elongation in the casting direction was 27.7%. The limiting drawing ratio did not deteriorate until the Fe content was 0.4%. When the Fe content was 0.4% and 0.8%, the limiting drawing ratios were 2.0 and 1.7, respectively.
A scraper was attached to an unequal-diameter twin-roll caster without requiring large modifications. This caster was used as a 1000 mm diameter single roll caster equipped with a scraper, and its strip casting ability was tested. The effects of the scraper angle and load, the roll speed, and the pouring temperature of the molten metal on the scribed surface, thickness distribution and average strip thickness were investigated. The scribed surface characteristics were sound and the thickness distribution was flat when the scraper angle was 60° and the scraper load was in the range of 1 to 4 kg. When the scraper load was more than 1 kg, the thickness distribution was uneven. The average strip thickness decreased as the roll speed increased. The pouring temperature of the molten metal influenced the evenness of the solidified layer thickness. The solidified layer became even as the molten metal temperature was decreased. A strip cast with the determined optimal conditions was then cold rolled down to 1 mm to improve its surface quality.
The aluminum alloy Al–5%Mg–2%Si, the chemical content of which is close to that of the Magsimal-59 aluminum alloy commonly for die casting, was successfully cast into strips using a vertical high-speed twin-roll caster at a speed of 30 m/min. This means that Al–5%Mg–2%Si is suitable for the high-speed twin roll-casting. The as-cast Al–5%Mg–2%Si strip was then successfully cold-rolled to a thickness of 0.7 mm. Tension and cup tests were conducted on the cold-rolled annealed strips. The tensile stress was 205 MPa and the elongation was 20% for a thickness of 1 mm. The limiting drawing ratio was 2.0 at a 0.7 mm thickness. The present results demonstrates that Al–5%Mg–2%Si can be used for die casting and sheet forming. This means that use of this alloy for both sheet forming and die casting could eliminate the need for the separation of wrought aluminum alloys from cast aluminum prior to processing at recycling plants.
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