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SUPPLEMENT 4 TALAT Lecture 1301

The Rolling of Aluminium: the Process and the Product

24 pages, 29 figures Basic Level prepared by Roy Woodward, Aluminium Federation, Birmingham

Objectives: - to provide sufficient information on the rolling of aluminium and the characteristics of rolled products to ensure that students, users and potential users can understand the production features that affect properties and economics - to show how, in consequence, alloy choice for an end application depends not only on the characteristics required for that end use but also on semi-fabrication requirements. Prerequisites: - General knowledge in materials engineering - Some knowledge about aluminium alloy constitution and heat treatment Date of Issue: 1994 EAA - European Aluminium Association

1301 The Rolling of Aluminium: the Process and the Product

Table of contents 1301 The Rolling of Aluminium: the Process and the Product ........................................ 2 1301.01 Introduction ..................................................................................................... 2 1301.02 Sheet Products ................................................................................................. 6 1301.03 Plate ............................................................................................................... 13 1301.04 Properties of Rolled Products ........................................................................ 13 1301.05 Literature........................................................................................................ 23 1301.06 List of Figures................................................................................................ 24

1301.01 Introduction
Rolled products, i.e. sheet, plate and foil constitute almost 50 % of all aluminium alloys used (see Figure 1301.01.01). In North America the packaging industry consumes the majority of the sheet and foil for making beverage cans, foil containers and foil wrapping (Figure 1301.01.02). Sheet is also used extensively in building for roofing and siding, in transport for airframes, road and rail vehicles, in marine applications, including offshore platforms, and superstructures and hulls of boats. Also, while relatively little is currently used in the manufacture of high volume production automobiles, it is expected that the next decade will see sheet used for both space frames and body panels, a market that could easily match the 2 million tons now used for beverage cans. Plate is used for airframes, military vehicles and bridges, ships superstructures, cryogenic and chemical vessels and as tooling plate for the production of plastic products. Foil applications outside packaging include electrical equipment, insulation for buildings, lithographic plate and foil for heat exchangers (this lecture deals only with sheet and plate).
SHEET, PLATE & FOIL 43% SOUTH AMERICA 4% NORTH AMERICA 34%

EXTRUSIONS 25%

OTHERS 4% PACIFIC 29%

ROD, BAR & WIRE 7%

CASTINGS 21%

EUROPE, AFRICA & MIDDLE EAST 33%

By PRODUCT
CONTAINERS & PACKAGING 22% ELECTRICAL 10%

By REGION
BUILDING & CONSTRUCTION 21%

TRANSPORTATION 23%

OTHERS 24%

By END-USE MARKET

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Training in Aluminium Application Technologies

Western World Shipments of Aluminium 1991

1301.01.01

TALAT 1301

This wide range of products demands combinations of properties that span the whole range available from the aluminium alloy portfolio (see also TALAT lecture 1501.05), i.e. high strength, good corrosion resistance, good formability, good machinability, high toughness, good ballistic performance etc. (Figures 1301.01.03 and 1301.01.04) Also since in many cases the materials with which the aluminium alloys compete are relatively low cost, for example tin-plate, paper, wood, mild steel and plastics, it is essential that the cost of the aluminium products are themselves as low as possible, consistent with the achievement of the required properties. Since the cost of smelting aluminium is unlikely to be further reduced to any degree it is, therefore, essential that semi-fabrication costs are kept to a minimum.
K TONNES CANS OTHER PACKAGING ROAD VEHICLES RESIDENTIAL SIDING OTHER BUILDING AIR CONDITIONERS / APPLIANCES HOUSEHOLD & FOIL AIRCRAFT PLATE AIRCRAFT SHEET COOKING UTENSILS LITHOGRAPHIC SHEET MOBILE HOMES 2,013 361 298 190 155 140 133 110 96 50 50 35

Source: Aluminum Association

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Training in Aluminium Application Technologies

1990 Sheet, Plate & Foil Markets by Product Type (N. America)

1301.01.02

OTHER PROPERTIES
AUTOMOBILE STRUCTURES DECORATIVE, ROAD & RAIL CONTAINERS, CANS, TRANSPORT, ELECTRICAL, MARINE STRUCTURES, COOKING UTENSILS CRYOGENICS MILITARY

AIRCRAFT

YIELD STRENGTH

MODULUS DENSITY
CAN BODIES (3004)

STRESS CORROSION TOUGHNESS

CAN END (5182) GAS CYLINDERS (6082) Al-Zn-Mg PRESSURE CABIN (2024) Al-Mg-Si-Cu Al-Zn-Mg-Cu Al-Li-Mg-Cu

Al-Mg (3%) Al-Mg (5%) Al Al-Mn Al-Mg-Si Al-Mg-Si-Mn

FATIGUE UTS WELD ABILITY U.T.S.

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Training in Aluminium Application Technologies

Range of Properties and Uses of Aluminium Alloys

1301.01.03

TALAT 1301

All aluminium alloys can be rolled to sheet but, with a few notable exceptions mentioned below, the ones utilised are from the 1000, 3000 and 5000 series which are work hardening alloys (Figure 1301.01.05). However, the 2000, 7000 and 8000 heat treatable alloys are used for airframes, 2000 and 6000 series for automobiles and the 6000 series for some pressure vessels and containers. Examples exist for the use of plate in all alloys while foil is almost all from the 1000 series. Figure 1301.01.06 shows some typical alloys used for specific end-use applications. (As indicated in other lectures, while there are some 300 different wrought aluminium alloys, probably 80 % of the applications are covered by perhaps 30 alloys).

REQUIRED CHARACTERISTIC LOWER MELTING POINT INCREASED CONDUCTIVITY INCREASED ELASTIC MODULUS DECREASED DENSITY STRESS CORROSION RESISTANCE SACRIFICIAL CORROSION

ALLOYING ELEMENT Si B Li Li Cr, Zr, Ag Zn

PRODUCT BRAZING SHEET, FOIL CONDUCTOR STRIP AEROSPACE SHEET AEROSPACE SHEET AIRCRAFT SHEET HEAT EXCHANGERS CLAD PRODUCTS HEAT EXCHANGERS DECORATIVE APPLICATIONS

VACUUM BRAZING RESPONSE RESPONSE TO CHEMICAL or ELECTROCHEMICAL TREATMENT

Mg Si, Cu, Cr

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Training in Aluminium Application Technologies

Some Alloying Elements Employed to Give Special Characteristics

1301.01.04

Mn

3000 AL-Mn

WORK
5000 AL Mg-Mn 5000 AL-Mg 7000 AL-Zn-Mg 7000 Al-Zn-Mg-Cu 2000 AL-Cu 2000 AL-Cu-Mg

HARDENING ALLOYS

Mg 1000 AL Zn Cu

PRECIPITATION HARDENING ALLOYS

Si Li

6000 AL-Mg-Si-Mn 8000 AL-Li-Cu-Mg

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Training in Aluminium Application Technologies

Main Alloy Types Available as Sheet and Plate

1301.01.05

TALAT 1301

ALLOY
1060 1100 3003, 3004 5005, 5050 5052, 5657 5085, 5086 5454, 5456 5182, 5356

APPLICATION
WORK-HARDENING ALLOYS CHEMICAL EQUIPMENT, TANKERS. COOKING UTENSILS, DECORATIVE PANELS. CHEMICAL EQUIPMENT, STORAGE TANKS, BEVERAGE CAN BODIES. AUTOMOTIVE TRIM, ARCHITECTURAL APPLICATIONS. MARINE STRUCTURES, STORAGE TANKS, RAIL CARS. PRESSURE VESSELS, ARMOUR PLATE. CYROGENIC TANKS, BEVERAGE CAN ENDS. HEAT TREATABLE ALLOYS

2219 2014, 2024 6061, 6063 6082, 6351 6009, 6010 7004, 7005 7019, 7039 7075, 7079, 7050, 7010, 7150
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HIGH TEMPERATURE (eg high speed aircraft). AIRFRAMES, AUTOBODY SHEET. MARINE STRUCTURES, HEAVY ROAD TRANSPORT, RAIL CARS, AUTOBODY SHEET. MISSILES, ARMOUR PLATE, MILITARY BRIDGES. AIRFRAMES, TOOLING PLATE.

Typical Applications of some Aluminium Sheet & Plate Alloys

1301.01.06

The starting stock for most rolled products is the DC (Direct Chill semi-continuous cast) ingot (see Figure 1301.01.07). The size of the ingot depends on the size of the DC unit available, the hot rolling mill capacity, volume required for a particular end use and to some extent the alloys being cast. Ingots up to over 20 tons in weight, 500 - 600 mm thick, 2000 mm wide and 8000 mm long are produced.

MOULD

LIQUID METAL

SOLID INGOT

WATER CURTAIN

BOTTOM BLOCK

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D.C. Casting

1301.01.07

TALAT 1301

1301.02 Sheet Products

The DC ingot is usually cooled after casting to room temperature and then re-heated to around 500 C prior to successive passes through a hot rolling mill where it is reduced in thickness to about 4 - 6 mm (Figures 1301.02.01 and 1301.02.02). The temperature of pre-heat of the ingot and the time held at that temperature is important for some alloys since a process of homogenisation takes place which renders the material in the best condition for rolling and the achievement of subsequent properties. The strip from the hot rolling mill is coiled for transport to the cold mill which might be on the same site or elsewhere. Cold mills, in a wide range of types and sizes are available; some are single stand, others 3 stand and some 5 stand (Figures 1301.02.03 and 1301.02.04). Cold rolling speeds vary but modern mills operate at exit speeds as high as 3000 m per minute. A modern complex including melting furnaces, DC casting facilities, pre-heat furnaces, hot mill, cold mill and annealing furnaces involves a very large capital investment which can only be fully justified on financial grounds if a big market is assured. Obviously, if such facilities are not fully utilised the economic viability is threatened. As indicated above, however, hot mill coil can be obtained for further reduction in cold mills of lower capacity/speed/ complexity.

REVERSING BREAKDOWN AND FINISHING MILL

COILER

INGOT 480 - 580 C 600 mm thickness 280 - 350 C 5 - 8 mm thickness alu

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Training in Aluminium Application Technologies

Single Stand Hot Mill

1301.02.01

TALAT 1301

REVERSING BREAKDOWN MILL TANDEM MILL COILER

INGOT

RE-ROLL COIL

500 - 600 C 600 mm

400 - 500 C 20 - 30 mm Conventional Breakdown Mill / Hot Tandem Mill Operation

250 - 350 C 2.3 - 5.0 mm

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1301.02.02

COILER / DE-COILER

REVERSING COLD MILL

COILER / DE-COILER

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Single Stand Reversing Cold Mill

1301.02.03

Although most sheet is produced by conventional hot mills, some considerable effort has been made by aluminium producers in the United States, Canada and Europe to reduce both the capital and production costs by the development of continuous strip casting methods (Figure 1301.02.05) whereby hot metal is poured into some form of strip caster, thus eliminating the DC casting and hot break-down mills (Figure 1301.02.06). To date, however, only a limited range of alloy compositions can be produced in this way with end uses found mainly in foil and building sheet.

TALAT 1301

COILER / DE-COILER

REVERSING COLD MILLS

COILER / DE-COILER

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Multi Stand Reversing Cold Mill

1301.02.04

TWO-HIGH COMPACTION HOT LIQUID METAL FEED TWIN BELT CASTER MILL

TWO STAND TANDEM MILL COILER

420 - 460 C 20 - 30 mm

380 - 410 C 12 - 15 mm

180 - 250 C 2 - 3.5 mm

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Continuous Strip Casting Line

1301.02.05

Final sheet properties for the work hardening alloys in the 1000, 3000 and 5000 series are achieved either by temper rolling or temper annealing. In the former case the strip is reduced by a fixed amount of cold work to achieve the required temper, in the latter it is rolled to a hard temper and then back annealed to achieve the required strength. While a given set of mechanical properties, eg proof stress, tensile strength and elongation can be achieved by both routes, other characteristics, particularly formability, can be influenced by the particular production route chosen. When 2000, 6000 and 8000 sheet is needed the cold mill strip is sometimes continuously heat treated to achieve optimum economics, but the cost of such equipment is high and when relatively small volumes are needed the sheet is either heat treated individually or in coils. Continuous heat treatment lines include tension levellers which ensure that the distortion created by water quenching is removed. For individual sheets stretching is necessary to achieve the required flatness.

TALAT 1301

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Training in Aluminium Application Technologies

Hazelett Twin Belt Slab Caster

1301.02.06

ALLOYTEMPER

USE

COMPOSITION (wt %) MAXIMUM UNLESS SHOWN AS A RANGE Cu Fe Mg Mn Si

LONGITUDINAL MECHANICAL PROPERTIES UTS (ksi) 43 0.2% YS (ksi) 41 ELONG. (%) 2.0

3004 H19

CAN BODY

0.25 0.70

0.8-1.3

1.0-1.5

0.30

5182H28

CAN END

0.15 0.35

4.0-5.0

0.2-0.5

0.20

55

49

7.0

5042H19

TAB

0.15 0.35

3.0-4.0

0.2-0.5

0.20

50

47

5.0

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Composition and Properties of Aluminium Alloys used in Can Making

1301.02.07

In the past 20 years much effort has been made by the aluminium industry and mill producers to ensure that cold rolled products have the specific characteristics required for satisfactory end use and that they can compete from a cost point of view with competitor materials. Properties such as strength, formability, toughness and corrosion resistance are controlled in the main by alloy choice, rolling deformation schedule and thermal treatments, before, during and after rolling. Perhaps the best example is the development of the alloys used for beer can ends, bodies and tear-off tabs (Figures 1301.02.07 and 1301.02.08). The match of formability, strength, resistance to scoring, tearing ability and not least cost have been achieved by careful control of the parameters outlined above. However, other requirements such as surface finish, flatness and gauge uniformity have been achieved by careful attention to the mechanics and chemistry of the rolling process. The control of surface finish in sheet products is essential, particularly in applications where surface defects mar appearance, but also in those cases where the surface of the sheet influences subsequent forming operations by affecting lubricant retention and pick-up on dies. This has been shown to be very

TALAT 1301

important in the production of beverage cans and will play an increasing role in the manufacture of auto-body parts. In hot rolling a knowledge of the influence of the starting stock surface condition, surface condition of the rolls and lubrication used has been necessary, as have the effect of corresponding parameters in the cold mill with the full understanding of the effect of roll coatings, arcs of contact etc achieved by very detailed study.

RIVET

PULL RING

CAN END

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Example of Extensive Forming Required to Produce Beverage Can Easy-Opening End

1301.02.08

ROLLING FORCES

OVER-ROLL EDGES

CUT SHEET INTO NARROW STRIPS

FIBRE LENGTH = L +

FIBRE LENGTH = L

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One Way in which Rolling Produces Bad Shape Sheet

1301.02.09

When sheet is rolled its final flatness depends on a number of characteristics of the starting stock and of mill features. If bad shape results during rolling, ie some parts of the strip are longer than others, buckling occurs and this, in many cases, can be removed by tension levelling whereby the strip is stretched sufficiently so that short parts are extended to the point where they have the same length of the long parts and the out of shape disappears (Figure 1301.02.09). However, attention to the cross section shape of the in-going product, i.e. DC slab or hot mill coil, can greatly improve the final shape. Also a most powerful tool is the control of the cold roll contour. This can be achieved by bending the rolls by means of jacks so that parts of the roll that want to roll long strip

TALAT 1301

10

are adjusted and by alteration of the distribution of the rolling lubricant so that hot parts of the roll that would roll long are cooled (Figure 1301.02.10)

CONTOURING SCREW DOWN

CONTOUR JACK

4 HIGH WORK ROLL BENDING

CONTOUR JACK

PUSH-UP

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One Method of Use of Jacks for Roll Bending

1301.02.10

STRIP

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Shape Measurement

1301.02.11

Obviously, the mill cannot make these adjustments itself and it is necessary to measure the shape of the outgoing strip and then instruct the mill controls. It is impossible to judge the shape by slacking off the outgoing tension since this would grossly interfere with production schedules and result in considerable scrap. In consequence, methods have been devised whereby the actual shape of the outgoing strip, which, because it is under tension, can look flat, is assessed by measuring the residual stress in the strip long parts have low stresses. Various methods have been developed (Figure 1301.02.11). The signal from the shape metre is fed to the mill control jacks and lubricant sprays and rapid adjustment achieved (Figure 1301.02.12). In many modern installations concerned with the high volume production, for instance in the canning TALAT 1301 11

industry, the very stringent flatness requirements are achieved by combinations of mill control and by the use of tension levellers. Gauge control is achieved in much the same way as flatness, i.e. by continuously measuring outgoing strip thickness and adjusting the roll bite accordingly. Without such control it would not be possible to produce easyopening can-ends! (Figure 1301.02.13).

1. ROLL BENDING JACKS 2. STRESSOMETER MEASURING ROLL 3. SIGNAL TRANSMISSION 4. CONTROL EQUIPMENT 5. DISPLAY UNIT FOR STRIP SHAPE 6. ROLL-COOLANT SWITCHING DEVICE

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Automatic Flatness Control System

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Training in Aluminium Application Technologies

1301.02.12

GAUGE CONTROL ESSENTIAL TO ENSURE CORRECT TEARING

STRIP TOO THICK

STRIP TOO THIN

STRIP JUST RIGHT

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Score Line in Can Ends

1301.02.13

TALAT 1301

12

1301.03 Plate
While perhaps 80 % of all sheet used is made from the 3000 and 5000 work hardening series alloys, plate, as indicated earlier, is drawn from the whole range with civil aircraft and military applications demanding the strong, heat treatable 2000, 7000 and 8000 series. All plate is produced by the DC casting/hot rolling route and while surface finish is important in some cases, the final product is often surface machined. Of great importance, however, in addition to strength are properties such as toughness, stress corrosion resistance, machinability and fatigue strength. These are achieved by careful control of alloying elements and by special thermal treatments. In this latter context it is important to note that in all cases, with the exception of the aluminium-zinc-magnesium alloys, a rapid quenching rate is needed to produce high mechanical strengths. In sheet products quenching usually results in distortion which can be seen and removed. In plate the rigidity of the product is sufficient to avoid distortion but very high residual stresses can result which, if not removed, can either adversely effect the product performance in service or cause distortion when the plate is machined. Control stretching removes this residual stress but it involves presses with load capacity of say 5000 tonnes thus adding to production costs.

1301.04 Properties of Rolled Products

Typical mechanical, physical, chemical and fabrication properties and characteristics of a range of rolled aluminium alloys, tempers and heat treatments are given in the following tables extracted from the aluminium databank ALUSELECT (Figures 1301.04.01 till Figure 1301.04.09). Note that these data are not guaranteed minimum properties, but have been harmonized between the various European aluminium producers and pertain also to other types of wrought products as indicated. There are in addition a great number of specialty sheet and plate alloys which are being produced for specific applications, e.g. carbody sheet metal parts. These alloys have characteristics to suit special demands such as formability. Full details can be provided by the metal producers. To select the right alloy for a specific application is often a difficult task. Useful hints may be obtained from several other lectures within the TALAT series, e.g. Lecture 1501 and Lecture 1502 as well as from further information and application examples in ALUSELECT. For the selection of minimum guaranteed property values of rolled products for design and ordering purposes reference is made to the new European standards EN 485.

TALAT 1301

13

Printed from: ALUSELECT Databank

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Harmonised Property Data for Aluminium 1050

1301.04.01

TALAT 1301

14

Printed from: ALUSELECT Databank

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Harmonised Property Data for Aluminium Alloy 2024

1301.04.02

TALAT 1301

15

Printed from: ALUSELECT Databank

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Harmonised Property Data for Aluminium Alloy 3103

1301.04.03

TALAT 1301

16

Printed from: ALUSELECT Databank

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Harmonised Property Data for Aluminium Alloy 5005

1301.04.04

TALAT 1301

17

Printed from: ALUSELECT Databank

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Harmonised Property Data for Aluminium Alloy 5251

1301.04.05

TALAT 1301

18

Printed from: ALUSELECT Databank

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Harmonised Property Data for Aluminium Alloy 5754

1301.04.06

TALAT 1301

19

Printed from: ALUSELECT Databank

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Harmonised Property Data for Aluminium Alloy 5083

1301.04.07

TALAT 1301

20

Printed from: ALUSELECT Databank

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Harmonised Property Data for Aluminium Alloy 6082

1301.04.08

TALAT 1301

21

Printed from: ALUSELECT Databank

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Harmonised Property Data for Aluminium Alloy 7075

1301.04.09

TALAT 1301

22

1301.05 Literature
Aluminium Federation Ltd., U.K., Properties of Aluminium Aluminium Taschenbuch, Edition 1984, Aluminium Verlag, Dsseldorf ALUSELECT, European Aluminium Association, Brussels. Databank for aluminium alloys, properties, applications and standards. Edition 1990 Broner Engineering, Product overview. (Mill control systems for the metals industry). 1991 EN 485 Parts 1 - 4, Aluminium and aluminium alloys, Strip, sheet and plate products, edition 1994 Hatch, J.E.: Aluminium Properties and Physikal Metallurgy, American Siciety for Metals, ASM, Metals Park, Ohio, 1984 McDonald, I.R.: Shape control - the modern approach. Review of three decades of controlling rolling variables to ensure that the final product is to the dimensions required. Aluminium Today, May 1991, pp. 34, 40 Nardini, D., Calderbank, I.G., Waterson, K.: A critical review of the finite element modelling requirements for flat rolling. Presented at Institute of Metals Conference on Mathematical Models for Metals and Materials Applications, 1214 October, 1987, Sutton Coldfield. Nussbaum, A.I.: Flat rolled process technology for the nineties from molten aluminium to finished sheet (Review). Light Met. Age, April 1991, pp. 8-83 Ostermann, F.: Aluminium materials technology for automobile construction. Mechanical Engineering Publications Ltd., London, 1993

TALAT 1301

23

1301.06 List of Figures

Figure No. Figure Title (Overhead) 1301.01.01 Western World Shipments of Aluminium 1991 1301.01.02 1990 Sheet, Plate & Foil Markets by Product Type (N.America) 1301.01.03 Range of Properties and Uses of Aluminium Alloys 1301.01.04 Some Alloying Elements Employed to Give Special Characteristics 1301.01.05 Main Alloy Types Available as Sheet and Plate 1301.01.06 Typical Applications of some Aluminium Sheet & Plate Alloys 1301.01.07 D.C.Casting 1301.02.01 Single Stand Hot Mill 1301.02.02 Conventional Breakdown Mill/ Hot Tandem Mill Operation 1301.02.03 Single Stand Reversing Cold Mill 1301.02.04 Multi Stand Reversing Cold Mill 1301.02.05 Continuous Strip Casting Line 1301.02.06 Hazelett Twin Belt Slab Caster 1301.02.07 Composition and Properties of Aluminium Alloys Used in Can Making 1301.02.08 Example of Extensive Forming Required to Produce Beverage Can EasyOpening End 1301.02.09 One Way in which Rolling Produces Bad Shape Sheet 1301.02.10 One Method of Use of Jacks for Roll Bending 1301.02.11 Shape Measurement 1301.02.12 Automatic Flatness Control System 1301.02.13 Score Line in Can Ends 1301.04.01 Harmonized Property Data for Aluminium 1050 1301.04.02 Harmonized Property Data for Aluminium Alloy 2024 1301.04.03 Harmonized Property Data for Aluminium Alloy 3103 1301.04.04 Harmonized Property Data for Aluminium Alloy 5005 1301.04.05 Harmonized Property Data for Aluminium Alloy 5251 1301.04.06 Harmonized Property Data for Aluminium Alloy 5754 1301.04.07 Harmonized Property Data for Aluminium Alloy 5083 1301.04.08 Harmonized Property Data for Aluminium Alloy 6082 1301.04.09 Harmonized Property Data for Aluminium Alloy 7075

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