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Interface Formation During Fusion™ Casting of AA3003/AA4045 Aluminum Alloy Ingots

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Abstract

Fusion™ casting is a unique Direct Chill continuous casting process whereby two different alloys can be cast simultaneously, producing a laminated ingot for rolling into clad sheet metal such as AA3003/AA4045 brazing sheet. Better understanding of the wetting and interface formation process during Fusion™ casting is required to further improve process yields and also explore use of other alloy systems for new applications. In this research, AA3003-core/AA4045-clad ingots were cast using a well-instrumented lab-scale Fusion™ casting system. As-cast Fusion™ interfaces were examined metallurgically and by mechanical testing. Computational fluid dynamic analyses of the FusionTM casts were also performed. It was shown that the liquid AA4045-clad alloy was able to successfully wet and create an oxide-free, metallurgical, and mechanically sound interface with the lightly oxidized AA3003-core shell material. Based on the results of this study, it is proposed that the bond formation process at the alloys interface during casting is a result of discrete penetration of AA4045 liquid at defects in the preexisting AA3003 oxide, dissolution of underlying AA3003 by liquid AA4045, and subsequent bridging between penetration sites. Spot exudation on the AA3003 chill cast surface due to remelting and inverse segregation may also improve the wetting and bonding process.

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Acknowledgments

The authors would like to acknowledge Simon Barker, Mark Gallerneault, Paul Nolan, Don Doutre at Novelis Global Technologies Labs in Kingston, ON, Canada and Kennesaw, Georgia, USA for their encouragement and support throughout this study. We also thank Rosa Ortega Pelayo, Amir Baserinia, and the technical staff at the University of Waterloo, Department of Mechanical and Mechatronics Engineering, for their generous contributions to this work. Funding for this study was provided by Novelis Inc. and the National Science and Engineering Research Council of Canada (NSERC).

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Authors and Affiliations

  1. Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, ON, Canada

    Massimo Di Ciano (Ph.D. Student, Research Assistant), E. J. F. R. Caron (Post-Doctoral Fellow, Research and Technology Advisor), D. C. Weckman (Professor) & M. A. Wells (Professor)

  2. Canada Revenue Agency, Ottawa, ON, Canada

    E. J. F. R. Caron (Post-Doctoral Fellow, Research and Technology Advisor)

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  1. Massimo Di Ciano
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  2. E. J. F. R. Caron
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  4. M. A. Wells
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Correspondence to Massimo Di Ciano.

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Manuscript submitted July 6, 2015.

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Di Ciano, M., Caron, E.J.F.R., Weckman, D.C. et al. Interface Formation During Fusion™ Casting of AA3003/AA4045 Aluminum Alloy Ingots. Metall Mater Trans B 46, 2674–2691 (2015). https://doi.org/10.1007/s11663-015-0432-9

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