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Intermetallics and Aluminium for (Beverage) Cans

Intermetallics and Aluminium for (Beverage) Cans. Dr. Havovy Cama Alcan International Limited, Banbury Laboratory, Southam Road, Banbury OX16 2SP. Email: havovy.cama@alcan.com. Topics. A brief Introduction of Alcan Inc. Definition of intermetallics and can stock

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Intermetallics and Aluminium for (Beverage) Cans

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  1. Intermetallics andAluminium for (Beverage) Cans Dr. Havovy Cama Alcan International Limited, Banbury Laboratory, Southam Road, Banbury OX16 2SP. Email: havovy.cama@alcan.com

  2. Topics • A brief Introduction of Alcan Inc. • Definition of intermetallics and can stock • Production and processing of can stock alloys • Effect on intermetallic particles • Techniques to characterise intermetallic particles • Ways of enhancing can stock performance

  3. Recent History Primary Metal Aluminium Fabrication Americas & Asia Aluminium Fabrication Europe Packaging • Merger of • Alcan Aluminium Limited • Algroup • 17th October, 2000. • New Company Alcan Inc. (name adopted since March 2001) • Global Provider of Aluminium, Packaging and Solutions

  4. Research and Technology - Alcan Inc. R&D Budget - 2000

  5. Alcan Inc. By Sector Geographical Repartition Other 9,000 Primary 17,000 Packaging 17,000 Europe 23,000 Fabrication Europe 12,000 Fabrication Americas & Asia 7,000 North America 21,000 Number of Employees = 53000

  6. Aluminium Processing HOMOGENISATION CASTING ROLLING

  7. Typical processing route for Canstock Alloys DC Cast Ingot Approx. 660mm x 1850mm x 8600mm AA3104 (CBS),AA5182 (CES) Scalping Rolling face (+ side faces) Preheat / Homogenisation 475- 630 °C Hot Roll Break Down Mill to ~ 35mm Hot Tandem Mill to2-3mm Target exit temp 300-350 °C Cold Roll Final gauge < 250 µm Finishing Operations Post Lub application / Lacquering To customer specification

  8. DC Casting of Sheet Ingots

  9. Continuous Casting of Sheet Ingots

  10. Homogenisation

  11. Pusher Furnace .

  12. Breakdown Mill

  13. Cropping & Tandem Mill Rolling

  14. Cold Rolling

  15. Products

  16. Products

  17. New Product Applications after the Merger

  18. World Beverage Can Market for Al China Middle East South East Asia South Africa South America Central America Japan US&Canada Europe 2000 estimate (total 233 billion cans) 15% increase 1995 (total 202 billion cans)

  19. Banbury Laboratory Banbury Located 26 miles north of Oxford - 2 miles off jn. 11 on M40

  20. Projects at Banbury Laboratories Raw Materials Metallurgy Surface Sciences Process and Product Modelling Technical Customer Support

  21. Importance of Intermetallic Type forAluminium Canstock Performance

  22. Importance of Improving Can Stock Performance(The Canning Market) • Probably the single largest use of aluminium. • 12% of total global Al output used to make beverage cans • Market is still evolving • Cost reduction. • Weight reduction (down gauging). • Pressure from non-aluminium materials. • Need for product innovation.

  23. Aluminium Beverage Can Can End (5XXX Alloy - Mg rich) Can Body (3XXX Alloy - Mn rich)

  24. Drawn and Ironed (DI) Cans The DI cans are cleaned, decorated and lacquered at the customer plant prior to filling them with beverage.

  25. Drawing and Ironing (D&I) Process Cup on Punch Ironing Dies Ironed untrimmed can Redraw Die Cooling Ports Dome tooling

  26. wt.% Mn 2.0 Can Body Stock AA3004 <0.3Si 1.5 <0.7Fe <0.25Cu 1.0 <0.2Si <0.2Si AA5017 AA3104 <0.35Fe <0.35Fe <0.6Si <0.15Cu <0.15Cu <0.8Fe <0.1Cr <0.1Cr 0.5 0.02-0.25Cu <0.25Si Tab Stock Can End Stock <0.4Fe AA5182 AA5042 AA5052 <0.1Cu 0.15-0.35Cr 0.0 0 1 3 4 5 2 wt.% Mg Schematic Diagram AA Compositions of Canning Materials

  27. Can End Manufacture

  28. Cans in the 21st CenturyThinner, stronger and different shapes

  29. .406 Gauge (inches) Gauge (mm) .356 .305 .254 .203 • Technical Improvements • Down gauging, • Light weighting (reduced 25 - 30 % in last 20 yrs)

  30. Ingot: 0.66 m x 1.850 m x 8.6 m

  31. What are Intermetallic Particles ? 50 m • These are large particles (10-100 m) formed in the matrix during solidification of the melt.

  32. Constituent Particle Formation During Solidification Major Alloying Elements Trace Chemistry Solidification Conditions Grain Refiner • As-cast Particle • Population • Phase type • Size Distribution • Spatial Distribution • Morphology

  33. Feature Detection and Classification (FDC) Technique • The apparent concentration of Fe+Mn vs. Si of each point is plotted • Reference to the literature and experimental data on standard samples have led to boundaries between the phases being determined • Great care should be taken to allow for • particle size • solute effects • neighbouring phases • partial transformation 25 6 or 3 a app wt% Fe b 0 5.0 app wt% Si

  34. Feature Detection and Classification (FDC) Technique Al6Fe a Note: Duplex particles fall in both classifications, depending upon the position of the probe analysis point.

  35. Intermetallic Extraction & Analysis • The technique was developed at Sintef during the 1980s, enabling sufficient quantities of dry butanol to be distilled for the reliable extraction and collection in the absence of H2O, of sufficient particulate for subsequent analysis. • Extracted Particles are ground and analysed using X-ray diffraction and resultant traces are compared with those from known intermetallic types Al + butanol  Al-butoxide + H2

  36. X-Ray Diffraction of Intermetallics grinding Sample (+ petroleum jelly) Zero reflection Si disc X-ray detector Co X-ray tube  evaporation Ultrasonic + methanol

  37. XRD Traces Peaks used in calibration curve are marked using */+

  38. XRD calibration curve Log Peak ratio IA/IB 0 1 X=Fraction phase A • Comparison of peak positions and relative peak intensity with standard spectra give phase identification • Comparison of peak intensity ratios with standard calibration curves gives estimate of relative concentration of phases • For multiple phase mixtures spectra are complex and interpretation difficult

  39. Bridgman Furnace furnace alumina crucible solid-liquid interface thermal shield water bath rolling 'O' ring seal water cooled jacket stepper motor controlled drive rod

  40. Effect of Casting Speed and Alloy Composition on Intermetallic Phase Selection Al-1.25%Fe-0.25%Mn -0.2%Si-1.2%Mg-0.2%Cu Al-0.5%Fe-1.0%Mn -0.2%Si-1.2%Mg-0.2%Cu Al-0.5%Fe-1.0%Mn -0.4%Si-1.2%Mg-0.2%Cu Increase Fe/Mn Base Alloy Increase Si

  41. Effect of Alloy Composition andCasting Conditions on Intermetallics • Their composition and crystallographic structure depends upon the alloy composition and casting velocity of the ingot and cooling rate of the melt. • The type of intermetallics can change during processing • Their size depends on casting velocity • Increasing the casting velocity decreases particle size. • Size of particles affects final product performance (recrystallisation, can scoring).

  42. Equilibrium Phase Diagrams Al6(Fe,Mn) c=Al(Fe,Mn)Si c Mg2Si • Results only as good as database used • Metastable phases formed during casting. Depending on homogenisation time and temperature, they transform totally or partially to equilibrium phases.

  43. Homogenisation T(oC) 2 stage heating HTR Time (Hours) Depending on type of furnace, homogenisation times can vary from a few hours to up to a day.

  44. Effect of Time on Amount of Alpha Phase in AA3104 After Isothermal Exposure at 550 oC In the temperature range 550-630 °C, the amount of Al6(Fe,Mn) transformed to -Al(Fe,Mn)Si increases with increasing exposure time until it reaches a maximum (equilibrium) concentration determined by the alloy composition and homogenisation temperature. The transformation rate is initially rapid and then slows down.

  45. The Effect of Si Content on the Type of Intermetallic Present after Homogenization Increasing the Si content in the alloy increases the rate of the Al6(Fe,Mn) to -Al(Fe,Mn)Si transformation.

  46. Homogenisation of 3xxx AlloysAA3104: Al-0.4%Fe-0.9%Mn-1.2%Mg-0.2%Cu- 0.2%Si Mg2Si  Si  Si Al6(Fe,Mn) Temperature

  47. Homogenisation of 3xxx AlloysAA3104: Al-0.4%Fe-0.9%Mn-1.2%Mg-0.2%Cu-0.2%Si 20 µm After Isothermal Heat Treatment at 600 °C for 15 mins Cell Edges c-Al(Fe,Mn)Si Al6(Fe,Mn)

  48. Homogenisation of 3xxx AlloysAA3104: Al-0.4%Fe-0.9%Mn-1.2%Mg-0.2%Cu- 0.2%Si 100nm 100nm 100nm After Ramped Heat Treatment ° TEM images of AA3104 ramped to 300 C then isothermally treated. ° ° ° 400 C / 12m 450 C / 5m 450 C /15m

  49. Particle Break-up During Rolling (CBS)  Breakdown mill rolling produces slab  Hot rolling produces reroll  Cold rolling produces final gauge sheet

  50. Improved Can Body Stock • Thinner • Downgauge further • Good strength • Solid solution strengthening, strain hardening • Controlled by alloying and thermomechanical processing • Strength limited by customer tooling performance • Galling control • Need for continuous die cleaning for good can surface • Believed to be controlled by correct size and amount of alpha phase • Earing control • To minimise metal wastage after D&I process • Controlled by alloying and thermomechanical processing • Cost • Controlled by cost of alloying additions and final gauge

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