Sponsor: Idaho Operations Office, Department of Energy
This project is to develop an innovative manufacturing technique, spray rolling, to produce aluminum net-shape products. This technique will require less energy and generate less scrap than conventional processes (e.g., ingot casting), and, consequently, enable the development of materials with lower environmental impacts in both the processing and the final products. Spray rolling combines spray forming, identified as one of the highest priority needs in the Aluminum Industry Technology Roadmap, with rolling for the net-shape manufacturing of Al strip. Spray rolling consists of atomizing a liquid metal with a high velocity, controlled temperature inert gas, quenching the metal droplets in-flight (via convection cooling by entrained inert gas) to about 70% solid fraction, and directing the spray between mill rolls. The metal is consolidated into strip while still in a semi-solid and highly formable condition. Compared to twin roll casting, we believe that spray rolling will improve the metallurgical homogeneity and the production rate of aluminum strip. Furthermore, in comparison with conventional spray forming, spray rolling may eliminate strip porosity, particularly at the deposit/substrate interface, while ensuring flat strip profile and improving yields. The main objectives of the project are (1) to demonstrate the feasibility of the spray rolling process at the bench-scale level, (2) to evaluate material properties of spray-rolled aluminum strip alloys, (3) to demonstrate 2X scalability of the process and to document technical hurdles to further scale up, and (4) to initiate technology transfer to industry for eventual commercialization of the process.
This program is organized for an effective collaboration among the University of California, the Colorado School of Mines (CSM), and the Idaho National Engineering and Environmental Laboratory (INEEL). Industrial cost-sharing will be provided jointly by Inductotherm Corp. (Rancocas, NJ), Pichiney Rolled Products (Ravensworth, WV), Metals Technology, Inc. (Northridge, CA), and Alcoa, Inc. (Pittsburgh, PA).