From Direct Strip Casting of Metals and Alloys: Processing, Microstructure and Properties

1.1 Introduction

Direct strip casting (DSC) is a near-net-shape casting process used for a number of years to produce a range of aluminium, copper, zinc and lead alloys with various steel grades recently becoming commercially viable. Large-scale production of other important metals is limited but substantial progress on the pilot-plant scale has been made for magnesium. In principle, most metals and alloys are amenable to direct casting into plate, strip or ribbons. However, a sound metallurgical understanding of these materials is needed to gauge their suitability for casting into thin-gauge strip. From a metallurgical viewpoint, account must be taken of the melting point of the alloy, freezing range, oxidation resistance in both the liquid and solid state, heat transfer behaviour, fluidity of the melt, the corrosive nature of the melt, and the number and type of liquid-to-solid and solid-state transformations that may occur. This chapter provides the metallurgical background necessary for understanding microstructural evolution of various metals and alloys during DSC. There is a particular emphasis on iron, aluminium, magnesium, copper and titanium alloys as these are the major candidates for large-scale production by this processing route.

1.2 Metallurgy of ferrous alloys

Chapter 3 provides a brief overview of the evolution of DSC for various alloy systems, including the rapid increase in popularity since the 1980's for DSC of iron alloys. Before discussing the as-cast structure of iron alloys produced by this casting route, it is important to outline some important metallurgical characteristics of these engineering materials. A large number...

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Ingots and Casting Stock
Ingots and casting stock are metal and alloy product forms designed for foundry work, die casting, investment casting, and other metal casting applications.
Metal Castings and Cast Stock
Castings and cast stock are metals, alloys, polymers and other materials that are cast into bar, rod, angle, channel, tee, or other shapes.
Metal Casting Services
Metal casting involves the shaping of free-flowing liquid metals through the use of dies, molds or patterns.
Master Alloys and Alloying Additives
Master alloys and alloying additives are alloy element concentrates, grain refiners, hardeners, deoxidants and other agents added into a melt or metal powder blend to produce a particular alloy, modify a melt or alter processing characteristics.
Magnesium and Magnesium Alloys
Magnesium and magnesium alloys are nonferrous metals with low density, good ductility, moderate strength, and good corrosion resistance.

Topics of Interest

2.1 Introduction Solidification is the transformation of liquid into the solid crystalline state via the nucleation of the solid phase and its subsequent growth to consume the liquid. The...

4.6 Cast strip quality A major advantage of DSC lies in the reduction and/or elimination of the large number of secondary processing steps required to produce strip in an integrated mill. However,...

5.1 Introduction An important metallurgical challenge associated with the development of direct strip casting is the need to reassess our understanding of the relationship between microstructure and...

4.1 Introduction The previous chapter describes various continuous casting processes, the emergence of direct strip casting (DSC) and compares this and the other processes, with particular reference...

4.2 Overview of process control in strip casting Direct strip casting is a much simpler process than the more conventional continuous casting routes since a number of secondary processing stages are...