In-line method of making T or O temper aluminum alloy sheets

Abstract

A method of making aluminum alloy sheet in a continuous in-line process is provided. A continuously-cast aluminum alloy strip is optionally quenched, hot or warm rolled, annealed or heat-treated in-line, optionally quenched, and preferably coiled, with additional hot, warm or cold rolling steps as needed to reach the desired gauge. The process can be used to make aluminum alloy sheet of T or O temper having the desired properties, in a much shorter processing time. The T or O temper may be selected by annealing the strip to achieve an O temper or solution heat treating the strip to achieve a T temper, and, if a T temper is desired, quenching the strip subsequent to the solution heat treating. The invention further provides a hot or warm rolling step wherein the strip is substantially reduces to a final thickness about 10-65% from a casting thickness.

1 . A method of manufacturing T or O temper aluminum alloy sheet in an in-line sequence comprising the steps of: 
 (i) providing a thin cast aluminum alloy strip having a first thickness;    (ii) quenching the strip with a first quench to a hot or warm rolling temperature;    (iii) hot or warm rolling the strip to a final thickness that is about 10-65% reduced from the first thickness;    (iv) selectively proceeding according to a first set of criteria depending on whether a T or O temper is desired, and    (v) quenching the strip with a second quench if a T temper is desired.    
     
     
         2 . The method of  claim 1 , wherein the first set of criteria comprises solution heat treating for a T temper.  
     
     
         3 . The method of  claim 1 , wherein the first set of criteria comprises annealing the strip for an O temper.  
     
     
         4 . The method of  claim 1 , further comprising the step of quenching the strip with the second quench if an O temper is desired.  
     
     
         5 . The method of  claim 1 , further comprising the step of not quenching the strip with the second quench if an O temper is desired.  
     
     
         6 . The method of  claim 1 , wherein the second quench quenches the strip to a temperature in the range of about 110° to 200° F. to achieve a T4 temper.  
     
     
         7 . The method of  claim 1 , wherein the second quench quenches the strip to a temperature in the range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         8 . The method of  claim 1 , wherein the second quench quenches the strip to a temperature in the range of about 110° to 200° F. and reheated to a temperature range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         9 . The method of  claim 1 , wherein the second quench is an air quench.  
     
     
         10 . The method of  claim 1 , wherein the second quench is a combination air and water quench.  
     
     
         11 . The method of  claim 1 , wherein the aluminum alloy includes manganese up to 0.25 weight percent.  
     
     
         12 . The method of  claim 1 , wherein the strip as cast from the caster has a first thickness in a range of about 0.06-0.15 inches.  
     
     
         13 . The method of  claim 1 , wherein the strip after the hot or warm rolling step has a final thickness in a range of about 0.02-0.13 inches.  
     
     
         14 . The method of  claim 1 , further including the step of tension leveling the strip after step (v).  
     
     
         15 . The method of  claim 1 , further including the step of coiling the strip after step (v).  
     
     
         16 . The method of  claim 1 , wherein a total time for the method to be performed is between the range of about 10 and 50 seconds.  
     
     
         17 . The method of  claim 1 , wherein the aluminum strip after step (v) is characterized by sufficient strength to permit tension to be applied to the strip.  
     
     
         18 . A method of manufacturing T or O temper aluminum alloy sheet in an in-line sequence comprising the steps of: 
 (i) providing a thin cast aluminum alloy strip having a first thickness;    (ii) hot or warm rolling the strip to a final thickness that is about 10-65% reduced from the first thickness of the strip as cast;    (iii) selectively proceeding according to a first set of criteria depending whether a T or O temper is desired, and    (iv) quenching the strip with a quench if a T temper is desired    
     
     
         19 . The method of  claim 18 , wherein the first set of criteria comprises solution heat treating for a T temper.  
     
     
         20 . The method of  claim 18 , wherein the first set of criteria comprises annealing the strip for an O temper.  
     
     
         21 . The method of  claim 18 , further comprising the step of quenching the strip if an O temper is desired.  
     
     
         22 . The method of  claim 18 , further comprising the step of not quenching the strip if an O temper is desired.  
     
     
         23 . The method of  claim 18 , wherein the quench quenches the strip to a temperature range of about 110° to 200° F. to achieve a T4 temper.  
     
     
         23 . The method of  claim 18 , wherein quench quenches the strip to a temperature range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         23 . The method of  claim 18 , wherein the quench quenches strip to a temperature range of about 110° to 200° F. and reheated to a temperature range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         23 . The method of  claim 18 , wherein the quench is an air quench.  
     
     
         23 . The method of  claim 18 , wherein the quench is a combination air and water quench.  
     
     
         24 . The method of  claim 18 , wherein the aluminum alloy includes manganese up to 0.25 weight percent.  
     
     
         25 . The method of  claim 18 , wherein the strip as cast from the caster has a thickness in a range of about 0.06-0.15 inches.  
     
     
         26 . The method of  claim 18 , wherein the strip after the hot or warm rolling step has a thickness in a range of about 0.02-0.13 inches.  
     
     
         27 . The method of  claim 18 , further including the step of tension leveling the strip after step (iv).  
     
     
         28 . The method of  claim 18 , further including the step of coiling the strip after step (iv).  
     
     
         29 . The method of  claim 18 , wherein a total time for the method to be performed is between the range of about 10 and 50 seconds.  
     
     
         30 . The method of  claim 18 , wherein the aluminum strip after step (v) is characterized by sufficient strength to permit tension to be applied to the strip.  
     
     
         31 . A method of manufacturing T or O temper aluminum alloy sheet in an in-line sequence comprising the steps of: 
 (i) providing a thin cast aluminum alloy strip having a first thickness, wherein the aluminum alloy includes up to 0.25 weight percent of manganese;    (ii) optionally quenching the strip with a first quench to a hot or warm rolling temperature;    (iii) hot or warm rolling the strip to a final thickness;    (iv) step of selectively proceeding according to a first set of criteria depending on whether a T or O is temper desired, and    (v) quenching the strip with a second quench if a T temper is desired.    
     
     
         32 . The method of  claim 31 , wherein the first set of criteria comprises solution heat treating for a T temper.  
     
     
         33 . The method of  claim 31 , wherein the first set of criteria comprises annealing the strip for an O temper.  
     
     
         34 . The method of  claim 31 , further comprising the step of quenching the strip with the second quench if an O temper is desired.  
     
     
         35 . The method of  claim 31 , further comprising the step of not quenching the strip with the second quench if an O temper is desired.  
     
     
         36 . The method of  claim 31 , wherein the second quench quenches the strip to a temperature range of about 110° to 200° F. to achieve a T4 temper.  
     
     
         37 . The method of  claim 31 , wherein the second quench quenches the strip to a temperature range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         38 . The method of  claim 31 , wherein the second quench quenches the strip to a temperature range of about 110° to 200° F. and reheated to a temperature range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         39 . The method of  claim 31 , wherein the second quench is an air quench.  
     
     
         40 . The method of  claim 31 , wherein the second quench is a combination air and water quench.  
     
     
         41 . The method of  claim 31 , wherein the strip as cast from the caster has a thickness in a range of about 0.06-0.15 inches.  
     
     
         42 . The method of  claim 31 , wherein the strip after the hot or warm rolling step has a thickness in a range of about 0.02-0.13 inches.  
     
     
         43 . The method of  claim 31 , further including the step of tension leveling the strip after step (v).  
     
     
         44 . The method of  claim 31 , further including the step of coiling the strip after step (v).  
     
     
         45 . The method of  claim 31 , wherein the strip has a first thickness after casting and a final thickness after the hot or warm rolling, the final thickness that is about 10-65% reduced from the first thickness.  
     
     
         46 . The method of  claim 31 , wherein a total time for the method to be performed is between the range of about 10 and 50 seconds.  
     
     
         47 . The method of  claim 31 , wherein the aluminum strip after step (v) is characterized by sufficient strength to permit tension to be applied to the strip.  
     
     
         48 . A method of manufacturing auto body parts made from T or O temper aluminum alloy sheet comprising the steps of: 
 (i) providing a thin cast aluminum alloy strip having a first thickness;    (ii) optionally quenching the strip with a first quench to a hot or warm rolling temperature;    (iii) hot or warm rolling the strip to a final thickness that is about 10-65% reduced from the first thickness;    (iv) selectively proceeding according to a first set of criteria depending on whether a T or O temper is desired,    (v) quenching the strip with a second quench if a T temper is desired, and    (vi) forming the T or O tempers into auto body panels or reinforcements.    
     
     
         49 . The method of  claim 48 , wherein the first set of criteria comprises solution heat treating for a T temper.  
     
     
         50 . The method of  claim 48 , wherein the first set of criteria comprises annealing the strip for an O temper.  
     
     
         51 . The method of  claim 48 , further comprising the step of quenching the strip with the second quench if an O temper is desired.  
     
     
         52 . The method of  claim 48 , further comprising the step of not quenching the strip with the second quench if an O temper is desired.  
     
     
         53 . The method of  claim 48 , wherein the second quench quenches the strip to a temperature in the range of about 110° to 200° F. to achieve a T4 temper.  
     
     
         54 . The method of  claim 48 , wherein the second quench quenches the strip to a temperature in the range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         55 . The method of  claim 48 , wherein the second quench quenches the strip to a temperature in the range of about 110° to 200° F. and reheated to a temperature range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         56 . The method of  claim 48 , wherein the aluminum alloy includes manganese up to 0.25 weight percent.  
     
     
         57 . The method of  claim 48 , wherein the strip as cast from the caster has a first thickness in a range of about 0.06-0.15 inches.  
     
     
         58 . The method of  claim 48 , wherein the strip after the hot or warm rolling step has a final thickness in a range of about 0.02-0.13 inches.  
     
     
         59 . The method of  claim 48 , further including the step of tension leveling the strip after step (v).  
     
     
         60 . The method of  claim 48 , further including the step of coiling the strip after step (v).  
     
     
         61 . The method of  claim 48 , wherein a total time for the method to be performed is between the range of about 10 and 50 seconds.  
     
     
         62 . The method of  claim 48 , wherein the aluminum strip after step (v) is characterized by sufficient strength to permit tension to be applied to the strip.  
     
     
         63 . A method of manufacturing T or O temper aluminum alloy sheet without cold rolling in an in-line sequence comprising the steps of: 
 (i) providing a thin cast aluminum alloy strip having a first thickness;    (ii) optionally quenching the strip with a first quench to a hot or warm rolling temperature;    (iii) hot or warm rolling the strip to a final thickness;    (iv) selectively proceeding according to a first set of criteria depending on a whether a T or O temper is desired,    (v) quenching the strip with a second quench if a T temper is desired, and    (vi) coiling the temper without cold rolling prior to the coiling.    
     
     
         64 . The method of  claim 63 , wherein the first set of criteria comprises solution heat treating for a T temper.  
     
     
         65 . The method of  claim 63 , wherein the first set of criteria comprises annealing the strip for an O temper.  
     
     
         66 . The method of  claim 63 , further comprising the step of quenching the strip with the second quench if an O temper is desired.  
     
     
         67 . The method of  claim 63 , further comprising the step of not quenching the strip with the second quench if an O temper is desired.  
     
     
         68 . The method of  claim 63 , wherein the second quench quenches the strip to a temperature in the range of about 110° to 200° F. to achieve a T4 temper.  
     
     
         69 . The method of  claim 63 , wherein the second quench quenches the strip to a temperature in the range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         70 . The method of  claim 63 , wherein the second quench quenches the strip to a temperature in the range of about 110° to 200° F. and reheated to a temperature range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         71 . The method of  claim 63 , wherein the strip has a first thickness after casting and a final thickness after the hot or warm rolling, the final thickness that is about 10-65% reduced from the first thickness.  
     
     
         72 . The method of  claim 63 , wherein a total time for the method to be performed is between the range of about 10 and 50 seconds.  
     
     
         73 . The method of  claim 63 , wherein the aluminum strip after step (v) is characterized by sufficient strength to permit tension to be applied to the strip.  
     
     
         74 . A method of manufacturing T or O temper aluminum alloy sheet in an in-line sequence comprising the steps of: 
 (i) providing a thin cast aluminum alloy strip having a first thickness;    (ii) optionally quenching the strip with a first quench to a hot or warm rolling temperature;    (iii) hot or warm rolling the strip to a thickness in at least one hot or warm rolling station to a final thickness that is about 10-65% reduced from the first thickness;    (iv) selectively proceeding according to a first set of criteria depending on whether a T or O temper is desired, and    (v) quenching the strip with a second quench if a T temper is desired.    
     
     
         75 . The method of  claim 74 , wherein the first set of criteria comprises solution heat treating for a T temper.  
     
     
         76 . The method of  claim 74 , wherein the first set of criteria comprises annealing the strip for an O temper.  
     
     
         77 . The method of  claim 74 , further comprising the step of quenching the strip with the second quench if an O temper is desired.  
     
     
         78 . The method of  claim 74 , further comprising the step of not quenching the strip with the second quench if an O temper is desired.  
     
     
         79 . The method of  claim 74 , wherein the second quench quenches the strip to a temperature in the range of about 110° to 200° F. to achieve a T4 temper.  
     
     
         80 . The method of  claim 1 , wherein the second quench quenches the strip to a temperature in the range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         81 . The method of  claim 74 , wherein the second quench quenches the strip to a temperature in the range of about 110° to 200° F. and reheated to a temperature range of about 250° F. to 350° F. to achieve a T6 temper.  
     
     
         82 . The method of  claim 74 , wherein a total time for the method to be performed is between the range of about 10 and 50 seconds.  
     
     
         83 . The method of  claim 74 , wherein the aluminum strip after step (v) is characterized by sufficient strength to permit tension to be applied to the strip.