System and method of producing multi-layered alloy products

Abstract

System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.

What is claimed is: 
     
         1 . A method comprising:
 producing a first aluminum alloy having a horizontal upper surface;   producing a second aluminum alloy;   heating the second aluminum alloy to a first temperature to form a liquid second aluminum alloy, wherein the first temperature is at least 1° C. higher than the liquidus temperature of the second aluminum alloy;   delivering the liquid second aluminum alloy to the horizontal upper surface of the first aluminum alloy while the first aluminum alloy is substantially stationary; and   contacting the liquid second aluminum alloy with the first aluminum alloy to form a first multi-layered aluminum alloy product.   
     
     
         2 . The method of  claim 1 , further comprising:
 applying a flux to the horizontal upper surface of the first aluminum alloy before the delivering step.   
     
     
         3 . The method of  claim 2 , wherein applying the flux comprises brushing a salt-based compound onto the horizontal upper surface of the first aluminum alloy. 
     
     
         4 . The method of  claim 1 , wherein the producing the first aluminum alloy comprises one of the following techniques:
 direct chill ingot casting, permanent mold casting, slab casting, plate casting, and melting and alloying.   
     
     
         5 . The method of  claim 1 , wherein the producing the second aluminum alloy comprises one of the following techniques:
 direct chill ingot casting, permanent mold casting, slab casting, plate casting, and melting and alloying.   
     
     
         6 . The method of  claim 1 , wherein the first temperature is at least 5° C. higher than the liquidus temperature of the second aluminum alloy. 
     
     
         7 . The method of  claim 6 , wherein the first temperature is at least 10° C. higher than the liquidus temperature of the second aluminum alloy. 
     
     
         8 . The method of  claim 7 , wherein the first temperature is at least 200° C. higher than the liquidus temperature of the second aluminum alloy. 
     
     
         9 . The method of  claim 1 , further comprising:
 scalping the first aluminum alloy.   
     
     
         10 . The method of  claim 1 , wherein the producing the second aluminum alloy comprises one of the following techniques:
 melting and alloying.   
     
     
         11 . The method of  claim 1 , further comprising:
 producing a third aluminum alloy;   heating the third aluminum alloy to a second temperature to form a liquid third aluminum alloy, wherein the second temperature is at least 1° C. higher than the liquidus temperature of the third aluminum alloy; and   delivering the liquid third aluminum alloy to the horizontal upper surface of the first multi-layered aluminum alloy product while the first multi-layered aluminum alloy product is substantially stationary; and   contacting the liquid third aluminum alloy with the first multi-layered aluminum alloy product to form a second multi-layered aluminum alloy product.   
     
     
         12 . The method of  claim 11 , wherein the second temperature is at least 5° C. higher than the liquidus temperature of the third aluminum alloy. 
     
     
         13 . The method of  claim 12 , wherein the second temperature is at least 10° C. higher than the liquidus temperature of the third aluminum alloy. 
     
     
         14 . The method of  claim 11 , further comprising:
 scalping the first aluminum alloy.   
     
     
         15 . The method of  claim 11 , wherein the producing the second aluminum alloy comprises one of the following techniques:
 melting and alloying.