Metal products having improved surface properties and methods of making the same

Abstract

Provided herein are continuously cast aluminum alloy products exhibiting uniform surface characteristics. The aluminum alloy products have a first surface comprising a width, wherein the first surface comprises an average of 50 exudates or less per square centimeter across the width of the first surface. Also provided herein are methods of making aluminum alloy products having improved surface characteristics. Further provided are methods and systems for manufacturing aluminum alloy products, such as sheets, having reduced surface defects.

What is claimed is: 
     
         1 . An aluminum alloy product, comprising:
 a first surface comprising a width, wherein the first surface comprises an average of 50 exudates or less per square centimeter (cm 2 ) across the width of the first surface,   wherein the exudates comprise a plurality of intermetallic particles.   
     
     
         2 . The aluminum alloy product of  claim 1 , wherein the exudates have an average diameter of from about 50 μm to about 300 μm. 
     
     
         3 . The aluminum alloy product of  claim 1 , wherein the exudates extend from the first surface into an interior of the aluminum alloy product to a depth of about 10 μm to about 100 μm. 
     
     
         4 . The aluminum alloy product of  claim 1 , wherein the exudates comprise a plurality of iron-containing intermetallic particles. 
     
     
         5 . The aluminum alloy product of  claim 1 , wherein the aluminum alloy product comprises a 1xxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or an 8xxx series aluminum alloy. 
     
     
         6 . The aluminum alloy product of  claim 1 , further comprising meniscus oscillation marks. 
     
     
         7 . The aluminum alloy product of  claim 6 , wherein an average spacing between the meniscus oscillation marks in the aluminum alloy product is about 1.4 mm or less. 
     
     
         8 . A continuous casting system, comprising:
 a pair of moving opposed casting surfaces;   a casting cavity between the pair of moving opposed casting surfaces; and   a molten metal injector having a molten metal injector nozzle,   wherein a top or bottom surface of the molten metal injector nozzle has a distal most end that is positioned at a vertical distance above at least one moving casting surface of the pair of moving opposed casting surfaces.   
     
     
         9 . The continuous casting system of  claim 8 , wherein the vertical distance between the distal most end of the molten metal injector nozzle and the at least one moving casting surface is about 1.4 mm or less. 
     
     
         10 . The continuous casting system of  claim 8 , wherein the pair of moving opposed casting surfaces is a pair of moving opposed belts.