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Rolling Aluminum Rolling Aluminum: From the Mine Through the Mill ACKNOWLEDGEMENTS This manual has been prepared with information and assistance from The Aluminum Association and member companies represented on the Sheet and Plate Division’s Technology Committee. SHEET & PLATE DIVISION MEMBER COMPANIES Alcoa Inc. JW Aluminum Aleris Rolled Products Kaiser Aluminum and ALSCO Metals Corp. Chemical Corporation AMAG Rolling GmbH Koenig & Vits, Inc. ARCO Aluminum, Inc. Logan Aluminum, Inc. Golden Aluminm Nichols Aluminum Gulf Aluminium Rolling Novelis Inc. Mill Co. Rio Tinto Alcan Impol Aluminum Corp. United Aluminum Corporation Jupiter Aluminum Corporation Wise Metals Group USE OF INFORMATION The use of any information contained herein by any member or non-member of The Aluminum Association is entirely voluntary. The Aluminum Association has used its best efforts in compiling the information contained in this book. While the Association believes that its compilation procedures are reliable, it does not warrant, either expressly or implied, the accuracy or completeness of this information. The Aluminum Association assumes no responsibility or liability for the use of the information herein. All Aluminum Association published standards, data, specifications and other technical materials are reviewed and revised, reaffirmed or withdrawn on a periodic basis. Users are advised to contact The Aluminum Association to ascertain whether the information in this publication has been superseded in the interim between publication and proposed use. The Aluminum Association, Inc. 1525 Wilson Blvd. Suite 600 Arlington, VA 22209 www.aluminum.org © Copyright 2008. Unauthorized reproduction by photocopy or any other method is illegal. First Printing June 1990 Third Edition December 2007 Rolling Aluminum: From the Mine Through the Mill HOW TO USE THIS PUBLICATION his publication enlarges upon the information presented in The Aluminum Association DVD “Rolling Aluminum: From the Mine Through the Mill”. TThe expanded explanations of various aspects of aluminum production and rolling appear where they are mentioned in the DVD. The user who wants to learn the general features of aluminum production and rolling will find them summarized in the DVD and the early paragraphs of each section of the manual and in its Self-Test Questions and Answers. For readers who want to understand these subjects more thoroughly, the full text of the manual provides more detailed explanations. The manual may also be used as a ready-reference, by consulting its subheaded Table of Contents and / or alphabetical index. Metric values of the US customary units in the manual have been included for the convenience of the reader and are not intended as precise arithmetic conversions. Where the products ( foil / sheet / plate) are defined by their thickness range, the actual metric gauge definition has also been included for reference. Finally, the loose-leaf format permits the easy insertion of product information, additional notes or future informational updates. ABOUT THE ALUMINUM ASSOCIATION he Aluminum Association is an industry-wide trade organization representing US and foreign producers of aluminum, leading manufacturers of semi-fabricated aluminum pTroducts, secondary smelters and suppliers to the aluminum industry. The Association’s aims are to increase public and industrial understanding of alu - minum and the aluminum industry and — through its technical, statistical, marketing and information activities — to serve industries, consumers, financial analysts, educa - tors, government agencies and the public generally. For the aluminum industry and those industries that use aluminum, The Association helps develop standards and designation systems, helps prepare codes and specifica - tions involving aluminum products and studies technical problems of the industry. The Association maintains and periodically issues industry-wide statistics and records which are used as an authoritative source. Association members also join together on a number of commodity and end-market committees to conduct industry-wide market development programs. Rolling Aluminum: From the Mine through the Mill CONTENTS Section-Page INTRODUCTION Advantages of Aluminum . 1-1 1 Flat-Rolled Aluminum . 1-2 Aluminum Sheet Applications . 1-2 Aluminum Plate Applications . 1-2 Aluminum Foil Applications . 1-2 Specialty Products . 1-2 Definitions: Plate, Sheet, Foil . 1-4 Rolling Aluminum: General Description . 1-4 Technological Advances . 1-5 Self-Test Questions . 1-7 PRODUCTION OF ALUMINUM AND ITS ALLOYS Bauxite Mining . 2-1 2 Alumina Refining . 2-1 Aluminum Reduction: The Hall-Heroult Process . 2-2 Alloying . 2-5 Aluminum Alloy Series . 2-5 Heat-Treatable Alloys . 2-6 Non- Heat-Treatable Alloys . 2-6 Recycled Aluminum Scrap . 2-7 Addition of Alloying Elements . 2-7 Self-Test Questions . 2-9 PREPARATION OF ALUMINUM ALLOYS FOR ROLLING Metal Cleaning: Fluxing and Filtration . 3-1 3 Fluxing . 3-1 Alloy Sample Analysis . 3-1 Filtration . 3-2 Additives . 3-3 Continuous Casting of Sheet or Plate . 3-3 DC Ingot Casting . 3-6 Electromagnetic Casting (EMC ) . 3-7 Scalping . 3-7 Pre-Heating . 3-8 Purposes of Pre-Heating . 3-8 Pre-Heating Methods . 3-8 Self-Test Questions . 3-9 CONTENTS 6 THE ALUMINUM ROLLING MILL Description and Features . 4-1 4 Single-Stand and Tandem Mills . 4-3 Mill Rolls . 4-3 Roll Configurations . 4-4 Hot or Cold Rolling . 4-6 Hot Rolling : Metallurgical Effects . 4-7 Cold Rolling: Metallurgical Effects . 4-7 Self-Test Questions . 4-9 SHEET ROLLING OPERATIONS Breakdown Mill Parameters . 5-1 5 Breakdown Coolant /Lubricant Applications . 5-2 Breakdown Rolling . 5-3 Intermediate Hot Rolling . 5-3 Sheet Hot Rolling : The Tandem Mill . 5-4 Coiling and Edge Trimming . 5-5 Annealing . 5-6 Purposes of Annealing . 5-6 Full Annealing . 5-6 Partial Annealing . 5-7 Stabilization Annealing . 5-7 Annealing Methods . 5-7 Batch Annealing /Treatment . 5-7 Sheet Annealing /Treatment . 5-7 Cold Rolling . 5-8 Gauge and Profile Control . 5-8 Texturing and Embossing . 5-10 Self-Test Questions . 5-11 SHEET FINISHING Solution Heat Treating . 6-1 6 Metallurgical Function of Solution Heat Treating . 6-1 Solution Heat Treatment : “Soaking” . 6-2 Quenching . 6-2 Natural Aging (Precipitation Hardening ) . 6-3 Artificial Aging (Precipitation Heat Treatment) . 6-3 Slitting . ..
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