Twin roll casting of Al-Mg alloy with high added impurity content

Abstract

The microstructural evolution during twin roll casting (TRC) and downstream processing of AA5754 Al alloy with high added impurity content have been investigated. Strip casts with a high impurity content resulted in coarse α-Al grains and complex secondary phases. The grain size and centreline segregation reduced significantly on the addition of Al-Ti-B grain refiner (GR). Coarse-dendrite arm spacing (DAS) “floating” grains are observed in the impure alloy (IA) with higher volume in the GR strips. Two dimensional (2D) metallographic analysis of the as-cast strip suggests secondary phases (Fe bearing intermetallics and Mg2Si) are discrete and located at the α-Al cell/grain boundaries, while three dimensional (3D) analysis of extracted particles revealed that they were intact, well interconnected and located in interdendritic regions. Homogenizing heat treatment of the cast strip breaks the interconnective networks and modifies the secondary phases to more equiaxed morphology. During rolling, the eqiaxed secondary phases align along the rolling direction. X-ray diffraction (XRD) analysis suggests that α-Al(FeMn)Si and Mg2Si are the predominant secondary phases that formed during casting and remain throughout the downstream processing of the GR-IA. The high impurity sheet processed from TRC resulted in superior strength and ductility than the sheet processed from small book mould ingot casting. This study, have shown that the twin roll casting process can tolerate higher impurity levels and produce formable sheets from recycled aluminium for structural applications.