Simultaneous multi-alloy casting
View Patent ↗A method of casting a multi-layered metal ingot including the steps of delivering a metallic divider member into a direct chill mold, pouring a first molten metal into the mold on one side of the divider member, and pouring a second molten metal into the mold on the other side of the divider member, and allowing the first molten metal and the second molten metal solidify to form a metal ingot which includes the divider metal layer disposed there between.
1. A multi-layered rolled aluminum product comprising:
(i) at least two distinct aluminum layers, wherein a first distinct aluminum layer has a different composition than a second distinct aluminum layer;
(ii) wherein the multi-layered rolled aluminum product is made by a process comprising:
(A) direct chill casting a multi-layered slab, the direct chill casting process comprising:
(1) flowing a first molten aluminum alloy in a direct chill casting apparatus;
(2) providing an aluminum barrier layer;
(3) flowing a second molten aluminum alloy into a direct chill casting apparatus,
(4) wherein the second molten aluminum alloy has a different composition than the first molten aluminum alloy,
(5) wherein the aluminum barrier layer prevents the first molten aluminum alloy from intermixing with the second molten aluminum alloy;
(6) forming the first distinct aluminum layer from the first molten aluminum alloy; and
(7) forming the second distinct aluminum layer from the second molten aluminum alloy; and
(B) rolling the multi-layered slab to form the multi-layered rolled aluminum product.
2. The product of claim 1 , wherein the aluminum barrier layer comprises the same composition as the first molten aluminum alloy.
3. The product of claim 2 , wherein the providing step comprises establishing the aluminum barrier layer, and wherein the direct chill casting processes comprises minimally melting the aluminum barrier layer.
4. The product of claim 3 , wherein the minimally melting step comprises destabilizing oxides of the aluminum barrier layer.
5. The product of claim 3 , wherein the aluminum barrier layer is a first aluminum barrier layer, wherein the direct chill casting comprises:
flowing a third molten aluminum alloy into the direct chill casting apparatus;
providing a second aluminum barrier layer; and
forming a third distinct aluminum layer;
wherein the second aluminum barrier layer prevents the third molten aluminum alloy from intermixing with at least one of the first and second molten aluminum alloys, and wherein the multi-layered slab includes the first, second and third distinct aluminum layers.
6. The product of claim 5 , wherein the second aluminum barrier layer comprises the same composition as at least one of the first and second molten aluminum alloys.
7. The product of claim 6 , wherein the second aluminum barrier layer comprises the same composition as the first aluminum barrier layer.
8. The product of claim 5 , wherein the second aluminum barrier layer comprises a different composition than the first aluminum barrier layer.
9. The product of claim 5 , wherein the third molten aluminum alloy has a different composition than at least one of the first and second molten aluminum alloys.
10. The product of claim 9 , wherein the third distinct aluminum layer has a different composition than at least one of the first and second distinct aluminum layers.
11. The product of claim 5 , wherein the third molten aluminum alloy has the same composition as at least one of the first and second molten aluminum alloys.
12. The product of claim 11 , wherein the third distinct aluminum layer has the same composition as at least one of the first and second distinct aluminum layers.
13. The product of claim 3 , wherein the multi-layered rolled aluminum product is brazing sheet.
14. The product of claim 13 , wherein the brazing sheet is included in a heat exchanger.
15. The product of claim 3 , wherein the multi-layered rolled aluminum product is included in an architectural product.
16. The product of claim 3 , wherein the multi-layered rolled aluminum product is a reflector sheet.
17. The product of claim 3 , further comprising:
anodizing the multi-layered rolled aluminum product to form an anodized multi-layered rolled aluminum product.