System and method of producing multi-layered alloy products

1. A method comprising:

producing a first aluminum alloy having a horizontal upper surface;

heating the first aluminum alloy to a first temperature to form a heated first aluminum alloy, wherein the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy;

producing a liquid second aluminum alloy;

heating the liquid second aluminum alloy to a second temperature wherein the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy; and

contacting the liquid second aluminum alloy with the horizontal upper surface of the heated first aluminum alloy thereby producing a first multi-layered aluminum alloy product, wherein the heating the first aluminum alloy step occurs before the contacting step.

2. The method of claim 1 , wherein the heating steps occur concomitantly.

3. The method of claim 1 , further comprising:

scalping the first aluminum alloy before heating the first aluminum alloy.

4. The method of claim 1 , further comprising:

applying a flux to the horizontal upper surface of the first aluminum alloy before the contacting step.

5. The method of claim 4 , wherein applying the flux comprises brushing a salt-based compound onto the horizontal upper surface of the first aluminum alloy.

6. 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 and plate casting.

7. The method of claim 1 , wherein the producing the second aluminum alloy comprises one of the following techniques:

melting and alloying.

8. The method of claim 1 , wherein the contacting step comprises:

moving the heated first aluminum alloy in a first direction;

positioning the liquid second aluminum alloy substantially adjacent to the heated first aluminum alloy; and

delivering the liquid second aluminum alloy over the horizontal upper surface of the heated first aluminum alloy.

9. The method of claim 1 , further comprising:

heating the first multi-layered aluminum alloy product to a third temperature, wherein the third temperature is at least about 1° C. lower than the lesser of the eutectic temperatures of the first and second aluminum alloys;

producing a third aluminum alloy;

heating the third aluminum alloy to a fourth temperature, wherein the fourth temperature is at least about 5° C. higher than the liquidus temperature of the third aluminum alloy; and

contacting the third aluminum alloy with the first multi-layered aluminum alloy product thereby producing a second multi-layered aluminum alloy product.

10. The method of claim 9 , wherein the heating the first multi-layered aluminum alloy product step, the heating the third aluminum alloy step, and the contacting the third aluminum alloy step occur concomitantly.

11. The method of claim 9 , wherein the heating the first multi-layered aluminum alloy product step is concomitant to the heating the third aluminum alloy step.

12. The method of claim 11 , wherein the contacting the third aluminum alloy step is concomitant to at least one of the heating the first multi-layered aluminum alloy product step and the heating the third aluminum alloy step.

13. A method comprising:

producing a first aluminum alloy having a horizontal upper surface;

heating the first aluminum alloy to a first temperature to form a heated first aluminum alloy, wherein the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy;

producing a second aluminum alloy;

heating the second aluminum alloy to a second temperature, wherein the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy; and

contacting the liquid second aluminum alloy with the horizontal upper surface of the heated first aluminum alloy thereby producing a first multi-layered aluminum alloy product, wherein the heating the first aluminum alloy step occurs before the contacting step.

14. The method of claim 13 , wherein the heating steps occur concomitantly.

15. The method of claim 13 , further comprising:

scalping the first aluminum alloy before heating the first aluminum alloy.

16. The method of claim 13 , further comprising:

applying a flux to the horizontal upper surface of the first aluminum alloy before the contacting step.

17. The method of claim 16 , wherein applying the flux comprises brushing a salt-based compound onto the horizontal upper surface of the first aluminum alloy.

18. The method of claim 13 , wherein the producing the first aluminum alloy comprises one of the following techniques:

direct chill ingot casting, permanent mold casting, slab casting and plate casting.

19. The method of claim 13 , wherein the producing the second aluminum alloy comprises one of the following techniques:

melting and alloying.

20. The method of claim 13 , wherein the contacting step comprises:

moving the heated first aluminum alloy in a first direction;

positioning the second aluminum alloy substantially adjacent to the heated first aluminum alloy; and

delivering the second aluminum alloy over the horizontal upper surface of the heated first aluminum alloy.

21. A method comprising:

producing a first aluminum alloy having a horizontal surface;

heating the first aluminum alloy to a first temperature to form a heated first aluminum alloy, wherein the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy;

producing a liquid second aluminum alloy;

heating the liquid second aluminum alloy to a second temperature, wherein the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy; and

contacting the liquid second aluminum alloy with the horizontal surface of the heated first aluminum alloy thereby producing a first multi-layered aluminum alloy product, wherein the heating the first aluminum alloy step occurs before the contacting step.