Work

Effect of In Situ Al Roll Coating on Strip Surface Quality in Traditional Twin-Roll Casting of Aluminum Alloys

Year: 2025

Type: article

Abstract: The twin-roll casting (TRC) process is widely used in the aluminum industry due to its cost efficiency and continuous production capability. However, maintaining consistently high surface quality remains challenging due to complex heat transfer behavior at the roll/strip interface. This study examines the critical influence of roll surface conditions, especially the formation of an Al coating layer, on solidification behavior and resulting strip quality in the TRC of an Al-5Mg alloy. Experimental results demonstrated that casting without an Al coating layer led to surface defects such as hot tears and porosity due to insufficient cooling. In contrast, strips produced with a stable Al coating layer exhibited excellent surface quality with no surface defects. Numerical simulations further indicated that a stable Al coating enhanced the interfacial heat transfer coefficient (up to 30,000 W/m2K), ensuring effective cooling and complete solidification before the strip exited the roll nip. Moreover, simulations validated the feasibility of using steel rolls in industrial applications, provided the coating layer was consistently maintained. This research highlights the significance of roll surface control in improving TRC product quality.

Source: Metals

DOI: 10.3390/met15040377

Authors: Han-Gyoung Cho, Young Do Kim, Min-Seok Kim

Institution: Hanyang University

Language: English

Topic: Metallurgical Processes and Thermodynamics

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $3,137

Funder: Ministry of Trade, Industry and Energy