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Study of the corrosion behaviour of Twin Roll cast AA3XXX and AA8XXX series material

Book - Dissertation

The production of aluminium foil products is typically done by means of Direct
Chill (DC) casting. However, this casting technique requires the need for
expensive hot rolling facilities, to ensure a proper reduction in thickness of the
foil products. Therefore, an alternative technique, which does not require the
need for such expensive hot rolling facilities, became of significant interest for
the aluminium industry. This casting technique is known as Twin Roll casting
(TRC), and has several other advantages to the conventional DC casting,
besides the lack of need for hot rolling facilities. Some of these advantages are:
lower emission of green house gasses, due to lower energy requirements, and
reduced spatial requirements for the casting facilities.
The Twin Roll casting process is a unique casting technique that produces a
material quite different from conventional DC cast material. In general, TRC
material has a more refined microstructure, with finer intermetallic particles,
and a higher degree of supersaturation of alloying elements in the matrix.
Additionally, due to the unique casting method a centre line segregation is
often present inside the TRC materials, and this is a main concern in terms of
corrosion, especially for heat exchanger applications where the materials’ cross-
sections are exposed. In this work the focus will lie on the Twin Roll cast AA3xxx
and AA8xxx series. These AA3xxx and AA8xxx series are typically used in
applications that require good corrosion properties, like for instance in heat
exchangers used in the automotive industry, and in food containers in the food
packaging industry. Therefore, the focus of this work will be on the study of this
unique microstructure and the effect it has on the corrosion behaviour. This
work will provide a better understanding of the evolution of the microstructure
and corrosion behaviour along the different steps of production. Furthermore, in
this work possible adaptions to the chemical composition of the alloys, with the
aim to improve their corrosion behaviour, will be investigated.
Publication year:2021