Table of Contents
Journal of Metallurgy
Volume 2016 (2016), Article ID 1038950, 13 pages
http://dx.doi.org/10.1155/2016/1038950
Review Article

Review on Vertical Twin-Roll Strip Casting: A Key Technology for Quality Strips

Department of Mechanical Engineering, Institute of Technical Education and Research, Siksha ‘O’ Anusandhan University, Khandagiri Square, Bhubaneswar 751030, India

Received 21 March 2016; Revised 21 June 2016; Accepted 11 July 2016

Academic Editor: Menahem Bamberger

Copyright © 2016 Seshadev Sahoo. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Linked References

  1. R. Wechsler, “The status of twin-roll casting technology,” Scandinavian Journal of Metallurgy, vol. 32, no. 1, pp. 58–63, 2003. View at Google Scholar
  2. N. Zapuskalov, “Comparison of continuous strip casting with conventional technology,” ISIJ International, vol. 43, no. 8, pp. 1115–1127, 2003. View at Publisher · View at Google Scholar · View at Scopus
  3. C. Gras, M. Meredith, and J. D. Hunt, “Microdefects formation during the twin-roll casting of Al-Mg-Mn aluminium alloys,” Journal of Materials Processing Technology, vol. 167, no. 1, pp. 62–72, 2005. View at Publisher · View at Google Scholar · View at Scopus
  4. H. Bessemer, “Improvement in the manufacture of iron and steel,” U.S. Patent No. 49053, 1865.
  5. K. Shibuya and M. Ozawa, “Strip casting techniques for steel,” ISIJ International, vol. 31, no. 7, pp. 661–668, 1991. View at Publisher · View at Google Scholar · View at Scopus
  6. A. L. Robson and G. L. Thompson, “Direct casting of thin strip,” Materials World, vol. 3, no. 5, pp. 222–224, 1995. View at Google Scholar
  7. D.-K. Choo, S. Lee, H.-K. Moon, and T. Kang, “Analysis and prevention of cracking during strip casting of AISI 304 stainless steel,” Metallurgical and Materials Transactions A, vol. 32, no. 9, pp. 2249–2258, 2001. View at Publisher · View at Google Scholar · View at Scopus
  8. M. Ha, J. Choi, S. Jeong, H. Moon, S. Lee, and T. Kang, “Analysis and prevention of microcracking phenomenon occurring during strip casting of an AISI 304 stainless steel,” Metallurgical and Materials Transactions A, vol. 33, no. 5, pp. 1487–1497, 2002. View at Publisher · View at Google Scholar · View at Scopus
  9. M. Toshirou, N. Katsumi, F. Hisahiko, and O. Shirou, “Development and commercialization of twin roll strip caster,” IHI Engineering Review, vol. 42, no. 1, pp. 1–9, 2009. View at Google Scholar
  10. J. Zeng, R. Koitzsch, H. Pfeifer, and B. Friedrich, “Numerical simulation of the twin-roll casting process of magnesium alloy strip,” Journal of Materials Processing Technology, vol. 209, no. 5, pp. 2321–2328, 2009. View at Publisher · View at Google Scholar · View at Scopus
  11. T. Haga, K. Takahashi, M. Ikawa, and H. Watari, “A vertical-type twin roll caster for aluminum alloy strips,” Journal of Materials Processing Technology, vol. 140, no. 1–3, pp. 610–615, 2003. View at Publisher · View at Google Scholar · View at Scopus
  12. R. P. Tavares and R. I. L. Guthrie, “Computational fluid dynamics applied to twin-roll casting,” Canadian Metallurgical Quarterly, vol. 37, no. 3-4, pp. 241–250, 1998. View at Publisher · View at Google Scholar · View at Scopus
  13. T. Haga and S. Suzuki, “Study on high-speed twin-roll caster for aluminum alloys,” Journal of Materials Processing Technology, vol. 143-144, no. 1, pp. 895–900, 2003. View at Publisher · View at Google Scholar · View at Scopus
  14. J. G. Lee, S. S. Park, S. B. Lee, H.-T. Chung, and N. J. Kim, “Sheet fabrication of bulk amorphous alloys by twin-roll strip casting,” Scripta Materialia, vol. 53, no. 6, pp. 693–697, 2005. View at Publisher · View at Google Scholar · View at Scopus
  15. H.-S. Di, Y.-L. Li, Z.-L. Ning, Z. Li, X. Liu, and G.-D. Wang, “New processing technology of twin roll strip casting of AZ31B magnesium trip,” Materials Science Forum, vol. 488-489, pp. 615–618, 2005. View at Publisher · View at Google Scholar · View at Scopus
  16. T. Haga and S. Suzuki, “A high speed twin roll caster for aluminum alloy strip,” Journal of Materials Processing Technology, vol. 113, no. 1–3, pp. 291–295, 2001. View at Publisher · View at Google Scholar · View at Scopus
  17. S. Sahoo, A. Kumar, B. K. Dhindaw, and S. Ghosh, “High speed twin roll casting of aluminum-copper strips with layered structure,” Materials and Manufacturing Processes, vol. 28, no. 1, pp. 61–65, 2013. View at Publisher · View at Google Scholar · View at Scopus
  18. H. Fiedler, M. Jurisch, P. Preiss et al., “Thin strip casting by a twin roller pilot plant,” Materials Science and Engineering A, vol. 133, pp. 671–675, 1991. View at Publisher · View at Google Scholar · View at Scopus
  19. H. Yasunaka, K. Taniguchi, M. Kokita, and T. Inoue, “Surface quality of stainless steel type 304 cast by twin-roll type strip caster,” ISIJ International, vol. 35, no. 6, pp. 784–789, 1995. View at Publisher · View at Google Scholar · View at Scopus
  20. M. Yukumoto and H. Yamane, “Thin strip casting of Ni base alloys by twin roll process,” ISIJ International, vol. 35, no. 6, pp. 778–783, 1995. View at Publisher · View at Google Scholar · View at Scopus
  21. T. Haga, H. Sakaguchi, H. Watari, and S. Kumai, “High speed twin roll casting of 6061 alloy strips,” Archives of Materials Science and Engineering, vol. 31, no. 1, pp. 49–52, 2008. View at Google Scholar
  22. H. Sakaguchi, T. Haga, H. Watari, and S. Kumai, “High speed twin roll casting of 6016 aluminum alloy strip,” Jouranl of Achievements in Materials And Manufacturing Engineering, vol. 20, no. 1-2, pp. 495–498, 2007. View at Google Scholar
  23. K. Miyazawa and J. Szekely, “Mathematical-model of the splat cooling process using the twin-roll technique,” Metallurgical Transactions A, vol. 12, no. 6, pp. 1047–1057, 1981. View at Publisher · View at Google Scholar · View at Scopus
  24. T. Saitoh, H. Hojo, H. Yaguchi, and C. G. Kang, “Two-dimensional model for twin-roll continuous casting,” Metallurgical Transactions B, vol. 20, no. 3, pp. 381–390, 1989. View at Publisher · View at Google Scholar · View at Scopus
  25. H. Murakami, M. Hasan, and R. I. L. Guithrie, “A mathematical model for avertical twin-roll caster,” in Proceedings of the Process Technology Conference, vol. 10, pp. 347–354, Toronto, Canada, April 1992.
  26. S.-W. Lee, “A computer modelling of flowfield and solidification in rotating bank of twin-roll strip casting,” Korean Journal of Chemical Engineering, vol. 10, no. 3, pp. 182–187, 1993. View at Publisher · View at Google Scholar · View at Scopus
  27. S. M. Hwang and Y. H. Kang, “Analysis of flow and heat transfer in twin-roll strip casting by finite element method,” Journal of Engineering for Industry, vol. 117, no. 3, pp. 304–315, 1995. View at Publisher · View at Google Scholar · View at Scopus
  28. S. H. Seyedein and M. Hasan, “Numerical simulation of turbulent flow and heat transfer in the wedge-shaped liquid metal pool of a twin-roll caster,” Numerical Heat Transfer—Part A: Applications, vol. 31, no. 4, pp. 393–410, 1997. View at Publisher · View at Google Scholar · View at Scopus
  29. J.-G. Chang and C.-I. Weng, “Analysis of flow and heat transfer in twin-roll strip casting process,” International Journal of Heat and Mass Transfer, vol. 41, no. 2, pp. 475–487, 1998. View at Publisher · View at Google Scholar · View at Scopus
  30. R. I. L. Guthrie and R. P. Tavares, “Mathematical and physical modelling of steel flow and solidification in twin-roll/horizontal belt thin-strip casting machines,” Applied Mathematical Modelling, vol. 22, no. 11, pp. 851–872, 1998. View at Publisher · View at Google Scholar · View at Scopus
  31. C. A. Santos, J. A. Spim Jr., and A. Garcia, “Modeling of solidification in twin-roll strip casting,” Journal of Materials Processing Technology, vol. 102, no. 1, pp. 33–39, 2000. View at Publisher · View at Google Scholar · View at Scopus
  32. M. Gupta and Y. Sahai, “Mathematical modeling of fluid flow, heat transfer, and solidification in two-roll melt drag thin strip casting of steel,” ISIJ International, vol. 40, no. 2, pp. 144–152, 2000. View at Publisher · View at Google Scholar · View at Scopus
  33. W.-S. Kim, D.-S. Kim, and A. V. Kuznetsov, “Simulation of coupled turbulent flow and heat transfer in the wedge-shaped pool of a twin-roll strip casting process,” International Journal of Heat and Mass Transfer, vol. 43, no. 20, pp. 3811–3822, 2000. View at Publisher · View at Google Scholar · View at Scopus
  34. D.-S. Kim, W.-S. Kim, and A. V. Kuznetsov, “Analysis of coupled turbulent flow and solidification in the wedge-shaped pool with different nozzles during twin-roll strip casting,” Numerical Heat Transfer; Part A: Applications, vol. 41, no. 1, pp. 1–17, 2002. View at Publisher · View at Google Scholar · View at Scopus
  35. M. A. Cruchaga, D. J. Celentano, and R. W. Lewis, “Modelling of twin-roll strip casting processes,” Communications in Numerical Methods in Engineering, vol. 19, no. 8, pp. 623–635, 2003. View at Publisher · View at Google Scholar · View at Zentralblatt MATH · View at Scopus
  36. Y.-C. Miao, X.-M. Zhang, H.-S. Di, and G.-D. Wang, “Numerical simulation of the fluid flow, heat transfer, and solidification of twin-roll strip casting,” Journal of Materials Processing Technology, vol. 174, no. 1–3, pp. 7–13, 2006. View at Publisher · View at Google Scholar · View at Scopus
  37. J. W. Bae, C. G. Kang, and S. B. Kang, “Mathematical model for the twin roll type strip continuous casting of magnesium alloy considering thermal flow phenomena,” Journal of Materials Processing Technology, vol. 191, no. 1–3, pp. 251–255, 2007. View at Publisher · View at Google Scholar · View at Scopus
  38. G. M. Cao, C. G. Li, Z. Y. Liu, D. Wu, G. D. Wang, and X. H. Liu, “Numerical simulation of molten pool and control strategy of kiss point in a twin-roll strip casting process,” Acta Metallurgica Sinica, vol. 21, no. 6, pp. 459–468, 2008. View at Publisher · View at Google Scholar · View at Scopus
  39. X. M. Zhang, Z. Y. Jiang, L. M. Yang, X. H. Liu, G. D. Wang, and A. K. Tieu, “Modelling of coupling flow and temperature fields in molten pool during twin-roll strip casting process,” Journal of Materials Processing Technology, vol. 187-188, pp. 339–343, 2007. View at Publisher · View at Google Scholar · View at Scopus
  40. Y. Fang, Z.-M. Wang, Q.-X. Yang et al., “Numerical simulation of the temperature fields of stainless steel with different roller parameters during twin-roll strip casting,” International Journal of Minerals, Metallurgy and Materials, vol. 16, no. 3, pp. 304–308, 2009. View at Publisher · View at Google Scholar · View at Scopus
  41. B. Wang, J.-Y. Zhang, J.-F. Fan, S.-L. Zhao, S.-B. Ren, and K.-C. Chou, “Modelling of melt flow and solidification in the twin-roll strip casting process,” Steel Research International, vol. 80, no. 3, pp. 218–222, 2009. View at Publisher · View at Google Scholar · View at Scopus
  42. H. Zhao, P. Li, and L. He, “Coupled analysis of temperature and flow during twin-roll casting of magnesium alloy strip,” Journal of Materials Processing Technology, vol. 211, no. 6, pp. 1197–1202, 2011. View at Publisher · View at Google Scholar · View at Scopus
  43. Q. Li, Y. K. Zhang, L. G. Liu et al., “Effect of casting parameters on the freezing point position of the 304 stainless steel during twin-roll strip casting process by numerical simulation,” Journal of Materials Science, vol. 47, no. 9, pp. 3953–3960, 2012. View at Publisher · View at Google Scholar · View at Scopus
  44. A. Hadadzadeh and M. A. Wells, “Mathematical modeling of thermo-mechanical behavior of strip during twin roll casting of an AZ31 magnesium alloy,” Journal of Magnesium and Alloys, vol. 1, no. 2, pp. 101–114, 2013. View at Publisher · View at Google Scholar
  45. C. Shoudong and C. Jingchao, “Micromodel of simulation on twin-roll continuous casting od thin strip solidification structure,” Rare Metal Materials and Engineering, vol. 42, no. 1, pp. 14–18, 2013. View at Google Scholar · View at Scopus
  46. A. Hadadzadeh, M. A. Wells, and I.-H. Jung, “Scale-up modeling of the twin roll casting process for AZ31 magnesium alloy,” Journal of Manufacturing Processes, vol. 16, no. 4, pp. 468–478, 2015. View at Publisher · View at Google Scholar · View at Scopus
  47. S. Sahoo, A. Kumar, B. K. Dhindaw, and S. Ghosh, “Modeling and experimental validation of rapid cooling and solidification during high-speed twin-roll strip casting of Al-33 wt pct Cu,” Metallurgical and Materials Transactions B, vol. 43, no. 4, pp. 915–924, 2012. View at Publisher · View at Google Scholar · View at Scopus
  48. S. Sahoo and S. Ghosh, “Heat transfer, solidification, and microstructural evolution in al-33Cu alloy during the starting of twin roll strip casting,” Steel Research International, vol. 85, no. 2, pp. 207–218, 2014. View at Publisher · View at Google Scholar · View at Scopus
  49. Y.-S. Lee, H.-W. Kim, and J.-H. Cho, “Process parameters and roll separation force in horizontal twin roll casting of aluminum alloys,” Journal of Materials Processing Technology, vol. 218, pp. 48–56, 2015. View at Publisher · View at Google Scholar · View at Scopus
  50. J.-J. Park, “Numerical analyses of cladding processes by twin-roll casting: Mg-AZ31 with aluminum alloys,” International Journal of Heat and Mass Transfer, vol. 93, pp. 491–499, 2016. View at Publisher · View at Google Scholar · View at Scopus
  51. K. Shibuya, F. Kogiku, M. Yukumoto, S. Miyake, M. Ozawa, and T. Kan, “Development of a rapid solidification process with a double-roller method,” Materials Science and Engineering, vol. 98, pp. 25–28, 1988. View at Publisher · View at Google Scholar · View at Scopus
  52. R. Cook, P. G. Grocock, P. M. Thomas, D. V. Edmonds, and J. D. Hunt, “Development of the twin-roll casting process,” Journal of Materials Processing Technology, vol. 55, no. 2, pp. 76–84, 1995. View at Publisher · View at Google Scholar · View at Scopus
  53. N. Zapuskalov and M. Vereschagin, “Effect of technological factors on strip profile in twin-roll casting process,” ISIJ International, vol. 38, no. 10, pp. 1107–1113, 1998. View at Publisher · View at Google Scholar · View at Scopus
  54. F.-X. Huang, X.-H. Wang, and W.-J. Wang, “Microstructures of austenitic stainless steel produced by twin-roll strip caster,” Journal of Iron and Steel Research International, vol. 19, no. 2, pp. 57–61, 2012. View at Publisher · View at Google Scholar · View at Scopus
  55. S. Das, N. S. Lim, H. W. Kim, and C. G. Park, “Effect of rolling speed on microstructure and age-hardening behaviour of Al-Mg-Si alloy produced by twin roll casting process,” Materials and Design, vol. 32, no. 8-9, pp. 4603–4607, 2011. View at Publisher · View at Google Scholar · View at Scopus
  56. B. Jiang, W. Liu, D. Qiu, M.-X. Zhang, and F. Pan, “Grain refinement of Ca addition in a twin-roll-cast Mg-3Al-1Zn alloy,” Materials Chemistry and Physics, vol. 133, no. 2-3, pp. 611–616, 2012. View at Publisher · View at Google Scholar · View at Scopus
  57. S. Das, N. S. Barekar, O. El Fakir et al., “Effect of melt conditioning on heat treatment and mechanical properties of AZ31 alloy strips produced by twin roll casting,” Materials Science and Engineering A, vol. 620, pp. 223–232, 2014. View at Publisher · View at Google Scholar · View at Scopus
  58. H. Wang, L. Zhou, Y. Zhang, Y. Cai, and J. Zhang, “Effects of twin-roll casting process parameters on the microstructure and sheet metal forming behavior of 7050 aluminum alloy,” Journal of Materials Processing Technology, vol. 233, pp. 186–191, 2016. View at Publisher · View at Google Scholar
  59. R. Nakamura, T. Haga, S. Kumai, and H. Watari, “Casting of aluminum alloy clad strip using a vertical type tandem twin roll caster,” Advanced Materials Research, vol. 97–101, pp. 1053–1056, 2010. View at Publisher · View at Google Scholar · View at Scopus
  60. K. Neh, M. Ullmann, M. Oswald, F. Berge, and R. Kawalla, “Twin roll casting and strip rolling of several magnesium alloys,” Materials Today: Proceedings, vol. 2, supplement 1, pp. S45–S52, 2015. View at Publisher · View at Google Scholar
  61. M. Chen, X.-D. Hu, B. Han, X.-H. Deng, and D.-Y. Ju, “Study on the microstructural evolution of AZ31 magnesium alloy in a vertical twin-roll casting process,” Applied Physics A: Materials Science and Processing, vol. 122, no. 2, pp. 1–10, 2016. View at Publisher · View at Google Scholar · View at Scopus
  62. B. Forbord, B. Andersson, F. Ingvaldsen, O. Austevik, J. A. Horst, and I. Skauvik, “The formation of surface segregates during twin roll casting of aluminium alloys,” Materials Science and Engineering A, vol. 415, no. 1-2, pp. 12–20, 2006. View at Publisher · View at Google Scholar · View at Scopus
  63. J. D. Hwang, H. J. Lin, J. S. C. Jang, W. S. Hwang, and C. T. Hu, “Relationship between flow characteristics and surface quality in inclined twin roll strip casting,” ISIJ International, vol. 36, no. 6, pp. 690–699, 1996. View at Publisher · View at Google Scholar · View at Scopus
  64. T. Mizoguchi, K.-I. Miyazawa, and Y. Ueshima, “Relation between surface quality of cast strips and meniscus profile of molten pool in the twin roll casting process,” ISIJ International, vol. 36, no. 4, pp. 417–423, 1996. View at Publisher · View at Google Scholar · View at Scopus
  65. S. A. Lockyer, M. Yun, J. D. Hunt, and D. V. Edmonds, “Micro- and macrodefects in thin sheet twin-roll cast aluminum alloys,” Materials Characterization, vol. 37, no. 5, pp. 301–310, 1996. View at Publisher · View at Google Scholar · View at Scopus
  66. D. J. Monaghan, M. B. Henderson, J. D. Hunt, and D. V. Edmonds, “Microstructural defects in high productivity twin-roll casting of aluminium,” Materials Science and Engineering A, vol. 173, no. 1-2, pp. 251–254, 1993. View at Publisher · View at Google Scholar · View at Scopus
  67. M. Yun, S. Lokyer, and J. D. Hunt, “Twin roll casting of aluminium alloys,” Materials Science and Engineering A, vol. 280, no. 1, pp. 116–123, 2000. View at Publisher · View at Google Scholar · View at Scopus
  68. S. Sahoo, “Effect of process parameters on solidification of Al-33Cu strip in high speed twin roll strip casting- A numerical study,” IOP Conference Series Materials Science and Engineering, vol. 75, no. 1, Article ID 012013, 2015. View at Publisher · View at Google Scholar
  69. S. Sahoo and S. Ghosh, “Microstructure evolution of eutectic Al-Cu strips by high-speed twin-roll strip casting process,” Applied Physics A, vol. 121, no. 1, pp. 45–50, 2015. View at Publisher · View at Google Scholar · View at Scopus