DEPSCoR: Prediction of Texture and Formability of Continuous Cast AA 5000 and 2000 Series Aluminum Alloy Sheets and Their Quality Improvement

Prediction of Texture and Formability of Continuous Cast AA 5000 and 2000 Series Aluminum Alloy Sheets and Their Quality Improvement James G. Morris, Chi-Sing Man, and Tongguang Zhai Abstract Aluminum sheet produced by continuous casting (CC) provides an energy savings of 25 percent and an economic savings of 14 percent over sheet made ITom conventional direct chill (DC) cast ingots. With the help of the Light Metals Research Labs (LMRL) and subsequently the Center for Aluminum Technology (CAT) at the University of Kentucky, Commonwealth Aluminum Corporation (CAC) has successfully produced CC AA 3000 and 5000 series aluminum alloy sheets using the Hazelett twin-belt technology, which have properties similar to their DC counterparts. The present research project extends the work on 3000 and 5000 series aluminum alloys to the 2000 series age hardenable aluminum alloys, which will be a new venture for both the continuous cast aluminum industry and CAe. The goal of the proposed research project is to develop two mathematical models, one for quantification of the texture evolution in CC aluminum alloy sheets as a function of processing parameters, and the other for prediction of formability and plastic anisotropy of these sheets by taking into account the effects of texture, grain shape, and precipitate particles. These models wilI be based on thorough experimental investigation of the evolution of microstructure and texture, and their effects on formability of the alloys. These models wilI show the effect of alloy composition, hot rolling procedure and homogenization practice on the texture evolution during cold rolling and annealing. They will subsequently allow the prediction of formability both ITom a mechanical anisotropy point of view as well as ITom a limit strain consideration. It is anticipated that these models wilI be valuable in the optimization of the processing of continuous cast aluminum alloys and the development of aluminum alloys for industrial thermo-mechanical processing. The work plan of the proposed work is outlined below: " To study the evolution of microstructure and texture during cold rolling of CC aluminum alloy sheets. " To study the evolution of microstructure and texture during annealing of hot and cold rolled CC aluminum alloy sheets. " To quantify the effect of alloy composition, initial texture and microstructure on the texture evolution in CC aluminum alloys. " To extend the approach recently advocated by Man and study the effects of texture, grain shape, and precipitate particles on formability and plastic anisotropy ofCC aluminum alloys. " To develop quantitative analytical relations that allow the determination of texture evolution during the production process of CC aluminum alloy sheets and enable the prediction of formability of these alloy products. LMRL and subsequently CAT have been working with CAC (the leading manufacturer of Hazelett cast aluminum sheets in North America) for 15 years on several R&D programs with Hazelett cast aluminum alloys. The team is uniquely qualified to work on the proposed research. I