US 10,618,107 B2Granted

Variable thickness continuous casting for tailor rolling

AssigneeGM Global Technology Operations LLC

InventorsTyson W. Brown, Anil K. Sachdev

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Abstract

Methods of forming a high-strength metal alloy precursor by tailor-casting strips having a tailored thickness across a width of a strip material are provided. The tailor-cast strips have varying thickness throughout the width, which can then be further tailor rolled to a final required thickness profile/tailored thickness. Such tailor-casting method can be conducted by contacting a patterned surface of a casting roller or a casting block with a liquid high-strength metal alloy in a continuous casting process. The present disclosure provides methods of continuously casting a strip having varying thickness across the width allows for improved product in subsequent processing, like tailor rolling. Methods of making a high-strength metal alloy structural automotive component from a tailor-cast blank having a tailored thickness are also provided.

Claims18

Dependent claims

A method of forming a metal alloy precursor having a tailored thickness comprising:

contacting a patterned surface of either a casting roller or a casting block with a liquid metal alloy in a continuous casting process to solidify the alloy and create a profiled strip, wherein the patterned surface includes at least a first surface region comprising a first depth and a second surface region comprising a distinct second depth and the profiled strip defines a longitudinal lengthwise axis and a lateral widthwise axis transverse to the longitudinal lengthwise axis so that the contacting creates an asymmetrical thickness profile across the lateral widthwise axis in the profiled strip, wherein a ratio of a first region having a maximum thickness (tmax) across the lateral widthwise axis to a second region having a minimum thickness (tmin) across the lateral widthwise axis is greater than or equal to about 2.3, wherein the maximum thickness (tmax) ranges from greater than or equal to about 8 mm to less than or equal to about 25 mm and the minimum thickness (tmin) ranges from greater than or equal to about 3 mm to less than or equal to about 10 mm;
and
cooling the profiled strip having the asymmetrical thickness profile to form the metal alloy precursor having the tailored thickness.

A method of forming a metal alloy precursor having a tailored thickness comprising:

contacting a patterned surface of either a casting roller or a casting block with a liquid metal alloy in a continuous casting process to solidify the alloy and create a profiled strip, wherein the patterned surface includes at least a first surface region comprising a first depth and a second surface region comprising a distinct second depth and the profiled strip defines a longitudinal lengthwise axis and a lateral widthwise axis transverse to the longitudinal lengthwise axis so that the contacting creates an asymmetrical thickness profile across the lateral widthwise axis in the profiled strip, wherein a ratio of a first region having a maximum thickness (tmax) across the lateral widthwise axis to a second region having a minimum thickness (tmin) across the lateral widthwise axis is greater than or equal to about 2.3, wherein a maximum width of the first region is greater than or equal to about 60 mm to less than or equal to about 100 mm and a maximum width of the second region is greater than or equal to about 60 mm to less than or equal to about 125 mm;
and
cooling the profiled strip having the asymmetrical thickness profile to form the metal alloy precursor having the tailored thickness.

A method of forming a tailored rolled blank of a metal alloy comprising:

contacting a patterned surface of either a casting roller or a casting block with a liquid metal alloy in a continuous casting process to solidify the alloy and create a profiled strip, wherein the patterned surface includes at least a first surface region comprising a first depth and a second surface region comprising a distinct second depth and the profiled strip defines a longitudinal lengthwise axis and a lateral widthwise axis transverse to the longitudinal lengthwise axis so that the contacting creates a first asymmetrical thickness profile across the lateral widthwise axis in the profiled strip, wherein a ratio of a first region having a maximum thickness (tmax) across the lateral widthwise axis to a second region having a minimum thickness (tmin) across the lateral widthwise axis is greater than or equal to about 2.3, the maximum thickness (tmax) ranges from greater than or equal to about 8 mm to less than or equal to about 25 mm and the minimum thickness (tmin) ranges from greater than or equal to about 3 mm to less than or equal to about 10 mm;
cooling the strip having the first asymmetrical thickness profile;
and
tailor rolling the strip between at least two tailor rollers to define a second asymmetrical thickness profile that is at least about 50% thinner than the first asymmetrical thickness profile to create a tailored rolled strip with variable thickness widthwise.

1 more element

Dependencies are inferred from the claim text.

Facts

Application: 15/098,712Filed 14 Apr 2016
Published: US 2017/0297092 A119 Oct 2017
Granted: 14 Apr 2020
Term ends: Not estimatedThe source records don’t support an estimate.

Classification17 codes

B22D 11/1206
Accessories for subsequent treating or working cast stock in situ: for plastic shaping of strands
B21B 1/12
For rolling structural sections, i.e. work of special cross-section, e.g. angle steel: in a continuous process , i.e. without reversing stands
B21B 1/463
For rolling metal immediately subsequent to continuous casting: in a continuous process, i.e. the cast not being cut before rolling
B21B 3/02
Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of…:…