# US 7,407,713 B2 · Simultaneous multi-alloy casting > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,407,713 B2 - Document ID: US7407713B2 - Status: Granted - Kind: B2 - Application number: 10/744,971 - Filed: 2003-12-22 - Published: 2004-07-15 - Granted: 2008-08-05 - Earliest claimed: 2001-10-23 - Assignees: Alcoa Inc. - Inventors: Raymond J. Kilmer; James L. Kirby - Web page: https://patentgrep.com/patent/US7407713B2 ## CPC - B22D 19/16: for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills (casting compound ingots B22D7/02) - B22D 11/007: {of composite ingots, i.e. two or more molten metals of different compositions being used to integrally cast the ingots (casting of composite ingots in definite lengths B22D7/02)} - B22D 11/008: {of clad ingots, i.e. the molten metal being cast against a continuous strip forming part of the cast product} - B32B 15/016: {all layers being formed of aluminium or aluminium alloys} - C22C 21/00: Alloys based on aluminium - C22C 21/10: with zinc as the next major constituent - Y10T 428/12229: Intermediate article [e.g., blank, etc.] - Y10T 428/12486: Laterally noncoextensive components [e.g., embedded, etc.] - Y10T 428/12493: Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] - Y10T 428/12639: Adjacent, identical composition, components - Y10T 428/12736: Al-base component - Y10T 428/12764: Next to Al-base component - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C22C: ALLOYS (treatment of alloys C21D, C22F) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of casting a multi-layered metal ingot including the steps of delivering a metallic divider member into a direct chill mold, pouring a first molten metal into the mold on one side of the divider member, and pouring a second molten metal into the mold on the other side of the divider member, and allowing the first molten metal and the second molten metal solidify to form a metal ingot which includes the divider metal layer disposed there between. ## Claims ### Claim 1 A multi-layered rolled aluminum product comprising: (i) at least two distinct aluminum layers, wherein a first distinct aluminum layer has a different composition than a second distinct aluminum layer; (ii) wherein the multi-layered rolled aluminum product is made by a process comprising: (A) direct chill casting a multi-layered slab, the direct chill casting process comprising: (1) flowing a first molten aluminum alloy in a direct chill casting apparatus; (2) providing an aluminum barrier layer; (3) flowing a second molten aluminum alloy into a direct chill casting apparatus, (4) wherein the second molten aluminum alloy has a different composition than the first molten aluminum alloy, (5) wherein the aluminum barrier layer prevents the first molten aluminum alloy from intermixing with the second molten aluminum alloy; (6) forming the first distinct aluminum layer from the first molten aluminum alloy; and (7) forming the second distinct aluminum layer from the second molten aluminum alloy; and (B) rolling the multi-layered slab to form the multi-layered rolled aluminum product. ### Claim 2 (depends on 1) The product of claim 1, wherein the aluminum barrier layer comprises the same composition as the first molten aluminum alloy. ### Claim 3 (depends on 2) The product of claim 2, wherein the providing step comprises establishing the aluminum barrier layer, and wherein the direct chill casting processes comprises minimally melting the aluminum barrier layer. ### Claim 4 (depends on 3) The product of claim 3, wherein the minimally melting step comprises destabilizing oxides of the aluminum barrier layer. ### Claim 5 (depends on 3) The product of claim 3, wherein the aluminum barrier layer is a first aluminum barrier layer, wherein the direct chill casting comprises: flowing a third molten aluminum alloy into the direct chill casting apparatus; providing a second aluminum barrier layer; and forming a third distinct aluminum layer; wherein the second aluminum barrier layer prevents the third molten aluminum alloy from intermixing with at least one of the first and second molten aluminum alloys, and wherein the multi-layered slab includes the first, second and third distinct aluminum layers. ### Claim 6 (depends on 5) The product of claim 5, wherein the second aluminum barrier layer comprises the same composition as at least one of the first and second molten aluminum alloys. ### Claim 7 (depends on 6) The product of claim 6, wherein the second aluminum barrier layer comprises the same composition as the first aluminum barrier layer. ### Claim 8 (depends on 5) The product of claim 5, wherein the second aluminum barrier layer comprises a different composition than the first aluminum barrier layer. ### Claim 9 (depends on 5) The product of claim 5, wherein the third molten aluminum alloy has a different composition than at least one of the first and second molten aluminum alloys. ### Claim 10 (depends on 9) The product of claim 9, wherein the third distinct aluminum layer has a different composition than at least one of the first and second distinct aluminum layers. ### Claim 11 (depends on 5) The product of claim 5, wherein the third molten aluminum alloy has the same composition as at least one of the first and second molten aluminum alloys. ### Claim 12 (depends on 11) The product of claim 11, wherein the third distinct aluminum layer has the same composition as at least one of the first and second distinct aluminum layers. ### Claim 13 (depends on 3) The product of claim 3, wherein the multi-layered rolled aluminum product is brazing sheet. ### Claim 14 (depends on 13) The product of claim 13, wherein the brazing sheet is included in a heat exchanger. ### Claim 15 (depends on 3) The product of claim 3, wherein the multi-layered rolled aluminum product is included in an architectural product. ### Claim 16 (depends on 3) The product of claim 3, wherein the multi-layered rolled aluminum product is a reflector sheet. ### Claim 17 (depends on 3) The product of claim 3, further comprising: anodizing the multi-layered rolled aluminum product to form an anodized multi-layered rolled aluminum product.