# US 7,611,778 B2 · Simultaneous multi-alloy casting

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- Number: US 7,611,778 B2
- Document ID: US7611778B2
- Status: Granted
- Kind: B2
- Application number: 11/777,638
- Filed: 2007-07-13
- Published: 2008-02-28
- Granted: 2009-11-03
- Earliest claimed: 2001-10-23
- Assignees: Alcoa Inc.
- Inventors: Raymond J. Kilmer; James L. Kirby
- Web page: https://patentgrep.com/patent/US7611778B2

## 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 brazing sheet comprising:
a first aluminum metal layer; and
a second aluminum metal layer connected to the first aluminum metal layer, wherein the second aluminum metal layer has a different composition than the first aluminum metal layer;
wherein the brazing sheet is produced 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 a 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 barrier layer prevents the first molten aluminum alloy from intermixing with the second molten aluminum alloy;
(6) forming the first 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 brazing sheet.

### Claim 2 (depends on 1)

The brazing sheet of claim 1, wherein, after the rolling step (B), the first aluminum metal layer is uniformly thick across the brazing sheet, and the second aluminum metal layer is uniformly thick across the brazing sheet.

### Claim 3 (depends on 2)

The brazing sheet of claim 2, wherein one of the first aluminum metal layer and the second aluminum metal layer is a clad layer of the brazing sheet, and the other of the first aluminum metal layer and the second aluminum metal layer is a core layer of the brazing sheet.

### Claim 4 (depends on 3)

The brazing sheet of claim 3, wherein the clad layer comprises an AA4000 series aluminum alloy.

### Claim 5 (depends on 3)

The brazing sheet of claim 3, wherein the core layer comprises one of an AA1000, 5000, 6000 or 7000 series alloy.