1. A Alcan International Limited© Alcan International Limited Intermetallics and Aluminium for (Beverage) Cans Dr. Havovy Cama Alcan International Limited, Banbury Laboratory, Southam Road, Banbury OX16 2SP. Email: havovy.cama@alcan.com

2. A Alcan International Limited© Alcan International Limited Topics A brief Introduction of Alcan Inc. Definition of intermetallics and can stock Production and processing of can stock alloys ?Effect on intermetallic particles ?Techniques to characterise intermetallic particles Ways of enhancing can stock performance

3. A Alcan International Limited© Alcan International Limited Recent History Merger of ?Alcan Aluminium Limited ?Algroup ?17 th October, 2000. ?New Company Alcan Inc. (name adopted since March 2001) Global Provider of Aluminium, Packaging and Solutions Primary Metal Aluminium Fabrication Americas & Asia Aluminium Fabrication Europe Packaging

4. A Alcan International Limited© Alcan International Limited Research and Technology - Alcan Inc. R&D Budget - 2000

5. A Alcan International Limited© Alcan International Limited Alcan Inc. Number of Employees = 53000 Packaging 17,000 Fabrication Europe 12,000 Fabrication Americas & Asia 7,000 Primary 17,000 By Sector Other 9,000 Europe 23,000 North America 21,000 Geographical Repartition

6. A Alcan International Limited© Alcan International Limited Aluminium Processing CASTING HOMOGENISATION ROLLING

7. A Alcan International Limited© Alcan International Limited Typical processing route for Canstock Alloys DC Cast Ingot Approx. 660mm x 1850mm x 8600mm AA3104 (CBS), AA5182 (CES) Scalping Rolling face (+ side faces) Preheat / Homogenisation 475- 630 °C Hot Roll Break Down Mill to ~ 35mm Hot Tandem Mill to 2-3mm Target exit temp 300-350 °C Cold Roll Final gauge < 250 µm Finishing Operations Post Lub application / Lacquering To customer specification

8. A Alcan International Limited© Alcan International Limited DC Casting of Sheet Ingots

9. A Alcan International Limited© Alcan International Limited Continuous Casting of Sheet Ingots

10. A Alcan International Limited© Alcan International Limited Homogenisation

11. A Alcan International Limited© Alcan International Limited. Pusher Furnace

12. A Alcan International Limited© Alcan International Limited Breakdown Mill

13. A Alcan International Limited© Alcan International Limited Cropping & Tandem Mill Rolling

14. A Alcan International Limited© Alcan International Limited Cold Rolling

15. A Alcan International Limited© Alcan International Limited Products

16. A Alcan International Limited© Alcan International Limited Products

17. A Alcan International Limited© Alcan International Limited New Product Applications after the Merger

18. A Alcan International Limited© Alcan International Limited World Beverage Can Market for Al 1995 (total 202 billion cans) 2000 estimate (total 233 billion cans) 15% increase Japan US&Canada Europe China Middle East South East Asia South Africa South America Central America

19. A Alcan International Limited© Alcan International Limited Banbury Laboratory Located 26 miles north of Oxford - 2 miles off jn. 11 on M40 Banbury

20. A Alcan International Limited© Alcan International Limited Projects at Banbury Laboratories Raw Materials Metallurgy Surface Sciences Process and Product Modelling Technical Customer Support

21. A Alcan International Limited© Alcan International Limited Importance of Intermetallic Type for Aluminium Canstock Performance

22. A Alcan International Limited© Alcan International Limited Importance of Improving Can Stock Performance (The Canning Market) Probably the single largest use of aluminium. ?12% of total global Al output used to make beverage cans Market is still evolving ?Cost reduction. ?Weight reduction (down gauging). ?Pressure from non-aluminium materials. ?Need for product innovation.

23. A Alcan International Limited© Alcan International Limited Aluminium Beverage Can Can End (5XXX Alloy - Mg rich) Can Body (3XXX Alloy - Mn rich)

24. A Alcan International Limited© Alcan International Limited Drawn and Ironed (DI) Cans The DI cans are cleaned, decorated and lacquered at the customer plant prior to filling them with beverage.

25. A Alcan International Limited© Alcan International Limited Drawing and Ironing (D&I) Process Cup on Punch Redraw Die Cooling Ports Dome tooling Ironed untrimmed can Ironing Dies

26. A Alcan International Limited© Alcan International Limited Schematic Diagram AA Compositions of Canning Materials 01 2 345 0.0 0.5 1.0 1.5 2.0 wt.% Mg wt.% Mn AA3004 AA3104 AA5017 AA5182 AA5042 AA5052 Can Body Stock Can End Stock Tab Stock <0.3Si <0.7Fe <0.25Cu <0.25Si <0.4Fe <0.1Cu 0.15-0.35Cr <0.6Si <0.8Fe 0.02-0.25Cu <0.2Si <0.35Fe <0.15Cu <0.1Cr <0.2Si <0.35Fe <0.15Cu <0.1Cr

27. A Alcan International Limited© Alcan International Limited Can End Manufacture

28. A Alcan International Limited© Alcan International Limited Cans in the 21 st Century Thinner, stronger and different shapes

29. A Alcan International Limited© Alcan International Limited Gauge (inches).406.356.305.254.203 Gauge (mm) Technical Improvements Down gauging, Light weighting (reduced 25 - 30 % in last 20 yrs)

30. A Alcan International Limited© Alcan International Limited Ingot: 0.66 m x 1.850 m x 8.6 m

31. A Alcan International Limited© Alcan International Limited What are Intermetallic Particles ? These are large particles (10-100  m) formed in the matrix during solidification of the melt. 50  m

32. A Alcan International Limited© Alcan International Limited Constituent Particle Formation During Solidification As-cast Particle Population Phase type Size Distribution Spatial Distribution Morphology Trace Chemistry Solidification Conditions Grain Refiner Major Alloying Elements

33. A Alcan International Limited© Alcan International Limited The apparent concentration of Fe+Mn vs. Si of each point is plotted Reference to the literature and experimental data on standard samples have led to boundaries between the phases being determined Great care should be taken to allow for ?particle size ?solute effects ?neighbouring phases ?partial transformation Feature Detection and Classification (FDC) Technique app wt% Fe app wt% Si 0 5.0 25   6 or 3

34. A Alcan International Limited© Alcan International Limited Feature Detection and Classification (FDC) Technique Note: Duplex particles fall in both classifications, depending upon the position of the probe analysis point.  Al 6 Fe

35. A Alcan International Limited© Alcan International Limited The technique was developed at Sintef during the 1980s, enabling sufficient quantities of dry butanol to be distilled for the reliable extraction and collection in the absence of H 2 O, of sufficient particulate for subsequent analysis. Extracted Particles are ground and analysed using X-ray diffraction and resultant traces are compared with those from known intermetallic types Intermetallic Extraction & Analysis Al + butanol  Al-butoxide + H 2

36. A Alcan International Limited© Alcan International Limited X-Ray Diffraction of Intermetallics Ultrasonic + methanol evaporation grinding Sample (+ petroleum jelly) Zero reflection Si disc  Co X-ray tube X-ray detector

37. A Alcan International Limited© Alcan International Limited XRD Traces Peaks used in calibration curve are marked using */+

38. A Alcan International Limited© Alcan International Limited XRD Comparison of peak positions and relative peak intensity with standard spectra give phase identification Comparison of peak intensity ratios with standard calibration curves gives estimate of relative concentration of phases For multiple phase mixtures spectra are complex and interpretation difficult 01 X=Fraction phase A Log Peak ratio I A /I B calibration curve

39. A Alcan International Limited© Alcan International Limited Bridgman Furnace solid-liquid interface water cooled jacket water bath stepper motor controlled drive rod alumina crucible rolling 'O' ring seal thermal shield furnace

40. A Alcan International Limited© Alcan International Limited Effect of Casting Speed and Alloy Composition on Intermetallic Phase Selection Al-1.25%Fe-0.25%Mn -0.2%Si-1.2%Mg-0.2%Cu Al-0.5%Fe-1.0%Mn -0.2%Si-1.2%Mg-0.2%Cu Al-0.5%Fe-1.0%Mn -0.4%Si-1.2%Mg-0.2%Cu Increase Fe/MnBase AlloyIncrease Si

41. A Alcan International Limited© Alcan International Limited Effect of Alloy Composition and Casting Conditions on Intermetallics Their composition and crystallographic structure depends upon the alloy composition and casting velocity of the ingot and cooling rate of the melt. ?The type of intermetallics can change during processing Their size depends on casting velocity ?Increasing the casting velocity decreases particle size. ?Size of particles affects final product performance (recrystallisation, can scoring).

42. A Alcan International Limited© Alcan International Limited Equilibrium Phase Diagrams Results only as good as database used Metastable phases formed during casting. Depending on homogenisation time and temperature, they transform totally or partially to equilibrium phases. Al 6 (Fe,Mn) Mg 2 Si cc  c =Al(Fe,Mn)Si

43. A Alcan International Limited© Alcan International Limited Homogenisation Depending on type of furnace, homogenisation times can vary from a few hours to up to a day. T( o C) Time (Hours) HTR 2 stage heating

44. A Alcan International Limited© Alcan International Limited In the temperature range 550-630 °C, the amount of Al 6 (Fe,Mn) transformed to  -Al(Fe,Mn)Si increases with increasing exposure time until it reaches a maximum (equilibrium) concentration determined by the alloy composition and homogenisation temperature. The transformation rate is initially rapid and then slows down. Effect of Time on Amount of Alpha Phase in AA3104 After Isothermal Exposure at 550 o C

45. A Alcan International Limited© Alcan International Limited Increasing the Si content in the alloy increases the rate of the Al 6 (Fe,Mn) to  -Al(Fe,Mn)Si transformation. The Effect of Si Content on the Type of Intermetallic Present after Homogenization

46. A Alcan International Limited© Alcan International Limited Homogenisation of 3xxx Alloys AA3104: Al-0.4%Fe-0.9%Mn-1.2%Mg-0.2%Cu- 0.2%Si Al 6 (Fe,Mn) Temperature Mg 2 Si   Si

47. A Alcan International Limited© Alcan International Limited Homogenisation of 3xxx Alloys AA3104: Al-0.4%Fe-0.9%Mn-1.2%Mg-0.2%Cu-0.2%Si 20 µm After Isothermal Heat Treatment at 600 °C for 15 mins Cell Edges Al 6 (Fe,Mn)  c -Al(Fe,Mn)Si

48. A Alcan International Limited© Alcan International Limited Homogenisation of 3xxx Alloys AA3104: Al-0.4%Fe-0.9%Mn-1.2%Mg-0.2%Cu- 0.2%Si 450  C /15m 100nm 450  C / 5m 100nm 400  C / 12m TEM images of AA3104 ramped to 300  C then isothermally treated. After Ramped Heat Treatment

49. A Alcan International Limited© Alcan International Limited Particle Break-up During Rolling (CBS)  Breakdown mill rolling produces slab  Hot rolling produces reroll  Cold rolling produces final gauge sheet

50. A Alcan International Limited© Alcan International Limited Improved Can Body Stock Thinner ?Downgauge further Good strength ?Solid solution strengthening, strain hardening ?Controlled by alloying and thermomechanical processing ?Strength limited by customer tooling performance Galling control ?Need for continuous die cleaning for good can surface ?Believed to be controlled by correct size and amount of alpha phase Earing control ?To minimise metal wastage after D&I process ?Controlled by alloying and thermomechanical processing Cost ?Controlled by cost of alloying additions and final gauge

51. A Alcan International Limited© Alcan International Limited Wall Ironing Process (CBS Manufacture) Ironing Die Entry Exit Punch Travel Direction Score lines Galling

52. A Alcan International Limited© Alcan International Limited Improved Canstock (With respect to Galling resistance) Need enough alpha particles of optimum size Can be obtained by increasing the Si concentration Decreasing homogenisation temperature

53. A Alcan International Limited© Alcan International Limited Improved Can Body Stock Thinner ?Downgauge further Good strength ?Solid solution strengthening, strain hardening ?Controlled by alloying and thermomechanical processing ?Strength limited by customer tooling performance Galling control ?Need for continuous die cleaning for good can surface ?Believed to be controlled by correct size and amount of alpha phase Earing control ?To minimise metal wastage after D&I process ?Controlled by alloying and thermocmechanical processing Cost ?Controlled by cost of alloying additions and final gauge

54. A Alcan International Limited© Alcan International Limited

55. A Alcan International Limited© Alcan International Limited CBS Performance

56. A Alcan International Limited© Alcan International Limited Can End Stock - AA5182 Al-0.04%Si-0.16%Fe-0.040%Cu-0.48%Mn-4.60%Mg Al 6 (Fe,Mn) Mg 5 Al 8 Tau - AlCuMg Mg 2 Si

57. A Alcan International Limited© Alcan International Limited Improved Can End Stock Good strength ?Solid solution strengthening, strain hardening ?Controlled by alloying and thermomechanical processing Good Formability ?Reduce number of coarse particles Earing control ?To minimise metal wastage during seaming ?Controlled by alloying and thermomechanical processing Cost ?Controlled by cost of alloying additions and final gauge

58. A Alcan International Limited© Alcan International Limited CES Performance

59. A Alcan International Limited© Alcan International Limited Always let the upstream end of your business know what the downstream end is doing. (Prepared By R. A. Ricks - Alcan International Ltd.)