Mechanical properties of three typical aluminum alloy strips prepared by twin-roll casting

Twin-roll casting (TRC) is a near-net shape processing technology that has found widespread application across various series of Al alloys. In this study, the process-structure-property relationships of 2099, 3003, and 6082 Al alloy strips prepared by TRC and traditional rolling (TR) methods were investigated. It shows that the tensile strength and fatigue strength of 2099-TRC are lower than 2099-TR, which is attributed to the reduced solid solubility of copper (Cu) elements resulting from the precipitation of Cu-rich micron phases and the presence of microstructure inhomogeneities. While both 3003-TRC and 3003-TR materials exhibit similar yield and tensile strength, the occurrence of casting micro-void defects in 3003-TRC leads to an accelerated accumulation of fatigue damage, consequently diminishing its fatigue strength. Conversely, 6082-TRC demonstrates an enhanced fatigue strength relative to 6082-TR. This improvement is primarily linked to the higher yield strength and comparable fatigue resistance observed in the former. In light of these findings, the TRC process holds promise for enhancing the fatigue performance of 6xxx Al alloy strips with good elongation. However, for 2xxx and 3xxx alloy strips with comparatively lower elongation, the TRC process enhancements may be necessary to realize similar benefits. The insights gleaned from this study could offer valuable reference and guidance for optimizing both the TRC process itself and the fatigue performance of Al alloy strips.