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A new continuous castingContinuous casting process for aluminum alloysAluminum alloy, jointly developed by Golden AluminumAluminum (GAI) and SMS Group, building on GAI’s 40 years of block castingCasting experience, is the new “Nexcast®” process designed to produce aluminumAluminum sheet with high end of life scrapScrap content, including high alloyed aluminumAluminum grades like AA5xxx and heat-treatable 6xxxAl-Mg-Si alloys (6xxx) series alloys, typically inaccessible to traditional continuous castingContinuous casting processes. Nexcast® overcomes the limitations through a specially designed, continuously moving mold that produces a rapidly cooled 20 mm thick slab. Alloy elements and impurities kept in solid solutions directly influence microstructure evolutionMicrostructure evolution during downstream hot and cold rolling and annealingAnnealing. Tailored texturesTexture and grain refinement are achieved through the control of key process parametersProcess parameter. “Nexcast®” offers distinct metallurgical advantages over twin roll casting (TRC) as well as a shorter processing sequence and significantly lower energy consumption compared to direct chill (DC) casting. The result is a cost-effective, high-performance sheet product suitable not only for packaging but also for demanding applications in transportation, automotiveAutomotive body structures, beverage can stock and emerging material needs in electrification. Nexcast® redefines continuous castingContinuous casting for aluminumAluminum by enabling broad alloy compatibility, high scrapScrap input, and final propertiesProperties comparable to those of DC-cast sheet.

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Expanding Alloy Capability in Continuous Casting of Aluminum Sheet

  • 会议论文

  • 发表日期：

    2026年

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  • Peter von Czarnowski,
  • Mitchell Holtzer-Steiner,
  • Markus Fischer,
  • Babak Taleb-Araghi,
  • Juergen Hirsch

摘要

A new continuous castingContinuous casting process for aluminum alloysAluminum alloy, jointly developed by Golden AluminumAluminum (GAI) and SMS Group, building on GAI’s 40 years of block castingCasting experience, is the new “Nexcast®” process designed to produce aluminumAluminum sheet with high end of life scrapScrap content, including high alloyed aluminumAluminum grades like AA5xxx and heat-treatable 6xxxAl-Mg-Si alloys (6xxx) series alloys, typically inaccessible to traditional continuous castingContinuous casting processes. Nexcast® overcomes the limitations through a specially designed, continuously moving mold that produces a rapidly cooled 20 mm thick slab. Alloy elements and impurities kept in solid solutions directly influence microstructure evolutionMicrostructure evolution during downstream hot and cold rolling and annealingAnnealing. Tailored texturesTexture and grain refinement are achieved through the control of key process parametersProcess parameter. “Nexcast®” offers distinct metallurgical advantages over twin roll casting (TRC) as well as a shorter processing sequence and significantly lower energy consumption compared to direct chill (DC) casting. The result is a cost-effective, high-performance sheet product suitable not only for packaging but also for demanding applications in transportation, automotiveAutomotive body structures, beverage can stock and emerging material needs in electrification. Nexcast® redefines continuous castingContinuous casting for aluminumAluminum by enabling broad alloy compatibility, high scrapScrap input, and final propertiesProperties comparable to those of DC-cast sheet.