WO2024137582A1

WO2024137582A1 - Continuous casting apparatus belt design

Info

Publication number: WO2024137582A1
Application number: PCT/US2023/084752
Authority: WO
Inventors: Alp Manavbasi; Simon William BARKER
Original assignee: Novelis Inc.
Priority date: 2022-12-21
Filing date: 2023-12-19
Publication date: 2024-06-27

Abstract

A side dam for a continuous metal casting apparatus includes an insulator and a belt system having an endless belt. The endless belt includes a belt surface, and the endless belt is movable relative to the insulator such that a portion of the belt surface is configured to face a casting cavity of the continuous metal casting apparatus as the endless belt is moved. In some examples, the endless belt is movable in a plane of motion that is perpendicular to the belt surface.

Description

CONTINUOUS CASTING APPARATUS BELT DESIGN

FIELD OF THE INVENTION

[0001] This application relates to a continuous casting apparatus for casting metal product. More particularly, this application relates to continuous casting apparatus belt designs which modify or replace a standard steel, aluminum, or copper belt.

BACKGROUND

[0002] Continuous casters, such as twin belt casters, single belt casters and recirculating block casters, are commonly used for producing strip ingots (continuous metal strips) from molten metals, particularly aluminum alloys. In casters of this kind, a casting cavity is formed between continuously moving casting surfaces and molten metal is introduced into the casting cavity on a continuous basis. Heat is withdrawn from the metal via the casting surfaces and the metal solidifies in the form of a strip ingot that is continuously withdrawn from the casting cavity by the moving casting surfaces. The heat flux through the casting surfaces (heat extracted from the solidifying metal) must be carefully controlled to achieve cast strip ingots of good surface quality and to avoid distortion of the casting cavity. Different metals (e.g. aluminum alloys) require different levels of heat flux for proper casting on a continuous basis, so it is important to be able to control the casting apparatus to provide the required levels of heat flux for a particular metal being cast.

[0003] The primary heat flux control is usually achieved by applying cooling water to the casting belts or blocks. In most belt casters, this is done on the back face of the belt in the region where the belt passes though the casting cavity. However, the heat flux is often adjusted more precisely by additional means. For example, belt casters have been provided with porous ceramic coatings over the metal belts. Such coatings may optionally be partially or completely filled with a high conductivity inert gas, such as helium, to provide further refinement. In such cases, the expense of maintaining a consistent ceramic coating and the cost of the inert gas have made such procedures economically unattractive.

[0004] It is also known to apply a layer of a volatile or partially volatile liquid, e.g. a parting agent, typically including an oil, onto the casting surfaces before they come into contact with the molten metal. This layer is often referred to as “belt dressing” or as a “parting layer”. The thickness of the layer can be varied to provide for control of heat flux to the underlying casting surfaces. The use of such oils, however, may adversely affect the surface quality of the cast strip ingot (particularly ingots made from aluminum alloys containing high levels of alloying elements, including magnesium), and may give rise to environmental issues, particularly when excessive applications are required in order to achieve the desired degree of heat flux control.

SUMMARY

[0005] The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0006] According to some examples, an endless belt for a continuous metal casting apparatus includes a belt that is modified with a texture or barrier layer. The endless belt includes a belt surface that is modified so that the need to use a parting agent is either reduced or eliminated. In a twin belt caster, the apparatus may comprise two endless belts, wherein at least one of the endless belts has the texture or barrier layer described herein. In some aspects, both belts have the texture or barrier layer described herein. Each belt may have the same texture or barrier layer or may have different textures or barrier layers.

[0007] Described herein is a casting apparatus for continuously casting a metal strip article, wherein the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum and wherein the barrier layer is at least one of a Gibbsite-A1(OH)3 barrier layer, a pseudo -boehmite barrier layer, a complete boehmite layer, or a stable and cohesive oxide layer.

[0008] Also described herein is a method of forming an endless casting belt, the method comprising: (a) providing an aluminum endless casting belt; and (b) treating the aluminum endless casting belt by at least a first hydrothermal treatment to form a pseudo-boehmite barrier layer on at least one surface of the aluminum endless casting belt providing a treated aluminum endless casting belt.

[0009] In certain aspects, the hydrothermal treatment comprises boiling in water or steamtreating. The hydrothermal treatment comprises submerging the aluminum endless casting belt in water at a temperature from 90 °C to 150 °C for a period of time from 1 hour to 10 hours. In some cases, treating the aluminum endless casting belt is conducted with at least one additive. Optionally, treating the aluminum endless casting belt further comprises anodizing the treated aluminum endless casting belt in an organic or inorganic acid solution to form a crystalline aluminum oxide layer. In some cases the treating further comprises a second hydrothermal treatment or a post-anodizing sealing treatment of the crystalline aluminum oxide layer.

[0010] Also described herein is a method of forming the endless casting belt, the method comprising: (a) providing an aluminum endless casting belt; (b) anodizing the aluminum endless casting belt in an inorganic acid to form an amorphous aluminum oxide layer on at least one surface of the aluminum endless casting belt; and (c) converting the amorphous aluminum oxide layer to at least one of a Gibbsite-A1(OH)3 barrier layer, a pseudo-boehmite barrier layer, a complete boehmite layer, or a cohesive and stable oxide layer.

[0011] In some non-limiting examples, converting the amorphous aluminum oxide layer comprises hydrothermally treating the amorphous aluminum oxide layer. Optionally, the method described herein further comprises applying a post-anodizing sealing treatment to the amorphous aluminum oxide layer, optionally with at least one additive. In some cases, the amorphous aluminum oxide layer is a nano-porous amorphous aluminum oxide layer, or the amorphous aluminum oxide layer is a nonporous micron-scale or submicron-scale amorphous aluminum oxide layer.

[0012] Optionally, the method described herein further comprises forming channels on the aluminum endless casting belt before anodizing the aluminum endless casting belt, or templating the amorphous aluminum oxide layer. In certain aspects, the endless casting belt further comprises a metal foil layer, wherein the metal foil layer comprises titanium, copper, nickel, brass, stainless steel, or any combination thereof. The metal foil can have a mesh size from 0.70 to 1.5 cm and openings from 30 to 95%. In other examples, the endless casting belt further comprises a carbon fiber layer.

[0013] Further described herein is a casting apparatus for continuously casting a metal strip article, wherein the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum, copper, or steel and wherein the barrier layer comprises a carbon fiber layer. The endless casting belt further comprises a metal foil layer in contact with the carbon fiber layer.

[0014] Also described herein is a method of forming the endless casting belt of any preceding illustration, the method comprising: (a) providing an aluminum endless casting belt; and (b) treating the aluminum endless casting belt with a masking agent to form a textured aluminum endless casting belt.

[0015] Various implementations described in the present disclosure can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a schematic of a continuous metal casting apparatus described herein.

[0017] Figure 2 is a panel of digital images showing a comparison of surfaces described herein according to an example described herein.

[0018] Figure 3 is a panel of analytical images showing a comparison of surfaces described herein according to an example described herein.

[0019] Figure 4 shows a digital image of a surface treated endless casting belt described herein according to an example described herein. [0020] Figure 5 shows a digital image of expanded metal foils described herein according to an example described herein.

DETAILED DESCRIPTION

[0021] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

Definitions and Descriptions

[0022] In this description, reference is made to alloys identified by aluminum industry designations, such as “ ’sseerriieess”” or “6xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0023] As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0024] As used herein, the meaning of “metals” includes pure metals, alloys, and metal solid solutions unless the context clearly dictates otherwise. [0025] As used herein, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a twin block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.

[0026] As used herein, the meaning of “a, “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.

[0027] As used herein, a plate generally has a thickness of greater than approximately 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than approximately 15 mm, greater than approximately 20 mm, greater than approximately 25 mm, greater than approximately 30 mm, greater than approximately 35 mm, greater than approximately 40 mm, greater than approximately 45 mm, greater than approximately 50 mm, or greater than approximately 100 mm.

[0028] As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from approximately 4 mm to approximately 15 mm. For example, a shate may have a thickness of approximately 4 mm, approximately 5 mm, approximately 6 mm, approximately 7 mm, approximately 8 mm, approximately 9 mm, approximately 10 mm, approximately 11 mm, approximately 12 mm, approximately 13 mm, approximately 14 mm, or approximately 15 mm.

[0029] As used herein, a sheet generally refers to an aluminum product having a thickness of less than approximately 4 mm (e.g., less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm). For example, a sheet may have a thickness of approximately 0.1 mm, approximately 0.2 mm, approximately 0.3 mm, approximately 0.4 mm, approximately 0.5, approximately 0.6 mm, approximately 0.7 mm, approximately 0.8 mm, approximately 0.9 mm, approximately 1 mm, approximately 1.1 mm, approximately 1.2 mm, approximately 1.3 mm, approximately 1.4 mm, approximately 1.5 mm, approximately 1.6 mm, approximately 1.7 mm, approximately 1.8 mm, approximately 1.9 mm, approximately 2 mm, approximately 2.1 mm, approximately 2.2 mm, approximately 2.3 mm, approximately 2.4 mm, approximately 2.5 mm, approximately 2.6 mm, approximately 2.7 mm, approximately 2.8 mm, approximately 2.9 mm, approximately 3 mm, approximately 3.1 mm, approximately 3.2 mm, approximately 3.3 mm, approximately 3.4 mm, approximately 3.5 mm, approximately 3.6 mm, approximately 3.7 mm, approximately 3.8 mm, or approximately 3.9 mm.

[0030] As used herein, a foil generally refers to an aluminum alloy product having a thickness of less than about 0.2 mm, less than about 0. 1 mm, less than about 0.09 mm, less than about 0.08 mm, less than about 0.07 mm, less than about 0.06 mm, or less than about 0.05 mm.

[0031] Reference may be made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0032] As used herein, the “high strength temper” refers to a temper in which the aluminum alloy is artificially aged to peak age strength. For example, a 6xxx series aluminum alloy can be solution heat treated and artificially aged to a T6 temper to obtain a peak age strength. Additionally, exemplary high strength tempers can include T6, T7, T8, or T9 tempers.

[0033] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C.

[0034] All ranges disclosed herein are to be understood to encompass both endpoints and any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10. All values modified by “approximately” include the exact value as well.

Endless Casting Belt Comprising a Base Layer and a Barrier Layer

[0035] Figure 1 illustrates a continuous casting system 100. As illustrated in the example of Figure 1, the continuous casting system 100 is a twin belt system with two endless casting belts 104 A and 104B having casting surfaces. Although reference will be made to the twin belt system, the continuous casting system 100 may be any type of continuous casting system, including but not limited to a twin belt caster, a twin roll caster, a single roll caster, or a twin block caster. The endless casting belts 104 A and 104B are rotated continuously, and molten metal 102 is introduced from an injector 110 (sometimes referred to as a nose tip or nosepiece) into a thin mold or casting cavity 106 formed between the confronting regions of the endless casting belts 104A and 104B. The solidified product 108 is continuously ejected from the casting cavity 106.

[0036] The casting apparatus for continuously casting a metal strip article comprises an endless casting belt. In some aspects, the endless casting belt comprises a base layer and a barrier layer. The base layer in these aspects comprises aluminum. The barrier layer is formed or placed on top of the base layer so that the base layer will be in contact with the molten metal. The barrier layer is formed so that it is at least one of a Gibbsite-aluminum hydroxide layer (Gibbsite-A1(OH)₃ layer), a pseudo-boehmite layer, or a complete boehmite layer.

[0037] The base layer of the endless casting belt may comprise an aluminum material. In some aspects, the aluminum material is a 5xxx or 6xxx aluminum alloy The aluminum alloy may be in F temper or may be heat treated. In some aspects, the aluminum alloy in in T6 temper, such as an AA6061 aluminum material in T6 temper. The base layer may have a thickness from 1 to 2 mm, e.g., from 1.2 to 1.8 mm, or from 1.4 to 1.6 mm. In some aspects, the base layer has a thickness of approximately 1 mm, approximately 1.1 mm, approximately 1.2 mm, approximately 1.3 mm, approximately 1.4 mm, approximately 1.5 mm, approximately 1.6 mm, approximately 1.7 mm, approximately 1 .8 mm, approximately 1 .9 mm, or approximately 2 mm.

[0038] In certain aspects, a parting agent is typically applied to endless casting belts, regardless of the belt’s composition, in order to prevent the solidified strip from sticking to the belt. Surprisingly and unexpectedly, by including a barrier layer on top of the base layer, e.g., facing the solidified strip, the need to use a parting agent is reduced or entirely eliminated. The barrier layer comprises a Gibbsite-A1(OH)₃ layer, a pseudo-boehmite layer, a complete boehmite layer, or combinations thereof The barrier layer may be formed by a variety of methods, so long as the final resulting barrier layer results in the reduction or elimination of the need to use a parting agent.

[0039] The barrier layer may have a thickness from 10 nanometers to 1 micron, e.g., from 25 nanometers to 750 nanometers, from 50 nanometers to 500 nanometers, or from 75 nanometers to 250 nanometers. In some aspects, the barrier layer has a thickness of approximately 10 nm, approximately 15 nm, approximately 20 nm, approximately 25 nm, approximately 30 nm, approximately 35 nm, approximately 40 nm, approximately 45 nm, approximately 50 nm, approximately 55 nm, approximately 60 nm, approximately 65 nm, approximately 70 nm, approximately 75 nm, approximately 80 nm, approximately 85 nm, approximately 90 nm, approximately 95 nm, approximately 100 nm, approximately 125 nm, approximately 150 nm, approximately 175 nm, approximately 200 nm, approximately 225 nm, approximately 250 nm, approximately 275 nm, approximately 300 nm, approximately 325 nm, approximately 350 nm, approximately 375 nm, approximately 400 nm, approximately 425 nm, approximately 450 nm, approximately 475 nm, approximately 500 nm, approximately 525 nm, approximately 550 nm, approximately 575 nm, approximately 600 nm, approximately 625 nm, approximately 650 nm, approximately 675 nm, approximately 700 nm, approximately 725 nm, approximately 750 nm, approximately 775 nm, approximately 800 nm, approximately 825 nm, approximately 850 nm, approximately 875 nm, approximately 900 nm, approximately 925 nm, approximately 950 nm, approximately 975 nm, and/or approximately 1000 nm. Optionally, the thickness can be greater than 1000 nm. The thickness refers to the height of the barrier layer from the bottom of the barrier layer in contact with the top of the base layer to the top of the barrier layer which would contact the solidified strip. [0040] As used herein, a Gibbsite- A1(OH)₃ layer refers to a mineral form of aluminum hydroxide that is formed by stacking octahedral sheets of aluminum hydroxide. Each layer has an octahedral coordinated aluminum 3⁺ cation sandwiched between two layers of hydroxide anion, resulting in each hydroxyl being bonded to two aluminums, resulting in two thirds of available octahedral sites being occupied. Gibbsite-A1(OH)₃ may have small crystals, e.g., less than 2 microns in diameter. In certain aspects, the Gibbsite-A1(OH)₃ layer can form a stable oxide layer on the aluminum surface that allows the aluminum alloy to be continuously cast with minimal parting agent or no parting agent at all. The desirable Gibbsite- A1(OH)₃ layer forms preferably at casting temperatures of from 690 °C to 720 °C (e.g., 695 °C to 715 °C, 691 °C to 719 °C, 700 °C to 720 °C, or from 690 °C to 710 °C), for example about 690 °C, about 691 °C, about 692 °C, about 693 °C, about 694 °C, about 695 °C, about 696 °C, about 697 °C, about 698 °C, about 699 °C, about 700 °C, about 701 °C, about 702 °C, about 703 °C, about 704 °C, about 705 °C, about 706 °C, about 707 °C, about 708 °C, about 709 °C, about 710 °C, about 711 °C, about 712 °C, about 713 °C, about 714 °C, about 715 °C, about 716 °C, about 717 °C, about 718 °C, about 719 °C, or about 720 °C.

[0041] As used herein, a complete boehmite layer is an aluminum oxide hydroxide layer that is dimorphous. The stable oxide layer formed from initial Boehmite layers may improve wettability of aluminum surfaces and may improve heat flux.

Methods of Forming an Aluminum Endless Casting Belt

[0042] Prior to forming the barrier layer, the base layer may be cleaned. Methods for cleaning the base layer include solvent cleaning, acid cleaning, base cleaning, surfactant cleaning, or the like. Optionally, the entry cleaning can be performed using a solvent (e.g., an aqueous or organic solvent). Optionally, one or more additives can be added to the solvent. In some aspects, the entry cleaning can be performed using an acid (e.g., an acid electrolyte, described in detail below). In some non-limiting examples, the entry cleaner can be sprayed onto one or more surfaces of the continuous coil. In some aspects, the cleaning step can be performed by spraying water and/or a cleaning solution onto one or more surfaces of the continuous coil at a pressure of from about 2 bar to about 4 bar. For example, the surfaces of the continuous coil can be sprayed at a pressure of about 2 bar, 2.1 bar, 2.2 bar, 2.3 bar, 2.4 bar, 2.5 bar, 2.6 bar, 2.7 bar, 2.8 bar, 2.9 bar, 3 bar, 3.1 bar, 3.2 bar, 3.3 bar, 3.4 bar, 3.5 bar, 3.6 bar, 3.7 bar, 3.8 bar, 3.9 bar, 4 bar, or anywhere in between. Additionally, the entry cleaner can be heated prior to application to one or more surfaces of the continuous coil. In some non-limiting examples, the entry cleaner can be heated to a temperature of from about 85 °C to about 100 °C. For example, the entry cleaner can be heated to a temperature of about 85 °C, 86 °C, 87 °C, 88 °C, 89 °C, 90 °C, 91 °C, 92 °C, 93 °C, 94 °C, 95 °C, 96 °C, 97 °C, 98 °C, 99 °C, 100 °C, or anywhere in between. The cleaning is conducted in order to remove localized distortions, oxide build up, and other defects that may affect application and/or formation of the barrier layer on the base layer. The cleaned endless casting belt is then provided to begin formation/application of the barrier layer.

[0043] After cleaning the aluminum endless casting belt surface, it can be steam treated or boiled in water with or without specific additives to form stable pseudo-boehmite layer that will provide barrier layer and also modify the heat flux in a similar way parting agent provides on the conventional copper and steel belts used for continuous casting of aluminum alloys.

Method 1

[0044] In some non-limiting examples, a method of forming the endless casting belt described herein includes providing an aluminum endless casting belt and treating the aluminum endless casting belt by a hydrothermal treatment to form a pseudo-boehmite barrier layer on at least one surface of the aluminum endless casting belt.

[0045] In some aspects, the hydrothermal treatment includes boiling the endless casting belt in water (e.g., in a bath) at a temperature of from about 90 °C to about 150 °C (e.g., from about 90 °C to about 140 °C, from about 100 °C to about 130 °C, from about 95 °C to about 145 °C, or from about 100 °C to about 125 °C). In some aspects, the water is heated to a temperature of approximately 90 °C, aapppprrooxxiimmaatteellyy 9911 °C, approximately 92 °°CC,, aapppprrooxxiimmaatteellyy 9933 °C, approximately 94 °C, approximately 95 °C, approximately 96 °C, approximately 97 °C, approximately 98 ^°C, approximately 99 ° C, approximately 100 °C, approximately 101 °C, approximately 102 °C, approximately 103 C, approximately 104 °C, approximately 105 °C, approximately 106 °C, approximately 107 °C, approximately 108 °C, approximately 109 °C, approximately 110 °C, approximately 111 °C, approximately 112 °C, approximately 113 °C, approximately 114 °C, approximately 115 ° C, approximately 116 °C, approximately 117 °C, approximately 118 °C, approximately 119 °C, approximately 120 °C, approximately 121 °C, approximately 122 °C, approximately 123 °C, approximately 124 °C, approximately 125 °C, approximately 126 °C, approximately 127 °C, approximately 128 °C, approximately 129 °C, approximately 130 °C, approximately 131 °C, approximately 132 °C, approximately 133 °C, approximately 134 °C, approximately 135 °C, approximately 136 °C, approximately 137 °C, approximately 138 °C, approximately 139 °C, approximately 140 °C, approximately 141 °C, approximately 142 °C, approximately 143 °C, approximately 144 °C, approximately 145 °C, approximately 146 °C, approximately 147 °C, approximately 148 °C, approximately 149 °c, and/or approximately 150 °C. The endless casting belt may be placed in the heated water for a time period from 1 to 10 hours, e.g., approximately 1 hour, approximately 2 hours, approximately 3 hours, approximately 4 hours, approximately 5 hours, approximately 6 hours, approximately 7 hours, approximately 8 hours, approximately 9 hours, or approximately 10 hours.

[0046] In some aspects, the hydrothermal treatment includes steam treating. The steam treatment may be conducted at a temperature of at least 100 °C. In some aspects, the steam treatment occurs at a temperature of approximately 100 °C, approximately 101 °C, approximately 102 °C, approximately 103 °C, approximately 104 °C, approximately 105 °C, approximately 106 °C, approximately 107 °C, approximately 108 °C, approximately 109 °C, approximately 110 °C, approximately 111 °C, approximately 112 °C, approximately 113 °C, approximately 114 °C, approximately 115 °C, approximately 116 °C, approximately 117 °C, approximately 118 °C, approximately 119 °C, approximately 120 °C, approximately 121 °C, approximately 122 °C, approximately 123 °C, approximately 124 °l ', approximately 125 °C, approximately 126 °C, approximately 127 °C, approximately 128 °C, approximately 129 °C, approximately 130 °C, approximately 131 °C, approximately 132 °C, approximately 133 °C, approximately 134 °C, approximately 135 °C, approximately 136 °C, approximately 137 °C, approximately 138 °C, approximately 139 °C, approximately 140 °C, approximately 141 °C, approximately 142 °c, approximately 143 °C, approximately 144 °C, approximately 145 °C, approximately 146 °C, approximately 147 °C, approximately 148 °C, approximately 149 °C, and/or approximately 150 °C. The endless casting belt may be exposed to the steam for a time period from 0.1 to 10 hours, e.g., approximately 6 minutes, approximately 12 minutes, approximately 18 minutes, approximately 24 minutes, approximately 30 minutes, approximately 36 minutes, approximately 42 minutes, approximately 48 minutes, approximately 54 minutes, approximately 1 hour, approximately 2 hours, approximately 3 hours, approximately 4 hours, approximately 5 hours, approximately 6 hours, approximately 7 hours, approximately 8 hours, approximately 9 hours, or approximately 10 hours. The steam treatment may occur in a closed chamber, optionally under pressure. For example, the pressure may range from 1 psig to 100 psig (e.g., from 5 psig to 95 psig, from 10 psig to 90 psig, from 15 psig to 85 psig, from 20 psig to 80 psig, from 2 psig to 99 psig, from 1 psig to 99 psig, or from 2 psig to 100 psig). For examples, the pressure may be about 1 psig, about 2 psig, about 3 psig, about 4 psig, about 5 psig, about 6 psig, about 7 psig, about 8 psig, about 9 psig, about 10 psig, about 11 psig, about 12 psig, about 13 psig, about 14 psig, about 15 psig, about 16 psig, about 17 psig, about 18 psig, about 19 psig, about 20 psig, about 21 psig, about 22 psig, about 23 psig, about 24 psig, about 25 psig, about 26 psig, about 27 psig, about 28 psig, about 29 psig, about 30 psig, about 31 psig, about 32 psig, about 33 psig, about 34 psig, about 35 psig, about 36 psig, about 37 psig, about 38 psig, about 39 psig, about 40 psig, about 41 psig, about 42 psig, about 43 psig, about 44 psig, about 45 psig, about 46 psig, about 47 psig, about 48 psig, about 49 psig, about 50 psig, about 51 psig, about 52 psig, about 53 psig, about 54 psig, about 55 psig, about 56 psig, about 57 psig, about 58 psig, about 59 psig, about 60 psig, about 61 psig, about 62 psig, about 63 psig, about 64 psig, about 65 psig, about 66 psig, about 67 psig, about 68 psig, about 69 psig, about 70 psig, about 71 psig, about 72 psig, about 73 psig, about 74 psig, about 75 psig, about 76 psig, about 77 psig, about 78 psig, about 79 psig, about 80 psig, about 81 psig, about 82 psig, about 83 psig, about 84 psig, about 85 psig, about 86 psig, about 87 psig, about 88 psig, about 89 psig, about 90 psig, about 91 psig, about 92 psig, about 93 psig, about 94 psig, about 95 psig, about 96 psig, about 97 psig, about 98 psig, about 99 psig, or about 100 psig. Aluminum steam treatments are disclosed in US Patent No. 5,496,417, the entire contents and disclosure of which are incorporated herein by reference.

[0047] In some cases, the hydrothermal treatment may be conducted in the presence of additives. In some aspects, the additives are accelerating agents or chemical reagents that assist in the development of the barrier layer. Exemplary additives include a surface property-modifying agent such as an adhesion promoter, a coupling agent, a corrosion inhibitor, or a pretreatment.

[0048] Application of the chemical additive produces a thin layer of the additive on the endless casting belt. In certain aspects, the chemical additive layer can be up to about 50 nm thick (e.g., up to about 45 nm thick, up to about 40 nm thick, up to about 35 nm thick, up to about 30 nm thick, up to about 25 nm thick, up to about 20 nm thick, up to about 15 mn thick, up to about 10 nm thick, or up to about 5 nm thick). The chemical additive can be applied by rolling the endless casting belt with a solution containing the chemical additive, by spraying the endless casting belt with a solution containing the chemical additive, by immersing the endless casting belt in a solution containing the chemical additive, or by electrophoretic application. A curing step or chemical reaction can optionally be performed.

Method 2

[0049] In certain further aspects, treating the aluminum endless casting belt further comprises anodizing the hydrothermally treated aluminum endless casting belt in an organic or inorganic acid solution to form a cohesive and stable aluminum oxide layer.

[0050] In some aspects, anodizing is performed to provide a thin anodized film surface. The anodizing is accomplished by contacting the continuous coil surface with an electrolyte and flowing an electric current (e.g., an alternating current (AC) or a direct current (DC)) through the electrolyte. Suitable electrolytes include, for example, aqueous solutions containing inorganic acids such as phosphoric acid, nitric acid, sulfuric acid, phosphonic acid, or combinations of these. Other exemplary electrolytes include aqueous solutions of sodium nitrate, sodium chloride, potassium nitrate, magnesium chloride, sodium acetate, copper sulfate, potassium chloride, magnesium nitrate, potassium nitrate, calcium chloride, lithium chloride, sodium carbonate, potassium carbonate, calcium carbonate, sodium bicarbonate, ammonium acetate, silver nitrate, ferric chloride, ammonium pentaborate, boric acid, citric acid, ammonium adipate, ammonium phosphate monobasic, or any combination thereof, among others. In some non-limiting examples, the aqueous electrolyte solution can include from about 1 wt. % to about 30 wt. % of the electrolyte (e.g., from about 5 wt. % to about 25 wt. % or from about 10 wt. % to about 20 wt. %) with the remainder water. For example, the aqueous electrolyte solution can include about 1 %, about 2 %, about 3 %, about 4 %, about 5 %, about 6 %, about 7 %, about 8 %, about 9 %, about 10 %, about 11 %, about 12 %, about 13 %, about 14 %, about 15 %, about 16 %, about 17 %, about 18 %, about 19 %, about 20 %, about 21 %, about 22 %, about 23 %, about 24 %, about 25 %, about 26 %, about 27 %, about 28 %, about 29 %, about 30 %, or anywhere in between.

[0051] In certain cases, DC power can be ramped up to from about ± 5 VDC to about ± 30 VDC at a rate of from 1 Volt per minute (V/min) to about 15 V/m (e.g., from about 2.5 V/min to about 12/5 V/min, from about 5 V/min to about 10 V/min, or from about 2.5 V/min to about 15 V/min). Additionally, after ramping, the endless casting belt can be anodized by dwelling the endless casting belt in the energized electrolyte bath for a dwell time of from about 1 minute to about 30 minutes (e.g., from about 2 min to about 28 min, from about 3 min to about 26 min, from about 4 min to about 25 min, from about 5 min to about 22.5 min, from about 6 min to about 20 min, from about 7 min to about 17.5 min, or from about 8 min to about 15 min). For example, the endless casting belt can have a dwell time in the energized electrolyte bath for about 1 min, about 1 .5 min, about 2 min, about 2.5 min, about 3 min, about 3.5 min, about 4 min, about 4.5 min, about 5 min, about 5.5 min, about 6 min, about 6.5 min, about 7 min, about 7.5 min, about 8 min, about 8.5 min, about 9 min, about 9.5 min, about 10 min, about 10.5 min, about 11 min, about 11.5 min, about 12 min, about 12.5 min, about 13 min, about 13.5 min, about 14 min, about 14.5 min, about 15 min, about 15.5 min, about 16 min, about 16.5 min, about 17 min, about 17.5 min, about 18 min, about

18.5 min, about 19 min, about 19.5 min, about 20 min, about 20.5 min, about 21 min, about 21.5 min, about 22 min, about 22.5 min, about 23 min, about 23.5 min, about 24 min, about 24.5 min, about 25 min, about 25.5 min, about 26 min, about 26.5 min, about 27 min, about 27.5 min, about 28 min, about 28.5 min, about 29 min, about 29.5 min, or about 30 min. In some examples, current flow in the electrolyte releases oxygen ions that can migrate to the surface of the aluminum alloy endless casting belt and combine with aluminum on the surface of the aluminum alloy endless casting belt, thus forming highly cohesive and stable alumina (AI₂O₃).

[0052] Figure 2 shows surface microghraphs of an as-cast 5182 aluminum metal on a copper mold with a parting agent (panel A), a 6061-T6 aluminum metal mold with a parting agent (panel B), and a hydorthermally treated aluminum metal mold without a parting agent (panel C). The aluminum metal mold was hydrothermally treated in a boiling water bath for 3 hours. Mold surfaces were finished with 2000 grit mechanical grinding. Each sample was subjected to a simulated continuous casting procedure. As shown in Figure 2, the hydrothermally treated aluminum mold provided the most uniform and defect free surface even though there was no parting agent used during casting. This clearly shows that hydrothermal treatment on an aluminum alloy mold generates a pseudo-boehmite and subsequent stable and cohesive oxide layer, and it modifies the heat flux to obtain smoother and less defective surfaces compared to smooth copper and aluminum endless casting belts used with parting agents.

[0053] Figure 3 shows the surface topography of as-cast metal samples provided by the endless belt, the samples described in the example of Figure 2 above. As shown in Figure 3, the surface topography of as-cast metal exhibited little, if any, variation. Thus, the surface metallurgical integrity and compositional distribution of the metal cast with the hydrothermally treated aluminum exhibited a comparable product when compared to endless casting belt samples using a parting agent. Accordingly, hydrothermally treated aluminum endless casting belts can be used without parting agents to obtain good surface quality on as-cast metals.

Method 3

[0054] In some cases, the endless casting belt can be prepared by a plurality of methods or a combination of methods. For example, the endless casting belt can be prepared by combining Method 1 and Method 2 detailed above. In certain aspects combining Method 1 and Method 2 can form a cohesive and stable aluminum oxide layer on the surface of the endless casting belt, and can enhance the overall integrity, barrier layer, and thermal properties of the endless casting belt. Accordingly, enhanced overall integrity, barrier layer, and thermal properties can provide an endless casting belt capable of providing a continuously-cast metal product without added parting agents. Additionally, after forming the crystalline aluminum oxide layer, the endless casting belt can be further hydrothermally treated and/or sealed in a post-anodizing treatment to form gibbsite, pseudo-boehmite, and/or boehmite phases, and a subsequent stable and cohesive oxide layer on the surface of the endless casting belt.

Method 4

[0055] In some non-limiting examples, the endless casting belt can be subjected to a patterning technique before anodizing and/or hydrothermal treatment. In some examples, the endless casting belt can be subjected to a laser lithography technique to provide a plurality of indentations etched into the endless casting belt surface. The indentations can be arranged in any desired pattern on the surface of the endless casting belt. The pattern can be provided by programming the laser etching apparatus to move the laser relative to the endless casting belt at a pulsing mode. The indentations can be exposed nano-scale and/or micro-scale channels. The indentations can have any desired spacing, ranging from a uniform spacing separated by a non-etched surface to overlapping indentations. For example, the indentations can be formed such that a plurality of indentations forms a singly indented area. Distance between indentations, depth of each indentation, and diameter of each indentation can be adjusted by modifying various parameters of the laser apparatus, relative to the belt surface, including raster speed, laser energy levels, laser pulse duration, and the like, and are known and variable according to a person having ordinary skill in the art. The indentation diameter can range from about 20 pm to about 25 pm (e g., about 20 pm, about 21 pm, about 22 pm, about 23 pm, about 24 pm, or about 25 pm). The indentations can be of any geometrical shape, including triangular, square, rectangular, circular, elliptical, polygonal, or the like. In some cases, the indentations can have a non-geometrical shape (e.g., a freeform curve, an amoebic mass, or the like).

[0056] Other indentation characteristics, including indentation morphology, can be controlled by the laser etching apparatus. Optionally, aluminum etching chemicals commonly known in the art can be used to further control the indentation morphology. For example, the endless belt caster can be laser-etched in a desired pattern and followed by exposure to an acid etch. In some examples, performing an acid etch after a laser etch can create desirable concave craters to simulate a shotblasting morphology. Figure 4 shows an example for some of the surface textures obtained after pulsed laser application on aluminum with different size, depth, and distribution of indentation textures. Aluminum belt surfaces can be texturized (e.g., roughened, softened, smoothed, or the like) by using any one of, or a combination of pulsed laser exposure, continuous laser exposure, acid etching, hydrothermal treatment, anodizing, post anodizing hydrothermal treatment, or postanodizing sealing treatment.

Method 5

[0057] In some cases, the aluminum endless casting belt can be metal plated. For example, the aluminum endless casting belt can be texturized as described in Method 4 to provide specific surface textures on the aluminum endless casting belt surface to deposit copper, nickel, or any other suitable metal plating on the aluminum endless casting belt. In certain aspects, the aluminum endless casting belt can be metal plated after cleaning and/or after zincating the aluminum endless casting belt. Optionally, metallic plating can be applied to an anodized aluminum endless casting belt surface, with or without hydrothermal treatment, as described in Method 2.

[0058] The metal plating can be applied to an entirety of the casting surface of the aluminum endless casting belt, or only a portion of the casting surface of the aluminum endless casting belt. For example, the aluminum endless casting belt can have a casting surface that is a hybrid aluminum, copper, and/or nickel surface. Copper, nickel, or any other suitable metal, plated onto the aluminum endless casting belt can improve the solidification of the metal being cast by the aluminum endless casting belt with improved and/or tailored as-cast surface quality. Accordingly, the metal plating can be applied in any desired pattern, for example, to impart one or a plurality of surface characteristics to the metal being cast. In some cases, the pattern of the metal plating can be determined by the laser etching process described in Method 4.

[0059] In certain cases, a metal-plated hybrid design can exploit synergistic simultaneous surface textures and functionalities, including high heat flux and high durability. For example, a difference in heat flux in aluminum and copper can be used to variably solidify the metal being cast during the continuous casting process. Varied solidification can provide varied and tailored surface characteristics to the metal being cast in a single operation. For example, the as-cast metal can be provided with a surface including smooth portions, roughened portions, textured portions, and the like, without further surface treatments.

Method 6

[0060] In some cases, the aluminum endless casting belt can be a hybrid belt by incorporating expanded metal foils on the surface of the aluminum endless casting belt. The expanded metal foils can be applied to a cleaned and bare aluminum endless casting belt, a pseudo-boehmite coated aluminum endless casting belt, a cleaned and anodized aluminum endless casting belt, or an anodized and hydorthermally treated aluminum endless casting belt. Expanded metal foils are commercially available and, in one example, known by the trade name MicroGrid® (Dexmet Corporation (Wellingford, CT, USA)). These expanded metal foils are produced from ductile and high-temperature resistant metals including titanium, copper, nickel, brass, stainless steel, Monel™, or any other metal that can withstand temperatures greater than 700 °C while maintaining the optimum thermal conductivity and coefficient of thermal expansion.

[0061] For example, commercially available expanded metal foils are shown in Figure 5. A typical expanded metal foil with diamond mesh sizes ranging from .031" to .500" can be used for producing the hybrid belt. An open area of the mesh can range from as low as 30 % to as high as 95 %. As shown in Figure 5, other examples can include expandable metal foils with variable thicknesses and varying surfaces. The varying surfaces can be flattened, smoothed, rough, or any other suitable mesh surface, including Distex Brick, Double Distex Brick, Selvage Edge, or Solid Intersperse as shown in Figure 5. In some cases, the expanded metal foil can include a Side Dam. In certain examples, Selvage Edge and/or Solid Intersperse designs can incorporate the Side Dam where the Side Dam can be positioned on an edge of the aluminum endless casting belt. Alternatively, expanded metal foils or any other woven metal mesh can be embedded into and/or joined to the surface of the aluminum endless casting belt by roll-forming, roll bonding, or any other suitable method. Additionally, the method described herein can provide an alternative method to conventional embossing techniques.

[0062] Alternatively, any woven metal mesh configurations can be incorporated into the aluminum endless casting belt described herein. In some cases, an anodized expanded titanium foil can be welded to the anodized aluminum endless casting belt and enhance the integrity of the hybrid belt described herein. Aluminum and titanium welding is described in U.S. Pat. No. 4,486,647 and incorporated herein by reference.

Method 7

[0063] In other aspects, the endless casting belt can be produced from high modulus carbon fibers. In some non-limiting examples, suitable carbon fibers with high thermal conductivity are commercially available and known by the trade name XN100® having a thermal conductivity of 900 W/mK, XN90® having a thermal conductivity of 450 W/mK, or XN80® having a thermal conductivity of 300 W/mK (Nippon Graphite Fiber Corporation (Tokyo, Japan)). Suitable carbon fibers can be incorporated into the endless casting belt in the form of a yam, a fabric, a prepreg, a chopped fiber, or a milled fiber. Preferably, a fabric and/or prepreg carbon fiber material is more suitable for building a hybrid endless casting belt to be used in continuous casting machine. In comparison, copper exhibits a thermal conductivity of about 400 W/mK, and aluminum alloys exhibit thermal conductivities of about 200 W/mK. Thus, carbon fibers, exhibiting high thermal conductivities, can provide a continuous casting belt suitable for casting aluminum alloys without using a parting agent.

ILLUSTRATIONS OF PREFERRED EMBODIMENTS

[0064] Illustration 1 is a casting apparatus for continuously casting a metal strip article, wherein the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum and wherein the barrier layer is at least one of a Gibbsite- A1(OH)3 barrier layer, a pseudo-boehmite barrier layer, a complete boehmite layer, or a stable and cohesive oxide layer.

[0065] Illustration 2 is a method of forming the endless casting belt of any preceding or subsequent illustration, the method comprising: (a) providing an aluminum endless casting belt; and (b) treating the aluminum endless casting belt by at least a first hydrothermal treatment to form a pseudo-boehmite barrier layer on at least one surface of the aluminum endless casting belt providing a treated aluminum endless casting belt.

[0066] Illustration 3 is the method of any preceding or subsequent illustration, wherein the hydrothermal treatment comprises boiling in water or steam-treating.

[0067] Illustration 4 is the method of any preceding or subsequent illustration, wherein the hydrothermal treatment comprises submerging the aluminum endless casting belt in water at a temperature from 90 °C to 150 °C for a period of time from 1 hour to 10 hours.

[0068] Illustration 5 is the method of any of any preceding or subsequent illustration, wherein treating the aluminum endless casting belt is conducted with at least one additive.

[0069] Illustration 6 is the method of any of any preceding or subsequent illustration, wherein treating the aluminum endless casting belt further comprises anodizing the treated aluminum endless casting belt in an organic or inorganic acid solution to form a crystalline aluminum oxide layer.

[0070] Illustration 7 is the method of any preceding or subsequent illustration, wherein the treating further comprises a second hydrothermal treatment or a post-anodizing sealing treatment of the crystalline aluminum oxide layer.

[0071] Illustration 8 is a method of forming the endless casting belt of any preceding or subsequent illustration, the method comprising: (a) providing an aluminum endless casting belt; (b) anodizing the aluminum endless casting belt in an inorganic acid to form an amorphous aluminum oxide layer on at least one surface of the aluminum endless casting belt; and (c) converting the amorphous aluminum oxide layer to at least one of a Gibbsite-A1(OH)3 barrier layer, a pseudo-boehmite barrier layer, a complete boehmite layer, or a cohesive and stable oxide layer.

[0072] Illustration 9 is the method of any preceding or subsequent illustration, wherein converting the amorphous aluminum oxide layer comprises hydrothermally treating the amorphous aluminum oxide layer. [0073] Illustration 10 is the method of any preceding or subsequent illustration, further comprising applying a post-anodizing sealing treatment to the amorphous aluminum oxide layer, optionally with at least one additive.

[0074] Illustration 11 is the method of any of any preceding or subsequent illustration, wherein the amorphous aluminum oxide layer is a nano -porous amorphous aluminum oxide layer.

[0075] Illustration 12 is the method of any of any preceding or subsequent illustration, wherein the amorphous aluminum oxide layer is a nonporous micron-scale or submicron-scale amorphous aluminum oxide layer.

[0076] Illustration 13 is the method of any of any preceding or subsequent illustration, further comprising forming channels on the aluminum endless casting belt before anodizing the aluminum endless casting belt.

[0077] Illustration 14 is the method of any of any preceding or subsequent illustration, further comprising templating the amorphous aluminum oxide layer.

[0078] Illustration 15 is the casting apparatus of any preceding or subsequent illustration, wherein the endless casting belt further comprises a metal foil layer.

[0079] Illustration 16 is the casting apparatus of any preceding or subsequent illustration, wherein the metal foil layer comprises titanium, copper, nickel, brass, stainless steel, or any combination thereof.

[0080] Illustration 17 is the casting apparatus of any preceding or subsequent illustration, wherein the metal foil has a mesh size from 0.70 to 1.5 cm and openings from 30 to 95%.

[0081] Illustration 18 is the casting apparatus of any preceding or subsequent illustration, wherein the endless casting belt further comprises a carbon fiber layer.

[0082] Illustration 19 is a casting apparatus for continuously casting a metal strip article, wherein the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum, copper, or steel and wherein the barrier layer comprises a carbon fiber layer.

[0083] Illustration 20 is the casting apparatus of any preceding or subsequent illustration, wherein the endless casting belt further comprises a metal foil layer in contact with the carbon fiber layer. [0084] Illustration 21 is a method of forming the endless casting belt of any preceding illustration, the method comprising: (a) providing an aluminum endless casting belt; and (b) treating the aluminum endless casting belt with a masking agent to form a textured aluminum endless casting belt.

[0085] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims that follow.

Claims

CLAIMS What is claimed is:

1. A casting apparatus for continuously casting a metal strip article, wherein the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum and wherein the barrier layer is at least one of a Gibbsite- A1(OH)₃ barrier layer, a pseudo-boehmite barrier layer, a complete boehmite layer, or a stable and cohesive oxide layer.

2. A method of forming the endless casting belt of claim 1 , the method comprising:

(a) providing an aluminum endless casting belt; and

(b) treating the aluminum endless casting belt by at least a first hydrothermal treatment to form a pseudo-boehmite barrier layer on at least one surface of the aluminum endless casting belt providing a treated aluminum endless casting belt.

3. The method of claim 2, wherein the hydrothermal treatment comprises boiling in water or steam-treating.

4. The method of claim 1 or 2, wherein the hydrothermal treatment comprises submerging the aluminum endless casting belt in water at a temperature from 90 °C to 150 °C for a period of time from 1 hour to 10 hours.

5. The method of any of claims 2 4, wherein treating the aluminum endless casting belt is conducted with at least one additive.

6. The method of any of claims 2 — 5, wherein treating the aluminum endless casting belt further comprises anodizing the treated aluminum endless casting belt in an organic or inorganic acid solution to form a crystalline aluminum oxide layer.

7. The method of claim 6, wherein the treating further comprises a second hydrothermal treatment or a post-anodizing sealing treatment of the crystalline aluminum oxide layer.

8. A method of forming the endless casting belt of claim 1 , the method comprising:

(a) providing an aluminum endless casting belt;

(b) anodizing the aluminum endless casting belt in an inorganic acid to form an amorphous aluminum oxide layer on at least one surface of the aluminum endless casting belt; and (c) converting the amorphous aluminum oxide layer to at least one of a Gibbsite- A1(OH)₃ barrier layer, a pseudo-boehmite barrier layer, a complete boehmite layer, or a cohesive and stable oxide layer.

9. The method of claim 8, wherein converting the amorphous aluminum oxide layer comprises hydrothermally treating the amorphous aluminum oxide layer.

10. The method of claim 8 or 9, further comprising applying a post-anodizing sealing treatment to the amorphous aluminum oxide layer, optionally with at least one additive.

11. The method of any of claims 8 — 10, wherein the amorphous aluminum oxide layer is a nano-porous amorphous aluminum oxide layer.

12. The method of any of claims 8 — 10, wherein the amorphous aluminum oxide layer is a nonporous micron-scale or submicron-scale amorphous aluminum oxide layer.

13. The method of any of claims 8 — 12, further comprising forming channels on the aluminum endless casting belt before anodizing the aluminum endless casting belt.

14. The method of any of claims 8 13, further comprising templating the amorphous aluminum oxide layer.

15. The casting apparatus of claim 1 , wherein the endless casting belt further comprises a metal foil layer.

16, The casting apparatus of claim 15, wherein the metal foil layer comprises titanium, copper, nickel, brass, stainless steel, or any combination thereof.

17. The casting apparatus of claim 15 or 16, wherein the metal foil has a mesh size from 0.70 to 1.5 cm and openings from 30 to 95%.

18. The casting apparatus of claim 1, wherein the endless casting belt further comprises a carbon fiber layer.

19. A casting apparatus for continuously casting a metal strip article, wherein the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum, copper, or steel and wherein the barrier layer comprises a carbon fiber layer.

20. The casting apparatus of claim 19, wherein the endless casting belt further comprises a metal foil layer in contact with the carbon fiber layer.

21. A method of forming the endless casting belt of claim 1 , the method comprising:

(a) providing an aluminum endless casting belt; and

(b) treating the aluminum endless casting belt with a masking agent to form a textured aluminum endless casting belt.