Methods for forming a work roll and a dulled gloss finish on a metal substrate

Patent metadata

Field	Value
Publication number	US-9914160-B2
Application number	US-201715683139-A
Country	US
Kind code	B2
Filing date	Aug 22, 2017
Priority date	Mar 15, 2013
Publication date	Mar 13, 2018
Grant date	Mar 13, 2018

Abstract

This application discloses methods of preparing a work roll for applying a dulled gloss finish on a metal substrate surface. The resulting finish has a fairly uniform glossiness with a slightly matted appearance and with minimal directionality. The work rolls have an Ra value of from 0.2 to 0.4 μm and an Rz value of less than 3.0 μm. Methods of forming a dulled gloss finish on a metal substrate are also described herein.

First claim

The invention claimed is:

1. A method of preparing a work roll for applying a dulled gloss finish on a metal substrate surface, comprising:
(a) roughening an unfinished work roll surface to form a roughened work roll surface, wherein the roughened work roll has an Ra of 0.20 μm or less and an Rz of 2.00 μm or less;
(b) polishing the roughened work roll surface to form a polished work roll surface having an Ra of less than 0.015 μm and an Rz of less than 0.25 μm;
(c) uniformly roughening the polished work roll surface to form a uniformly roughened work roll surface having an Ra of from 0.35 μm to 0.45 μm and an Rz of less than 5 μm; and
(d) finishing the uniformly roughened work roll surface to form a work roll surface, wherein the work roll surface has an Ra value of from 0.2 to 0.4 μm and an Rz value of less than 3.0 μm.

2. The method of claim 1 , further comprising treating one or both sides of the work roll.

3. The method of claim 2 , wherein the treating comprises one or more of texturing, controlled surface modification, media blasting, chrome coating, and embossing.

4. The method of claim 1 , wherein the work roll surface has an Ra value of from 0.22 μm to 0.37 μm.

5. The method of claim 1 , wherein the work roll surface has an Ra value of from 0.25 μm to 0.35 μm.

6. The method of claim 1 , wherein the work roll surface has an Rz value of less than 2.5 μm.

7. The method of claim 1 , wherein the work roll surface has an Rz value of less than 2.0 μm.

8. A method of forming a dulled gloss finish on a metal substrate, comprising:
(a) roughening an unfinished work roll surface to form a roughened work roll surface, wherein the roughened work roll has an Ra of 0.20 μm or less and an Rz of 2.00 μm or less;
(b) polishing the roughened work roll surface to form a polished work roll surface having an Ra of less than 0.015 μm and an Rz of less than 0.25 μm;
(c) uniformly roughening the polished work roll surface to form a uniformly roughened work roll surface having an Ra of from 0.35 μm to 0.45 μm and an Rz of less than 5 μm;
(d) finishing the uniformly roughened work roll surface to form a work roll surface, wherein the work roll surface has an Ra value of from 0.2 to 0.4 μm and an Rz value of less than 3.0 μm;
(e) inserting the work roll in a cold mill; and
(f) cold rolling the metal substrate with the work roll to achieve the dulled gloss finish on the metal substrate.

9. The method of claim 8 , further comprising treating one or both sides of the work roll after the finishing step.

10. The method of claim 9 , wherein the treating comprises one or more of texturing, controlled surface modification, media blasting, chrome coating, and embossing.

11. The method of claim 8 , wherein the metal substrate is aluminum or an aluminum alloy sheet.

12. The method of claim 8 , wherein the work roll surface has an Ra value of from 0.22 μm to 0.37 μm.

13. The method of claim 8 , wherein the work roll surface has an Ra value of from 0.25 μm to 0.35 μm.

14. The method of claim 8 , wherein the work roll surface has an Rz value of less than 2.5 μm.

15. The method of claim 8 , wherein the work roll surface has an Rz value of less than 2.0 μm.

Assignees

• Novelis Inc

Inventors

• Wright David Skingley
• Rawe Franz Josef

Classifications

• B21B2267/065

  Top and bottom roll have different diameters; Asymmetrical rolling · CPC title

• Y10T428/12993

  Surface feature [e.g., rough, mirror] · CPC title

• B41N1/083

  made of aluminium or aluminium alloys or having such surface layers (B41N1/086 takes precedence) · CPC title

• Y10T29/4956

  Fabricating and shaping roller work contacting surface element · CPC title

• B21B2003/001

  Aluminium or its alloys · CPC title