Microforming of Al-Si alloy foil by cold rolling

Micro-forming using the melt-spun foil was tried by the cold rolling. A nozzle pressing melt spinning method was adopted to cast the Al-14mass%Si foil. Al-14mass%Si was near to the eutectic, and the grain is very small. The thickness of the as-cast strip was 0.2mm. The nozzle pressing melt spinning method can cast the foil which thickness is thicker than 0.1mn with the sound surface. The average cooling rate of the melt-spun foil was about 105 °C/s. The cooling rate of the roll contact surface of the foil was higher than 105 °C/s. The as-cast foil was cold-rolled using a Cr-plated roll down to 0.1mm. The cold-rolled foil was recovered and polished. The micro-forming was operated by the cold-rolling using the roll with micro-die of V-groove. The rolling speed was 1m/min. The grooves were machined on the tip, and this tip was attached to the roll. The angle of the V-groove was 60 degrees, and depth was 1, 3, 5 and 10μm. The projection was formed by the cold rolling on the roll-contact surface of the foil. The height of the projections was about 0.1μm lower than the depth of the each groove.