U.S. patent application number 11/568312 was filed with the patent office on 2008-10-16 for metal laminate.
Invention is credited to William Russell Kingston.
Application Number | 20080251389 11/568312 |
Document ID | / |
Family ID | 38023731 |
Filed Date | 2008-10-16 |
United States Patent
Application |
20080251389 |
Kind Code |
A1 |
Kingston; William Russell |
October 16, 2008 |
Metal Laminate
Abstract
A method for making a metal laminate comprising at least one
plating step and at least one cold roll bonding step. A metal
laminate comprising a plurality of alternating structural layers
and non-structural layers, where the structural layers contribute
significantly to the overall strength of the metal laminate, while
the non-structural layers do not contribute significantly to the
overall strength of the metal laminate, but serve to bind the
structural layers together.
Inventors: |
Kingston; William Russell;
(Chino Hills, CA) |
Correspondence
Address: |
SHELDON MAK ROSE & ANDERSON PC
100 Corson Street, Third Floor
PASADENA
CA
91103-3842
US
|
Family ID: |
38023731 |
Appl. No.: |
11/568312 |
Filed: |
August 8, 2006 |
PCT Filed: |
August 8, 2006 |
PCT NO: |
PCT/US06/30996 |
371 Date: |
May 18, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60734517 |
Nov 7, 2005 |
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Current U.S.
Class: |
205/191 |
Current CPC
Class: |
C25D 5/48 20130101; C25D
5/10 20130101 |
Class at
Publication: |
205/191 |
International
Class: |
C25D 3/12 20060101
C25D003/12 |
Claims
1. A method for making a metal laminate, where the metal laminate
comprises three or more than three layers, the method comprising:
a) providing a first metal layer comprising a metal or metal alloy,
where the first metal layer further comprises a first, surface and
a second surface; b) providing a second metal layer comprising a
different metal or metal alloy than the first metal layer; c)
plating the second metal layer onto the second surface of the first
metal layer, thereby producing a combined first metal layer-second
metal layer; d) providing a third metal layer comprising a metal or
metal alloy that is a different metal or metal alloy than both the
first metal layer and the second metal layer; e) placing the third
metal layer onto the second metal layer of the combined first metal
layer-second metal layer, thereby producing a combined first metal
layer-second metal layer/third metal layer; and f) cold roll
bonding the third metal layer onto the second metal layer of the
combined first metal layer-second metal layer, thereby producing
the metal laminate.
2. The method of claim 1, where the first metal layer, or the third
metal layer or both the first metal layer and the third metal layer
are a steel selected from the group consisting of an austenitic
stainless steel of types 301, 304, 304L, 316 and 321, a ferritic
steel of types 409 and 430, a high nickel steel alloy of types 625,
600 C276, 860 and 865, a titanium stabilized low carbon steel that
meets the 1006 specification, a high carbon steel type 1050, a high
strength low alloy (HSLA) steel, a transformation-induced
plasticity (TRIP) steel, and a dual phase steel.
3. The method of claim 1, where the second metal layer comprises a
metal selected from the group consisting of nickel and copper.
4. The method of claim 1, where plating is performed by an
electrolytic process.
5. The method of claim 1, where plating is performed by an
electroless process.
6. The method of claim 1, further comprising diffusion bonding the
combined first metal layer-second metal layer.
7. The method of claim 1, where the first metal layer comprises a
thickness and the second metal layer comprises a thickness, and
where the thickness of the first metal layer is between 10 and
10,000 times greater than the thickness of the second metal layer
in the combined first metal layer-second metal layer after plating
the second metal layer onto the first metal layer but before cold
roll bonding.
8. The method of claim 1, where the first metal layer comprises a
thickness and the second metal layer comprises a thickness, and
where the thickness of the first metal layer is between 100 and
10,000 times greater than the thickness of the second metal layer
in the combined first metal layer-second metal layer after plating
the second metal layer onto the first metal layer but before cold
roll bonding.
9. The method of claim 1, where the first metal layer comprises a
thickness and the second metal layer comprises a thickness, and
where the thickness of the first metal layer is between 1000 and
10,000 times greater than the thickness of the second metal layer
in the combined first metal layer-second metal layer after plating
the second metal layer onto the first metal layer but before cold
roll bonding.
10. The method of claim 1, where the combined first metal
layer-second metal layer/third metal layer has a thickness, and
where the cold roll bonding reduces the thickness of the combined
first metal layer-second metal layer/third metal layer by between
10% and 95%.
11. The method of claim 1, further comprising diffusion
annealing/bonding the metal laminate.
12. The method of claim 11, further comprising cold reducing the
metal laminate one or more than one time after diffusion
annealing/bonding.
13. The method of claim 12, further comprising annealing the metal
laminate after cold reducing.
14. The method of claim 1, further comprising cold reducing the
metal laminate one or more than one time after cold roll
bonding.
15. The method of claim 14, further comprising annealing the metal
laminate after cold reducing.
16. The method of claim 1, where the first metal layer, the second
metal layer and the third metal layer each consists of a metal or
consists of a metal alloy.
17. The method of claim 1, where the metal laminate consists of two
different types of steel, and either nickel or copper.
18. The method of claim 1, where the metal laminate produced
consists of three layers.
19. A method for making a metal laminate, where the metal laminate
comprises five or more than five layers, the method comprising: a)
providing a first metal layer comprising a metal or metal alloy,
where the first metal layer further comprises a first surface and a
second surface; b) providing a second metal layer comprising a
different metal or metal alloy than the first metal layer; c)
plating the second metal layer onto the second surface of the first
metal layer, thereby producing a combined first metal layer-second
metal layer; d) providing a fifth metal layer comprising a metal or
metal alloy, where the fifth metal layer further comprises a first
surface and a second surface; e) providing a fourth metal layer
comprising a different metal or metal alloy than the fifth metal
layer; f) plating the fourth metal layer onto the first surface of
the fifth metal layer, thereby producing a combined fourth metal
layer-fifth metal layer. g) providing a third metal layer having
two outer surfaces, where the third metal layer comprises a
different metal or metal alloy than the first metal layer, the
second metal layer, the fourth metal layer and the fifth metal
layer; h) placing the third metal layer between the combined first
metal layer-second metal layer and the combined fourth metal
layer-fifth metal layer, thereby producing a combined first metal
layer-second metal layer/third metal layer/combined fourth metal
layer-fifth metal layer; and i) cold roll bonding together the
combined first metal layer-second metal layer/third metal
layer/combined fourth metal layer-fifth metal layer, thereby
producing the metal laminate.
20. A method for making a metal laminate, where the metal laminate
comprises five or more than five layers, the method comprising: a)
providing a first metal layer comprising a metal or metal alloy,
where the first metal layer further comprises a first surface and a
second surface; b) providing a second metal layer comprising a
different metal or metal alloy than the first metal layer; c)
providing a third metal layer having two outer surfaces; d)
providing a fourth metal layer comprising a metal or metal alloy;
e) providing a fifth metal layer comprising a metal or metal alloy,
where the fifth metal layer further comprises a first surface and a
second surface; f) plating the second metal layer onto one surface
of the third metal layer, and plating the fourth metal layer onto
the other surface of the third metal layer, thereby producing a
combined second metal layer-third metal layer-fourth metal layer;
g) placing the combined second metal layer-third metal layer-fourth
metal layer between the second surface of the first metal layer and
the first surface of the fifth metal layer, thereby producing a
first metal layer/combined second metal layer-third metal
layer-fourth metal layer/fifth metal layer; and h) cold roll
bonding together the first metal layer/combined second metal
layer-third metal layer-fourth metal layer/fifth metal layer,
thereby producing the metal laminate; where the second metal layer
and the fourth metal layer comprise a different metal or metal
alloy than any of the first metal layer, the second metal layer and
the third metal layer; and where the third metal layer comprises a
different metal or metal alloy than both the first metal layer and
the fifth metal layer.
21. The method of claim 19 or claim 20, where the first metal
layer, or the third metal layer, or the fifth metal layer, or both
the first metal layer and the third metal layer, or both the first
metal layer and the fifth metal layer, or both the third metal
layer and the fifth metal layer, or all of the first metal layer,
the third metal layer and the fifth metal layer comprise a steel
selected from the group consisting of an austenitic stainless steel
of types 301, 304, 304L, 316 and 321, a ferritic steel of types 409
and 430, a high nickels steel alloy of types 625, 600 C276, 860 and
865, a titanium stabilized low carbon steel that meets the 1006
specification, a high carbon steel type 1050, a high strength low
alloy (HSLA) steel, a transformation-included plasticity (TRIP)
steel, and a dual phase steel.
22. The method of claim 19 or claim 20, where the second metal
layer, or the fourth metal layer, or both the second metal layer
and the fourth metal layer, comprises a metal selected from the
group consisting of nickel and copper.
23. The method of claim 19 or claim 20, where plating is performed
by an electrolytic process.
24. The method of claim 19 or claim 20, where plating is performed
by an electroless process.
25. The method of claim 19, further comprising diffusion bonding
the combined first metal layer-second metal layer, or diffusion
bonding the combined fourth metal layer-fifth metal layer, or
diffusion bonding the combined first metal layer-second metal layer
and the combined fourth metal layer-fifth metal layer.
26. The method of claim 20, further comprising diffusion bonding
the combined second metal layer-third metal layer-fourth metal
layer.
27. The method of claim 19, where the first metal layer comprises a
thickness and the second metal layer comprises a thickness, and
where the thickness of the first metal layer is between 10 and
10,000 times greater than the thickness of the second metal layer
in the combined first metal layer-second metal layer after plating
the second metal layer onto the first metal layer but before cold
roll bonding.
28. The method of claim 19, where the first metal layer comprises a
thickness and the second metal layer comprises, a thickness, and
where the thickness of the first metal layer is between 100 and
10,000 times greater than the thickness of the second metal layer
in the combined first metal layer-second metal layer after plating
the second metal layer onto the first metal layer but before cold
roll bonding.
29. The method of claim 19, where the first metal layer comprises a
thickness and the second metal layer comprises a thickness, and
where the thickness of the first metal layer is between 1000 and
10,000 times greater than the thickness of the second metal layer
in the combined first metal layer-second metal layer after plating
the second metal layer onto the first metal layer but before cold
roll bonding.
30. The method of claim 19, where the fifth metal layer comprises a
thickness and the fourth metal layer comprises a thickness, and
where the thickness of the fifth metal layer is between 10 and
10,000 times greater than the thickness of the fourth metal layer
in the combined fourth metal layer-fifth metal layer after plating
the fourth metal layer onto the fifth metal layer but before cold
roll bonding.
31. The method of claim 19, where the fifth metal layer comprises a
thickness and the fourth metal layer comprises a thickness, and
where the thickness of the fifth metal layer is between 100 and
10,000 times greater than the thickness of the fourth metal layer
in the combined fourth metal layer-fifth metal layer after plating
the fourth metal layer onto the fifth metal layer but before cold
roll bonding.
32. The method of claim 19, where the fifth metal layer comprises a
thickness and the fourth metal layer comprises a thickness, and
where the thickness of the fifth metal layer is between 1000 and
10,000 times greater than the thickness of the fourth metal layer
in the combined fourth metal layer-fifth metal layer after plating
the fourth metal layer onto the fifth metal layer but before cold
roll bonding.
33. The method of claim 20, where the second metal layer comprises
a thickness, the third metal layer comprises a thickness and the
fourth metal layer comprises a thickness, and where the thickness
of the third metal layer is between 10 and 10,000 times greater
than the thickness of the second metal layer, and than the
thickness of the fourth metal layer in the combined second metal
layer-third metal layer-fourth metal layer after plating the second
metal layer and the fourth metal layer onto the third metal layer
but before cold roll bonding.
34. The method of claim 20, where the second metal layer comprises
a thickness, the third metal layer comprises a thickness and the
fourth metal layer comprises a thickness, and where the thickness
of the third metal layer is between 100 and 10,000 times greater
than the thickness of the second metal layer, and than the
thickness of the fourth metal layer in the combined second metal
layer-third metal layer-fourth metal layer after plating the second
metal layer and the fourth metal layer onto the third metal layer
but before cold roll bonding.
35. The method of claim 20, where the second metal layer comprises
a thickness, the third metal layer comprises a thickness and the
fourth metal layer comprises a thickness, and where the thickness
of the third metal layer is between 1000 and 10,000 times greater
than the thickness of the second metal: layer, and than the
thickness of the fourth metal layer in the combined second metal
layer-third metal layer-fourth metal layer after plating the second
metal layer and the fourth metal layer onto the third metal layer
but before cold roll bonding.
36. The method of claim 19 or claim 20, where the fifth metal layer
comprises the same metal or metal alloy as the first metal
layer.
37. The method of claim 19 or claim 20, where the fifth metal layer
comprises a different metal or metal alloy than the first metal
layer.
38. The method of claim 19, where the combined first metal
layer-second metal layer comprises the same metal or metal alloy
combination as the combined fourth metal layer-fifth metal
layer.
39. The method of claim 19, where the combined first metal
layer-second metal layer comprises a different metal or metal alloy
combination than the combined fourth metal layer-fifth metal
layer.
40. The method of claim 19, where the combined first metal
layer-second metal layer/third metal layer/combined fourth metal
layer-fifth metal layer has a thickness, and where the cold roll
bonding reduces the thickness of the combined first metal
layer-second metal layer/third metal layer/combined fourth metal
layer-fifth metal layer by between 10% and 95%.
41. The method of claim 20, where the combined first metal
layer/combined second metal layer-third metal layer-fourth metal
layer/fifth metal layer has a thickness, and where the cold roll
bonding reduces the thickness of the first metal layer/combined
second metal layer-third metal layer-fourth metal layer/fifth metal
layer by between 10% and 95%.
42. The method of claim 19 or claim 20, further comprising
diffusion annealing/bonding the metal laminate.
43. The method of claim 19 or claim 20, further comprising cold
reducing the metal laminate one or more than one time after cold
roll bonding.
44. The method of claim 42, further comprising cold reducing the
metal laminate one or more than one time after diffusion
annealing/bonding.
45. The method of claim 43, further comprising annealing the metal
laminate after cold reducing.
46. The method of claim 44, further comprising annealing the metal
laminate after cold reducing.
47. The method of claim 19 or claim 20, where the first metal
layer, the second metal layer, the third metal layer, the fourth
metal layer and the fifth metal layer each consists of a metal or
consists of a metal alloy.
48. The method of claim 19 or claim 20, where the first metal layer
and the fifth metal layer each consists of the same type of steel,
and the third metal layer consists of a type of steel that is
different from the first metal layer and the fifth metal layer.
49. The method of claim 19 or claim 20, where the first metal
layer, the third metal layer and the fifth metal layer each
consists of a type of steel that is different from one another.
50. The method of claim 19 or claim 20, where the metal laminate
consists of two different types of steel, and either nickel or
copper.
51. The method of claim 19 or claim 20, where the metal laminate
consists of three different types of steel, and either nickel or
copper.
52. The method of claim 19 or claim 20, where the metal laminate
produced consists of five layers.
53. The method of claim 19 or claim 20, where the metal laminate
produced consists of seven layers.
54. The method of claim 19 or claim 20, where the metal laminate
produced consists of nine layers.
55. The method of claim 19 or claim 20, where the metal laminate
produced consists of eleven layers.
56. The method of claim 19 or claim 20, where the method further
comprises providing a sixth metal layer plated onto a seventh metal
layer, thereby producing a combined sixth metal layer-seventh metal
layer, and applying the sixth metal layer-seventh metal layer onto
the second surface of the fifth metal layer before cold roll
bonding to create a metal laminate comprising seven layers.
57. A metal laminate produced according to claim 1, or claim 19 or
claim 20.
58. A metal laminate comprising a first outer surface, a second
outer surface, a total thickness, a first metal layer, a third
metal layer, and an intermediate second metal layer between the
first metal layer and the third metal layer; where the first outer
surface is formed by the first metal layer, and the second outer
surface is formed by the third metal layer; where the first metal
layer, the second metal layer and the third metal layer each
comprises a metal or a metal alloy, or where the first metal layer,
the second metal layer and the third metal layer each consists of a
metal or consists of a metal alloy; and where the first metal layer
comprises a thickness, the second metal layer comprises a
thickness, and the third metal layer comprises a thickness, and
where the thickness of both the first metal layer and the third
metal layer are both between 10 and 10,000 times greater than the
thickness of the second metal layer in the metal laminate.
59. The metal laminate of claim 58, where the first metal layer and
the third metal layer are both a steel selected from the group
consisting of an austenitic stainless steel of types 301, 304,
304L, 316 and 321, a ferritic steel of types 409 and 430, a high
nickel steel alloy of types 625, 600 C276, 860 and 865, a titanium
stabilized low carbon steel that meets the 1006 specification, a
high carbon steel type 1050, a high strength low alloy (HSLA)
steel, a transformation-induced plasticity (TRIP) steel, and a dual
phase steel.
60. The metal laminate of claim 58, where the first metal layer
consists of a first type of steel and the third metal layer
consists of a second type of steel, and the first type of steel is
different from the second type of steel.
61. The metal laminate of claim 58, where the second metal layer
comprises a metal selected from the group consisting of nickel and
copper.
62. The metal laminate of claim 58, where the first metal layer,
the second metal layer and the third metal layer each consists of a
metal or consists of a metal alloy.
63. The metal laminate of claim 58, where the first metal layer
comprises a thickness, the second metal layer comprises a
thickness, and the third metal layer comprises a thickness, and
where the thickness of both the first metal layer and the third
metal layer are both between 100 and 10,000 times greater than the
thickness of the second metal layer in the metal laminate.
64. The metal laminate of claim 58, where the first metal layer
comprises a thickness, the second metal layer comprises a
thickness, and the third metal layer comprises a thickness, and
where the thickness of both the first metal layer and the third
metal layer are both between 1000 and 10,000 times greater than the
thickness of the second metal layer in the metal laminate.
65. A metal laminate comprising a tensile strength, and further
comprising a plurality of alternating structural layers and
non-structural layers; where the non-structural layers contribute
less than 1% of the tensile strength of the metal laminate, but
serve to bind the structural layers together; where the metal
laminate consists of an odd number of structural layers and an even
number of non-structural layers; where each of the structural
layers and the non-structural layers comprises a metal or a metal
alloy, or where each of the structural layers and the
non-structural layers consists of a metal or consists of a metal
alloy; and where each of the structural layers comprises a
thickness and each of the non-structural layers comprises a
thickness, and where the thickness of each of the structural layers
is between 10 and 10,000 times greater than the thickness of each
of the non-structural layers in the metal laminate.
66. The metal laminate of claim 65, where all of the structural
layers and the non-structural layers comprise a metal or metal
alloy.
67. The metal laminate of claim 65, where all of the structural
layers and the non-structural layers consist of a metal or metal
alloy.
68. The metal laminate of claim 65, where each structural layer
comprises a metal or metal alloy that is different from the metal
or metal alloy of each non-structural layer.
69. The metal laminate of claim 65, where each structural layer
consists of a metal or metal alloy that is different from the metal
or metal alloy of each non-structural layer.
70. The metal laminate of claim 65, where at least two structural
layers comprise a metal or metal alloy that is different from one
another.
71. The metal laminate of claim 65, comprising at least three
structural layers, a first structural layer comprising a first type
of steel, a second structural layer comprising a second type of
steel, and a third structural layer comprising a third type of
steel, where the first type of steel and the third type of steel
are different from the second type of steel, and where the first
type of steel is the same as the third type of steel.
72. The metal laminate of claim 65, comprising at least three
structural layers, a first structural layer comprising a first type
of steel, a second structural layer comprising a second type of
steel, and a third structural layer comprising a third type of
steel, where the first type of steel and the third type of steel
are different from the second type of steel, and where the first
type of steel is different from the third type of steel.
73. The metal laminate of claim 65, where each structural layer
comprises a steel selected from the group consisting of an
austenitic stainless steel of types 301, 304, 304L, 316 and 321, a
ferritic steel of types 409 and 430, a high nickel steel alloy of
types 625, 600 C276, 860 and 865, a titanium stabilized low carbon
steel that meets the 1006 specification, a high carbon steel type
1050, a high strength low alloy (HSLA) steel, a
transformation-induced plasticity (TRIP) steel, and a dual phase
steel.
74. The metal laminate of claim 65, comprising: a) a first
structural layer comprising a first type of steel, a second
structural layer comprising a second type of steel, and a third
structural layer comprising a third type of steel; and b) two
non-structural layers; where the first type of steel and the third
type of steel are stainless steel type 321; where the third type of
steel is a titanium stabilized low carbon steel; and where each
non-structural layer comprises nickel.
75. The metal laminate of claim 65, where each non-structural layer
comprises a metal selected from the group consisting of nickel and
copper.
76. The metal laminate of claim 65, where each non-structural layer
consists of a metal selected from the group consisting of nickel
and copper.
77. The metal laminate of claim 65, where each non-structural layer
comprises the same metal or metal alloy, or consists of the same
metal or metal alloy.
78. The metal laminate of claim 65, consisting of three structural
layers and two non-structural-layers.
79. The metal laminate of claim 65, consisting of four structural
layers and three non-structural layers.
80. The metal laminate of claim 65, consisting of five structural
layers and four non-structural layers.
81. The metal laminate of claim 65, consisting of six structural
layers and five non-structural layers.
82. The metal laminate of claim 65, comprising more than six
structural layers and more than five non-structural layers.
83. The metal laminate of claim 65, comprising three structural
layers and two non-structural layers, where one of the three the
structural layers comprises a low carbon steel, two of the three
the structural layers comprise UNS S32100 stainless steel, and both
non-structural layers comprise nickel.
84. The metal laminate of claim 65, comprising three structural
layers and two non-structural layers, where one of the three the
structural layers comprise types 409 ferritic steel, two of the
three the structural layers comprise type 625 high nickel steel
alloy, and both non-structural layers comprise nickel.
85. A commercial product comprising a metal laminate according to
claim 57.
86. A commercial product comprising a metal laminate according to
claim 58.
87. A commercial product comprising a metal laminate according to
claim 65.
88. The commercial product of claim 84, comprising a product
selected from the group consisting of an automobile part, tubing, a
home appliance, a counter top and a fuel cell.
89. The commercial product of claim 85, comprising a product
selected from the group consisting of an automobile part, tubing, a
home appliance, a counter top and a fuel cell.
90. The commercial product of claim 86, comprising a product
selected from the group consisting of an automobile part, tubing, a
home appliance, a counter top and a fuel cell.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present Application claims the benefit of U.S.
Provisional Patent Application 60/734,517, titled "Metal Laminate"
and filed Nov. 7, 2005, the contents of which are incorporated in
this disclosure by reference in their entirety
BACKGROUND
[0002] Metal laminates are used for many industrial applications
that require materials with a specific combination of mechanical
and physical properties not available in a single metal. Metal
laminates can be produced using a number of methods. For example,
metal laminates can be produced of two or more metals that are cold
roll bonded together resulting in a laminate that has different
properties on the surface of the laminate than within the laminate.
Disadvantageously, however, some metals do not form satisfactory
bonds to one another when cold roll bonded, or form a laminate that
is prone to cracking or separation during use. Further, some
laminates cannot be cold reduced after they have been cold roll
bonded.
[0003] In some cases, such as with laminates produced of two
different kinds of steel, there is no known method to produce a
laminate by cold roll bonding without including a separate
intermediate layer of a different metal. Disadvantageously,
however, making steel laminates by such cold roll bonding creates
laminates with relatively thick intermediate layers that do not
contribute to the strength of the laminate but that are necessary
to bind the steel layers together. Producing laminates of two
different kinds of steel by hot roll bonding, however, is expensive
and frequently produces a laminate prone to cracking or
separation.
[0004] Further, some applications require laminates comprising five
or more metal layers where the intermediate layers bond to both the
core layer and the surface layers, thereby holding the laminate
together. Disadvantageously, however, making metal laminates having
five or more layers is generally time consuming, and creates
laminates with relatively thick intermediate layers that do not
contribute to the strength of the laminate but that are necessary
to bind the layers that provide strength to the laminate.
[0005] Therefore, there is a heed for a new method for making a
metal laminate that is not associated with these disadvantages.
Further, there is a need for a metal laminate, particularly a steel
laminate, that is not associated with these disadvantages.
SUMMARY
[0006] According to one embodiment of the present invention, there
is provided a method for making a metal laminate, where the metal
laminate comprises three or more than three layers. The method
comprises, a) providing a first metal layer comprising a metal or
metal alloy, where the first metal layer further comprises a first
surface and a second surface; b) providing a second metal layer
comprising a different metal or metal alloy than the first metal
layer; c) plating the second metal layer onto the second surface of
the first metal layer, thereby producing a combined first metal
layer-second metal layer; d) providing a third metal layer
comprising a metal or metal alloy that is a different metal or
metal alloy than both the first metal layer and the second metal
layer; e) placing the third metal layer onto the second metal layer
of the combined first metal layer-second metal layer, thereby
producing a combined first metal layer-second metal layer/third
metal layer; and e) cold roll bonding the third metal layer onto
the second metal layer of the combined first metal layer-second
metal layer, thereby producing the metal laminate.
[0007] In one embodiment, the first metal layer, or the third metal
layer or both the first metal layer and the third metal layer are a
steel selected from the group consisting of an austenitic stainless
steel of types 301, 304, 304L, 316 and 321, a ferritic steel of
types 409 and 430, a high nickel steel alloy of types 625, 600
C276, 860 and 865, a titanium stabilized low carbon steel that
meets the 1006 specification, a high carbon steel type 1050, a high
strength low alloy (HSLA) steel, a transformation-induced
plasticity (TRIP) steel, and a dual phase steel. In another
embodiment, the second metal layer comprises a metal selected from
the group consisting of nickel and copper. In another embodiment,
plating is performed by an electrolytic process. In another
embodiment, plating is performed by an electroless process. In
another embodiment, the method further comprises diffusion bonding
the combined first metal layer-second metal layer. In another
embodiment, the first metal layer comprises a thickness and the
second metal layer comprises a thickness, and where the thickness
of the first metal layer is between 100 and 10,000 times greater
than the thickness of the second metal layer in the combined first
metal layer-second metal layer after plating the second metal layer
onto the first metal layer but before cold roll bonding. In another
embodiment, the first metal layer comprises a thickness and the
second metal layer comprises a thickness, and where the thickness
of the first metal layer is between 100 and 10,000 times greater
than the thickness of the second metal layer in the combined first
metal layer-second metal layer after plating the second metal layer
onto the first metal layer but before cold roll bonding. In another
embodiment, the first metal layer comprises a thickness and the
second metal layer comprises a thickness, and where the thickness
of the first metal layer is between 1000 and 10,000 times greater
than the thickness of the second metal layer in the combined first
metal layer-second metal layer after plating the second metal layer
onto the first metal layer but before cold roll bonding. In another
embodiment, the combined first metal layer-second metal layer/third
metal layer has a thickness, and where the cold roll bonding
reduces the thickness of the combined first metal layer-second
metal layer/third metal layer by between 10% and 95%. In another
embodiment, the method further comprises diffusion
annealing/bonding the metal laminate. In another embodiment, the
method further comprises cold reducing the metal laminate one or
more than one time after diffusion annealing/bonding. In another
embodiment, the method further comprises annealing the metal
laminate after cold reducing. In another embodiment, the method
further comprises cold reducing the metal laminate one or more than
one time after cold roll bonding. In another embodiment, the method
further comprises annealing the metal laminate after cold reducing.
In one embodiment, the first metal layer, the second metal layer
and the third metal layer each consists of a metal or consists of a
metal alloy. In one embodiment, the metal laminate consists of two
different types of steel, and either nickel or copper. In one
embodiment, the metal laminate produced consists of three
layers.
[0008] According to another embodiment of the present invention,
there is provided a method for making a metal laminate, where the
metal laminate comprises five or more than five layers. The method
comprises, a) providing a first metal layer comprising a metal or
metal alloy, where the first metal layer further comprises a first
surface and a second surface; b) providing a second metal layer
comprising a different metal or metal alloy than the first metal
layer; c) plating the second metal layer onto the second surface of
the first metal layer, thereby producing a combined first metal
layer-second metal layer; d) providing a fifth metal layer
comprising a metal or metal alloy, where the fifth metal layer
further comprises a first surface and a second surface; e)
providing a fourth metal layer comprising a different metal or
metal alloy than the fifth metal layer; f) plating the fourth metal
layer onto the first surface of the fifth metal layer, thereby
producing a combined fourth metal layer-fifth metal layer. g)
providing a third metal layer having two outer surfaces, where the
third metal layer comprises a different metal or metal alloy than
the first metal layer, the second metal layer, the fourth metal
layer and the fifth metal layer; h) placing the third metal layer
between the combined first metal layer-second metal layer and the
combined fourth metal layer-fifth metal layer, thereby producing a
combined first metal layer-second metal layer/third metal
layer/combined fourth metal layer-fifth metal layer; and i) cold
roll bonding together the combined first metal layer-second metal
layer/third metal layer/combined fourth metal layer-fifth metal
layer, thereby producing the metal laminate. According to another
embodiment of the present invention, there is provided a method for
making a metal laminate, where the metal laminate comprises five or
more than five layers. The method comprises, a) providing a first
metal layer comprising a metal or metal alloy, where the first
metal layer further comprises a first surface and a second surface;
b) providing a second metal layer comprising a different metal or
metal alloy than the first metal layer; c) providing a third metal
layer having two outer surfaces; d) providing a fourth metal layer
comprising a metal or metal alloy; e) providing a fifth metal layer
comprising a metal or metal alloy, where the fifth metal layer
further comprises a first surface and a second surface; f) plating
the second metal layer onto one surface of the third metal layer,
and plating the fourth metal layer onto the other surface of the
third metal layer, thereby producing a combined second metal
layer-third metal layer-fourth metal layer; g) placing the combined
second metal layer-third metal layer-fourth metal layer between the
second surface of the first metal layer and the first surface of
the fifth metal layer, thereby producing a first metal
layer/combined second metal layer-third metal layer-fourth metal
layer/fifth metal layer; and i) cold roll bonding together the
first metal layer/combined second metal layer-third metal
layer-fourth metal layer/fifth metal layer, thereby producing the
metal laminate; where the second metal layer and the fourth metal
layer comprise a different metal or metal alloy than any of the
first metal layer, the second metal layer and the third metal
layer; and where the third metal layer comprises a different metal
or metal alloy than both the first metal layer and the fifth metal
layer.
[0009] In one embodiment, the first metal layer, or the third metal
layer, or the fifth metal layer, or both the first metal layer and
the third metal layer, or both the first metal layer and the fifth
metal layer, or both the third metal layer and the fifth metal
layer, or all of the first metal layer, the third metal layer and
the fifth metal layer comprise a steel selected from the group
consisting of an austenitic stainless steel of types 301, 304,
304L, 316 and 321, a ferritic steel of types 409 and 430, a high
nickel steel alloy of types 625, 600 C276, 860 and 865, a titanium
stabilized low carbon steel that meets the 1006 specification, a
high carbon steel type 1050, a high strength low alloy (HSLA)
steel, a transformation-induced plasticity (TRIP) steel, and a dual
phase steel. In another embodiment, the second metal layer, or the
fourth metal layer, or both the second metal layer and the fourth
metal layer, comprises a metal selected from the group consisting
of nickel and copper. In another embodiment, plating is performed
by an electrolytic process. In another embodiment, plating is
performed by an electroless process. In another embodiment, the
method further comprises diffusion bonding the combined first metal
layer-second metal layer, or diffusion bonding the combined fourth
metal layer-fifth metal layer, or diffusion bonding the combined
first metal layer-second metal layer and the combined fourth metal
layer-fifth metal layer. In another embodiment, the method further
comprises diffusion bonding the combined second metal layer-third
metal layer-fourth metal layer. In another embodiment, the first
metal layer comprises a thickness and the second metal layer
comprises a thickness, and where the thickness of the first metal
layer is between 10 and 10,000 times greater than the thickness of
the second metal layer in the combined first metal layer-second
metal layer after plating the second metal layer onto the first
metal layer but before cold roll bonding. In another embodiment,
the first metal layer comprises a thickness and the second metal
layer comprises a thickness, and where the thickness of the first
metal layer is between 100 and 10,000 times greater than the
thickness of the second metal layer in the combined first metal
layer-second metal layer after plating the second metal layer onto
the first metal layer but before cold roll bonding. In another
embodiment, the first metal layer comprises a thickness and the
second metal layer comprises a thickness, and where the thickness
of the first metal layer is between 1000 and 10,000 times greater
than the thickness of the second metal layer in the combined first
metal layer-second metal layer after plating the second metal layer
onto the first metal layer but before cold roll bonding. In another
embodiment, the fifth metal layer comprises a thickness and the
fourth metal layer comprises a thickness, and where the thickness
of the fifth metal layer is between 10 and 10,000 times greater
than the thickness of the fourth metal layer in the combined fourth
metal layer-fifth metal layer after plating the fourth metal layer
onto the fifth metal layer but before cold roll bonding. In another
embodiment, the fifth metal layer comprises a thickness and the
fourth metal layer comprises a thickness, and where the thickness
of the fifth metal layer is between 100 and 10,000 times greater
than the thickness of the fourth metal layer in the combined fourth
metal layer-fifth metal layer after plating the fourth metal layer
onto the fifth metal layer but before cold roll bonding. In another
embodiment, the fifth metal layer comprises a thickness and the
fourth metal layer comprises a thickness, and where the thickness
of the fifth metal layer is between 1000 and 10,000 times greater
than the thickness of the fourth metal layer in the combined fourth
metal layer-fifth metal layer after plating the fourth metal layer
onto the fifth metal layer but before cold roll bonding. In another
embodiment, the second metal layer comprises a thickness, the third
metal layer comprises a thickness and the fourth metal layer
comprises a thickness, and where the thickness of the third metal
layer is between 10 and 10,000 times greater than the thickness of
the second metal layer, and than the thickness of the fourth metal
layer in the combined second metal layer-third metal layer-fourth
metal layer after plating the second metal layer and the fourth
metal layer onto the third metal layer but before cold roll
bonding. In another embodiment, the second metal layer comprises a
thickness, the third metal layer comprises a thickness and the
fourth metal layer comprises a thickness, and where the thickness
of the third metal layer is between 100 and 10,000 times greater
than the thickness of the second metal layer, and than the
thickness of the fourth metal layer in the combined second metal
layer-third metal layer-fourth metal layer after plating the second
metal layer and the fourth metal layer onto the third metal layer
but before cold roll bonding. In another embodiment, the second
metal layer comprises a thickness, the third metal layer comprises
a thickness and the fourth metal layer comprises a thickness, and
where the thickness of the third metal layer is between 1000 and
10,000 times greater than the thickness of the second metal layer,
and than the thickness of the fourth metal layer in the combined
second metal layer-third metal layer-fourth metal layer after
plating the second metal layer and the fourth metal layer onto the
third metal layer but before cold roll bonding. In another
embodiment, the fifth metal layer comprises the same metal or metal
alloy as the first metal layer. In another embodiment, the fifth
metal layer comprises a different metal or metal alloy than the
first metal layer. In another embodiment, the combined first metal
layer-second metal layer comprises the same metal or metal alloy
combination as the combined fourth metal layer-fifth metal layer.
In another embodiment, the combined first metal layer-second metal
layer comprises a different metal or metal alloy combination than
the combined fourth metal layer-fifth metal layer. In another
embodiment, the combined first metal layer-second metal layer/third
metal layer/combined fourth metal layer-fifth metal layer has a
thickness, and where the cold roll bonding reduces the thickness of
the combined first metal layer-second metal layer/third metal
layer/combined fourth metal layer-fifth metal layer by between 10%
and 95%. In another embodiment, the combined first metal
layer/combined second metal layer-third metal layer-fourth metal
layer/fifth metal layer has a thickness, and where the cold roll
bonding reduces the thickness of the first metal layer/combined
second metal layer-third metal layer-fourth metal layer/fifth metal
layer by between 10% and 95%. In another embodiment, the method
further comprises diffusion annealing/bonding the metal laminate.
In another embodiment, the method further comprises cold reducing
the metal laminate one or more than one time after cold roll
bonding. In another embodiment, the method further comprises cold
reducing the metal laminate one or more than one time after
diffusion annealing/bonding. In another embodiment, the method
further comprises diffusion annealing the metal laminate after cold
reducing. In another embodiment, the method further comprises
annealing the metal laminate after cold reducing. In another
embodiment, the first metal layer, the second metal layer, the
third metal layer, the fourth metal layer and the fifth metal layer
each consists of a metal or consists of a metal alloy. In another
embodiment, the first metal layer and the fifth metal layer each
consists of the same type of steel, and the third metal layer
consists of a type of steel that is different from the first metal
layer and the fifth metal layer. In another embodiment, the first
metal layer, the third metal layer and the fifth metal layer each
consists of a type of steel that is different from one another. In
another embodiment, the metal laminate consists of two different
types of steel, and either nickel or copper. In another embodiment,
the metal laminate consists of three different types of steel, and
either nickel or copper. In another embodiment, the metal laminate
produced consists of five layers. In another embodiment, the metal
laminate produced consists of seven layers. In another embodiment,
the metal laminate produced consists of nine layers. In another
embodiment, the metal laminate produced consists of eleven layers.
In another embodiment, the method further comprises providing a
sixth metal layer plated onto a seventh metal layer, thereby
producing a combined sixth metal layer-seventh metal layer, and
applying the sixth metal layer-seventh metal layer onto the second
surface of the fifth metal layer before cold roll bonding to create
a metal laminate comprising seven layers.
[0010] According to another embodiment of the present invention,
there is provided a metal laminate produced according to a method
of the present invention.
[0011] According to another embodiment of the present invention,
there is provided a metal laminate comprising a first outer
surface, a second outer surface, a total thickness, a first metal
layer, a third metal layer, and an intermediate second metal layer
between the first metal layer and the third metal layer; where the
first outer surface is formed by the first metal layer, and the
second outer surface is formed by the third metal layer; where the
first metal layer, the second metal layer and the third metal layer
each comprises a metal or a metal alloy, or where the first metal
layer, the second metal layer and the third metal layer each
consists of a metal or consists of a metal alloy; and where the
first metal layer comprises a thickness, the second metal layer
comprises a thickness, and the third metal layer comprises a
thickness, and where the thickness of both the first metal layer
and the third metal layer are both between 10 and 10,000 times
greater than the thickness of the second metal layer in the metal
laminate. In one embodiment, the first metal layer and the third
metal layer are both a steel selected from the group consisting of
an austenitic stainless steel of types 301, 304, 304L, 316 and 321,
a ferritic steel of types 409 and 430, a high nickel steel alloy of
types 625, 600 C276, 860 and 865, a titanium stabilized low carbon
steel that meets the 1006 specification, a high carbon steel type
1050, a high strength low alloy (HSLA) steel, a
transformation-induced plasticity (TRIP) steel, and a dual phase
steel. In another embodiment, the first metal layer consists of a
first type of steel and the third metal layer consists of a second
type of steel, and the first type of steel is different from the
second type of steel. In another embodiment, the second metal layer
comprises a metal selected from the group consisting of nickel and
copper. In another embodiment, the first metal layer, the second
metal layer and the third metal layer each consists of a metal or
consists of a metal, alloy. In another embodiment, the first metal
layer comprises a thickness, the second metal layer comprises a
thickness, and the third metal layer comprises a thickness, and
where the thickness of both the first metal layer and the third
metal layer are both between 100 and 10,000 times greater than the
thickness of the second metal layer in the metal laminate. In
another embodiment, the first metal layer comprises a thickness,
the second metal layer comprises a thickness, and the third metal
layer comprises a thickness, and where the thickness of both the
first metal layer and the third metal layer are both between 1000
and 10,000 times greater than the thickness of the second metal
layer in the metal laminate.
[0012] According to another embodiment of the present invention,
there is provided a metal laminate comprising a tensile strength,
and further comprising a plurality of alternating structural layers
and non-structural layers; where the non-structural layers
contribute less than 1% of the tensile strength of the metal
laminate, but serve to bind the structural layers together; where
the metal laminate consists of an odd number of structural layers
and an even number of non-structural layers; where each of the
structural layers and the non-structural layers comprises a metal
or a metal alloy, or where each of the structural layers and the
non-structural layers consists of a metal or consist of a metal
alloy; and where each of the structural layers comprises a
thickness and each of the non-structural layers comprises a
thickness, and where the thickness of each of the structural layers
is between 10 and 10,000 times greater than the thickness of each
of the non-structural layers in the metal laminate. In one
embodiment, all of the structural layers and the non-structural
layers comprise a metal or metal alloy. In another embodiment,
where all of the structural layers and the non-structural layers
consist of a metal or metal alloy. In another embodiment, each
structural layer comprises a metal or metal alloy that is different
from the metal or metal alloy of each non-structural layer. In
another embodiment, each structural layer consists of a metal or
metal alloy that is different from the metal or metal alloy of each
non-structural layer. In another embodiment, at least two
structural layers comprise a metal or metal alloy that is different
from one another. In another embodiment, the metal laminate further
comprises at least three structural layers, a first structural
layer comprising a first type of steel, a second structural layer
comprising a second type of steel, and a third structural layer
comprising a third type of steel, where the first type of steel and
the third type of steel are different from the second type of
steel, and where the first type of steel is the same as the third
type of steel. In another embodiment, the metal laminate further
comprises at least three structural layers, a first structural
layer comprising a first type of steel, a second structural layer
comprising a second type of steel, and a third structural layer
comprising a third type of steel, where the first type of steel and
the third type of steel are different from the second type of
steel, and where the first type of steel is different from the
third type of steel. In another embodiment, each structural layer
comprises a steel selected from the group consisting of an
austenitic stainless steel of types 301, 304, 304L, 316 and 321, a
ferritic steel of types 409 and 430, a high nickel steel alloy of
types 625, 600 C276, 860 and 865, a titanium stabilized low carbon
steel that meets the 1006 specification, a high carbon steel type
1050, a high strength low alloy (HSLA) steel, a
transformation-induced plasticity (TRIP) steel, and a dual phase
steel. In another embodiment, the metal laminate further comprises,
a) a first structural layer comprising a first type of steel, a
second structural layer comprising a second type of steel, and a
third structural layer comprising a third type of steel; and b) two
non-structural layers; where the first type of steel and the third
type of steel are stainless steel type 321; where the third type of
steel is a titanium stabilized low carbon steel; and where each
non-structural layer comprises nickel. In another embodiment, each
non-structural layer comprises a metal selected from the group
consisting of nickel and copper. In another embodiment, each
non-structural layer consists of a metal selected from the group
consisting of nickel and copper. In another embodiment, each
non-structural layer comprises the same metal or metal alloy, or
consists of the same metal or metal alloy. In another embodiment,
the metal laminate consists of three structural layers and two
non-structural layers. In another embodiment, the metal laminate
consists of four structural layers and three non-structural layers.
In another embodiment, the metal laminate consists of five
structural layers and four non-structural layers. In another
embodiment, the metal laminate consists of six structural layers
and five non-structural layers. In another embodiment, the metal
laminate comprises more than six structural layers and more than
five non-structural layers. In another embodiment, the metal
laminate comprises three structural layers and two non-structural
layers, where one of the three-structural layers comprises a low
carbon steel, two of the three structural layers comprise UNS
S32100 stainless steel, and both non-structural layers comprise
nickel. In another embodiment, the metal laminate comprises three
structural layers and two non-structural layers, where one of the
three structural layers comprises type 409 ferritic steel, two of
the three structural layers comprise type 625 high nickel steel
alloy, and both non-structural layers comprise nickel.
[0013] According to another embodiment of the present invention,
there is provided a commercial product comprising a metal laminate
according to the present invention. In one embodiment, the
commercial product comprises a product selected from the group
consisting of an automobile part, tubing, a home appliance, a
counter top and a fuel cell.
FIGURES
[0014] These and other features, aspects and advantages of the
present invention will become better understood with regard to the
following description, appended claims, and accompanying figures
where:
[0015] FIG. 1 is a partial cross-sectional view of a metal laminate
according to the present invention comprising three metal
layers;
[0016] FIG. 2 is a partial cross-sectional view of a metal laminate
according to the present invention comprising five metal
layers;
[0017] FIG. 3 is a partial cross-sectional view of a metal laminate
according to the present invention comprising seven metal
layers;
[0018] FIG. 4 is a partial cross-sectional view of a metal laminate
according to the present invention comprising nine metal layers;
and
[0019] FIG. 5 is a partial cutaway, lateral perspective view of a
tubing comprising a metal laminate of the present invention as
shown in FIG. 2.
DESCRIPTION
[0020] According to one embodiment of the present invention, there
is provided a method for making a metal laminate comprising at
least one plating step and at least one cold roll bonding step. In
one embodiment, the method comprises plating a first metal layer
with a second metal layer, and then cold roll bonding a third metal
layer onto the plated side of the plated first metal-second metal
layer to form a three layer metal laminate. In a preferred
embodiment, the first metal layer and the third metal layer are
both steel, and the first metal layer and the third metal layer are
different types of steel from one another. In another embodiment,
the method comprises plating a first metal layer with a second
metal layer, and then cold roll bonding a third metal layer between
two layers of the plated first metal-second metal layer to form a
metal laminate comprising five or more than five layers. In a
preferred embodiment, the outer metal layers and the central metal
layer of a five metal layer produced according to this method are
all steel, but the central metal layer comprises a different type
of steel than either of the two outer metal layers. In another
embodiment, the method comprises plating a metal layer onto both
sides of another metal layer, and then cold roll bonding the doubly
plated metal layer with at least one additional metal layer on each
side of the doubly plated metal layer by cold roll bonding to form
a metal laminate comprising five or more than five layers. In a
preferred embodiment, the outer metal layers and the central metal
layer of a five metal layer produced according to this method are
all steel, but the central metal layer comprises a different type
of steel than either of the two outer metal layers. According to
another embodiment of the present invention, there is provided a
metal laminate consisting of three layers, an outer first layer, an
intermediate second layer and an outer third layer, where the
intermediate second layer is relatively thin compared to both the
outer first layer and the outer third layer. In a preferred
embodiment, the first metal layer and the third metal layer are
both steel, and the first metal layer and the third metal layer are
different types of steel from one another. According to another
embodiment of the present invention, there is provided a metal
laminate comprising five or more than five layers, where the even
numbered layers counting from either of the outermost layers are
non-structural layers and are relatively thin compared to the odd
numbered layers which are structural layers. According to another
embodiment of the present invention, the metal laminate comprises
at least an outer first layer, an intermediate second layer, a
middle third layer, an intermediate fourth layer, and an outer
fifth layer, where the intermediate second layer and the
intermediate fourth layer are both relatively thin compared to the
third layer. In a preferred embodiment, each of the outer first
layer, the middle third layer and the outer fifth layer is a type
of steel and the middle third layer comprises different types of
steel from both of the outer first layer and the outer fifth layer.
In one embodiment, there is provided a laminate produced according
to any method of the present invention. In a preferred embodiment,
the laminate consists of three layers, or consists of five layers
or consists of seven layers or consists of nine layers or consists
of eleven layers. The method and laminate will now be disclosed in
greater detail.
[0021] As used in this disclosure, except where the context
requires otherwise, all amounts are given in percent of total
weight or total thickness.
[0022] As used in this disclosure, except where the context
requires otherwise, the term "comprise" and variations of the term,
such as "comprising," "comprises" and "comprised" are not intended
to exclude other additives, components, integers or steps.
[0023] All dimensions specified in this disclosure are by way of
example only and are not intended to be limiting. Further, the
proportions shown in these Figures are not necessarily to scale. As
will be understood by those with skill in the art with reference to
this disclosure, the actual dimensions of the laminate including
the thicknesses disclosed in this disclosure will be determined by
its intended use.
[0024] As used in this disclosure, except where the context
requires otherwise, the method steps disclosed and shown are not
intended to be limiting nor are they intended to indicate that each
step is essential to the method or that each step must occur in the
order disclosed.
[0025] As used in this disclosure, "cold roll bonding" comprises
rolling two or more layers of metal or metal alloy between two
rollers under sufficient pressure that the layers of metal or metal
alloy become a single laminate. As will be understood by those with
skill in the art with reference to this disclosure, cold roll
bonding sometimes comprises applying a low amount of added heat to
the layers to soften the layers, such as not more than 150.degree.
C., an amount insufficient by itself to bond the layers of metal or
metal alloy.
[0026] As used in this disclosure, the word "metal" means metal or
metal alloy. Therefore the "metal laminate" of the present
invention either consists of three or more than three types of
metals, three or more than three types of metal alloys, or one or
more than one type of metal and one or more than one type of metal
alloy; and "metal layer" means of a layer of metal or a layer of
metal alloy.
[0027] As used in this disclosure, "steel" and "steel alloy" refers
to a generally hard, strong, durable, malleable alloy of iron and
carbon, comprising between 0.001 and 1.5 percent carbon, with or
without other constituents selected from the group consisting of
aluminum, boron, chromium, cobalt, columbium/niobium, copper,
manganese (for example, austenitic manganese steel comprising
between 10% and 14% of manganese), molybdenum, nickel, phosphorous,
silicon, titanium, tungsten, vanadium and a combination of the
preceding.
[0028] As used in this disclosure, a "structural layer" refers to
an odd numbered layer of the finished laminate counting from either
outer surface layer, and a "non-structural layer" refers to an even
numbered layer of the finished laminate counting from either outer
surface layer.
[0029] According to one embodiment of the present invention, there
is provided a method for making a metal laminate, where the metal
laminate comprises three or more than three layers. Referring now
to FIG. 1, there is shown a partial cross-sectional view of a metal
laminate according to the present invention made according to the
method. As can be seen, the metal laminate 10 comprises a first
outer surface 12, a second outer surface 14, a total thickness 16,
a first metal layer 18, a third metal layer 20, and an intermediate
second metal layer 22 between the first metal layer 18 and the
third metal layer 20, and where the first outer surface 12 is
formed by the first metal layer 18, and where the second outer
surface 14 is formed by the third metal layer 20. Though the
present method is disclosed with respect to a metal laminate
consisting of three layers, metal laminates with more than three
layers, such as five layers, seven layers, nine layers, eleven
layers, and so forth, can also be produced using the method
disclosed for making a three layer metal laminate with additional
steps, as will be understood by those with skill in the art with
reference to this disclosure.
[0030] The method comprises, first, providing a first metal layer
18 comprising a metal or metal alloy. The first metal layer 18
comprises a first surface 24 and a second surface 26, and can be
any metal or metal alloy suitable for the intended use of the
finished metal laminate 10, as will be understood by those with
skill in the art with reference to this disclosure. For example, in
a preferred embodiment, the first metal layer 18 is a steel
selected from the group consisting of an austenitic stainless steel
of types 301, 304, 304L, 316 and 321, a ferritic steel of types 409
and 430, a high nickel steel alloy of types 625, 600 C276, 860 and
865, a titanium stabilized low carbon steel that meets the 1006
specification, a high carbon steel type 1050, a high strength low
alloy (HSLA) steel, a transformation-induced plasticity (TRIP)
steel, and a dual phase steel. The first surface 24 of the first
metal layer 18 becomes the first outer surface 12 of the metal
laminate 10 in the finished metal laminate 10.
[0031] Next, the method comprises providing a second metal layer
22. The second metal layer 22 comprises a different metal or metal
alloy than the first metal layer 18. In a preferred embodiment, the
second metal layer 22 comprises a metal selected from the group
consisting of nickel and copper.
[0032] Then, the method comprises plating the second metal layer 22
onto the second surface 26 of the first metal layer 18, thereby
producing a combined first metal layer 18-second metal layer 22. In
one embodiment, plating is performed by an electrolytic process. In
another embodiment, plating is performed by an electroless process
(also known as chemical plating or auto-catalytic plating).
[0033] In one embodiment, the method further comprises diffusion
bonding the combined first metal layer 18-second metal layer 22 by
heating the combined first metal layer 18-second metal layer 22 at
a suitable temperature and for a suitable time, as will be
understood by those with skill in the art with reference to this
disclosure. In a preferred embodiment, diffusion bonding is
performed in a continuous or batch anneal operation at a suitable
time and temperature to cause the layers to diffusion anneal/bond,
as will be understood by those with skill in the art with reference
to this disclosure.
[0034] The first metal layer 18 comprises a thickness and the
second metal layer 22 comprises a thickness. In one embodiment, the
thickness of the first metal layer 18 is between 10 and 10,000
times greater than the thickness of the second metal layer 22 in
the combined first metal layer 18-second metal layer 22 after
plating the second metal layer 22 onto the first metal layer 18 but
before cold roll bonding. In another embodiment, the thickness of
the first metal layer 18 is between about 100 and 10,000 times
greater than the thickness of the second metal layer 22 in the
combined first metal layer 18-second metal layer 22 after plating
the second metal layer 22 onto the first metal layer 18 but before
cold roll bonding. In one embodiment, the thickness of the first
metal layer 18 is between about 1000 and 10,000 times greater than
the thickness of the second metal layer 22 in the combined first
metal layer 18-second metal layer 22 after plating the second metal
layer 22 onto the first metal layer 18 but before cold roll
bonding. For example, in one embodiment of the present invention,
after plating but before cold roll bonding, the first metal layer
18 has a thickness of between about 0.01 mm and 2 mm. In another
embodiment, after plating but before cold roll bonding, the first
metal layer 18 has a thickness of between about 0.05 mm and 0.5 mm.
In another embodiment, after plating but before cold roll bonding,
the second metal layer 22 has a thickness of between about 0.0002
mm and 0.01 mm. In another embodiment, after plating but before
cold roll bonding, the second metal layer 22 has a thickness of
between about 0.0005 mm and 0.005 mm. In one embodiment, the
thickness of the first metal layer 18 is 0.25 mm after plating but
before cold roll bonding, and the thickness of the second metal
layer 22 is 0.001 mm after plating but before cold roll
bonding.
[0035] Then, the method comprises providing a third metal layer 20.
The third metal layer 20 comprises a different metal or metal alloy
than both the first metal layer 18 and the second metal layer 22.
The third metal layer 20 can be any metal or metal alloy suitable
for the intended use of the finished metal laminate 10, as will be
understood by those with skill in the art with reference to this
disclosure. For example, in a preferred embodiment, the third metal
layer 20 is a steel selected from the group consisting of an
austenitic stainless steel of types 301, 304, 304L, 316 and 321, a
ferritic steel of types 409 and 430, a high nickel steel alloy of
types 625, 600 C276, 860 and 865, a titanium stabilized low carbon
steel that meets the 1006 specification, a high carbon steel type
1050, a high strength low alloy (HSLA) steel, a
transformation-induced plasticity (TRIP) steel, and a dual phase
steel.
[0036] Next, the third metal layer 20 is cold roll bonded onto the
second metal layer 22 of the combined first metal layer 18-second
metal layer 22 thereby producing a finished metal laminate 10
according to the present invention. Cold roll bonding reduces the
thickness of the first metal layer 18-second metal layer 22/third
metal layer 20 by between 10% and 95% to produce the total
thickness 16 of the finished metal laminate 10 compared to the
thickness of the first metal layer 18-second metal layer 22/third
metal layer 20 immediately before cold roll bonding. For example;
in one embodiment, the thickness of the first metal layer 18-second
metal layer 22/third metal layer 20 immediately before cold roll
bonding is 8 mm while the total thickness 16 of the finished metal
laminate 10 after cold roll bonding is 3.2 mm. Similarly, for
example, in one embodiment, the thickness of the first metal layer
18-second metal layer 22/third metal layer 20 immediately before
cold roll bonding is 6 mm while the total thickness 16 of the
finished metal laminate 10 after cold roll bonding is 2.5 mm.
Similarly, for example, in another embodiment, the thickness of the
first metal layer 18-second metal layer 22/third metal layer 20
immediately before cold roll bonding is 0.12 mm while the total
thickness 16 of the finished metal laminate 10 after cold roll
bonding is 0.05 mm.
[0037] In a preferred embodiment, the method further comprises
diffusion annealing/bonding the metal laminate 10 in either a
continuous or batch anneal operation at a suitable time and
temperature to cause the layers to diffusion anneal/bond, as will
be understood by those with skill in the art with reference to this
disclosure.
[0038] In another embodiment, the method further comprises cold
reducing the metal laminate 10, one or more than one time after
cold roll bonding and, if performed, after diffusion
annealing/bonding. Cold reducing the metal laminate 10 further
reduces the total thickness 16 of the metal laminate 10 by an
additional 0.1% to 96% compared to the thickness of the metal
laminate 10 before cold reducing. For example, in one embodiment,
the total thickness of the metal laminate 10 is reduced by cold
reducing from a total thickness 16 of 2.5 mm to a total thickness
16 of 0.6 mm after cold reduction. For example, in another
embodiment, the total thickness of the metal laminate 10 is reduced
by cold reducing from a total thickness 16 of 3.2 mm to a total
thickness 16 of 2.0 mm after cold reduction. For example, in
another embodiment, the total thickness of the metal laminate 10 is
reduced by cold reducing from a total thickness 16 of 0.5 mm to a
total thickness 16 of 0.1 mm after cold reduction.
[0039] In another embodiment, the method further comprises
diffusion annealing/bonding the metal laminate 10 in a continuous
furnace or batch furnace after cold reducing the metal
laminate.
[0040] In a preferred embodiment, the first metal layer 18, the
second metal layer 22 and the third metal layer 20 each consists of
a metal or consists of a metal alloy. In another preferred
embodiment, the metal laminate 10 consists of two different types
of steel and either nickel or copper.
[0041] According to one embodiment of the present invention, there
is provided a method for making a metal laminate, where the metal
laminate comprises five or more than five layers, such as for
example, seven layers, nine layers or eleven layers. Referring now
to FIG. 2, there is shown a partial cross-sectional view of a metal
laminate according to the present invention consisting of five
layers. As can be seen, the five layer metal laminate 30 comprises
a first outer surface 32, a second outer surface 34, a total
thickness 36, a first metal layer 38, a third metal layer 40, an
intermediate second metal layer 42 between the first metal layer 38
and the third metal layer 40, a fifth metal layer 44 and an
intermediate fourth metal layer 46 between the third metal layer 40
and the fifth metal layer 44, where the first outer surface 32 is
formed by the first metal layer 38, and where the second outer
surface 34 is formed by the fifth metal layer 44. Though the
present method is disclosed specifically with respect to producing
a metal laminate consisting of five layers, metal laminates with
more than five layers, such as seven layers, nine layers, eleven
layers, and so forth, can also be produced according to this method
by repeating relevant steps prior to the cold rolling step, as will
be understood by those with skill in the art with reference to this
disclosure.
[0042] The method comprises, first, providing a first metal layer
38 comprising a metal or metal alloy. The first metal layer 38,
comprises a first surface 48 and a second surface 50, and can be
any metal or metal alloy suitable for the intended use of the
finished laminate 30, as will be understood by those with skill in
the art with reference to this disclosure. For example, in a
preferred embodiment, the first metal layer 38 is a steel selected
from the group consisting of an austenitic stainless steel of types
301, 304, 304L, 316 and 321, a ferritic steel of types 409 and 430,
a high nickel steel alloy of types 625, 600 C276, 860 and 865, a
titanium stabilized low carbon steel that meets the 1006
specification, a high carbon steel type 1050, a high strength low
alloy (HSLA) steel, a transformation-induced plasticity (TRIP)
steel, and a dual phase steel. The first surface 48 of the first
metal layer 38 becomes the first outer surface 32 of the metal
laminate 30 in the finished metal laminate 30.
[0043] Next, the method comprises providing a second metal layer
42. The second metal layer 42 comprises a different metal or metal
alloy than the first metal layer 38. In a preferred embodiment, the
second metal layer 42 comprises a metal selected from the group
consisting of nickel and copper.
[0044] Then, the method comprises plating the second metal layer 42
onto the second surface 50 of the first metal layer 38, thereby
producing a combined first metal layer 38-second metal layer 42. In
one embodiment, plating is performed by an electrolytic process. In
another embodiment, plating is performed by an electroless process
(also known as chemical plating or auto-catalytic plating).
[0045] In one embodiment, the method further comprises diffusion
bonding the combined first metal layer 38-second metal layer 42 by
heating the combined first metal layer 38-second metal layer 42 at
a suitable temperature and for a suitable time, as will be
understood by those with skill in the art with reference to this
disclosure. In a preferred embodiment, diffusion bonding is
performed in a continuous or batch anneal operation at a suitable
time and temperature to cause the layers to diffusion anneal/bond,
as will be understood by those with skill in the art with reference
to this disclosure.
[0046] The first metal layer 38 comprises a thickness and the
second metal layer 42 comprises a thickness. In one embodiment, the
thickness of the first metal layer 38 is between about 10 and
10,000 times greater than the thickness of the second metal layer
42 in the combined first metal layer 38-second metal layer 42 after
plating the second metal layer 42 onto the first metal layer 38 but
before cold roll bonding. In another embodiment, the thickness of
the first metal layer 38 is between about 100 and 10,000 times
greater than the thickness of the second metal layer 42 in the
combined first metal layer 38-second metal layer 42 after plating
the second metal layer 42 onto the first metal layer 38 but before
cold roll bonding. In one embodiment, the thickness of the first
metal layer 38 is between about 1000 and 10,000 times greater than
the thickness of the second metal layer 42 in the combined first
metal layer 38-second metal layer 42 after plating the second metal
layer 42 onto the first metal layer 38 but before cold roll
bonding. For example, in one embodiment of the present invention,
after plating but before cold roll bonding, the first metal layer
38 has a thickness of between about 0.01 mm and 2 mm. In another
embodiment, after plating but before cold roll bonding, the first
metal layer 38 has a thickness of between about 0.05 mm and 0.5 mm.
In another embodiment, after plating but before cold roll bonding,
the second metal layer 42 has a thickness of between about 0.0002
mm and 0.01 mm. In another embodiment, after plating but before
cold roll bonding, the second metal layer 42 has a thickness of
between about 0.0005 mm and 0.005 mm. In one embodiment, the
thickness of the first metal layer 38 is 0.25 mm after plating but
before cold roll bonding, and the thickness of the second metal
layer 42 is 0.001 mm after plating but before cold roll
bonding.
[0047] Then, the method comprises providing a fifth metal layer 44
comprising a metal or metal alloy. The fifth metal layer 44
comprises a first surface 52 and a second surface 54, and can be
any metal or metal alloy suitable for the intended use of the
finished metal laminate 30, as will be understood by those with
skill in the art with reference to this disclosure. For example, in
a preferred embodiment, the fifth metal layer 44 is a steel
selected from the group consisting of an austenitic stainless steel
of types 301, 304, 304L, 316 and 321, a ferritic steel of types 409
and 430, a high nickel steel alloy of types 625, 600 C276, 860 and
865, a titanium stabilized low carbon steel that meets the 1006
specification, a high carbon steel type 1050, a high strength low
alloy (HSLA) steel, a transformation-induced plasticity (TRIP)
steel, and a dual phase steel.
[0048] In one embodiment, the fifth metal layer 44 comprises the
same metal or metal alloy as the first metal layer 38. In another
embodiment, the fifth metal layer 44 comprises a different metal or
metal alloy than the first metal layer 38.
[0049] Next, the method comprises providing a fourth metal layer
46. The fourth metal layer 46 comprises a different metal or metal
alloy than the fifth metal layer 44. In a preferred embodiment, the
fourth metal layer 46 comprises a metal selected from the group
consisting of nickel and copper.
[0050] In one embodiment, the fourth metal layer 46 comprises the
same metal or metal alloy as the second metal layer 42. In another
embodiment, the fourth metal layer 46 comprises a different metal
or metal alloy than the second metal layer 42.
[0051] Then, the method comprises plating the fourth metal layer 46
onto the first surface 52 of the fifth metal layer 44, thereby
producing a combined fourth metal layer 46-fifth metal layer 44. In
one embodiment, plating is performed by an electrolytic process. In
another embodiment, plating is performed by an electroless process
(also known as chemical plating or auto-catalytic plating).
[0052] In one embodiment, the method further comprises diffusion
bonding the combined fourth metal layer 46-fifth metal layer 44 by
heating the combined fourth metal layer 46-fifth metal layer 44 at
a suitable temperature and for a suitable time, as will be
understood by those with skill in the art with reference to this
disclosure. In a preferred embodiment, diffusion bonding is
performed in a continuous or batch anneal operation at a suitable
time and temperature to cause the layers to diffusion anneal/bond,
as will be understood by those with skill in the art with reference
to this disclosure.
[0053] In one embodiment, the combined fourth metal layer 46-fifth
metal layer 44 comprises the same metal or metal alloy combination
as the combined first metal layer 38-second metal layer 42. In
another embodiment, the fourth metal layer 46-fifth metal layer 44
comprises a different metal or metal alloy combination than the
combined fourth metal layer 46-fifth metal layer 44.
[0054] The fifth metal layer 44 comprises a thickness and the
fourth metal layer 46 comprises a thickness. In one embodiment, the
thickness of the fifth metal layer 44 is between about 10 and
10,000 times greater than the thickness of the fourth metal layer
46 in the combined fifth metal layer 44-fourth metal layer 46 after
plating the fourth metal layer 46 onto the fifth metal layer 44 but
before cold roll bonding. In another embodiment, the thickness of
the fifth metal layer 44 is between about 100 and 10,000 times
greater than the thickness of the fourth metal layer 46 in the
combined fifth metal layer 44-fourth metal layer 46 after plating
the fourth metal layer 46 onto the fifth metal layer 44 but before
cold roll bonding. In one embodiment, the thickness of the fifth
metal layer 44 is between about 1000 and 10,000 times greater than
the thickness of the fourth metal layer 46 in the combined fifth
metal layer 44-fourth metal layer 46 after plating the fourth metal
layer 46 onto the fifth metal layer 44 but before cold roll
bonding. For example, in one embodiment of the present invention,
after plating but before cold roll bonding, the fifth metal layer
44 has a thickness of between about 0.01 mm and 2 mm. In another
embodiment, after plating but before cold roll bonding, the fifth
metal layer-44 has a thickness of between about 0.05 mm and 0.5 mm.
In another embodiment, after plating but before cold roll bonding,
the fourth metal layer 46 has a thickness of between about 0.0002
mm and 0.01 mm. In another embodiment, after plating but before
cold roll bonding, the fourth metal layer 46 has a thickness of
between about 0.0005 mm and 0.005 mm. In one embodiment, the
thickness of the fifth metal layer 44 is 0.25 mm after plating but
before cold roll bonding, and the thickness of the fourth metal
layer 46 is 0.001 mm after plating but before cold roll
bonding.
[0055] Next, the method comprises providing a third metal layer 40
having two outer surfaces. The third metal layer 40 comprises a
different metal or metal alloy than the first metal layer 38, the
second metal layer 42, the fourth metal layer 46 and the fifth
metal layer 44. In a preferred embodiment, the third metal layer is
a steel selected from the group consisting of an austenitic
stainless steel of types 301, 304, 304L, 316 and 321, a ferritic
steel of types 409 and 430, a high nickel steel alloy of types 625,
600 C276, 860 and 865, a titanium stabilized low carbon steel that
meets the 1006 specification, a high carbon steel type 1050, a high
strength low alloy (HSLA) steel, a transformation-induced
plasticity (TRIP) steel, and a dual phase steel.
[0056] Then, the third metal layer 40 is placed between the second
metal 42 side of the combined first metal layer 38-second metal
layer 42 and the fourth metal layer 46 side of the combined fourth
metal layer 46-fifth metal layer 44, thereby producing a combined
first metal layer 38 second metal layer 42/third metal layer
40/combined fourth metal layer 46-fifth metal layer 44. Next, the
combined first metal layer 38-second metal layer 42/third metal
layer 40/combined fourth metal layer 46-fifth metal layer 44 is
cold roll bonded together, thereby producing the metal laminate 30
according to the present invention. Cold roll bonding reduces the
thickness of the combined first metal layer 38-second metal layer
42/third metal layer 40/combined fourth metal layer 46-fifth metal
layer 44 by between 10% and 95% to produce the total thickness 36
of the finished metal laminate 30 compared to the thickness of the
combined first metal layer 38-second metal layer 42/third metal
layer 40/combined fourth metal layer 46-fifth metal layer 44
immediately before cold roll bonding. For example, in one
embodiment, the thickness of the combined first metal layer
38-second metal layer 42/third metal layer 40/combined fourth metal
layer 46-fifth metal layer 44 before cold roll bonding is 8.0 mm
while the total thickness 36 of the finished metal laminate 30
after cold roll bonding is 3.2 mm. Similarly for example, in one
embodiment, the thickness of the combined first metal layer
38-second metal layer 42/third metal layer 40/combined fourth metal
layer 46-fifth metal layer 44 before cold roll bonding is 6.0 mm
while the total thickness 36 of the finished metal laminate 30
after cold roll bonding is 2.5 mm. Similarly for example, in
another embodiment, the thickness of the combined first metal layer
38-second metal layer 42/third metal layer 40/combined fourth metal
layer 46-fifth metal layer 44 before cold roll bonding is 6.12 mm
while the total thickness 36 of the finished metal laminate 30
after cold roll bonding is 0.05 mm.
[0057] In an alternate embodiment, the method comprises providing a
first metal layer comprising a metal or metal alloy, where the
first metal layer further comprises a first surface and a second
surface; providing a second metal layer comprising a different
metal or metal alloy than the first metal layer; providing a third
metal layer having two outer surfaces; providing a fourth metal
layer comprising a metal or metal alloy; providing a fifth metal
layer comprising a metal or metal alloy, where the fifth metal
layer further comprises a first surface and a second surface. Next,
the second metal layer is plated onto one surface of the third
metal layer, and the fourth metal layer is plated onto the other
surface of the third metal layer, thereby producing a combined
second metal layer-third metal layer-fourth metal layer. Then, the
combined second metal layer-third metal layer-fourth metal layer is
placed between the second surface of the first metal layer and the
first surface of the fifth metal layer, thereby producing a first
metal layer/combined second metal layer-third metal layer-fourth
metal layer/fifth metal layer. Next, the first metal layer/combined
second metal layer-third metal layer-fourth metal layer/fifth metal
layer is cold roll bonded together, thereby producing the metal
laminate. The second metal layer and the fourth metal layer
comprise a different metal or metal alloy than any of the first
metal layer, the second metal layer and the third metal layer; and
the third metal layer comprises a different metal or metal alloy
than both the first metal layer and the fifth metal layer. Other
steps in this alternate embodiment correspond to steps disclosed
for other embodiments of the present method.
[0058] In a preferred embodiment, the method further comprises
diffusion annealing/bonding the metal laminate 30 in either a
continuous or batch anneal operation at a suitable time and
temperature to cause the layers to diffusion anneal/bond, as will
be understood by those with skill in the art with reference to this
disclosure.
[0059] In another embodiment, the method further comprises cold
reducing the metal laminate 30, one or more than one time after
cold roll bonding, or one or more than one time after diffusion
annealing/bonding or both one or more than one after cold roll
bonding and diffusion annealing/bonding. Cold reducing the metal
laminate 30 further reduces the total thickness 36 of the metal
laminate 30 by an additional 0.1% to 96% compared to the thickness
of the metal laminate 30 before cold reducing. For example, in one
embodiment, the total thickness of the metal laminate 30 is reduced
by cold reducing from a total thickness 36 of 2.5 mm to a total
thickness 36 of 0.6 mm after cold reduction. For example, in
another embodiment, the total thickness of the metal laminate 30 is
reduced by cold reducing from a total thickness 36 of 3.2 mm to a
total thickness 36 of 2.0 mm after cold reduction. For example, in
another embodiment, the total thickness of the metal laminate 30 is
reduced by cold reducing from a total thickness 36 of 0.5 mm to a
total thickness 36 of 0.1 mm after cold reduction.
[0060] In another embodiment, the metal laminate 30 is annealed in
a continuous furnace or batch furnace after being cold reduced.
[0061] In a preferred embodiment, the first metal layer 38, the
second metal layer 42, the third metal layer 40, the fourth metal
layer 46 and the fifth metal layer 44 each consists of a metal or
consists of a metal alloy. In another preferred embodiment, the
first metal layer 38 and the fifth metal layer 44 each consists of
the same type of steel, and the third metal layer 40 consists of a
type of steel that is different from the first metal layer 38 and
the fifth metal layer 44. In another preferred embodiment, the
first metal layer 38, the third metal layer 40 and the fifth metal
layer 44 each consists of a type of steel that is different from
one another. In another preferred embodiment, the metal laminate 30
consists of two different types of steel and either nickel or
copper, or copper or both nickel and copper. In another preferred
embodiment, the metal laminate 30 consists of three different types
of steel and either nickel or copper, or both nickel and
copper.
[0062] In another embodiment of the present invention, the method
further comprises providing a sixth metal layer corresponding to
the second metal layer 42 and the fourth metal layer 46 plated onto
a seventh metal layer corresponding to the first metal layer 38 and
the fifth metal layer 44, thereby producing a combined sixth metal
layer-seventh metal layer, and the method further comprises
applying the sixth metal layer-seventh metal layer onto the second
surface 54 of the fifth metal layer 44 before cold roll bonding to
create a metal laminate comprising seven layers. Referring now to
FIG. 3, there is shown is a partial cross-sectional view of a metal
laminate according to this embodiment of the present invention
comprising seven metal layers. As can be seen, the seven layer
metal laminate 60 comprises a first metal layer 62, a second metal
layer 64, a third metal layer 66, a fourth metal layer 68, a fifth
metal layer 70, a sixth metal layer 72 and a seventh metal layer
74. Other steps in this embodiment correspond to steps disclosed
for other embodiments of the present method. For example, as
disclosed above, the method can further comprise additional
annealing steps, and cold reducing steps as indicated for the three
layer laminate 10 and the five layer laminate 30, as will be
understood by those with skill in the art with reference to this
disclosure.
[0063] In another alternate embodiment, the method comprises
plating one outer surface of the third metal layer 40 with the
second metal layer 42, and other outer surface of the third metal
layer with the fourth metal layer 46 using processes corresponding
to the processes disclosed above to produce a combined second metal
layer 42-third metal layer 40-fourth metal layer 46. The method
further comprises plating one outer surface of a seventh metal
layer (corresponding to the first metal layer 38, third metal layer
40 and fifth metal layer 44) with a sixth metal layer
(corresponding to the second metal layer 42 and the fourth metal
layer 46) on one outer surface of the seventh metal layer, and
plating an eighth metal layer (also corresponding to the second
metal layer 42 and the fourth metal layer 46) on the other outer
surface of the seventh metal layer using processes corresponding to
the processes disclosed above to produce a combined sixth metal
layer-seventh metal layer-eight metal layer. Then, the method
comprises providing a ninth metal layer (also corresponding to the
first metal layer 38, third metal layer 40 and fifth metal layer
44) and cold rolling a first metal layer 38/combined second metal
layer 42-third metal layer 40-fourth metal layer 46/fifth metal
layer 44/combined sixth metal layer-seventh metal layer-eight metal
layer/ninth metal layer to produce a nine metal layer laminate
according to the present invention, as will be understood by those
with skill in the art with reference to this disclosure. Referring
now to FIG. 4, there is shown is a partial cross-sectional view of
a metal laminate according to this embodiment of the present
invention comprising nine metal layers. As can be seen, the nine
layer metal laminate 80 comprises a first metal layer 82, a second
metal layer 84, a third metal layer 86, a fourth metal layer 88, a
fifth metal layer 90, a sixth metal layer 92, a seventh metal layer
94, an eighth metal layer 96 and a ninth metal layer 98. Other
steps in this embodiment correspond to steps disclosed for other
embodiments of the present method. For example, as disclosed above,
the method can further comprise additional annealing steps, and
cold reducing steps as indicated for the three layer laminate 10
and the five layer laminate 30, as will be understood by those with
skill in the art with reference to this disclosure.
[0064] Further, as will be understood by those with skill in the
art with reference to this disclosure, eleven and more than eleven
metal layer laminates and so forth can also be produced using the
steps disclosed in this disclosure.
[0065] As indicated in this disclosure, the essential features of
this method are that each non-structural layer (the even numbered
layers in the finished laminate) are plated onto a structural layer
of the finished laminate (the odd numbered layers), and after
plating, all of the layers are cold roll bonded together.
[0066] According to another embodiment of the present invention,
there is provided a metal laminate. Referring again to FIG. 1,
there is shown is a partial cross-sectional view of a metal
laminate according to the present invention comprising three metal
layers. In a preferred embodiment, the metal laminate 10 is
produced using a method according to the present invention. In
another preferred embodiment, the metal laminate 10 consists of the
three layers shown in FIG. 1.
[0067] In one embodiment, the metal laminate 10 comprises a first
outer surface 12, a second outer surface 14, a total thickness 16,
a first metal layer 18, a third metal layer 20, and an intermediate
second metal layer 22 between the first metal layer 18 and the
third metal layer 20. As will be understood by those with skill in
the art with reference to this disclosure, the first outer surface
12 is formed by the first metal layer 18, and the second outer
surface 14 is formed by the third metal layer 20 when the metal
laminate 10 consists of only three layers. In one embodiment, the
first metal layer 18 and the third metal layer 20 are both a steel
selected from the group consisting of an austenitic stainless steel
of types 301, 304, 304L, 316 and 321, a ferritic steel of types 409
and 430, a high nickel steel alloy of types 625, 600 C276, 860 and
865, a titanium stabilized low carbon steel that meets the 1006
specification, a high carbon steel type 1050, a high strength low
alloy (HSLA) steel, a transformation-induced plasticity (TRIP)
steel, and a dual phase steel. The third metal layer 20 comprises a
different metal or metal alloy than the first metal layer 18. In a
preferred embodiment, the first metal layer 18 consists of a first
type of steel and the third metal layer 20 consists of a second
type of steel, and the first type of steel is different from the
second type of steel.
[0068] The second metal layer 22 comprises a different metal or
metal alloy than the first metal layer 18 and the third metal layer
20. In a preferred embodiment, the second metal layer 22 comprises
a metal selected from the group consisting of nickel and
copper.
[0069] In a preferred embodiment, the first metal layer 18, the
second metal layer 22 and the third metal layer 20 each consists of
a metal or consists of a metal alloy.
[0070] The first metal layer 18 comprises a thickness, the second
metal layer 22 comprises a thickness, and the third metal layer 20
comprises a thickness. In one embodiment, the thickness of both the
first metal layer 18 and the third metal layer 20 are both between
10 and 10,000 times greater than the thickness of the second metal
layer 22 in the metal laminate 10. In one embodiment, the thickness
of both the first metal layer 18 and the third metal layer 20 are
both between 100 and 10,000 times greater than the thickness of the
second metal layer 22 in the metal laminate 10. In one embodiment,
the thickness of both the first metal layer 18 and the third metal
layer 20 are both between 1000 and 10,000 times greater than the
thickness of the second metal layer 22 in the metal laminate 10.
For example, in one embodiment of the present invention, the first
metal layer 18 has a thickness of between 0.005 mm and 5 mm.
[0071] According to another embodiment of the present invention,
there is provided a metal laminate comprising a plurality of
alternating structural layers (the odd numbered layers counting
from the outer surface of the metal laminate) and non-structural
layers (the even numbered layers counting from the outer surface of
the metal laminate). The structural layers contribute significantly
to the overall strength of the metal laminate, while the
non-structural layers do not contribute significantly to the
overall strength of the metal laminate, but serve to bind the
structural layers together. A significant contribution to the
overall strength of the metal laminate is defined as 1% or more of
the final tensile strength of the laminate. Put another way, the
non-structural layers contribute less than 1% of the tensile
strength of the metal laminate, but serve to bind the structural
layers together.
[0072] In a preferred embodiment, all of the structural layers and
the non-structural layers comprise a metal or metal alloy. In
another preferred embodiment, all of the structural layers and the
non-structural layers consist of a metal or metal alloy. In a
preferred embodiment, each structural layer comprises a metal or
metal alloy that is different from the metal or metal alloy of each
non-structural layer. In a preferred embodiment, each structural
layer consists of a metal or metal alloy that is different from the
metal or metal alloy of each non-structural layer.
[0073] In one embodiment, at least two structural layers comprise a
metal or metal alloy that is different from one another. In a
preferred embodiment, the metal laminate comprises at least three
structural layers, a first structural layer comprising a first type
of steel, a second structural layer comprising a second type of
steel, and a third structural layer comprising a third type of
steel, where the first type of steel and the third type of steel
are different from the second type of steel. In another preferred
embodiment, the metal laminate comprises at least three structural
layers, a first structural layer comprising a first type of steel,
a second structural layer comprising a second type of steel, and a
third structural layer comprising a third type of steel, where the
first type of steel and the third type of steel are different from
the second type of steel, and where the first type of steel is
different from the third type of steel. Referring again to FIG. 2,
there is shown is a partial cross-sectional view of a metal
laminate according to the present invention comprising five metal
layers. In a preferred embodiment, the metal laminate 30 is
produced using a method according to the present invention. In
another preferred embodiment, the metal laminate 30 consists of the
five layers shown in FIG. 2, three structural layers and two
non-structural layers.
[0074] In one embodiment, the metal laminate 30 comprises a first
outer surface 32, a second outer surface 34, a total thickness 36,
a first metal layer 38 (a structural layer), a third metal layer 40
(a structural layer), an intermediate second metal layer 42 (a
non-structural layer) between the first metal layer 38 and the
third metal layer 40, a fifth metal layer 44 (a structural layer)
and an intermediate fourth metal layer 46 (a non-structural layer)
between the third metal layer 40 and the fifth metal layer 44. As
will be understood by those with skill in the art with reference to
this disclosure, the first outer surface 32 is formed by the first
metal layer 18, and the second outer surface 34 is formed by the
first metal layer 44 when the metal laminate 30 consists of only
five layers.
[0075] In one embodiment, each structural layer comprises a steel
selected from the group consisting of an austenitic stainless steel
of types 301, 304, 304L, 316 and 321, a ferritic steel of types 409
and 430, a high nickel steel alloy of types 625, 600 C276, 860 and
865, a titanium stabilized low carbon steel that meets the 1006
specification, a high carbon steel type 1050, a high strength low
alloy (HSLA) steel, a transformation-induced plasticity (TRIP)
steel, and a dual phase steel. In another embodiment, the
non-structural layers are a metal selected from the group
consisting of nickel and copper.
[0076] In another embodiment, each non-structural layer comprises a
metal selected from the group consisting of nickel and copper. In
another preferred embodiment, all non-structural layers consist of
the same metal or metal alloy.
[0077] As will be understood by those with skill in the art with
reference to this disclosure, the metal laminate can consist of any
number of structural layers, where the number of structural layers
is X, with a number of non-structural layers, where the number of
non-structural layers is X-1. In one embodiment, the metal laminate
30 comprises more than the five layers as shown in FIG. 2. In a
preferred embodiment, the metal laminate 60 consists of seven
layers as shown in FIG. 3. In another preferred embodiment, the
metal laminate 80 consists of nine layers, as shown in FIG. 4. The
metal laminate can consist of a greater number of layers than nine
layers, such as eleven layers or thirteen layers, as will be
understood by those with skill in the art with reference to this
disclosure.
[0078] Each structural layer comprises a thickness and each
non-structural layer comprises a thickness. In one embodiment, the
thickness of each structural layer is between 10 and 10,000 times
greater than the thickness of each non-structural layer. In another
embodiment, the thickness of each structural layer is between 100
and 10,000 times greater than the thickness of each non-structural
layer. In another embodiment, the thickness of each structural
layer is between 1000 and 10,000 times greater than the thickness
of each non-structural layer. For example, in one embodiment of the
present invention, the thickness of each structural layer is
between 0.005 mm and 5 mm, while the thickness of each
non-structural layer is between 0.0001 mm and 0.01 mm.
[0079] According to another embodiment of the present invention,
there is provided a commercial product comprising a metal laminate
according to the present invention. In one embodiment, the
commercial product is selected from the group consisting of an
automobile part, tubing, a home appliance, a counter top and a fuel
cell. Referring now to FIG. 5, there is shown a partial cutaway,
lateral perspective view of a tubing 100 comprising a metal
laminate 30 of the present invention as shown in FIG. 2.
EXAMPLE 1
Method for Making a Metal Laminate
[0080] A metal laminate according to the present invention was
produced using a method for making a metal laminate according to
the present invention as follows. First, a UNS S32100 stainless
steel coil 0.15 mm thick was purchased from ZAPP, USA (Dartmouth,
Mass. US). The stainless steel coil was electroplated by Thomas
Steel Strip, Corp. (Warren, Ohio US) with 0.001 mm of nickel on one
side, and then the resultant stainless steel-nickel laminate was
diffusion bonded by heating the stainless steel-nickel laminate in
a continuous annealing line at 1,000.degree. C.
[0081] Next, a layer of low carbon steel coil 3.7 mm thick was
placed between the nickel sides of two diffusion bonded stainless
steel-nickel laminates as produced above, and the five layers were
cold roll bonded together by Engineered Material Systems
(Attleboro, Mass. US) forming a five layer laminate with stainless
steel on both outer surfaces, low carbon steel in the middle and
relatively thin nickel layers between the stainless steel and low
carbon steel. The resultant five layer metal laminate had a total
thickness of about 1.6 mm. This five layer laminate was then
annealed in a batch furnace at 725.degree. C. for one hour
producing a five layer metal laminate of superior corrosion
resistance compared to carbon steel having the same thickness and
weight, and that will not delaminate or crack in service compared
to a similar three sheet laminate that does not include the
intermediate, non-structural layers, and does not waste valuable
nickel with relatively thick intermediate sheets of nickel as
compared to the steel layers.
EXAMPLE 2
Method for Making a Metal Laminate
[0082] A corrosion resistant metal laminate according to the
present invention was produced using a method for making a metal
laminate according to the present invention as follows. First, a
625 nickel-based alloy coil (comprising about 61% nickel) 0.10 mm
thick was purchased from ZAPP, USA. Next, a 409 stainless steel
coil 1.5 mm thick was purchased from Thomas Steel Strip and was
electroplated with 0.003 mm of nickel on both surfaces of the 409
stainless steel coil. This electroplated 409 coil was diffusion
bonded by heating the stainless steel-nickel laminate in a
continuous annealing line at 720.degree. C.
[0083] Next, the diffusion bonded stainless steel-nickel laminate
was placed between two 625 nickel based-alloy coils, and the five
layers were roll bonded together by Engineered Material Systems
forming a five layer laminate with 625 nickel-based alloy on both
outer surfaces, 409 stainless steel in the middle and nickel
between the stainless steel and the 625 nickel-based alloy. The
resultant five layer metal laminate had a total thickness of about
0.69 mm. This five layer laminate was then annealed in a batch
furnace at 800.degree. C. for one hour producing a five layer metal
laminate of superior corrosion and heat resistance compared to
ordinary stainless steel.
EXAMPLE 3
Method for Making a Metal Laminate
[0084] A metal laminate according to the present invention was
produced using a method for making a metal laminate according to
the present invention as follows. First, a UNS S32100 stainless
steel coil 0.25 mm thick was purchased from Combined Metals of
Chicago, LLC (Bellwood, Ill. US). The stainless steel coil was
electroplated by Thomas Steel Strip, Corp. (Warren, Ohio US) with
0.001 mm of nickel on one side, and then the resultant stainless
steel-nickel laminate was diffusion bonded by heating the stainless
steel-nickel laminate in a continuous annealing line at
1,000.degree. C.
[0085] Next, a layer of titanium stabilized low carbon steel
(Severstal North American, Inc. Dearborn Mich.) 3.4 mm thick was
placed between the nickel sides of two diffusion bonded stainless
steel-nickel laminates as produced above, and the five layers were
cold roll bonded together by Engineered Material Systems
(Attleboro, Mass. US) forming a five layer laminate with stainless
steel on both outer surfaces, titanium stabilized low carbon steel
in the middle and relatively thin nickel layers between the
stainless steel and titanium stabilized low carbon steel. The
resultant five layer metal laminate had a total thickness of about
1.5 mm. This five layer laminate was then annealed in a batch
furnace at 725.degree. C. for one hour producing a five layer metal
laminate of superior corrosion resistance compared to carbon steel
having the same thickness and weight, and that will not delaminate
or crack in service compared to a similar three sheet laminate that
does not include the intermediate, non-structural nickel layers,
and does not waste valuable nickel with relatively thick
intermediate sheets of nickel as compared to the steel layers.
[0086] Although the present invention has been discussed in
considerable detail with reference to certain embodiments, other
embodiments are possible to those skilled in the art. Therefore,
the scope of the appended claims should not be limited to the
description of the embodiments contained in this disclosure.
* * * * *