WO2007055764A2 - Metal laminate - Google Patents

Metal laminate Download PDF

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Publication number
WO2007055764A2
WO2007055764A2 PCT/US2006/030996 US2006030996W WO2007055764A2 WO 2007055764 A2 WO2007055764 A2 WO 2007055764A2 US 2006030996 W US2006030996 W US 2006030996W WO 2007055764 A2 WO2007055764 A2 WO 2007055764A2
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WO
WIPO (PCT)
Prior art keywords
metal layer
metal
thickness
steel
laminate
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Application number
PCT/US2006/030996
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French (fr)
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WO2007055764A3 (en
Inventor
William Russell Kingston
Original Assignee
William Russell Kingston
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Publication date
Application filed by William Russell Kingston filed Critical William Russell Kingston
Priority to US11/568,312 priority Critical patent/US20080251389A1/en
Publication of WO2007055764A2 publication Critical patent/WO2007055764A2/en
Publication of WO2007055764A3 publication Critical patent/WO2007055764A3/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/48—After-treatment of electroplated surfaces
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating

Definitions

  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the second metal layer comprises a metal selected from the group consisting of nickel and copper.
  • plating is performed by an electrolytic process.
  • plating is performed by an electroless process.
  • the method further comprises diffusion bonding the combined first metal layer- second metal layer.
  • 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.
  • 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.
  • 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.
  • 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% .
  • the method further comprises diffusion annealing/bonding the metal laminate.
  • the method further comprises cold reducing the metal laminate one or more than one time after diffusion annealing/bonding.
  • 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.
  • 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.
  • a method for making a metal laminate comprising 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
  • 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
  • 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.
  • 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 PCT/USOB/3O "ft.fi EU
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the third metal layer comprises a thickness
  • the fourth metal layer comprises a thickness
  • 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.
  • the second metal layer comprises a thickness
  • the third metal layer comprises a thickness
  • the fourth metal layer comprises a thickness
  • 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.
  • the second metal layer comprises a thickness
  • the third metal layer comprises a thickness
  • the fourth metal layer comprises a thickness
  • 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.
  • the fifth metal layer comprises the same metal or metal alloy as the first metal layer.
  • the fifth metal layer comprises a different metal or metal alloy than the first metal layer.
  • 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.
  • 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.
  • the combined first metal layer-second metal layer/third metal layer/combined fourth metal layer-rfifth 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 % .
  • 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% .
  • the method further comprises diffusion annealing/bonding the metal laminate.
  • the method further comprises cold reducing the metal laminate one or more than. one time after cold roll bonding.
  • the method further comprises cold reducing the metal laminate one or more than one time after diffusion annealing/bonding.
  • the method further comprises diffusion annealing the metal laminate after cold reducing.
  • the method further comprises annealing the metal laminate after cold reducing.
  • 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.
  • 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.
  • 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.
  • the metal laminate consists of two different types of steel, and either nickel or copper.
  • the metal laminate consists of three different types of steel, and either nickel or copper.
  • 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.
  • a metal laminate produced according to a method of the present invention.
  • 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 / U S Q B / 3 Cl > 99 S
  • 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.
  • 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.
  • the second metal layer comprises a metal selected from the group consisting of nickel and copper.
  • the first metal layer, the second metal layer and the third metal layer each consists of a metal or consists of a metal alloy.
  • the first metal layer comprises a thickness
  • the second metal layer comprises a thickness
  • 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.
  • the first metal layer comprises a thickness
  • the second metal layer comprises a thickness
  • the third metal layer comprises a thickness
  • 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.
  • 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 nonstructural 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • HSLA high strength low alloy
  • TRIP transformation-induced plasticity
  • 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.
  • each non-structural layer comprises a metal selected from the group consisting of nickel and copper.
  • each non-structural layer consists of a metal selected from the group consisting of nickel and copper.
  • each non-structural layer comprises the same metal or metal alloy, or consists of the same metal or metal alloy.
  • the metal laminate consists of three structural layers and two non-structural layers.
  • the metal laminate consists of four structural layers and three non-structural layers.
  • the metal laminate consists of 10 five structural layers and four non-structural layers.
  • the metal laminate consists of six structural layers and five non-structural layers.
  • the metal laminate comprises more than six structural layers and more than five non-structural layers.
  • 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.
  • 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.
  • a commercial product comprising a metal laminate according to the present invention.
  • 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.
  • Figure 1 is a partial cross-sectional view of a metal laminate according to the present invention comprising three metal layers;
  • Figure 2 is a partial cross-sectional view of a metal laminate according to the present invention comprising five metal layers;
  • Figure 3 is a partial cross-sectional view of a metal laminate according to the present invention comprising seven metal layers
  • Figure 4 is a partial cross-sectional view of a metal laminate according to the present invention comprising nine metal layers
  • Figure 5 is a partial cutaway, lateral perspective view of a tubing comprising a metal laminate of the present invention as shown in Figure 2.
  • a method for making a metal laminate comprising at least one plating step and at least one cold roll bonding step.
  • 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.
  • 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.
  • 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.
  • 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 .
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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 .
  • the laminate in one embodiment, there is provided a laminate produced according to any method of the present invention.
  • 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.
  • 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.
  • 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 ° C , an amount insufficient by itself to bond the layers of metal or metal alloy.
  • metal means metal or metal alloy. Therefore the word “metal” means metal or metal alloy. Therefore the word “metal” means metal or metal alloy. Therefore the word “metal” means metal or metal alloy. Therefore the word “metal” means metal or metal alloy. Therefore the word “metal” means metal or metal alloy. Therefore the word “metal” means metal or metal alloy. Therefore the word “metal” means metal or metal alloy. Therefore the word “metal” means metal or metal alloy. Therefore the word “metal” means metal or metal alloy. Therefore the word “metal” means metal or metal alloy.
  • 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.
  • 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.
  • a "structural layer” refers to an odd numbered layer of the finished laminate counting from either outer surface layer
  • a “non-structural layer” refers to an even numbered layer of the finished laminate counting from either outer surface layer.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the second metal layer 22 comprises a metal selected from the group consisting of nickel and copper.
  • 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.
  • plating is performed by an electrolytic process.
  • plating is performed by an electroless process (also known as chemical plating or auto-catalytic plating).
  • 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.
  • 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.
  • the first metal layer 18 comprises a thickness and the second metal layer 22 comprises a thickness.
  • 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.
  • 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.
  • 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.
  • the first metal layer 18 after plating but before cold roll bonding, has a thickness of between about 0.01 mm and 2 mm.
  • the first metal layer 18 after plating but before cold roll bonding, has a thickness of between about 0.05 mm and 0.5 mm.
  • the second metal layer 22 has a thickness of between about 0.0002 mm and 0.01 mm.
  • 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. 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.
  • 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.
  • 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
  • TRIP transformation-induced plasticity
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the method further comprises cold reducing the metal laminate
  • 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.
  • 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.
  • 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.
  • the method further comprises diffusion annealing/bonding the metal laminate 10 in a continuous furnace or batch furnace after cold reducing the metal laminate.
  • 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.
  • the metal laminate 10 consists of two different types of steel and either nickel or copper.
  • 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.
  • the metal laminate comprises five or more than five layers, such as for example, seven layers, nine layers or eleven layers.
  • Figure 2 there is shown a partial cross-sectional view of a metal laminate according to the present invention consisting of five layers .
  • 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.
  • 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.
  • 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 T/ ⁇ soB/ ' aogfiie
  • 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.
  • the method comprises providing a second metal layer 42.
  • the second metal layer 42 The second metal layer 42.
  • the second metal layer 42 comprises a different metal or metal alloy than the first metal layer 38.
  • the second metal layer 42 comprises a metal selected from the group consisting of nickel and copper.
  • 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.
  • plating is performed by an electrolytic process.
  • plating is performed by an electroless process (also known as chemical plating or auto-catalytic plating).
  • 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.
  • 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.
  • the first metal layer 38 comprises a thickness and the second metal layer 42 comprises a thickness .
  • 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.
  • 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 P 1 C T/ ' U S O- S / 3 Q «39 B
  • 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.
  • the first metal layer 38 after plating but before cold roll bonding, has a thickness of between about 0.01 mm and 2 mm.
  • the first metal layer 38 after plating but before cold roll bonding, has a thickness of between about 0.05 mm and 0.5 mm.
  • the second metal layer 42 has a thickness of between about 0.0002 mm and 0.01 mm.
  • the second metal layer 42 after plating but before cold roll bonding, 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. 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 hi the art with reference to this disclosure.
  • 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.
  • 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.
  • HSLA high
  • 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.
  • 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.
  • the fourth metal layer 46 comprises a metal selected from the group consisting of nickel and copper.
  • 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.
  • 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.
  • 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).
  • 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.
  • 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.
  • 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.
  • the fifth metal layer 44 comprises a thickness and the fourth metal layer 46 comprises a thickness.
  • 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.
  • 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.
  • 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.
  • the fifth metal layer 44 after plating but before cold roll bonding, has a thickness of between about 0.01 mm and 2 mm.
  • the fifth metal layer 44 after plating but before cold roll bonding, has a thickness of between about 0.05 mm and 0.5 mm.
  • the fourth metal layer 46 has a thickness of between about 0.0002 mm and 0.01 mm.
  • the fourth metal layer 46 after plating but before cold roll bonding, 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.
  • 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.
  • 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.
  • HSLA high strength low alloy
  • TRIP transformation-induced plasticity
  • 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.
  • 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.
  • 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.
  • 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.
  • 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 0.12 mm while the total thickness 36 of the finished metal laminate 30 after cold roll bonding is 0.05 mm.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the metal laminate 30 is annealed in a continuous furnace or batch furnace after being cold reduced.
  • 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.
  • the first metal layer 38 and the fifth metal layer 44 each consists of the same type of steel
  • 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.
  • 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.
  • the metal laminate 30 consists of two different types of steel and either nickel or copper, or copper or both nickel and copper.
  • the metal laminate 30 consists of three different types of steel and either nickel or copper, or both nickel and copper.
  • 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.
  • Figure 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.
  • 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.
  • 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.
  • 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.
  • a seventh metal layer corresponding to the first metal layer 38, third metal layer 40 and fifth metal layer 44
  • a sixth metal layer corresponding to the second metal layer 42 and the fourth metal layer 46
  • an eighth metal layer also corresponding to the second metal layer 42 and the fourth metal layer 46
  • 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.
  • Figure 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.
  • 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.
  • 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.
  • each nonstructural 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.
  • a metal laminate Referring again to Figure 1 , there is shown is a partial cross-sectional view of a metal laminate according to the present invention comprising three metal layers.
  • the metal laminate 10 is produced using a method according to the present invention.
  • the metal laminate 10 consists of the three layers shown in Figure 1.
  • 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.
  • 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.
  • 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.
  • 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.
  • the second metal layer 22 comprises a different metal or metal alloy than the first metal layer 18 and the third metal layer 20.
  • the second metal layer 22 comprises a metal selected from the group consisting of nickel and copper.
  • 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.
  • the first metal layer 18 comprises a thickness
  • the second metal layer 22 comprises a thickness
  • the third metal layer 20 comprises a thickness.
  • 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.
  • 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.
  • 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.
  • the first metal layer 18 has a thickness of between 0.005 mm and 5 mm.
  • 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 nonstructural layers contribute less than 1 % of the tensile strength of the metal laminate, but serve to bind the structural layers together.
  • 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. . In one embodiment, at least two structural layers comprise a metal or metal alloy that is different from one another.
  • 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.
  • 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.
  • a partial cross-sectional view of a metal laminate according to the present invention comprising five metal layers.
  • the metal laminate 30 is produced using a method according to the present invention.
  • the metal laminate 30 consists of the five layers shown in Figure 2, three structural layers and two non-structural layers.
  • 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.
  • 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.
  • 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.
  • the non-structural layers are a metal selected from the group consisting of nickel and copper.
  • 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.
  • 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-I .
  • the metal laminate 30 comprises more than the five layers as shown in Figure 2.
  • the metal laminate 60 consists of seven layers as shown in Figure 3.
  • the metal laminate 80 consists of nine layers, as shown in Figure 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.
  • Each structural layer comprises a thickness and each non-structural layer comprises a thickness.
  • the thickness of each structural layer is between 10 and 10,000 times greater than the thickness of each non-structural layer.
  • the thickness of each structural layer is between 100 and 10,000 times greater than the thickness of each non-structural layer.
  • the thickness of each structural layer is between 1000 and 10,000 times greater than the thickness of each non-structural layer.
  • 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.
  • a commercial product comprising a metal laminate according to the present invention.
  • the commercial product is selected from the group consisting of an automobile part, tubing, a home appliance, a counter top and a fuel cell.
  • Figure 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 Figure 2.
  • 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, MA US). The stainless steel coil was electroplated by Thomas Steel Strip, Corp. (Warren, OH 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 0 C.
  • 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, MA 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 0 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.
  • 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° C.
  • 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 ° C for one hour producing a five layer metal laminate of superior corrosion and heat resistance compared to ordinary stainless steel.
  • 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, IL US). The stainless steel coil was electroplated by Thomas Steel Strip, Corp. (Warren, OH 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 l,000°C.
  • a layer of titanium stabilized low carbon steel (Severstal North American, Inc. Dearborn MI) 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, MA 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 0 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 .

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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.

Description

METAL LAMINATE
CROSS-REFERENCE TO RELATED APPLICATIONS
The present Application claims the benefit of United States Provisional Patent Application 60/734,517, titled "Metal Laminate" and filed November 7, 2005, the contents of which are incorporated in this disclosure by reference in their entirety BACKGROUND
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.
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.
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.
Therefore, there is a need 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
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.
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 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 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.
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 P-C T / U S Cl B / 3 O 1(i 1P B
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.
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 PCT/USOB/3O "ft.fi EU
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 IP C T/" U S O S / 3 O 99 B
6 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-rfifth 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.
According to another embodiment of the present invention, there is provided a metal laminate produced according to a method of the present invention.
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 / U S Q B / 3 Cl >99 S
8 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.
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 nonstructural 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 10 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.
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
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:
Figure 1 is a partial cross-sectional view of a metal laminate according to the present invention comprising three metal layers;
Figure 2 is a partial cross-sectional view of a metal laminate according to the present invention comprising five metal layers;
Figure 3 is a partial cross-sectional view of a metal laminate according to the present invention comprising seven metal layers; Figure 4 is a partial cross-sectional view of a metal laminate according to the present invention comprising nine metal layers; and
Figure 5 is a partial cutaway, lateral perspective view of a tubing comprising a metal laminate of the present invention as shown in Figure 2.
DESCRIPTION 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.
As used in this disclosure, except where the context requires otherwise, all amounts are given in percent of total weight or total thickness. 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.
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.
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.
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 ° C , an amount insufficient by itself to bond the layers of metal or metal alloy.
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.
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. 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.
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 Figure 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.
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.
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.
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). 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.
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. 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.
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.
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. 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 P C YS U S O 6 / 3 O 9 lfi S
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.
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.
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.
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 Figure 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.
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 T/ϋsoB/'aogfiie
17 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. 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.
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).
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.
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 P1 C T/' U S O- S / 3 Q «39 B
18
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. 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 hi 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.
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.
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.
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.
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).
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.
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.
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.
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.
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 0.12 mm while the total thickness 36 of the finished metal laminate 30 after cold roll bonding is 0.05 mm.
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. 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.
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.
In another embodiment, the metal laminate 30 is annealed in a continuous furnace or batch furnace after being cold reduced.
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.
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 Figure 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. 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 Figure 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. 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. As indicated in this disclosure, the essential features of this method are that each nonstructural 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. According to another embodiment of the present invention, there is provided a metal laminate. Referring again to Figure 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 Figure 1.
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.
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.
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.
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.
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 nonstructural layers contribute less than 1 % of the tensile strength of the metal laminate, but serve to bind the structural layers together.
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. . 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 Figure 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 Figure 2, three structural layers and two non-structural layers.
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.
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.
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.
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-I . In one embodiment, the metal laminate 30 comprises more than the five layers as shown in Figure 2. In a preferred embodiment, the metal laminate 60 consists of seven layers as shown in Figure 3. In another preferred embodiment, the metal laminate 80 consists of nine layers, as shown in Figure 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.
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.
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 Figure 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 Figure 2.
EXAMPLE 1 METHOD FOR MAKING A METAL LAMINATE
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, MA US). The stainless steel coil was electroplated by Thomas Steel Strip, Corp. (Warren, OH 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 1,0000C.
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, MA 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 7250C 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
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° C. 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 ° 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
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, IL US). The stainless steel coil was electroplated by Thomas Steel Strip, Corp. (Warren, OH 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 l,000°C.
Next, a layer of titanium stabilized low carbon steel (Severstal North American, Inc. Dearborn MI) 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, MA 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 7250C 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 .
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.

Claims

WHAT IS CLAIMED IS:
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 farther 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 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.
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 nonstructural layers comprise a metal or metal alloy.
67. The metal laminate of claim 65, where all of the structural layers and the nonstructural 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 nonstructural layers.
80. The metal laminate of claim 65, consisting of five structural layers and four nonstructural layers.
81. The metal laminate of claim 65, consisting of six structural layers and five nonstructural 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 nonstructural 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 nonstructural 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 nonstructural 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.
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