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Foil Material Sourcing, Aluminum Foil For Appliances, Automotive – Sourcebook

Foils

Foil is defined as an unsupported thin metal sheet, typically aluminum, less than 200 micrometers (0.0079 inch) thick. Traditionally, an annealing (heat treatment) process was used to create foils, but it has become common practice to use a continuous casting process. Foils are commonly used as an impermeable barrier layer between two environments.
Continuous casting produces a finished product of rolls of metal foil. There are several different types of continuous casting used to produce foil. All continuous casting processes typically include either one or multiple rotating drums where heated or molten metal is pushed through in order to flatten it. The metal is then quenched with water to produce a final foil of desired thickness. These processes can occur either horizontally or vertically. For example, during the twin-drum strip casting process, the selected metal will be melted down and pushed through a pair of rotating drums to a specific thickness, then cooled with water. Another example of continuous casting involves the molten metal being pushed between two pairs of drums, in which each set of drums are located on either set of the molten sheet being created. The sets of drums are connected by a belt, which simultaneously guides the molten metal along the process line while flattening it.

The main advantages of continuous casting is its ability to optimize the foil production process, thus decreasing the amount of time and money needed. In addition, the metals sheets and rolls produced from continuous casting processes possess consistent physical characteristics.

Conductive layer
Electronics
Packaging