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Thin foils require cold rolling to reach the desired thickness and surface quality. They are more prone to surface damage than thicker metals, and so reliable monitoring is essential to the process.

Aluminum sheets of high purity (between 92-99% aluminum) can be reduced to a very small thickness by cold rolling. Reduction of the foil thickness is controlled by adjusting roll speed viscosity, and lubricant temperature, while the roll gap determines the thickness and length of the final foil product. 

Pure or low-alloy aluminum can be reduced from sheets about an inch (25mm) thick down to a foil of 0.0001in (0.0025mm) thick through cold-rolling processes. This is accomplished through a multiple-stand mill, or via several passes through a single-stand mill.

The impact of any surface defects in the metal can be exacerbated as the thickness is reduced, leading to tears or other structural imperfections. An automated inspection solution will pick up any issues at an early stage before major process problems occur.
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