Essential Readings in Light Metals: Cast Shop for Aluminum Production, Volume 3

Cover
Title Page
Copyright Page
TABLE OF CONTENTS
Preface
Lead Editors
Editorial Team
Part 1: Introduction
	The Role of Casting Technology in the Development of New and Improved Fabricated Products
Part 2: Furnaces, Melting, Fluxing, and Alloying
	Section Introduction
	Optimal Fuel Control of a Casting Furnace
	Na and Ca Pick-up from Hall Bath in Ingot Furnaces
	Alloying by Injection of Mg in an Al Melt
	Alloying of Molten Aluminium: Optimizing the Present and Preparing the Future
	Dissolution Mechanism for High Melting Point Transition Elements in Aluminum Melt
	A Technical Perspective on Molten Aluminum Processing
	Melt Treatment — Evolution and Perspectives
	Gas Fluxing of Molten Aluminum: An Overview
	Removal of Alkali Metals from Aluminum
	On the Kinetics of Removal of Sodium from Aluminum and Aluminum-Magnesium Alloys
	Removal of Lithium in Commercial Metal
	Current Technologies for the Removal of Iron from Aluminum Alloys
	Settling of Inclusions in Holding Furnaces: Modeling and Experimental Results
	Settling Phenomena in Casting Furnaces: A Fundamental and Experimental Investigation
	In-Line Salt Fluxing Process: The Solution to Chlorine Gas Utilization in Casthouses
	Recommended Reading
Part 3: Oxidation and Dross Processing
	Section Introduction
	Oxidation of Liquid Aluminum-Magnesium Alloys
	Metallurgy of Dross Formation on Al Melts
	Furnace Dross — Its Formation and Recovery
	New Process of Direct Metal Recovery from Drosses in the Aluminum Casthouse
	Melt Loss Evaluation
	Molten Salt Flux Composition Effects in Aluminum Scrap Remelting
	Recommended Reading
Part 4: Melt Quality: Degassing, Filtering, and Analysis
	Section Introduction
	Analysis and Thermodynamic Prediction of Hydrogen Solution in Solid and Liquid Multicomponent Aluminum Alloys
	A Radioscopie Technique to Observe Bubbles in Liquid Aluminum
	Molten Aluminium Purification
	Removal of Hydrogen from Molten Aluminium by Gas Purging
	Gas Fluxing of Molten Aluminum. Part 1: Hydrogen Removal
	Alcan Compact Degasser: A Trough-based Aluminum Treatment Process. Part I: Metallurgical Principles and Performance
	Dynamic Vacuum Treatment of Molten Aluminium and Its Alloys
	Ultrasonic Degassing of Molten Aluminum under Reduced Pressure
	Industrial Application of Open Pore Ceramic Foam for Molten Metal Filtration
	Deep Bed Filtration Theory Compared with Experiments
	Efficiency of Industrial Filters for Molten Metal Treatment: Evaluation of a Filtration Process Model
	Experimental and Numerical Study of Ceramic Foam Filtration
	The Influence of Grain Refiners on the Efficiency of Ceramic Foam Filters
	Aluminum Cleanliness Monitoring: Methods and Applications in Process Development and Quality Control
	Ultrasonic Technology for Measuring Molten Aluminum Quality
	In-line Treatment of Molten Aluminum
	Effects of Grain Refining Additions to Aluminum Alloys
	Removal of Inclusions — A Survey and Comparison of Principles
	The Impact of LiMCA Technology on the Optimization of Melt Cleanliness
	Recommended Reading
Part 5: Structure: Grain Refinement, Modification, and Microsegregation
	Section Introduction
	Grain Refinement in Aluminum Alloys
	Microstructure Control in Ingots of Aluminum Alloys with an Emphasis on Grain Refinement
	Studies of the Action of Grain-Refining Particles in Aluminum Alloys
	Heterogeneous Nucleation of an Al-Ti in Al-Ni-Si Alloys
	Zr-Poisoning of Grain Refiner Particles Studied in Al-Ni-Zr Amorphous Alloys
	Modelling of the Effectiveness of Al-Ti-B Refiners in Commercial Purity Aluminium
	The Effect of Alloy Content on the Grain Refinement of Aluminium Alloys
	A Comparison of the Behaviour of AlTiB and AlTiC Grain Refiners
	Design of Grain Refiners for Aluminium Alloys
	On the Mechanism of Grain Refinement by Ultrasonic Melt Treatment in the Presence of Transition Metals
	Modification and Refinement of Cast Al-Si Alloys
	Modification of Silicon in Eutectic and Hyper-Eutectic Al-Si Alloys
	Strobloy — The New Combined Grain Refiner and Modifier for Hypoeutectic AISi Foundry Alloys
	Factors Governing the Formation of Feathery Crystals in DC-cast Ingots
	Fir Tree Structures of 1000- and 5000-Series Aluminum Alloy Sheet Ingots
	Growth Mechanisms of Intermetallic Phases in DC Cast AAlxxx Alloys
	A Thermodynamic Study of Metastable Al-Fe Phase Formation in Direct Chill (DC)-Cast Aluminum Alloys Ingots
	The Generation of AlmFe in Dilute Aluminium Alloys with Different Grain Refining Additions
	Effects of Cooling Rate and Grain Refining on Constituent Phase Particle Size in As-Cast 3004 Alloy
	Predicting Microstructure and Microsegregation in Multicomponent Aluminum Alloys
	Modelling of the Thermo-Physical and Physical Properties for Solidification of Al-Alloys
	Recommended Reading
Part 6: Direct-Chill Casting
	Section Introduction
	Recent Developments in Semi-Continuous Casting of Aluminum Alloy Billets and Slabs
	DC Casting of Aluminium Alloys — Past, Present and Future
	Magnesium Direct Chill Casting: A Comparison with Aluminium
	New Hot-top Continuous Casting Method Featuring Application of Air Pressure to Mold
	The Variable Chill Depth Mould System
	New Casting Method for Improving Billet Quality
	Improvement of Billet Quality by Use of a Hot Top Mold with a Two Phase Lubrication
	Metallurgical Features of Sheet Ingot Cast by the Airslip™ Air-casting Process
	High Speed DC Casting of AA-6063 Extrusion Ingot
	Designing Sheet Ingot Moulds to Produce Rectangular Ingots of the Desired Thickness and Width
	HDC Process for Small Diameter Ingot
	Development of a New Starting Block Shape for the DC Casting of Sheet Ingots, Part I: Experimental Results
	NETCAST Shape Casting Technology: A Technological Breakthrough that Enhances the Cost Effectiveness of Aluminum Forgings
	Simultaneous Casting of Alloy Composites
	Novelis Fusion™: A Novel Process for the Future
	Detailed Modeling of a Metal Distributor by Means of a Combined Numerical and Physical Approach
	The Effect of Process Parameters on the Metal Distribution for DC Sheet Ingot Casting
	Heat Transfer Measurements during DC Casting of Aluminium. Part I: Measurement Technique
	Heat Transfer Measurements during DC Casting of Aluminium. Part II: Results and Verification for Extrusion Ingots
	The Measurement of Heat Flow within a DC Casting Mould
	Determination of the Thermal Boundary Conditions during Aluminum DC Casting from Experimental Data Using Inverse Modeling
	Advances for DC Ingot Casting: Part 2 - Heat Transfer and Casting Results
	Water Cooling in Direct Chill Casting: Part 1, Boiling Theory and Control
	Impact of Water Heat Extraction and Casting Conditions on Ingot Thermal Response during DC Casting
	Effect of Water Quality and Water Type on the Heat Transfer in DC Casting
	Recommended Reading
Part 7: Casting Defects and Their Control
	Section Introduction
	Practical Problems in Casting Aluminum DC Ingots
	Reduction of Ingot Bottom \"Bowing and Bumping\" in Large Sheet Ingot Casting
	An Empirical Model to Explain Cross-Section Changes of DC Sheet Ingot during Casting
	Mathematical Modelling of Butt Curl Deformation of Sheet Ingots. Comparison with Experimental Results for Different Starter Block Shapes
	The Mechanism of Pull-In during DC-Casting of Aluminium Sheet Ingots
	Coupled Stress, Thermal and Fluid Flow Modelling of the Start-up Phase of Aluminium Sheet Ingot Casting
	Investigations About Starting Cracks in DC Casting of 6063 Type Billets. Part I: Experimental Results
	Investigations About Starting Cracks in DC Casting of 6063 Type Billets. Part II: Modelling Results
	Inverse Solidification— A Theory of the Formation of the Surface on DC Cast Round Ingot
	Contribution to the Metallurgy of the Surfaces of Cast Aluminum
	Surface Formation on VDC Casting
	Wrinkling Phenomena to Explain Vertical Fold Defects in DC-Cast Al-Mg4.5
	Study of Shell Zone Formation in Lithographic and Anodizing Quality Aluminium Alloys: Experimental and Numerical Approach
	Coupled Modelling of Air-Gap Formation and Surface Exudation during Extrusion Ingot DC-Casting
	Macrosegregation Characteristics of Commercial Size Aluminum Alloy Ingot Cast by the Direct Chill Method
	Effects of Casting Practice on Macrosegregation and Microstructure of 2024 Alloy Billet
	Investigation in the Effects of the Casting Parameters on the Extent of Centerline Macrosegregation in DC Cast Sheet Ingots
	Effect of Grain Refining on Defect Formation in DC Cast Al-Zn-Mg-Cu Alloy Billet
	The Coupling of Macrosegregation with Grain Nucleation, Growth and Motion in DC Cast Aluminum Alloy Ingots
	Thermal Stresses in Continuous DC Casting of Al Alloys: Discussion of Hot Tearing Mechanisms
	Modelling of Fluid Flow and Stress Phenomena during DC Casting of Aluminium Alloys
	Thermomechanical Effects during Direct Chill and Electromagnetic Casting of Aluminum Alloys. Part I: Experimental Investigation
	Thermomechanical Effects during Direct Chill and Electromagnetic Casting of Aluminum Alloys. Part II: Numerical Simulation
	On the Mechanism of Surface Cracking in DC Cast 7xxx and 6xxx Extrusion Ingot Alloys
	Hot Tearing in Aluminium-Copper Alloys
	Measurement of the Onset of Hot Cracking in DC Cast Billets
	A Mathematical Model for Hot Cracking of Aluminium Alloys during DC Casting
	Prediction of Hot Tears in DC-Cast Aluminum Billets
	As-Cast Mechanical Properties of High Strength Aluminum Alloy
	Residual Stress Measurements for Studying Ingot Cracking
	Numerical Simulation of DC Casting; Interpreting the Results of a Thermo-Mechanical Model
	Cold Cracking during Direct-Chill Casting
	Recommended Reading
Part 8: Other Casting Methods
	Section Introduction
	The Mechanical and Metallurgical Characteristics of Twin-Belt Cast Aluminum Strip Using Current Hazelett Technology
	The Hunter Continuous Strip Casting Process
	CREM — A New Casting Process. Part II — Industrial Aspects
	Twin Roll Casting of Aluminium: The Occurrence of Structure Inhomogeneities and Defects in As Cast Strip
	Centre line Segregation in Twin Roll Cast Aluminum Alloy Slab
	Thin Gauge Twin-Roll Casting, Process Capabilities and Product Quality
	New Electromagnetic Rheocasters for the Production of Thixotropic Aluminum Alloy Slurries
	Remelt Ingot Production Technology
	Recommended Reading
Part 9: Heat Treatment
	Section Introduction
	Investigating the Alpha Transformation — A Solid-State Phase Change of Dispersed Intermetallic Particles from an Al6(Fe,Mn) Phase to an α-Al-(Fe,Mn)-Si Phase
	Precipitation of Dispersoids in DC-Cast AA3103 Alloy during Heat Treatment
	Modelling the Metallurgical Reactions during Homogenisation of an AA3103 Alloy
	Influence of Homogenizing on the Properties of Cast Aluminium Products
	Recommended Reading
Part 10: Safety
	Section Introduction
	Personal Protective Clothing: From Fundamental to a Global Strategy of Protection in the Casthouse Environment
	Why Does Molten Aluminum Explode at Underwater or Wet Surfaces?
	Investigation of Coatings Which Prevent Molten Aluminum/Water Explosions
	Hazards Associated with the Use of Bone Ash in Contact with Molten Aluminum
	Cause and Prevention of Explosions Involving Hottop Casting of Aluminum Extrusion Ingot
	Cause and Prevention of Explosions Involving DC Casting of Aluminum Sheet Ingot
	The Role of Automation in Explosion Prevention in Sheet Ingot Casting
	Hazards in Adding Scrap Copper to Molten Aluminum
	Recommended Reading
Author Index