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

Front Matter....Pages i-xx
The Role of Casting Technology in the Development of New and Improved Fabricated Products....Pages 1-11
Front Matter....Pages 13-13
Optimal Fuel Control of a Casting Furnace....Pages 15-20
Na and Ca Pick-up from Hall Bath in Ingot Furnaces....Pages 21-27
Alloying by Injection of Mg in an Al-Melt....Pages 28-32
Alloying of Molten Aluminum: Optimizing the Present and Preparing the Future....Pages 33-43
Dissolution Mechanism for High Melting Point Transition Elements in Aluminum Melt....Pages 44-50
A Technical Perspective on Molten Aluminum Processing....Pages 51-58
Melt Treatment — Evolution and Perspectives....Pages 59-64
Gas Fluxing of Molten Aluminum: An Overview....Pages 65-70
Removal of Alkali Metals from Aluminum....Pages 71-79
On the Kinetics of Removal of Sodium from Aluminum and Aluminum-Magnesium Alloys....Pages 80-92
Removal of Lithium in Commercial Metal....Pages 93-100
Current Technologies for the Removal of Iron from Aluminum Alloys....Pages 101-106
Settling of Inclusions in Holding Furnaces: Modeling and Experimental Results....Pages 107-114
Settling Phenomena in Casting Furnaces: A Fundamental and Experimental Investigation....Pages 115-125
In-Line Salt Fluxing Process: The Solution to Chlorine Gas Utilization in Casthouses....Pages 126-131
Back Matter....Pages 133-133
Front Matter....Pages 135-135
Oxidation of Liquid Aluminum — Magnesium Alloys....Pages 137-142
Metallurgy of Dross Formation on Al Melts....Pages 143-149
Furnace Dross — Its Formation and Recovery....Pages 150-156
New Process of Direct Metal Recovery from Drosses in the Aluminum Casthouse....Pages 157-164
Back Matter....Pages 181-181
Front Matter....Pages 135-135
Melt Loss Evaluation....Pages 165-172
Molten Salt Flux Composition Effects in Aluminum Scrap Remelting....Pages 173-180
Back Matter....Pages 181-181
Front Matter....Pages 183-183
Analysis and Thermodynamic Prediction of Hydrogen Solution in Solid and Liquid Multicomponent Aluminum Alloys....Pages 185-200
A Radioscopic Technique to Observe Bubbles in Liquid Aluminum....Pages 201-207
Molten Aluminium Purification....Pages 208-217
Removal of Hydrogen from Molten Aluminium by Gas Purging....Pages 218-225
Gas Fluxing of Molten Aluminum....Pages 226-233
The Alcan Compact Degasser: A Trough-Based Aluminum Treatment Process....Pages 234-238
Dynamic Vacuum Treatment of Molten Aluminium and Its Alloys....Pages 239-245
Ultrasonic Degassing of Molten Aluminum under Reduced Pressure....Pages 246-250
Industrial Application of Open Pore Ceramic Foam for Molten Metal Filtration....Pages 251-262
Deep Bed Filtration Theory Compared with Experiments....Pages 263-270
Efficiency of Industrial Filters for Molten Metal Treatment Evaluation of a Filtration Process Model....Pages 271-284
Experimental and Numerical Study of Ceramic Foam Filtration....Pages 285-290
The Influence of Grain Refiners on the Efficiency of Ceramic Foam Filters....Pages 291-295
Aluminium Cleanliness Monitoring: Methods and Applications in Process Development and Quality Control....Pages 296-304
Ultrasonic Technology for Measuring Molten Aluminum Quality....Pages 305-311
In-line Treatment of Molten Aluminum....Pages 312-317
Effects of Grain Refining Additions to Aluminum Alloys....Pages 318-323
Removal of Inclusions — A Survey and Comparison of Principles....Pages 324-331
Back Matter....Pages 339-340
Front Matter....Pages 183-183
The Impact of LiMCA Technology on the Optimization of Metal Cleanliness....Pages 332-337
Back Matter....Pages 339-340
Front Matter....Pages 341-341
Grain Refinement in Aluminum Alloys....Pages 343-353
Microstructure Control in Ingots of Aluminum Alloys with an Emphasis on Grain Refinement....Pages 354-365
Studies of the Action of Grain-Refining Particles in Aluminium Alloys....Pages 366-374
Heterogeneous Nucleation of α-Al in Al-Ni-Si Alloys....Pages 375-380
Zr-Poisoning of Grain Refiner Particles Studied in Al-Ni-Zr Amorphous Alloys....Pages 381-386
Modelling of the Effectiveness of Al-Ti-B Refiners in Commercial Purity Aluminium....Pages 387-392
The Effect of Alloy Content on the Grain Refinement of Aluminium Alloys....Pages 393-399
A Comparison of the Behaviour of AlTiB and AlTiC Grain Refiners....Pages 400-408
Design of Grain Refiners for Aluminium Alloys....Pages 409-414
On the Mechanism of Grain Refinement by Ultrasonic Melt Treatment in the Presence of Transition Metals....Pages 415-419
Modification and Refinement of Cast Al-Si Alloys....Pages 420-424
Modification of Silicon in Eutectic and Hyper-Eutectic Al-Si Alloys....Pages 425-432
Strobloy — The New Combined Grain Refiner and Modifier for Hypoeutectic AlSi Foundry Alloys....Pages 433-437
Factors Governing the Formation of Feathery Crystals in DC-Cast Ingots....Pages 438-451
Fir Tree Structure of 1000- and 5000-series Aluminum Alloy Sheet Ingots....Pages 452-459
Growth Mechanisms of Intermetallic Phases in DC Cast AA1XXX Alloys....Pages 460-465
A Thermodynamic Study of Metastable Al-Fe Phase Formation in Direct Chill (DC)-Cast Aluminum Alloy Ingots....Pages 466-474
The Generation of AlmFe in Dilute Aluminium Alloys with Different Grain Refining Additions....Pages 475-481
Effects of Cooling Rate and Grain Refining on Constituent Phase Particle Size in As-Cast 3004 Alloy....Pages 482-511
Back Matter....Pages 525-526
Front Matter....Pages 341-341
Predicting Microstructure and Microsegregation in Multicomponent Aluminum Alloys....Pages 512-518
Modelling of the Thermo-Physical and Physical Properties for Solidification of Al-Alloys....Pages 519-524
Back Matter....Pages 525-526
Front Matter....Pages 527-527
Recent Developments in Semi-Continuous Casting of Aluminum Alloy Billets and Slabs....Pages 529-533
D.C. Casting of Aluminium Alloys — Past, Present and Future....Pages 534-541
Magnesium Direct Chill Casting: A Comparison with Aluminium....Pages 542-549
New hot-top continuous casting method featuring application of air pressure to mold....Pages 550-555
The Variable Chill Depth Mould System....Pages 557-563
New Casting Method for Improving Billet Quality....Pages 564-570
Improvement of Billet Quality by Use of a Hot Top Mold with a Two Phase Lubrication....Pages 571-576
Metallurgical Features of Sheet Ingot Cast by the Airslip™ Air-Casting Process....Pages 577-583
High Speed D.C. Casting of AA-6063 Extrusion Ingot....Pages 584-590
Designing Sheet Ingot Moulds to Produce Rectangular Ingots of the Desired Thickness and Width....Pages 591-597
HDC Process for Small Diameter Ingot....Pages 598-604
Development of a New Starting Block Shape for the D.C. Casting of Sheet Ingots Part I: Experimental Results....Pages 605-611
Netcast™ Shape Casting Technology: A Technological Breakthrough that Enhances the Cost Effectiveness of Aluminum Forgings....Pages 612-618
Simultaneous Casting of Alloy Composites....Pages 619-627
Novelis Fusion™, A Novel Process for the Future....Pages 628-632
Detailed Modeling of a Metal Distributor by Means of a Combined Numerical and Physical Approach....Pages 633-639
The Effect of Process Parameters on the Metal Distribution for DC Sheet Ingot Casting....Pages 640-645
Heat Transfer Measurements during DC Casting of Aluminium Part I: Measurement Technique....Pages 646-652
Back Matter....Pages 703-704
Front Matter....Pages 527-527
The Measurement of Heat Flow Within a DC Casting Mould....Pages 653-658
Determination of the Thermal Boundary Conditions During Aluminum DC Casting from Experimental Data Using Inverse Modeling....Pages 659-664
Advances for DC Ingot Casting: Part 2 — Heat Transfer and Casting Results....Pages 665-671
Water Cooling in Direct Chill Casting : Part 1, Boiling Theory and Control....Pages 672-680
Impact of Water Heat Extraction and Casting Conditions on Ingot Thermal Response During D.C. Casting....Pages 681-689
Effect of Water Quality and Water Type on The Heat Transfer in DC Casting....Pages 690-695
Back Matter....Pages 696-701
Front Matter....Pages 703-704
Practical Problems in Casting Aluminum D.C. Ingot....Pages 705-705
Reduction of Ingot Bottom “Bowing and Bumping” in Large Sheet Ingot Casting....Pages 707-709
An Empirical Model to Explain Cross-Section Changes of D.C. Sheet Ingot During Casting....Pages 710-711
Mathematical Modelling of Butt Curl Deformation of Sheet Ingots. Comparison with Experimental Results for Different Starter Block Shapes....Pages 712-719
The Mechanism of Pull-In During DC-Casting of Aluminium Sheet Ingots....Pages 720-728
Coupled Stress, Thermal and Fluid Flow Modelling of the Start-up Phase of Aluminium Sheet Ingot Casting....Pages 729-736
Investigations about Starting Cracks in DC Casting of 6063 Type Billets. Part I: Experimental Results....Pages 737-742
Investigations about Starting Cracks in DC-Casting of 6063-Type Billets Part II: Modelling Results....Pages 743-748
Inverse Solidification — A Theory of the Formation of the Surface on D.C. Cast Round Ingot....Pages 749-755
Contribution to the Metallurgy of the Surfaces of Cast Aluminum....Pages 756-767
Surface Formation on VDC Casting....Pages 768-782
Wrinkling Phenomena to Explain Vertical Fold Defects in DC-Cast Al-Mg4.5....Pages 783-788
Study of Shell Zone Formation in Lithographic and Anodizing Quality Aluminum Alloys: Experimental and Numerical Approach....Pages 789-804
Back Matter....Pages 805-811
Front Matter....Pages 945-946
Coupled modelling of air-gap formation and surface exudation during extrusion ingot DC-casting....Pages 705-705
Macrosegregation Characteristics of Commercial Size Aluminum Alloy Ingot Cast by the Direct Chill Method....Pages 812-818
Effects of Casting Practice on Macrosegregation and Microstructure of 2024 Alloy Billet....Pages 819-824
Investigation in the Effects of Casting Parameters on the Extent of Centerline Macrosegregation in DC Cast Sheet Ingots....Pages 825-830
Effect of Grain Refining on Defect Formation in DC Cast Al-Zn-Mg-Cu Alloy Billet....Pages 831-841
The Coupling of Macrosegregation with Grain Nucleation, Growth and Motion in DC Cast Aluminum Alloy Ingots....Pages 842-847
Thermal Stresses in Continuous DC Casting of Al Alloys Discussion of Hot Tearing Mechanisms....Pages 848-853
Modellling of Fluid Flow and Stress Phenomena during DC Casting of Aluminium Alloys....Pages 854-861
Thermomechanical Effects during Direct Chill and Electromagnetic Casting of Aluminum Alloys Part I : Experimental Investigation....Pages 862-866
Thermomechanical Effects during Direct Chill and Electromagnetic Casting of Aluminum Alloys Part II : Numerical Simulation....Pages 867-876
On the Mechanism of Surface Cracking in DC Cast 7XXX and 6XXX Extrusion Ingot Alloys....Pages 877-886
Hot Tearing in Aluminium — Copper Alloys....Pages 887-894
Measurement of the Onset of Hot Cracking in DC Cast Billets....Pages 895-899
A Mathematical Model for Hot Cracking of Aluminium Alloys During D.C. Casting....Pages 900-906
Prediction of Hot Tears in DC-Cast Aluminum Billets....Pages 907-911
As-Cast Mechanical Properties of High Strength Aluminum Alloy....Pages 912-918
Residual Stress Measurements for Studying Ingot Cracking....Pages 919-924
Numerical Simulation of DC Casting; Interpreting the Results of a Thermo-Mechanical Model....Pages 925-932
Cold Cracking During Direct-Chill Casting....Pages 933-938
Back Matter....Pages 939-944
Front Matter....Pages 945-946
The Mechanical and Metallurgical Characteristics of Twin-Belt Cast Aluminum Strip Using Current Hazelett Technology....Pages 947-947
Back Matter....Pages 949-958
Front Matter....Pages 1011-1011
The Hunter Continuous Strip Casting Process....Pages 947-947
Crem — A New Casting Process Part II — Industrial Aspects....Pages 959-965
Twin Roll Casting of Aluminium: The Occurrence of Structure Inhomogeneities and Defects in as Cast Strip....Pages 966-971
Centre Line Segregation in Twin Roll Cast Aluminum Alloy Slab....Pages 972-980
Thin Gauge Twin-Roll Casting, Process Capabilities and Product Quality....Pages 981-988
New Electromagnetic Rheocasters for the Production of Thixotropic Aluminum Alloy Slurries....Pages 989-996
Remelt Ingot Production Technology....Pages 997-1002
Back Matter....Pages 1003-1010
Front Matter....Pages 1011-1011
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....Pages 1013-1013
Precipitation of Dispersoids in DC-Cast AA3103 Alloy during Heat Treatment....Pages 1015-1020
Modelling the Metallurgical Reactions during Homogenisation of an AA3103 Alloy....Pages 1021-1027
Influence of Homogenizing on the Properties of Cast Aluminium Products....Pages 1028-1035
Back Matter....Pages 1036-1042
Front Matter....Pages 1043-1043
Personal Protective Clothing: From Fundamentals to a Global Strategy of Protection in the Casthouse Environment....Pages 1045-1045
Why Does Molten Aluminum Explode at Underwater or Wet Surfaces?....Pages 1047-1056
Investigation of Coatings Which Prevent Molten Aluminum/Water Explosions....Pages 1057-1067
Hazards associated with the use of bone ash in contact with molten aluminum....Pages 1068-1073
Cause and Prevention of Explosions Involving Hot-Top Casting of Aluminum Extrusion Ingot....Pages 1074-1077
Cause and Prevention of Explosions Involving DC Casting of Aluminum Sheet Ingot....Pages 1078-1084
The Role of Automation in Explosion Prevention in Sheet Ingot Casting....Pages 1085-1090
Hazards in Adding Scrap Copper to Molten Aluminum....Pages 1091-1096
Back Matter....Pages 1097-1099
Back Matter....Pages 1101-1101
....Pages 1103-1105