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Aluminium Cast Shop

Explore how casting technology can help develop fabricated products with Aluminium Cast Shop. Learn about efficient fuel control of a casting furnace, alloying of molten aluminium and more.

Essential Readings in Light Metals – Volume 3 (2016)

Edited by John Grandfield and Dmitry Eskin



Part 1: Introduction

  • The Role of Casting Technology in the Development of
    New and Improved Fabricated Products

Part 2: Furnaces, Melting, Fluxing, and Alloying

  • Optimal Fuel Control of a Casting Furnace
  • Na and Ca Pick-up from Hall Bath in Ingot Furnaces
  • Alloying by Injection ofMg in an AIMelt
  • Alloying of Molten Alunrinium:
    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 CommercialMetal
  • 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

  • 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

  • Analysis and Thermodynamic Prediction of Hydrogen Solution in
    Solid and Liquid Multicomponent Aluminum Alloys
  • A Radioscopic 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

  • 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 AI-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 AlSi 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 lntermetallic 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

  • 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 AirslipTM 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 FusionTM: 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 I, 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

  • 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 1: 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 AI 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 1: 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 ofDC Casting;
    Interpreting the Results of a Thermo-Mechanical Model
  • Cold Cracking during Direct-Chill Casting
  • Recommended Reading

Part 8: Other Casting Methods

  • 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

  • Investigating the Alpha Transformation –
    A Solid-State Phase Change of Dispersed Intetmetallic 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

  • 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


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The most usuful figures and tables from this book

Sequence of Molten aluminium processing steps
[Figure 1 in A Technical Perspective on Molten Aluminum Processing]

 Typical Impurity Levels in Metal from Smelter and Remelt Sources
[Table 1 in A Technical Perspective on Molten Aluminum Processing]

Typical Impurity Concentrations in Some Aluminum Products.
[Figure 3 in A Technical Perspective on Molten Aluminum Processing]

Variation of metal cleanliness after long settling times;
here the average metal quality for a complete cast is plotted
as a function of total elapsed time.
[Figure 11 in Settling Phenomena in Casting Furnaces:
A Fundamental and Experimental Investigation

Inclusions in Aluminum
[Table I in Industrial Application of Open Pore Ceramic foam for Molten Metal Filtration]

Melt Cleaning Methods
[Table II in Industrial Application of Open Pore Ceramic foam for Molten Metal Filtration]

Metal prime head for different filters versus window size.
[Figure 17 in Industrial application of open pore ceramic foam for molten metal filtration]

Flow rates for different ceramic foam filters
[Figure 18 in Industrial application of open pore ceramic foam for molten metal filtration]