Aluminium Casting BooksAluminium reference books

Aluminium Direct Chill Casting

Aluminium Direct Chill Casting: learn about Effect of Cooling Rate and Melt Temperature on Solidification of Aluminum Alloys, Microsegregation, Solidification Reactions and Commercial Wrought Alloys with Manganese, Al–Mg–Si, Al–Mg–Si–Cu, Al–Mg–Mn, Al–Cu–Mn, Al–Mg–Zn–(Cu), and more.

In the book “Physical Metallurgy of Direct Chill Casting of Aluminium Alloys”
by Dmitry Eskin

BRIEF CONTENTS

Solidification of Aluminum Alloys

  • Effect of Cooling Rate and Melt Temperature on Solidification of Aluminum Alloys
  • Microsegregation in Aluminum Alloys
  • Solidification Reactions and Phase Composition
    • Commercial Aluminum
    • Wrought Alloys with Manganese (3XXX Series)
    • Al–Mg–Si Wrought Alloys (6XXX Series)
    • Al–Mg–Si–Cu Wrought Alloys (6XXX and 2XXX Series)
    • Al–Mg–Mn Wrought Alloys (5XXX Series)
    • Al–Cu–Mn (Mg, Si, Ni) Wrought Alloys (2XXX Series)
    • Al–Mg–Zn–(Cu) Wrought Alloys (7XXX Series)
    • Wrought Alloys Containing Lithium
      • Al–Cu–Li Commercial Alloys
      • Al–Li–Mg Commercial Alloys
      • Al–Li–Cu–Mg Commercial Alloys
    • Effect of Alloy Composition on Structure Formation: Grain Refinement
      • Mechanisms of Grain Refinement
      • Al–Sc–Zr Phase Diagram
      • Al–Ti–B Phase Diagram
      • Al–Ti–C Phase Diagram
    • References

Solidification Patterns and Structure Formation during Direct Chill Casting

  • Shape and Dimensions of the Billet Sump
  • Solidification Rate and Cooling Rate during DC Casting
  • Effects of Process Parameters on the Formation of Grain Structure
  • Effect of Process Parameters on the Amount of Nonequilibrium Eutectics
  • Effect of Process Parameters and Alloy Composition on the Occurrence of Some Casting Defects
  • References

Macrosegregation

  • Mechanisms of Macrosegregation
    • Historic Overview
    • Permeability
    • Convection-Driven Macrosegregation
    • Shrinkage-Driven Macrosegregation
    • Floating Grains and Macrosegregation
    • Deformation-Driven Macrosegregation
  • Effects of Process Parameters on Macrosegregation during DC Casting
    • Effect of Casting Speed on Macrosegregation during DC Casting
    • Effect of Melt Temperature on Macrosegregation during DC Casting
    • Dimensions of the Billet: Scaling Rule of Macrosegregation
    • Effect of Forced Convection on Macrosegregation during DC Casting
  • Effect of Composition on Macrosegregation: Macrosegregation in Commercial Aluminum Alloys
  • References

Hot Tearing

  • Thermal Contraction during Solidification
  • Mechanical Properties of Semi-Solid Alloys
    • Testing Techniques
    • Strength Properties of Aluminum Alloys in the Semi-Solid State
    • Ductility of Aluminum Alloys in the Semi-Solid State
  • Mechanisms and Criteria for Hot Tearing
    • Historic Overview of Hot Tearing Research and Suggested Mechanisms
    • Hot Tearing Criteria
      • Stress-Based Criteria
      • Strain-Based Criteria
      • Strain Rate-Based Criteria
      • Criteria Based on Other Principles
    • Application of Hot Tearing Criteria to DC Casting of Aluminum Alloys
    • Quest for a New Hot Tearing Criterion
  • Effects of Process Parameters on Hot Tearing during DC Casting
    • Thermo-Mechanical Behavior of a DC-Cast Billet (Ingot)
    • Effects of Composition and Casting Speed on Hot Tearing during DC Casting
    • Effect of Melt Temperature on Hot Tearing during DC Casting
    • Structural Features Associated with Hot Tearing in DC Casting
  • References

PREVIEW

Some usuful figures from this book

Figure 1.5 – Dependence of dendrite arm spacing
on the solidification rate in DC casting

Solidification shrinkage of aluminum alloys amounts to 6–8 vol.%.
In Figure 5.1: Development of volume solidifi cationshrinkage in an Al–4% Cu alloy
(Maney Publishing)

Figure 5.2 – Schematic representation of external signs of solidification shrinkage and
thermal contraction of an aluminium alloy (a)

Figure 5.34 – Shape distortions typical of DC-cast ingots.
A view from the short side of the ingot.