Cast Shop for Aluminum Production

 

Essential Readings in Light Metals – Volume 3 (2016)

Edited by John Grandfield and Dmitry Eskin

 

 

 

 

 

 

 

BRIEF CONTENTS

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 Al_mFe 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 Airslip^TM 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^TM: 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

PREVIEW

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]