Physical Metallurgy of Direct Chill Casting of Aluminum Alloys
by Dmitry G. Eskin
BRIEF CONTENTS
Direct Chill Casting: Development of the Technology
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
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.
