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

Description

ONE OF A FOUR-BOOK COLLECTION SPOTLIGHTING CLASSIC ARTICLES   Original research findings and reviews spanning all aspects of the science and technology of casting   Since 1971, The Minerals, Metals & Materials Society has published the Light Metals proceedings. Highlighting some of the most important findings and insights reported over the past four decades, this volume features the best original research papers and reviews on cast shop science and technology for aluminum production published in Light Metals from 1971 to 2011.   Papers have been divided into ten subject sections for ease of access. Each section has a brief introduction and a list of recommended articles for researchers interested in exploring each subject in greater depth.   Only 12 percent of the cast shop science and technology papers ever published in Light Metals were chosen for this volume. Selection was based on a rigorous review process. Among the papers, readers will find landmark original research findings and expert reviews summarizing current thinking on key topics at the time of publication.   From basic research to industry standards to advanced applications, the articles published in this volume collectively represent a complete overview of cast shop science and technology, supporting the work of students, researchers, and engineers around the world. Cover Title Page Copyright Page TABLE OF CONTENTS Preface Lead Editors Editorial Team Part 1: Introduction The Role of Casting Technology in the Development of New and Improved Fabricated Products Part 2: Furnaces, Melting, Fluxing, and Alloying Section Introduction Optimal Fuel Control of a Casting Furnace Na and Ca Pick-up from Hall Bath in Ingot Furnaces Alloying by Injection of Mg in an Al Melt Alloying of Molten Aluminium: 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 Commercial Metal 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 Section Introduction 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 Section Introduction Analysis and Thermodynamic Prediction of Hydrogen Solution in Solid and Liquid Multicomponent Aluminum Alloys A Radioscopie 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 Section Introduction 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 Al-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 AISi 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 Intermetallic 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 Section Introduction 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™ 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™: 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 1, 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 Section Introduction 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 I: 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 Al 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 I: 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 of DC Casting; Interpreting the Results of a Thermo-Mechanical Model Cold Cracking during Direct-Chill Casting Recommended Reading Part 8: Other Casting Methods Section Introduction 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 Section Introduction 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 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 Section Introduction 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 Author Index