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

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.

Table of Contents:
Preface xv Lead Editors xvii Editorial Team xix Part 1: Introduction The Role of Casting Technology in the Development of New and Improved Fabricated Products 1 W. Peterson Part 2: Furnaces, Melting, Fluxing, and Alloying Section Introduction 13 Optimal Fuel Control of a Casting Furnace 15 R. Bui and R. Ouellet Naand Ca Pick-up from Hall Bath in Ingot Furnaces 21 D. De Young Alloying by Injection of Mg in an Al Melt 28 E. Myrbostad and K. Vends Alloying of Molten Aluminium: Optimizing the Present and Preparing the Future 33 C. Sztur and G. Hudault Dissolution Mechanism for High Melting Point Transition Elements in Aluminum Melt 44 Y. Lee and S. Houser A Technical Perspective on Molten Aluminum Processing 51 P. Waite Melt Treatment — Evolution and Perspectives 59 P. Le Brun Gas Fluxing of Molten Aluminum: An Overview 65 G. Sigworth, E. Williams, and D. Chesonis Removal of Alkali Metals from Aluminum 71 E. Williams, R. McCarthy, S. Levy, and G. Sigworth On the Kinetics of Removal of Sodium from Aluminum and Aluminum-Magnesium Alloys 80 B. Kulunk and R. Guthrie Removal of Lithium in Commercial Metal 93 P. Achim and G. Dubé Current Technologies for the Removal of Iron from Aluminum Alloys 101 L. Zhang and L. Damoah Settling of Inclusions in Holding Furnaces: Modeling and Experimental Results 107 C. Sztur, F. Balestreri, J. Meyer, and B. Hannart Settling Phenomena in Casting Furnaces: A Fundamental and Experimental Investigation 115 J. Martin, G. Dubé, D. Frayce, andR. Guthrie In-Line Salt Fluxing Process: The Solution to Chlorine Gas Utilization in Casthouses 126 S. Leboeuf, C. Dupuis, B. Maltais, M. Thibault, and E. Smarason Recommended Reading 133 Part 3: Oxidation and Dross Processing Section Introduction 135 Oxidation of Liquid Aluminum-Magnesium Alloys 137 M. Silva and D. Talbot Metallurgy of Dross Formation on Al Melts 143 S. Freti, J. Bornand, and K. Buxmann Furnace Dross — Its Formation and Recovery 150 C. Moser New Process of Direct Metal Recovery from Drosses in the Aluminum Casthouse 157 G. Zahorka Melt Loss Evaluation 165 J. van Linden and H. Reavis Molten Salt Flux Composition Effects in Aluminum Scrap Remelting 173 J. van Linden and D. Stewart, Jr. Recommended Reading 181 Part 4: Melt Quality: Degassing, Filtering, and Analysis Section Introduction 183 Analysis and Thermodynamic Prediction of Hydrogen Solution in Solid and Liquid Multicomponent Aluminum Alloys 185 P. Anyalebechi A Radioscopie Technique to Observe Bubbles in Liquid Aluminum 201 M. Bertherat, T. Odièvre, M. Allibert, and P. Le Brun Molten Aluminium Purification 208 T. Engh and G. Sigworth Removal of Hydrogen from Molten Aluminium by Gas Purging 218 T. Engh and T. Pedersen Gas Fluxing of Molten Aluminum. Part 1: Hydrogen Removal 226 G. Sigworth Alcan Compact Degasser: A Trough-based Aluminum Treatment Process. Part I: Metallurgical Principles and Performance 234 P. Waite and R. Thiffault Dynamic Vacuum Treatment of Molten Aluminium and Its Alloys 239 A. Aarflot and F. Patak Ultrasonic Degassing of Molten Aluminum under Reduced Pressure 246 H. Xu, X. Jian, T. Meek, and Q. Han Industrial Application of Open Pore Ceramic Foam for Molten Metal Filtration 251 L. Gauckler, M. Waeber, C. Conti, and M. Jacob-Duliére Deep Bed Filtration Theory Compared with Experiments 263 T. Engh, B. Rasch, and E. Bathen Efficiency of Industrial Filters for Molten Metal Treatment: Evaluation of a Filtration Process Model 271 P. Netter and C. Conti Experimental and Numerical Study of Ceramic Foam Filtration 285 E. Laé, H. Duval, C. Rivière, P. Le Brun, and J. Gui Hot The Influence of Grain Refiners on the Efficiency of Ceramic FoamFilters 291 N. Towsey, W. Schneider, H. Krug, A. Hardman, and N. Keegan Aluminum Cleanliness Monitoring: Methods and Applications in Process Development and Quality Control 296 D. Doutre, B. Gariépy, J. Martin, and G. Dubé Ultrasonic Technology for Measuring Molten Aluminum Quality 305 T. Mansfield In-line Treatment of Molten Aluminum 312 L. Blayden and K. Brondyke Effects of Grain Refining Additions to Aluminum Alloys 318 R. Gennone, F. Coyle, and G. Farrior Removal of Inclusions — A Survey and Comparison of Principles 324 F. Frisvold, T. Engh, S. Johansen, and T. Pedersen The Impact of LiMCA Technology on the Optimization of Melt Cleanliness 332 C. Dupuis and R. Dumont Recommended Reading 339 Part 5: Structure: Grain Refinement, Modification, and Microsegregation Section Introduction 341 Grain Refinement in Aluminum Alloys 343 L. Mondolfo Micro structure Control in Ingots of Aluminum Alloys with an Emphasis on Grain Refinement 354 D. Granger Studies of the Action of Grain-Refining Particles in Aluminum Alloys 366 P. Schumacher and A. Greer Heterogeneous Nucleation of an Al-Ti in Al-Ni-Si Alloys 375 B. McKay, P. Cizek, P. Schumacher, and K O 'Reilly Zr-Poisoning of Grain Refiner Particles Studied in Al-Ni-Zr Amorphous Alloys 381 P. Schumacher, P. Cizek, and A. Bunn Modelling of the Effectiveness of Al-Ti-B Refiners in Commercial Purity Aluminium 387 A. Bunn, P. Evans, D. Bristow, and A. Greer The Effect of Alloy Content on the Grain Refinement of Aluminium Alloys 393 M. Easton and D. St John A Comparison of the Behaviour of AlTiB and AlTiC Grain Refiners 400 W. Schneider, M. Kearns, M. McGarry, and A. Whitehead Design of Grain Refiners for Aluminium Alloys 409 A. Tronche and A. Greer On the Mechanism of Grain Refinement by Ultrasonic Melt Treatment in the Presence of Transition Metals 415 D. Eskin, T. Atamanenko, L. Zhang, and L. Katgerman Modification and Refinement of Cast Al-Si Alloys 420 S. Lu and A. Hellawell Modification of Silicon in Eutectic and Hyper-Eutectic Al-Si Alloys 425 B. Heshmatpour Strobloy — The New Combined Grain Refiner and Modifier for Hypoeutectic AISi Foundry Alloys 433 E. Bondhus and T. Sagstad Factors Governing the Formation of Feathery Crystals in DC-cast Ingots 438 L. Gullman and L. Johansson Fir Tree Structures of 1000-and 5000-Series Aluminum Alloy Sheet Ingots 452 T. Otani, T. Kato, K. Ar ai, and R. Otsuka Growth Mechanisms of Intermetallic Phases in DC Cast AAlxxx Alloys 460 X. Chen A Thermodynamic Study of Metastable Al-Fe Phase Formation in Direct Chill (DC)-Cast Aluminum Alloys Ingots 466 C. Aliravci, J. Gruzleski, and M. Pekgüleryüz The Generation of AlmFe in Dilute Aluminium Alloys with Different Grain Refining Additions 475 W. Meredith, A. Greer, P. Evans, and R. Hamerton Effects of Cooling Rate and Grain Refining on Constituent Phase Particle Size in As-Cast 3004 Alloy 482 P. Anyalebechi, T. Rouns, and R. Sanders, Jr. Predicting Microstructure and Microsegregation in Multicomponent Aluminum Alloys 512 X. Yan, L. Ding, S. Chen, F. Xie, M. Chu, and Y. Chang Modelling of the Thermo-Physical and Physical Properties for Solidification of Al-Alloys 519 N. Sounders, X. Li, A. Miodownik, and J. Schillé Recommended Reading 525 Part 6: Direct-Chill Casting Section Introduction 527 Recent Developments in Semi-Continuous Casting of Aluminum Alloy Billets and Slabs 529 A. Nussbaum DC Casting of Aluminium Alloys — Past, Present and Future 534 W. Schneider Magnesium Direct Chill Casting: A Comparison with Aluminium 542 P. Baker and P. McGlade New Hot-top Continuous Casting Method Featuring Application of Air Pressure to Mold 550 R. Mitamura, T. Ito, Y. Takahashi, and T. Hiraoka The Variable Chill Depth Mould System 557 R. Wilkins New Casting Method for Improving Billet Quality 564 J. Faunae, F. Wagstaff, and H. Shaw Improvement of Billet Quality by Use of a Hot Top Mold with a Two Phase Lubrication 571 W. Schneider and E. Lossack Metallurgical Features of Sheet Ingot Cast by the Airslip™ Air-casting Process 577 J. Ekenes and F. Wagstaff High Speed DC Casting of AA-6063 Extrusion Ingot 584 S. Nawata, M. Kubota, and K. Yokota Designing Sheet Ingot Moulds to Produce Rectangular Ingots of the Desired Thickness and Width 591 C. Weaver, L. Y enta, G. Morin, and P. Meslage HDC Process for Small Diameter Ingot 598 Y. Ishii Development of a New Starting Block Shape for the DC Casting of Sheet Ingots, Part I: Experimental Results 605 W. Schneider, E. Jensen, and B. Corrupt NETCAST Shape Casting Technology: A Technological Breakthrough that Enhances the Cost Effectiveness of Aluminum Forgings 612 M. Anderson, R. Bruski, D. Groszkiewicz, and B. Wagstaff Simultaneous Casting of Alloy Composites 619 G. Binczewski and W. Kramer Novelis Fusion™: A Novel Process for the Future 628 T. Bischoff L. Hudson, and R. Wagstaff Detailed Modeling of a Metal Distributor by Means of a Combined Numerical and Physical Approach 633 R. Kieft, J. van Oord, F. Frinking, D. Bal, and H. van Schoonevelt The Effect of Process Parameters on the Metal Distribution for DC Sheet Ingot Casting 640 M. Fortier, A. Larouche, X. Chen, and Y. Caron Heat Transfer Measurements during DC Casting of Aluminium. Parti: Measurement Technique 646 J. Bakken and T. Bergström Heat Transfer Measurements during DC Casting of Aluminium. Part II: Results and Verification for Extrusion Ingots 653 E. Jensen, S. Johansen, T. Bergström, and J. Bakken The Measurement of Heat Flow within a DC Casting Mould 659 A. Prasad, J. Taylor, and I. Bainbridge Determination of the Thermal Boundary Conditions during Aluminum DC Casting from Experimental Data Using Inverse Modeling 665 I. Opstelten and J. Rabenberg Advances for DC Ingot Casting: Part 2 - Heat Transfer and Casting Results 672 G. Grealy, J. Davis, E. Jensen, P. Tonde I, and J. Moritz Water Cooling in Direct Chill Casting: Part 1, Boiling Theory and Control 681 J. Grandfield, A. Hoadley, and S. Instone Impact of Water Heat Extraction and Casting Conditions on Ingot Thermal Response during DC Casting 690 A. Larouche, Y. Caron, and D. Kocaefe Effect of Water Quality and Water Type on the Heat Transfer in DC Casting 696 L. Kiss, T. Meenken, A. Charette, Y. Lefebvre, and R. Lévesque Recommended Reading 703 Part 7: Casting Defects and Their Control Section Introduction 705 Practical Problems in Casting Aluminum DC Ingots 707 R. Dieffenbach Reduction of Ingot Bottom "Bowing and Bumping" in Large Sheet Ingot Casting 710 F. Sergerie and N. Bryson An Empirical Model to Explain Cross-Section Changes of DC Sheet Ingot during Casting 712 C. Weaver Mathematical Modelling of Butt Curl Deformation of Sheet Ingots. Comparison with Experimental Results for Different Starter Block Shapes 720 H. Fjaer and E. Jensen The Mechanism of Pull-In during DC-Casting of Aluminium Sheet Ingots 729 H. Fjaer and A. Hâkonsen Coupled Stress, Thermal and Fluid Flow Modelling of the Start-up Phase of Aluminium Sheet Ingot Casting 737 H. Fjaer, D. Mortensen, A. Hâkonsen, and E. Sorheim Investigations About Starting Cracks in DC Casting of 6063 Type Billets. Parti: Experimental Results 743 W. Schneider and E. Jensen Investigations About Starting Cracks in DC Casting of 6063 Type Billets. Part II: Modelling Results 749 E. Jensen and W. Schneider Inverse Solidification— A Theory of the Formation of the Surface on DC Cast Round Ingot 756 J. McCubbin Contribution to the Metallurgy of the Surfaces of Cast Aluminum 768 K. Buxmann Surface Formation on VDC Casting 783 I. Bainbridge, J. Taylor, and A. Dahle Wrinkling Phenomena to Explain Vertical Fold Defects in DC-Cast Al-Mg4.5 789 J. Davis and P. Mendez Study of Shell Zone Formation in Lithographic and Anodizing Quality Aluminium Alloys: Experimental and Numerical Approach 805 C. Brochu, A. Larouche, and R. Hark Coupled Modelling of Air-Gap Formation and Surface Exudation during Extrusion Ingot DC-Casting 812 D. Mortensen, B. Henriksen, M. M'Hamdi, and H. Fjaer Macrosegregation Characteristics of Commercial Size Aluminum Alloy Ingot Cast by the Direct Chill Method 819 M. Chu and J. Jacoby Effects of Casting Practice on Macrosegregation and Microstructure of 2024 Alloy Billet 825 R. Dorward and D. Beerntsen Investigation in the Effects of the Casting Parameters on the Extent of Centerline Macrosegregation in DC Cast Sheet Ingots 831 B. Gariepy and Y. Caron Effect of Grain Refining on Defect Formation in DC Cast Al-Zn-Mg-Cu Alloy Billet 842 R. Nadella, D. Eskin, and L. Katgerman The Coupling of Macrosegregation with Grain Nucleation, Growth and Motion in DC Cast Aluminum Alloy Ingots 848 M. Zaloznik, A. Kumar, H. Combeau, M. Bedel, P. Jarry, and E. Waz Thermal Stresses in Continuous DC Casting of Al Alloys: Discussion of Hot Tearing Mechanisms 854 J. Moriceau Modelling of Fluid Flow and Stress Phenomena during DC Casting of Aluminium Alloys 862 S. Flood, L. Katgerman, A. Langille, S. Rogers, and C. Reed Thermomechanical Effects during Direct Chill and Electromagnetic Casting of Aluminum Alloys. Part I: Experimental Investigation 867 J. Drezet and M. Plata Thermomechanical Effects during Direct Chill and Electromagnetic Casting of Aluminum Alloys. Part II: Numerical Simulation 877 J. Drezet, M. Rappaz, and Y. Krähenbühl On the Mechanism of Surface Cracking in DC Cast 7xxx and 6xxx Extrusion Ingot Alloys 887 S. Benum, D. Mortensen, H. Fjaer, H. Overlie, and O. Reiso Hot Tearing in Aluminium-Copper Alloys 895 D. Viano, D. StJohn, J. Grandfield, and C. Caceres Measurement of the Onset of Hot Cracking in DC Cast Billets 900 B. Commet, P. Delaire, J. Rabenberg, and J. Storm A Mathematical Model for Hot Cracking of Aluminium Alloys during DC Casting 907 L. Katgerman Prediction of Hot Tears in DC-Cast Aluminum Billets 912 J. Drezet, and M. Rappaz As-Cast Mechanical Properties of High Strength Aluminum Alloy 919 J. Wan, H. Lu, K. Chang, and J. Harris Residual Stress Measurements for Studying Ingot Cracking 925 S. Levy, R. Zinkham, and J. Carson Numerical Simulation of DC Casting; Interpreting the Results of a Thermo-Mechanical Model 933 W. Boender, A. Burghardt, and E. van Klaveren, and J. Rabenberg Cold Cracking during Direct-Chill Casting 939 D. Eskin, M. Lalpoor, and L. Katgerman Recommended Reading 945 Part 8: Other Casting Methods Section Introduction 947 The Mechanical and Metallurgical Characteristics of Twin-Belt Cast Aluminum Strip Using Current Hazelett Technology 949 W. Szczypiorski and R. Szczypiorski The Hunter Continuous Strip Casting Process 959 W. Stephens and G. Vassily CREM — A New Casting Process. Part II — Industrial Aspects 966 J. Riquet and J. Meyer Twin Roll Casting of Aluminium: The Occurrence of Structure Inhomogeneities and Defects in As Cast Strip 972 H. Westengen and K. Nes Centre line Segregation in Twin Roll Cast Aluminum Alloy Slab 981 L Jin, L. Morris, and J. Hunt Thin Gauge Twin-Roll Casting, Process Capabilities and Product Quality 989 O. Daaland, A. Espedal, M. Nedreberg, and L Alvestad New Electromagnetic Rheocasters for the Production of Thixotropic Aluminum Alloy Slurries 997 C. Vives Remelt Ingot Production Technology 1003 J. Grandfield Recommended Reading 1011 Part 9: Heat Treatment Section Introduction 1013 Investigating the Alpha Transformation — A Solid-State Phase Change of Dispersed Intermetallic Particles from an Al6(Fe,Mn) Phase to an a-Al-(Fe,Mn)-Si Phase 1015 D. Alexander, R. Hamerton, H. Cama, and A. Greer Precipitation of Dispersoids in DC-Cast AA3103 Alloy during Heat Treatment 1021 Y. Li and L. Arnberg Modelling the Metallurgical Reactions during Homogenisation of an AA3103 Alloy 1028 A. Hâkonsen, D. Mortensen, S. Benum, T. Pettersen, and T. Furu Influence of Homogenizing on the Properties of Cast Aluminium Products 1036 J. Langerweger Recommended Reading 1043 Part 10: Safety Section Introduction 1045 Personal Protective Clothing: From Fundamental to a Global Strategy of Protection in the Casthouse Environment 1047 P. Wallach Why Does Molten Aluminum Explode at Underwater or Wet Surfaces? 1057 L. Nelson, M. Eatough, and K. Guay Investigation of Coatings Which Prevent Molten Aluminum/Water Explosions 1068 D. Leon, R. Richter, and T. Levendusky Hazards Associated with the Use of Bone Ash in Contact with Molten Aluminum 1074 D. Doutre Cause and Prevention of Explosions Involving Hottop Casting of Aluminum Extrusion Ingot 1078 J. Ekenes and T. Saether Cause and Prevention of Explosions Involving DC Casting of Aluminum Sheet Ingot 1085 R. Richter and J. Ekenes The Role of Automation in Explosion Prevention in Sheet Ingot Casting 1091 D. Bernard Hazards in Adding Scrap Copper to Molten Aluminum 1097 W. Peterson Recommended Reading 1101 Author Index 1103

About the Author :
JOHN F. GRANDFIELD, PhD, is Director of Grandfield Technology Pty Ltd, a consulting and technology firm, and Adjunct Professor in the High Temperature Processing Group at Swinburne University of Technology. Dr. Grandfield has thirty years of experience in light metals research and technology, with an emphasis on smelting, continuous casting, and metal refining. In addition, he has conducted plant benchmarking audits and technology reviews, optimized existing technology, managed technology transfer, and developed and commercialized new technologies. DMITRY G. ESKIN, PhD, is a Professor of Solidification Research at Brunel University (UK). Internationally recognized for his work in physical metallurgy and solidification processing of light alloys, Dr. Eskin holds several patents and is the author or coauthor of five monographs and more than 160 scientific papers. Among his publications are Advanced Aluminum Alloys Containing Scandium, Multicomponent Phase Diagrams: Applications for Commercial Aluminum Alloys, and Physical Metallurgy of Direct Chill Casting of Aluminum Alloys.