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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.
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 andR. 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, andM. 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 andR. 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. StJohn
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, andR. 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, andM. Pekgüleryüz
The Generation of AlmFe in Dilute Aluminium Alloys with Different Grain Refining Additions 475
W. Meredith, A. Greer, P. Evans, andR. Hamerton
Effects of Cooling Rate and Grain Refining on Constituent Phase Particle Size in As-Cast 3004 Alloy 482
P. Anyalebechi, T. Rouns, andR. 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, andJ. 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, andR. 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, andJ. 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 andJ. Rabenberg
Advances for DC Ingot Casting: Part 2 - Heat Transfer and Casting Results 672
G. Grealy, J. Davis, E. Jensen, P. Tonde I, andJ. 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 andJ. 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, andE. 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 andM. 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, andJ. 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, andM. Rappaz
As-Cast Mechanical Properties of High Strength Aluminum Alloy 919
J. Wan, H. Lu, K. Chang, andJ. Harris
Residual Stress Measurements for Studying Ingot Cracking 925
S. Levy, R. Zinkham, andJ. Carson
Numerical Simulation of DC Casting; Interpreting the Results of a Thermo-Mechanical Model 933
W. Boender, A. Burghardt, andE. van Klaveren, andJ. 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 andR. 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 andJ. 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, andJ. Hunt
Thin Gauge Twin-Roll Casting, Process Capabilities and Product Quality 989
O. Daaland, A. Espedal, M. Nedreberg, andL 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
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