The Minerals, Metals & Materials Series Corleen Chesonis Editor

Light Metals 2019

123 Editor Corleen Chesonis Metal Quality Solutions, LLC Avonmore, PA, USA

ISSN 2367-1181 ISSN 2367-1696 (electronic) The Minerals, Metals & Materials Series ISBN 978-3-030-05863-0 ISBN 978-3-030-05864-7 (eBook) https://doi.org/10.1007/978-3-030-05864-7

Library of Congress Control Number: 2018964235

© The Minerals, Metals & Materials Society 2019, corrected publication 2019 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors, and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

This Springer imprint is published by the registered company Springer Nature Switzerland AG The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland Preface

It is my honor to present the Light Metals 2019 proceedings and to welcome you to the TMS 2019 Annual Meeting and Exhibition in San Antonio. I hope that being the second woman to edit this respected publication is an indication of increasing and ongoing inclusion and diversity in the light metals community. TMS has always been welcoming to me, both as a woman and as a chemical engineer rather than a metallurgist. The aluminum industry has continued to change in the past year with the announcement of Elysis, a joint venture to scale up and commercialize a revolutionary smelting technology that emits oxygen and eliminates greenhouse gases. If successful, this technology could help solve one of the major challenges of our industry and our world. In the meantime, a number of manufacturers have introduced certified low-carbon products and products made with 100% recycled metal. No matter what smelting technology is used in the future, recycling, reduced energy consumption, and lower environmental impact will continue to be important to our industry. These proceedings reflect an incredible effort by all the authors and their organizations in conducting their research and preparing the manuscripts that are published here. I would like to thank all of them for their work; their contributions continue to make Light Metals the pre-eminent annual publication for technical information on aluminum production processes. As in the past, this volume contains research and development papers on aluminum pro- cesses organized into the traditional Light Metals symposia: Alumina and Bauxite; Aluminum Alloys, Processing, and Characterization; Aluminum Reduction Technology; Cast Shop Technology; and Electrode Technology for Aluminum Production. It also includes two special symposia for 2019: Ultrasonic Processing of Liquid and Solidifying Alloys and Scandium Extraction and Use in Aluminum Alloys. We are honored to also have included papers on aluminum processing from two joint symposia: REWAS 2019: Cast Shop Recycling Tech- nologies and the TMS-DGM Symposium on Lightweight Metals: A Joint US-European Symposium on Challenges in Light Weighting the Transportation Industry. This last sym- posium is the result of a Memorandum of Understanding between TMS and the German Materials Society (DGM). I would like to thank the subject chairs and symposium organizers for all of their hard work: Sébastien Fortin, Hiromi Nagaumi, Marc Dupuis, Pierre-Yves Menet, Lorentz Petter Lossius, Nigel Ricketts, John Grandfield, Dmitry Eskin, Mertol Gökelma, Eric Nyberg, Wim Sillekens, Norbert Hort, and Jürgen Hirsch. I also appreciate the guidance of the previous editors, Olivier Martin and Arne Ratvik. Finally, my sincere thanks to all the wonderful staff at TMS who guided us through the production of these proceedings.

Corleen Chesonis

v Contents

Part I Alumina & Bauxite: Bayer Process and Non-conventional Processing Advances in Beneficiation of Low-Grade Bauxite ...... 3 Lala Behari Sukla, Archana Pattanaik and Debabrata Pradhan Leaching Kinetics of Thermally-Activated, High Silica Bauxite ...... 11 Hong Peng, Steven Peters and James Vaughan Rheological Improvements in Alumina Industry Clarification Circuits ...... 19 Lawrence J. Andermann Jr., Adrian Mullins, Cameron Smyth and Clive Roscoe Improving the Reliability of Fluidized Bed Alumina Calciners by Suitable Refractory Lining Selection ...... 27 Mariana A. L. Braulio, José R. Cunha, Austin J. Maxwell, Dean Whiteman and Victor C. Pandolfelli Valorization of Bauxite Residue: A Challenge that Leads to a Mentality Shift and Eventually Innovation ...... 33 Yiannis Pontikes Synchronous Desulfurization and Desilication of Low-Grade and High-Sulfur Bauxite by a Flotation Process ...... 35 Wencui Chai, Guihong Han, Yanfang Huang, Yijun Cao and Jiongtian Liu Preparing Alumina by an Electrolytic Method from Sulfuric Acid Leachate of Coal Fly Ash ...... 39 Yuan Shi, Kai-xi Jiang, Ting-an Zhang and Guo-zhi Lv

Part II Alumina & Bauxite: Bauxite Residue: Management and Valorization Use of Two Filtration Stages for Bauxite Residue ...... 47 Roberto Seno Jr., Rodrigo Aparecido Moreno and Heri Cristine Nakamura Environmental Friendly Transformation of the First and Oldest Alumina Refinery in the World ...... 57 Laurent Bonel, Philippe Clerin and Laurent Guillaumont Accelerating Bauxite Residue Remediation with Microbial Biotechnology ...... 69 T. C. Santini, K. Warren, M. Raudsepp, N. Carter, D. Hamley, C. McCosker, S. Couperthwaite, G. Southam, G. W. Tyson and L. A. Warren Simulation and Experiment Study on Carbonization Process of Calcified Slag with Different Ventilation Modes ...... 79 Guanting Liu, Liu Yan, Xiaolong Li, Weihua Sun, Zimu Zhang and Ting’an Zhang An Ecological Approach to the Rehabilitation of Bauxite Residue ...... 87 Elisa Di Carlo and Ronan Courtney

vii viii Contents

Quantitative X-Ray Diffraction Study into Bauxite Residue Mineralogical Phases ...... 93 John Vogrin, Harrison Hodge, Talitha Santini, Hong Peng and James Vaughan Technospheric Mining of Rare Earth Elements and Refractory Metals from Bauxite Residue ...... 101 John Anawati and Gisele Azimi Migration of Iron, Aluminum and Alkali Metal Within Pre-reduced-Smelting Separation of Bauxite Residue ...... 107 Jian Pan, Siwei Li, Deqing Zhu, Jiwei Xu and Jianlei Chou

Part III Aluminum Alloys, Processing and Characterization: Aluminum Alloy Development Influence of Amine Additives on the Electrodeposition of Aluminum from AlCl3-Dimethyl Sulfone Electrolytes ...... 115 S. A. Salman, Sangjae Kim, Kensuke Kuroda and Masazumi Okido Determination of the Intermetallic a-Phase Crystal Structure in Aluminum Alloys Solidified at Rapid Cooling Rates ...... 121 Joseph Jankowski, Michael Kaufman, Amy Clarke, Krish Krishnamurthy and Paul Wilson

Comparison of the Effects of B4C and SiC Reinforcement in Al-Si Matrix Alloys Produced via PM Method ...... 129 Yavuz Kaplan, Engin Tan, Hakan Ada and Sinan Aksöz The Effects of Manganese (Mn) Addition and Laser Parameters on the Microstructure and Surface Properties of Laser Deposited Aluminium Based Coatings ...... 135 O. S. Fatoba, S. A. Akinlabi and E. T. Akinlabi Understanding the Role of Cu and Clustering on Strain Hardening and Strain Rate Sensitivity of Al-Mg-Si-Cu Alloys...... 143 M. Langille, B. J. Diak, F. De Geuser, G. Guiglionda, S. Meddeb, H. Zhao, B. Gault, D. Raabe and A. Deschamps

Production of the AA2196-TiB2 MMCs via PM Technology ...... 153 Engin Tan, Yavuz Kaplan, Hakan Ada and Sinan Aksöz Retrogression-Reaging Behavior in Aluminum AA6013-T6 Sheet ...... 159 Katherine E. Rader, Jon T. Carter, Louis G. Hector Jr. and Eric M. Taleff

Part IV Aluminum Alloys, Processing and Characterization: Microstructures and Mechanical Properties of Aluminum Alloys Advanced Characterization of the Cyclic Deformation and Damage Behavior of Al-Si-Mg Cast Alloys Using Hysteresis Analysis and Alternating Current Potential Drop Method ...... 167 Jochen Tenkamp, Kevin Bleicher, Sven Klute, Karin Chrzan, Alexander Koch and Frank Walther 3-D Microstructural Distribution and Mechanical Analysis of HPDC Hypereutectic Al-Si Alloys via X-Ray Tomography ...... 177 J. Wang and S. M. Xiong Conditions for Retrogression Forming Aluminum AA7075-T6 Sheet ...... 187 Katherine E. Rader, Matthew B. Schick, Jon T. Carter, Louis G. Hector Jr. and Eric M. Taleff Contents ix

Influence of Silicon Phase Particles on the Thermal Conductivity of Al-Si Alloys ...... 193 Wenping Weng, Hiromi Nagaumi, Xiaodong Sheng, Weizhong Fan, Xiaocun Chen and Xiaonan Wang Influence of Microstructure Development on Mechanical Properties of AlSi7MgCu Alloy ...... 199 Davor Stanić, Zdenka Zovko Brodarac and Letian Li Fabrication and Characterization of Open Cell Aluminum Foams by Polymer Replication Method ...... 209 Ceren Yagsi and Ozgul Keles Hot and Cold Rolling Behavior of AA5083 Aluminium Alloy ...... 217 S. Das, Shiwani Meena and R. Sarvesha

Part V Aluminum Alloys, Processing and Characterization: Behavior of Casting Alloys Study on Tensile Behavior of High Vacuum Die-Cast AlSiMgMn Alloys...... 227 Haidong Zhao, Fei Liu, Chen Hu, Runsheng Yang and Fengzheng Sun The Effect of Manganese and Strontium on Iron Intermetallics in Recycled Al-7% Si Alloy ...... 235 James Mathew and Prakash Srirangam The Effect of Thermo-Mechanical Processing on the Microstructure and Mechanical Properties of Modified SIMA Treated Al-7Si Alloy ...... 241 Chandan Choudhary, K. L. Sahoo and D. Mandal Elevated-Temperature Low-Cycle Fatigue Behaviors of Al-Si 356 and 319 Foundry Alloys ...... 251 S. Chen, K. Liu and X.-G. Chen High Conductivity Al-Si-Mg Foundry Alloys—Market, Production, Optimization and Development ...... 259 Takeshi Saito, Petter Åsholt, Leonhard Heusler, Thomas Balkenhol and Kjetil R. Steen Influence of Die Soldering on Die Erosion and Soldering Layer Between Al Melts and Die in Al-Si-Fe Alloys ...... 271 Jong Min Kim, Jeong IL Youn and Young Jig Kim

Part VI Aluminum Alloys, Processing and Characterization: Simulations and Studies of Processing Coupled Fluid Flow and Heat Transfer Analysis of Ageing Heat Furnace ..... 279 Mircea Popa, Ioan Sava, Marin Petre, Cătălin Ducu, Sorin Moga, Alexandra-Valerica Nicola and Constantin-Nicușor Drăghici The Influence of the Distance Between the Plate and the Top Nozzles During the Soft Quenching Process of the 6061 Aluminium Alloy Plates ...... 285 Gheorghe Dobra, Ioan Sava, Carmen Nicoleta Stănică, Marin Petre, Cătălin Ducu, Sorin Moga and Cristian Nicușor Florescu Numerical Investigation on the Motion of Free-Floating Crystals During DC Casting of Aluminum Alloys ...... 295 Qipeng Dong, Hiromi Nagaumi, Haitao Zhang, Tianpeng Qu and Jingkun Wang x Contents

Numerical Modelling, Microstructural Evolution and Characterization of Laser Cladded Al-Sn-Si Coatings on Ti-6Al-4V Alloy ...... 305 O. S. Fatoba, E. T. Akinlabi, S. A. Akinlabi and M. F. Erinosho The Influence of Quenching and Stretching Process Conditions of Aluminium Alloy Plates on Residual Stresses ...... 315 Gheorghe Dobra, Ioan Sava, Cristian Theodor Stanescu, Cătălin Ducu, Sorin Moga, Decebal Dorin Bălășoiu and Dan Ion Păun Characteristics of Surface Properties of Aluminum Flat Products Related with Different Annealing Temperature and Cleaning Properties ...... 323 Emel Çalışkan, Sadık Kaan İpek, Ahmet Seisoğlu, Erdem Güler and Ali Ulus Comparative Electrochemical and Intergranular Corrosion-Resistance Testing of Wrought Aluminium Alloys ...... 331 Varužan Kevorkijan, Lucija Skledar, Marko Degiampietro, Irena Lesjak and Teja Krumpak Nature of Grain Boundary Precipitates and Stress Corrosion Cracking Behavior in Al 7075 and 7079 Alloys ...... 341 Ramasis Goswami

Part VII Aluminum Alloys, Processing and Characterization: Characterizations and Applications of Aluminum Alloys Effect of Homogenization on Al-Fe-Si Centerline Segregation of Twin-Roll Cast Aluminum Alloy AA 8011 ...... 351 Sooraj Patel and Jyoti Mukhopadhyay Effect of Mg and Si Content in Aluminum Alloys on Friction Surfacing Processing Behavior ...... 357 Jonas Ehrich, Arne Roos and Stefanie Hanke Mechanical Properties Evolution for 8xxx Foil Stock Materials by Alloy Optimization—Literature Review and Experimental Research ...... 365 Erik Santora, Josef Berneder, Florian Simetsberger and Martin Doberer Effects of Zr Additions on Structure and Microhardness Evolution of Eutectic Al-6Ni Alloy ...... 373 Chanun Suwanpreecha, Phromphong Pandee, Ussadawut Patakham, David C. Dunand and Chaowalit Limmaneevichitr Microstructure and Mechanical Properties of an Al-Zr-Er High Temperature Alloy Microalloyed with Tungsten ...... 379 A. R. Farkoosh, David Dunand and David N. Seidman Effect of Nickel Foil Thickness on Microstructure and Microhardness of Steel/Aluminium Alloy Dissimilar Laser Welding Joints ...... 385 Xiaonan Wang, Xiaming Chen, Wenping Weng, Hiromi Nagaumi and Jingzhe Zhou Residual Stress Characterization for Marine Gear Cases in As-Cast and T5 Heat Treated Conditions with Application of Neutron Diffraction ...... 395 Joshua Stroh and Dimitry Sediako Microstructural and Dry Sliding Friction Studies of Aluminum Matrix Composites Reinforced PKS Ash Developed via Friction Stir Processing...... 401 R. S. Fono-Tamo, Esther Titilayo Akinlabi and Jen Tien-Chien Contents xi

Part VIII Aluminum Alloys, Processing and Characterization: Casting and Solidification Comparison of Diversified Casting Methods on Mechanical and Microstructural Properties of 5754 Aluminum Alloy for Automotive Applications ...... 409 Ali Ulaş Malcıoğlu, Çisem Doğan and Canan İnel The Effect of High Speed Direct Chill Casting on Microstructure and Mechanical Properties of Al-Mg-Si-Fe Alloy ...... 417 Haitao Zhang, Dongtao Wang, Jianzhong Cui, Hiromi Nagaumi and Weizhong Fan Multi-Component High Pressure Die Casting (M-HPDC): Temperature Influence on the Bond Strength of Metal-Plastic-Hybrids Manufactured by M-HPDC ...... 423 Patrick Messer, Arthur Bulinger, Uwe Vroomen and Andreas Bührig-Polaczek On Microstructures, Textures and Formability of AA6xxx Alloy Sheets from DC and CC Processing ...... 429 Xiyu Wen, Randall Bowers and Shridas Ningileri Prototyping of a High Pressure Die Cast Al-Si Alloy Using Plaster Mold Casting to Replicate Corresponding Mechanical Properties ...... 435 Toni Bogdanoff, Ehsan Ghassemali, Martin Riestra and Salem Seifeddine Reduction of Aluminium Ingot Cooling Time in DC Casting Process ...... 443 Josée Colbert and André Larouche Impact of the Main Casting Process Parameters on Floating Crystals in Al Alloy DC-Cast Ingots ...... 451 Mousa Javidani, Martin Fortier and Josée Colbert

Part IX Aluminum Alloys, Processing and Characterization: Poster Session I—Development of Aluminum Alloy Processing Effect of Cu Addition on the Microstructure, Mechanical and Thermal Properties of a Piston Al-Si Alloy ...... 463 Suwaree Chankitmunkong, Dmitry G. Eskin and Chaowalit Limmaneevichitr Effects of Sc and Zr Addition on Microstructure and Mechanical Properties of Al-3Cu-2Li Alloy ...... 471 Yang Wang, Zheng Li and Ruizhi Wu Effects on Microstructure Evolution of Al-9Si-0.3Mg Alloy by Pyrometallurgically Produced Sr Master Alloy ...... 481 İbrahim Göksel Hizli and Derya Dışpınar Microstructure Characterization and Properties of Cast Al-Si-Fe-Zn Alloys with High Thermal Conductivity ...... 487 Chun Zou, Gu Zhong, Chu Qiu and Xinghui Gui Effects of Ag on the Microstructures and Mechanical Properties of Al-Mg Alloys ...... 493 Haitao Zhang and Bo Zhang

Part X Aluminum Alloys, Processing and Characterization: Poster Session II—Characterizations of Aluminum Alloys The Preparation Methods and Application of Aluminum Foam ...... 501 Xia Duan, Zhiwei Dai, Rong Xu, Ronghui Mao and Binna Song xii Contents

The Effects of Solidification Cooling Rates on the Mechanical Properties of an Aluminum Inline-6 Engine Block ...... 505 Joshua Stroh, Austin Piche, Dimitry Sediako, Anthony Lombardi and Glenn Byczynski Improvements for the Recognition Rate of Surface Defects of Aluminum Sheets ...... 513 Xiaoming Liu, Ke Xu and Dongdong Zhou

Part XI Aluminum Reduction Technology: Cell Technology Development and Modeling How to Limit the Heat Loss of Anode Stubs and Cathode Collector Bars in Order to Reduce Cell Energy Consumption ...... 521 Marc Dupuis Transformation of a Potline from Conventional to a Full Flexible Production Unit ...... 533 Roman Düssel, Albert Mulder and Louis Bugnion Modernisation of Sumitomo S170 Cells at Boyne Smelters Limited ...... 543 Chris Corby, Hao Zhang, Madeleine Lewis and James Roberts Environmental Aspects of UC RUSAL’s Aluminum Smelters Sustainable Development ...... 553 Viktor Mann, Viktor Buzunov, Vitaly Pingin, Aleksey Zherdev and Vyacheslav Grigoriev Copper Insert Collector Bar for Energy Reduction in 360 KA Smelter ...... 565 Amit Jha, Amit Gupta, Vinay Tiwari, Shashidhar Ghatnatti, K. K. Pandey and S. K. Anand New Resource-Saving Technologies for Lining the Cathode with Un-shaped Lining Materials ...... 573 Aleksandr V. Proshkin, Vitaly V. Pingin, Viktor Kh. Mann, Yuri M. Shtefanyuk and Anton S. Orlov Amperage Increase from 195 to 240 kA Through Pot Upgrading ...... 583 Liu Ming, Yang Xiaodong, Liu Yafeng and Lu Yanfeng

Part XII Aluminum Reduction Technology: Cell Design and Modelling A Transient Model of the Anodic Current Distribution in an Aluminum Electrolysis Cell ...... 595 Sébastien Guérard and Patrice Côté A Numerical Study of Gas Production and Bubble Dynamics in a Hall-Héroult Reduction Cell ...... 605 A. Cubeddu, V. Nandana and U. Janoske Thermoelectrical Design of Startup Fuses for Aluminum Reduction Cells ...... 615 André Felipe Schneider, Donald P. Ziegler, Timothée Turcotte, Daniel Richard, Pascal Lavoie, Ryan Soncini and Jayson Tessier Modelling Study of Exhaust Rate Impact on Heat Loss from Aluminium Reduction Cells ...... 625 Alexander Arkhipov, Ievgen Necheporenko, Alexander Mukhanov, Nadia Ahli and Khawla AlMarzooqi Finite Element Analysis of a Cylindrical Cathode Collector Bars Design ...... 637 Olivier Lacroix, Richard Beeler, Hicham Chaouki, Louis Gosselin and Mario Fafard Contents xiii

CFD Modeling of Alumina Diffusion and Distribution in Aluminum Smelting Cells ...... 645 Xiaozhen Liu, Youjian Yang, Zhaowen Wang, Wenju Tao, Tuofu Li and Zhibin Zhao Study on Side Ledge Behavior Under Current Fluctuations Based on Coupled Thermo-electric Model ...... 647 Hongliang Zhang, Qiyu Wang, Jie Li, Hui Guo, Jingkun Wang and Tianshuang Li

Part XIII Aluminum Reduction Technology: Joint Session Alumina Feeding and Alumina Scale Formation Alumina Feeding and Raft Formation: Raft Collection and Process Parameters ...... 659 Sindre Engzelius Gylver, Nina Helene Omdahl, Ann Kristin Prytz, Astrid Johanne Meyer, Lorentz Petter Lossius and Kristian Etienne Einarsrud Evolution of Mechanical Resistance of Alumina Raft Exposed to the Bath in Hall-Héroult Cells ...... 667 Sándor Poncsák, L. Rakotondramanana, László I. Kiss, T. Roger, S. Guérard and J.-F. Bilodeau Dynamic Modelling of Alumina Feeding in an Aluminium Electrolysis Cell .... 675 V. Bojarevics Development of a Mathematical Model to Follow Alumina Injection ...... 683 Thomas Roger, László Kiss, Kirk Fraser, Sándor Poncsák, Sébastien Guérard and Jean-François Bilodeau The Micro- and Macrostructure of Alumina Rafts ...... 689 Sindre Engzelius Gylver, Nina Helene Omdahl, Stein Rørvik, Ingrid Hansen, Andrea Nautnes, Sofie Nilssen Neverdal and Kristian Etienne Einarsrud Alumina Scale Composition and Growth Rate in Distribution Pipes ...... 697 Ingrid Bokn Haugland, Ole Kjos, Arne Røyset, Per Erik Vullum, Thor Anders Aarhaug and Maths Halstensen Investigation on Scale Formation in Aluminium Industry by Means of a Cold-Finger...... 707 Daniel Perez Clos, Petter Nekså, Sverre Gullikstad Johnsen and Ragnhild E. Aune

Part XIV Aluminum Reduction Technology: Joint Session with Electrode Technology Dry Barrier Powder Performance Update ...... 723 Richard Jeltsch Investigation of Refractory Degradation in Hall-Héroult Cell ...... 731 Bhavya Narang, Shanmukh Rajgire, Amit Gupta, Mahesh Sahoo and J. P. Nayak Thermogravimetric Analysis of Thermal Insulating Materials Exposed to Sodium Vapor ...... 737 Raymond Luneng, Zhaohui Wang, Arne Petter Ratvik and Tor Grande Innovative Anode Coating Technology to Reduce Anode Carbon Consumption in Aluminum Electrolysis Cells ...... 745 Ali Jassim, Najeeba Al Jabri, Saleh A. Rabbaa, Edouard G. Mofor and Jamil Jamal Theory and Practice of High Temperature Gas Baking Technology for Aluminium Electrolysis Cells ...... 753 Li Yingwu, Wang Xudong and Wu Chengbo xiv Contents

Research and Application of Direct Welding Technology on Super Large Section Conductor ...... 761 Xudong Wang, Liying Wu, Qingguo Bai and Qianqian Wei

Part XV Aluminum Reduction Technology: Fundamentals in Cell Behavior, Inert Anodes and Other Research Transfer Processes in the Bath of High Amperage Aluminium Reduction Cell ...... 773 Andrey Zavadyak, Peter Polyakov, Andrey Yasinskiy, Iliya Puzanov, Yuri Mikhalev, Sergey Shakhrai, Nikita Sharypov, Olga Yushkova and Andrey Polyakov Microstructure and Properties Analysis of Aluminium Smelter Crust ...... 779 Shanghai Wei, Jingjing Liu, Chathuni Ranaweera, Tania Groutso and Mark Taylor Sideledge in Aluminium Cells: Further Considerations Concerning the Trench at the Metal-Bath Boundary ...... 787 Asbjørn Solheim, Eirik Hjertenæs, Kati Tschöpe, Marian Kucharik and Nancy Jorunn Holt In Situ Evolution of the Frozen Layer Under Cold Anode ...... 795 Donald Picard, Jayson Tessier, Dany Gauthier, Houshang Alamdari and Mario Fafard Aluminum Electrolysis with Multiple Vertical Non-consumable Electrodes in a Low Temperature Electrolyte ...... 803 Guðmundur Gunnarsson, Guðbjörg Óskarsdóttir, Sindri Frostason and Jón Hjaltalín Magnússon Anode Overvoltages on the Industrial Carbon Blocks ...... 811 Peter Polyakov, Andrey Yasinskiy, Andrey Polyakov, Andrey Zavadyak, Yuri Mikhalev and Iliya Puzanov Development of a Drag Probe for In Situ Velocity Measurement of Molten Aluminum in Electrolysis Cell ...... 817 Samaneh Poursaman, Mounir Baiteche, Donald Picard, Donald Ziegler, Louis Gosselin and Mario Fafard

Part XVI Aluminum Reduction Technology: Environmental Issues including PFC Emissions Understanding of Co-evolution of PFC Emissions in EGA Smelter with Opportunities and Challenges to Lower the Emissions ...... 829 Ali Jassim, Sergey Akhmetov, Abdalla A. Alzarooni, Daniel Whitfield and Barry Welch Results from Fluoride Emission Reduction Projects in Alcoa Baie-Comeau ..... 837 Yves Béliveau, Stephen J. Lindsay, Stephan Broek, Julie Dontigny, Carl Doré, Diego Oitaben and Sylvain Bouthillier Validation of PFC Slope at Alcoa Canadian Smelters with Anode Effect Assessment and Future Implications to Add Low Voltage Emissions into Total PFC Emissions ...... 849 Christine Dubois, Eliezer Batista, Luis Espinoza-Nava and Alexandre Dubreuil SPL as a Carbon Injection Source in an EAF: A Process Study ...... 857 Vishnuvardhan Mambakkam, Robert Alicandri and Kinnor Chattopadhyay Contents xv

Migration Behavior of Fluorides in Spent Potlining During Vacuum Distillation Method ...... 867 Nan Li, Lei Gao and Kinnor Chattopadhyay

HF and SO2 Multipoint Monitoring on Large Gas Treatment Centers (GTCs) with Prewarning Abilities...... 873 Anders Sørhuus, Sivert Ose and Eivind Holmefjord DFT Study on COS Oxidation Reaction Mechanism ...... 879 Jie Li, Tianshuang Li, Hongliang Zhang, Jingkun Wang, Kena Sun and Jin Xiao

Part XVII Aluminum Reduction Technology: Cell Operations, Control and Improvements Lengthy Power Interruptions and Pot Line Shutdowns ...... 887 Alton Tabereaux and Stephen Lindsay High Amperage Operation at Alcoa Deschambault Booster Section ...... 897 Patrice Doiron, Jayson Tessier and Donald Paul Ziegler Potroom Operations Contributing to Fugitive Roof Dust Emissions from Aluminium Smelters ...... 905 David S. Wong, Margaret M. Hyland, Nursiani I. Tjahyono and David Cotton Advancement in Control Logic of Hindalco Low Amperage Pots ...... 913 Shanmukh Rajgire, Amit Jha, Amit Gupta, Manoj Chulliparambil, Saroj Choudhary, Gaurav Verma, Vibhav Upadhyay and Senthil Nath

Part XVIII Aluminum Reduction Technology: Poster Session Study on Preparation of Lithium Carbonate from Lithium-Rich Electrolyte .... 923 Wei Wang, Weijie Chen, Yuzhi Li and Kejing Wang The Application of the “Remote Data-Diagnosis Technology Service” (RDTS) for Aluminum Pot Line ...... 929 Bo Hong, Qinghong Tian, Xiaobing Yi and Zhuojun Xie

Part XIX Cast Shop Technology: EHS and Cast House Operation No Personnel in Hazard Zones ...... 939 Arild Håkonsen, Britt Elin Gihleengen and Vegard Innerdal The Industrial Application of Molten Metal Analysis (LIBS) ...... 945 James Herbert, Jorge Fernandez, Robert De Saro and Joe Craparo Sheet Ingot Casting Improvements at TRIMET Essen ...... 953 N. Towsey, G. Scheele, A. Luetzerath and E. Schoell Automated Billet Surface Inspection ...... 961 Jean-Pierre Gagné,Rémi St-Pierre, Pascal Côté and Francis Caron Optical Emission Spectrometry (OES) Data-Driven Inspection of Inclusions in Wrought Aluminium Alloys ...... 967 Varužan Kevorkijan, TomažŠustar, Irena Lesjak, Marko Degiampietro and Janez Langus Hydrogen Measurements Comparison in EN-AW 5083 Alloy ...... 973 Luisa Marzoli, Federica Pascucci, Giuseppe Esposito, Silvia Koch, Giulio Timelli and Marcel Rosefort xvi Contents

Part XX Cast Shop Technology: Casting and Cast House Products Macrosegregation Modelling of Large Sheet Ingots Including Grain Motion, Solidification Shrinkage and Mushy Zone Deformation ...... 983 Dag Mortensen, Øyvind Jensen, Gerd-Ulrich Grün and Andreas Buchholz Effect of Reversing Rotational Magnetic Field on Grain Size Refinement ...... 991 Akihiro Minagawa, Koichi Takahashi and Shin-ichi Shimasaki A Reduction in Hot Cracking via Microstructural Modification in DC Cast Billets ...... 999 Kathleen Bennett, Elli Tindall, Samuel R. Wagstaff and Kenzo Takahashi Analysis of the Interplay Between Thermo-solutal Convection and Equiaxed Grain Motion in Relation to Macrosegregation Formation in AA5182 Sheet Ingots ...... 1007 Akash Pakanati, Knut Omdal Tveito, Mohammed M’Hamdi, Hervé Combeau and Miha Založnik Grain Refinement of Commercial EC Grade 1370 Aluminium Alloy for Electrical Applications ...... 1015 Massoud Hassanabadi, Shahid Akhtar, Lars Arnberg and Ragnhild E. Aune

Effects of CO2 Cover Gas and Yttrium Additions on the Oxidation of AlMg Alloys ...... 1025 N. Smith, B. Gleeson, W. Saidi, A. Kvithyld and G. Tranell Behaviour of Aluminium Carbide in Al-Melts During Re-melting ...... 1033 Mertol Gökelma, Trygve Storm Aarnæs, Jürgen Maier, Bernd Friedrich and Gabriella Tranell Study of Controllable Inclusion Addition Methods in Al Melt ...... 1041 Jiawei Yang, Sarina Bao, Shahid Akthar and Yanjun Li

Part XXI Cast Shop Technology: Melt Treatment Furnace Atmosphere and Dissolved Hydrogen in Aluminium ...... 1051 Martin Syvertsen, Anne Kvithyld, Eilif Gundersen, Inge Johansen and Thorvald Abel Engh Miniature Vacuum Degassing System ...... 1057 Allen Chan and Ray Peterson Impact of the Filter Roughness on the Filtration Efficiency for Aluminum Melt Filtration ...... 1063 Claudia Voigt, Björn Dietrich, Mark Badowski, Margarita Gorshunova, Gotthard Wolf and Christos G. Aneziris Influence of the Wetting Behavior on the Aluminum Melt Filtration ...... 1071 Claudia Voigt, Lisa Ditscherlein, Eric Werzner, Tilo Zienert, Rafal Nowak, Urs Peuker, Natalia Sobczak and Christos G. Aneziris Aluminium Filtration by Bonded Particle Filters ...... 1081 Anne Kvithyld, Martin Syvertsen, Sarina Bao, Ulrik Aalborg Eriksen, Inge Johansen, Eilif Gundersen, Shahid Akhtar, Terje Haugen and Britt Elin Gihleengen Evaluation of Filtration Efficiency of Ceramic Foam Filters (CFF) Using a Hydraulic Water System ...... 1089 Massoud Hassanabadi, Petr Bilek, Shahid Akhtar and Ragnhild E. Aune Contents xvii

Drain Free Filtration (DFF)—A New CFF Technology ...... 1097 Ulf Tundal, Idar Steen, Åge Strømsvåg, Terje Haugen, John Olav Fagerlie and Arild Håkonsen Laboratory Scale Study of Reverse Priming in Aluminium Filtration ...... 1105 Sarina Bao, Martin Syvertsen, Freddy Syvertsen, Britt Elin Gihleengen, Ulf Tundal and Tanja Pettersen Estimation of Aluminum Melt Filtration Efficiency Using Automated Image Acquisition and Processing ...... 1113 Hannes Zedel, Robert Fritzsch, Shahid Akhtar and Ragnhild E. Aune

Part XXII Cast Shop Technology: Continuous Casting Horizontal Single Belt Casting of Aluminum Sheet Alloys ...... 1123 Roderick Guthrie and Mihaiela Isac Cast Strip Surface Topography Study and Thermomechanical Processing of 1050 Alloy Produced by One Copper Shell Roll Caster ...... 1131 Dionysios Spathis, John Tsiros and Andreas Mavroudis Influence of Strip Thickness on As-Cast Material Properties of Twin-Roll Cast Aluminum Alloys ...... 1137 Vakur Uğur Akdoğan, Cemil Işıksaçan, Hatice Mollaoğlu Altuner, Onur Birbaşar and Mert Günyüz Softening Behavior of Direct Chill and Twin-Roll Cast AA 3105 Alloy ...... 1143 Mert Gülver, Onur Meydanoglu and Cemil Işıksaçan

Part XXIII Cast Shop Technology: Energy Joint Session Aluminum Holding Furnace Optimal Design Using the CFD Method and Factorial Approach ...... 1151 Mohamed I. Hassan Ali, Saeed Alshehhi and Cynthia Belt Artificial Intelligence to Optimize Melting Processes: An Approach Combining Data Acquisition and Modeling ...... 1159 Amin Rostamian, Stéphane Lesquereux, Marc Bertherat and Michel Rappaz Oxy-Fuel Technologies for Improved Efficiency in Aluminum Scrap Melting ...... 1165 Xavier Paubel, Frank Rheker, Sarah Juma, Stew Jepson, Dietmar Wieck and Bill Ollerton Electromagnetic Transfer and Circulation (ETAC) of Molten Aluminum Metal and Its Alloys ...... 1173 Robert Fritzsch and Jim Grayson Optimized Electromagnetic Stirring in Melting and Holding Furnaces ...... 1179 Joakim Andersson

Part XXIV Electrode Technology for Aluminum Production: Electrodes—Raw Materials and Paste Plant Changing the Fineness of Calcined Petroleum Coke with Ball Race Mills ...... 1187 Jens-Peter Thiel, Jan Paepcke and Arne Hilck How to Appreciate the Coal Tar Pitch Impregnation on Coke Material? ...... 1195 Quentin Bernabé, Salima Belbachir, Christophe Bouché, Fabien Gaudière, Pierre-Louis Perrin, Laurent Vonna and Roger Gadiou xviii Contents

A Study of Elastic and Crack Resistance Properties of the Anode Carbon Material ...... 1205 Dag Herman Andersen, Fabian Dedecker, Sacha Emam and Martin Walderhaug Challenges and Opportunities of Vacuum Compaction: Lessons Learnt from Retrofitting EGA-JA Paste Plant to Vacuum Compaction ...... 1213 Bienvenu Ndjom, Muhammad Shafiq Malik, Ahmed Al Marzouqi, Tapan Kumar Sahu, Saleh Ahmed Rabba and Najeeba Al Jabri Carbon Block Tracking Package Based on Vision Technology ...... 1221 Pierre Mahieu, Xavier Genin, Christophe Bouché, David Brismalein and Hervé Pédroli Physical and Chemical Characterization of Bio-Pitch as a Potential Binder for Anode ...... 1229 Ying Lu, Roozbeh Mollaabbasi, Donald Picard, Donald Ziegler and Houshang Alamdari Anode Quality Monitoring Using Advanced Data Analytics ...... 1237 Bilal Azennoud, Ameline Bernard, Vincent Bonnivard and Hervé Pedroli Reactivity of Coke in Relation to Sulfur Level and Microstructure ...... 1247 Gøril Jahrsengene, Stein Rørvik, Arne Petter Ratvik, Lorentz Petter Lossius, Richard G. Haverkamp and Ann Mari Svensson

Part XXV Electrode Technology for Aluminum Production: Electrodes—Baking Development of a New Baking Furnace Design Without Headwall to Increase Anode Production Capacity ...... 1257 Arnaud Bourgier, J. P. Schneider, Lise Lavigne, Yves Tremblay, Allan Graham and Meaghan Noonan Risk Assessment of Fire and Explosion Incident in Anode Baking Furnace and Operational Practices ...... 1269 Kalpataru Samal, Suryakanta Nayak and Pulak Patra The Optimization of Soaking Time to Reduce Fuel Consumption While Keeping Good Baked Anode Quality ...... 1275 S. S. Sijabat, Firman Ashad, Ivan Ermisyam, Ade Buandra, Daniel Jimmy P. Hutauruk and Ivan Eko Yudho

Influence of Coke Calcining Level on Anode Real Density, LC and Other Properties Using a Constant Baking Cycle...... 1281 Christopher Kuhnt, Les Edwards, Marvin Lubin and Kevin Harp In Situ Monitoring of Pit Gas Composition During Baking of Anodes for Aluminum Electrolysis ...... 1291 Trond Brandvik, Thor A. Aarhaug, Heiko Gaertner, Arne P. Ratvik and Tor Grande Measurement of Anode Anisotropy by Micro X-Ray Computed Tomography ...... 1293 Stein Rørvik and Lorentz Petter Lossius Experimental Study on Preparation of Prebake Anodes with High Sulfur Petroleum Coke Desulfurized at High Temperatures ...... 1301 Shoulei Gao, Jilai Xue, Guanghui Lang, Rui Liu, Chongai Bao, Zhiguo Wang and Fali Zhang Contents xix

Electrochemical Behaviour of Carbon Anodes Produced with Different Mixing Temperatures and Baking Levels—A Laboratory Study ...... 1311 Camilla Sommerseth, Rebecca Jayne Thorne, Wojciech Gebarowski, Arne Petter Ratvik, Stein Rørvik, Hogne Linga, Lorentz Petter Lossius and Ann Mari Svensson

Part XXVI Electrode Technology for Aluminum Production: Cathodes and Electrode Technology Carbon Cathode Wear in Aluminium Electrolysis Cells ...... 1321 Samuel Senanu, Zhaohui Wang, Arne Petter Ratvik and Tor Grande Observation on the Creep and Cracking of Graphite Cathode in Laboratory Aluminum Electrolysis ...... 1323 Yunfei Lian, Jilai Xue, Cheng Zhang, Haipeng Li and Xuan Liu

Electrolytic Properties and Element Migration Behavior of Fe-TiB2 Composite Cathode ...... 1329 Yudong Liang, Lijun Wang, Dengpeng Chai, Shengzhong Bao, Tingting Niu, Junwei Wang and Ying Liu

Chemical Properties of Chromium Oxide in KF-NaF-AlF3 Based Low Temperature Electrolyte Melt ...... 1335 Shengzhong Bao, Yudong Liang, Dengpeng Chai, Zhirong Shi, Guanghui Hou and Yanhui Liu

Part XXVII Electrode Technology for Aluminum Production: Poster Session Study Finer Fines in Anode Formulation (Case Study: Almahdi Hormozal Aluminium Smelter) ...... 1345 Alireza Fardani, Mohsen Ameri Siahooei and Borzu Baharvand

Part XXVIII REWAS 2019: Cast Shop Recycling Technologies: Cast Shop and Recycling Session LIBS Based Sorting—A Solution for Automotive Scrap ...... 1351 Georg Rombach and Nils Bauerschlag A Method for Assessment of Recyclability of Aluminum from Incinerated Household Waste ...... 1359 Mertol Gökelma, Ingrid Meling, Ece Soylu, Anne Kvithyld and Gabriella Tranell The Vertical Floatation Decoater for Efficient, High Metal Yield Decoating and Delacquering of Aluminum Scrap ...... 1367 Robert De Saro and Sam Luke Positive Material Identification (PMI) Capabilities in the Metals Secondary Industry: An Analysis of XRF and LIBS Handheld Analyzers ...... 1375 Leslie Brooks and Gabrielle Gaustad Aluminum Alloys in Autobodies: Sources and Sinks ...... 1381 Ayomipo Arowosola, Gabrielle Gaustad and Leslie Brooks Manufacturing of Hydrogen on Demand Using Aluminum Can Scrap with Near Zero Waste ...... 1385 Jed Checketts and Neale R. Neelameggham xx Contents

Isothermal Hot Pressing of Skimmed Aluminium Dross: Influence of the Main Processing Parameters on In-House Molten-Metal Recovery ...... 1389 Varužan Kevorkijan

Part XXIX Scandium Extraction and Use in Aluminum Alloys: Scandium Markets and Extraction Scandium Solvent Extraction ...... 1395 Nigel J. Ricketts Refining Technology of Scandium Concentrate Obtained from Bauxite Residue ...... 1403 A. G. Suss, A. B. Kozyrev, S. N. Gorbachev, O. V. Petrakova and A. V. Panov Improved Technology of Scandium Recovery from Solutions of Bauxite Residue Carbonation Leaching ...... 1407 O. V. Petrakova, A. B. Kozyrev, A. G. Suss, S. N. Gorbachev and A. V. Panov Experimental Study of Pre-concentration from Silicate Containing Rare Earth Ore with Scandium by Magnetic Separation ...... 1415 Peng Yan, Guifang Zhang, Bo Li, Lei Gao, Zhe Shi, Hua Wang and Yindong Yang

Part XXX Scandium Extraction and Use in Aluminum Alloys: Aluminium Scandium Alloys

Grain Refinement of Al4CuTi Based Alloy with Zr, Sc, Er and TiB2 ...... 1423 Jiehua Li, Sajjad Amhad and Peter Schumacher Optimised Composition and Process Design to Develop Sc-Enhanced Wrought Al-Si Alloys ...... 1431 Jayshri Dumbre, Timothy Langan, Thomas Dorin and Nick Birbilis Developments in Aluminum-Scandium-Ceramic and Aluminum-Scandium-Cerium Alloys ...... 1439 David Weiss Developing an Optimized Homogenization Process for Sc and Zr Containing Al-Mg-Si Alloys ...... 1445 Steven Babaniaris, Mahendra Ramajayam, Lu Jiang, Timothy Langan and Thomas Dorin Effect of Scandium on Wire Arc Additive Manufacturing of 5 Series Aluminium Alloys ...... 1455 Andrew Sales and Nigel J. Ricketts Heat Treatments for Precipitation of Scandium-Containing Dispersoids in an Si-Containing Aluminum Alloys ...... 1463 Timothy Langan, Mahendra Ramjayam, Paul Sanders, Thomas Wood and Thomas Dorin

Effect of Mg Content on Al3Sc-Dispersoid Formation in Cast Billets of Al-Mg-Sc Alloys ...... 1469 Carson Williams, Tom Wood, Paul Sanders and Timothy Langan Contents xxi

Part XXXI TMS-DGM Symposium on Lightweight Metals: A Joint US-European Symposium on Challenges in Light Weighting the Transportation Industry: Aluminum A Novel Flexible SSM and HPDC Equipment to Process Secondary Aluminium Alloys for Decarbonising Lightweight Parts in Automotive Sector ...... 1475 Fabrizio D’Errico, Guido Perricone and Mattia Alemani The Effects of Strontium Addition on the Microstructures and Mechanical Properties of Al-7Si Alloy Reinforced with In Situ Al3Ti Particulates ...... 1485 Siming Ma and Xiaoming Wang Mechanical and Microstructural Characterization of Ultrasonic Metal Welded Large Cross Section Aluminum Wire/Copper Terminal Joints ...... 1491 Andreas Gester, Guntram Wagner, Ingo Kesel and Friedhelm Guenter The Dependence of Local Strain Distribution on Quench Rate for Extruded Al-Mg-Si-Mn-Fe Alloys ...... 1499 Mojtaba Mansouri Arani, Nick Parson, Mei Li and Warren J. Poole The Effect of Through Thickness Texture Variation on the Anisotropic Mechanical Response of an Extruded Al-Mn-Fe-Si Alloy...... 1503 Jingqi Chen, Warren J. Poole and Nick C. Parson Increasing the Strength and Electrical Conductivity of AA6101 Aluminum by Nanostructuring ...... 1507 Rilee C. Meagher, Mathew L. Hayne, Julie DuClos, Casey F. Davis, Terry C. Lowe, Tamás Ungár and Babak Arfaei Assessing the Impact of Texture and Its Gradients on the Forming Limits of an AA6xxx Sheet Alloy ...... 1515 Jishnu J. Bhattacharyya, Nathan Peterson, Fatih Sen, Richard Burrows, David Anderson, Vishwanath Hegadekatte and Sean R. Agnew

Part XXXII Ultrasonic Processing of Liquid and Solidifying Alloys: Fundamental Studies of Ultrasonic Processing Investigation on Acoustic Streaming During Ultrasonic Irradiation in Aluminum Melts ...... 1527 Takuya Yamamoto and Sergey Komarov Acoustic Cavitation Measurements and Modeling in Liquid Aluminum ...... 1533 Iakovos Tzanakis, Gerard Serge Bruno Lebon, Tungky Subroto, Dmitry Eskin and Koulis Pericleous Understanding the Highly Dynamic Phenomena in Ultrasonic Melt Processing by Ultrafast Synchrotron X-ray Imaging ...... 1539 Jiawei Mi, Dmitry Eskin, Thomas Connolley and Kamel Fezzaa The Influence of Ultrasound on the Microstructure Formation During Solidification of A356 Ingots Processed via a 2-Zone Induction Melting Furnace ...... 1545 Yang Xuan, Aqi Dong and Laurentiu Nastac Resonance from Contactless Ultrasound in Alloy Melts ...... 1551 C. E. H. Tonry, G. Djambazov, A. Dybalska, V. Bojarevics, W. D. Griffiths and K. A. Pericleous xxii Contents

In Situ Tomographic Observation of Dendritic Growth in Mg/Al Matrix Composites ...... 1561 Enyu Guo, A. B. Phillion, Zongning Chen, Huijun Kang, Tongmin Wang and Peter D. Lee Anomalous Nucleation in Undercooled Melts Processed by Electromagnetic Levitation ...... 1569 Robert W. Hyers, Jie Zhao, Gwendolyn P. Bracker, Rainer Wunderlich and Hans Fecht Modeling of the Effect of Ultrasonic Frequency and Amplitude on Acoustic Streaming ...... 1573 Young Ki Lee, Jeong IL Youn and Young Jig Kim Mechanisms of Grain Formation During Ultrasonic Solidification of Commercial Purity Magnesium ...... 1579 B. Nagasivamuni, Gui Wang, David H. StJohn and Matthew S. Dargusch

Part XXXIII Ultrasonic Processing of Liquid and Solidifying Alloys: Mechanisms and Applications of Ultrasonic Processing Effect of Ultrasonication on the Solidification Microstructure in Al and Mg-Alloys...... 1589 X. Zhang, H. R. Kotadia, J. Depner, M. Qian and A. Das Development and Application of Large-Sized Sonotrode Systems for Ultrasonic Treatment of Molten Aluminum Alloys ...... 1597 Sergey Komarov and Takuya Yamamoto Altering the Microstructure Morphology by Ultrasound Melt Processing During 6XXX Aluminium DC-Casting ...... 1605 G. Salloum-Abou-Jaoude, D. G. Eskin, G. S. B. Lebon, C. Barbatti, P. Jarry and M. Jarrett Effect of Acoustic Streaming on Degassing Level of A356 Al Alloy by Ultrasonic Melt Treatment ...... 1611 Jeong II Youn, Young Ki Lee, Young Jig Kim and Ja Wook Koo Cellular Automation Finite Element Modeling of the Evolution of the As-Cast Microstructure of an Ultrasonically Treated Al-2Cu Alloy ...... 1617 Gui Wang, Paul Croaker, Matthew Dargusch, Damian McGuckin and David StJohn In Situ Detection of Non-metallic Inclusions in Aluminum Melt (1xxx)—Comparison Between a Newly Developed Ultrasonic Technique and LiMCA and PoDFA Method ...... 1623 Friederike Feikus, Florian Funken, Thomas Waschkies and Andreas Bührig-Polaczek Crystallization Behavior of Iron-Containing Intermetallic Compounds in Al-Si Alloy Under Ultrasonic Treatment ...... 1631 Yubo Zhang, Tongmin Wang and Tingju Li Microstructure and Mechanical Properties of Dispersion-Strengthened Aluminum-Magnesium Alloys Obtained Using Ultrasonic Treatment of Melt ... 1637 Alexander Vorozhtsov, Anton Khrustalev, Ilya Zhukov, Alexander Kozulin and Evgeny Alifirenko Contents xxiii

Correction to: High Conductivity Al-Si-Mg Foundry Alloys—Market, Production, Optimization and Development ...... C1 Takeshi Saito, Petter Åsholt, Leonhard Heusler, Thomas Balkenhol and Kjetil R. Steen Author Index ...... 1641 Subject Index...... 1649 About the Editor

Corleen Chesonis is currently a consultant in aluminum metal treatment and molten metal quality with Metal Quality Solu- tions, LLC. She started her career with the Alcoa Technical Center in 1979, after receiving an M.S. in chemical engineering from Carnegie Mellon University. She worked as a research engineer on the Alcoa Smelting Process, the Hall-Héroult pro- cess, and organic matrix composite manufacturing processes. She completed her Ph.D. in chemical engineering in 1991 from the University of Pittsburgh as a part-time student while working at Alcoa. In 1992, she began working in Ingot Tech- nology at the Alcoa Technical Center. She did research and plant support in the area of metal treatment and molten metal quality for more than 20 years. In 2016, she retired from Alcoa, but has remained active in the aluminum industry as a consul- tant. She has published 15 papers in the Cast Shop Technology field and has served as a session chair at multiple TMS meet- ings. She also served as subject chair for the Cast Shop Tech- nology Symposium at the 2004 TMS Annual Meeting.

xxv Program Organizers

Alumina and Bauxite

Sébastien Fortin is R&D Principal Advisor for Bauxite and Alumina at Rio Tinto Aluminium Technology Solutions— ARDC. He holds a Ph.D. in inorganic chemistry from Université de Montréal. His career started at the Alcan Arvida Research and Development Centre in 2000, as a postdoctoral fellow conducting studies on heat exchangers scaling and cleaning. He spent the first 7 years of his career in R&D, driving projects on various aspects of the Bayer process, from bauxite characterization and Bayer process chemistry, to fil- tration and solid–liquid separation. He then spent nearly 4 years in operations, as process engineer at both Vaudreuil (Canada) and QAL (Australia) refineries, looking after redside and whiteside operation, where he made significant contributions in process improvements and equipment cleaning best practice. For the following 6 years, he was Bauxite and Alumina R&D Team Manager, successively at Gardanne (France) and ARDC, leading teams specializing in refinery process devel- opment, technical support, bauxite processability, and solid– liquid separation. Since the middle of 2017, he has been in charge of technical and strategic projects for Bauxite and Alumina R&D in the Atlantic region. His field of expertise is mainly bauxite and Bayer process chemistry. He is cur- rently Rio Tinto, Atlantic, representative on the International Aluminium Institute’s Bauxite and Alumina Committee.

xxvii xxviii Program Organizers

Aluminum Alloys, Processing, and Characterization

Hiromi Nagaumi is a Professor and Director of High- performance Metal Structural Materials Research Institute of Soochow University. He obtained his Ph.D. in metallurgical engineering at University of Electro-Communications (Japan) in 1997. He joined Nippon Light Metal Company as a senior research engineer in the casting research and development center from 1997 to 2007 and worked as vice-director from 2007 to 2009. Then, he worked for CHINALCO Suzhou Research Institute for Nonferrous Metals as vice-president and chief scientist from 2010 to 2017. In 2017, Hiromi joined Soochow University. He has long been engaged in the research of advanced melting and casting of aluminum alloys, and the design of new high-strength and high-toughness aluminum alloy materials for the lightweight of automobile. He first proposed the theory to predict the formation of porosities and hot-tearing within large-scale casting ingots. He successfully designed a new high-thermal conductivity aluminum alloys (180 W/m.K). He also managed to develop a new high-strength and toughness 6xxx alloys for automobile application (yield strength >380MPa, elongation >10%, fatigue strength >145MPa). He has served The Minerals, Metals & Materials Society (TMS) as session chair for Aluminum Alloys over several years.

Aluminum Reduction Technology

Marc Dupuis has been a consultant specializing in the appli- cations of mathematical modeling for the aluminum industry since 1994, the year he founded his own consulting company, GeniSim Inc. Before that, he graduated with a Ph.D. in chemical engineering from Laval University in Quebec City in 1984 and then worked for 10 years as a research engineer for Alcan International. His main research interests are the devel- opment of mathematical model of the Hall-Héroult cell dealing with the thermoelectric, thermomechanic, electromagnetic, and hydrodynamic aspect of the problem. He was also involved in the design of experimental high amperage cells and the retrofit of many existing cell technologies. Program Organizers xxix

Cast Shop Technology

Pierre-Yves Menet is Casting & Recycling R&D Group Manager at C-TEC, Constellium Technology Center in Voreppe, France. He graduated from Ecole Centrale Paris in 1989 with a master's degree in material science and engineering. In his career, he has held several positions from innovative research and development to industrialization of new processes and products as well as process optimization. Over this course, he has contributed to the continuous or semi-continuous casting process development of many products, slabs, billets, and strip, in most of the alloys of interest for the aluminum transformation industry including the recycling, remelting, and elaboration steps. During those projects, his main focus and motivation have been on developing process automation to ensure safety and quality and develop our understanding through process modeling. He also put together and structured the team within Constellium in charge of identifying and deploying good practices across Constellium casthouses. Today, his main interest is on making our profession more attractive to young talents and on developing the use of external (electromagnetic/ ultrasonic) fields in the casting and recycling process.

Cast Shop Technology: Energy Joint Session

Pierre-Yves Menet (see above)

REWAS 2019: Cast Shop Recycling Technologies

Mertol Gökelma is a Postdoctoral Researcher in the Depart- ment of Materials Science and Engineering at Norwegian University of Science and Technology (NTNU), Trondheim, Norway. He finished his B.Sc. at Dokuz Eylul University, Turkey in Metallurgical Engineering and Materials Science, and his M.Sc. and Ph.D. in Metallurgical Engineering at RWTH Aachen University, Germany. He worked as a research assistant for four years at the Institute of Process Technology and Metal Recycling (IME), RWTH. His research interests focus on process metallurgy of nonferrous metals and he has been involved in different R&D projects including recycling of magnesium black dross, recycling and refining of precious metals, powder synthesis of titanium alloys and metallothermic reduction of oxides. The main focus of his research is recycling and refining of aluminum as well as the behavior of non- metallic inclusions in Al melts. xxx Program Organizers

Electrode Technology for Aluminum Production

Lorentz Petter Lossius is Principal Engineer with Hydro Aluminium. He was educated at the Norwegian University of Science and Technology with an M.Sc. in Chemistry, Instru- mental Analysis in 1986, and completed his Dr.ing. at NTNU in 1991 with the thesis “Removing Impurities from Secondary Alumina”. In 1992–1993, he worked as a postdoc at the Université de Fribourg, Switzerland, studying Mg-battery electrochemistry, and from 1993 to 1996, he worked with Prof. Harald A. Øye as a research assistant/group leader at SINTEF/NTNU. In 1996, he joined Hydro Aluminium and is today Principal Engineer in the Anode Production section of the Primary Metal Technology research division. His main areas of work are research on anode raw materials and paste plant processing including pilot-scale studies, and development of laboratory methods and reference materials for X-ray characterization of in-plant process streams. Since 2002, he has been a Technical Expert in ISO Tech- nical Committee 226 “Materials for the production of primary aluminium”, in 2006 as Convenor for Working Group 4 Smelter Grade Fluorides, and since 2011 Chair of ISO/TC226. He is Secretary of ASTM Sub-committee D02.05 “Proper- ties of fuels, petroleum coke and carbon material”, and he is Committee Member of the biannual Norwegian X-ray Con- ference. He has authored and co-authored more than 40 papers, most based on original work performed at the Hydro plant and facilities in Årdal, Norway. He was an advisor in the selection of anode-related papers for the TMS Essential Readings in Light Metals collection (2013).

Scandium Extraction and Use in Aluminum Alloys

Nigel Ricketts is Technical Director of Altrius Engineering Services, a consulting and technology firm in Brisbane, Aus- tralia. He has a Bachelor of Applied Science in metallurgy (South Australian Institute of Technology) and a Ph.D. in chemical engineering (Monash University). He has more than 30 years’ experience in extractive met- allurgy and metal alloys research and development. He has conducted commissioning and plant operations, managed technology transfer, and developed and commercialised a number of technologies. He remains active in research with a current focus on copper and scandium extractive metallurgy and aluminum–scandium alloy development. He has five patents and has more than 30 conference and journal papers to his credit. Program Organizers xxxi

John Grandfield is Director of Grandfield Technology Pty Ltd, a consulting and technology firm, and Adjunct Professor at Swinburne University of Technology in the High Temperature Processing Group. He has a Bachelor of Applied Science in metallurgy (RMIT), an M.Sc. in mathematical modelling (Monash University), and a Ph.D. in materials science (University of Queensland). He has 30 years’ experience in light metals research and technology in smelting, continuous casting, and metal refining (Rio Tinto Alcan, CASTcrc, and CSIRO). He has conducted plant benchmarking audits and technology reviews, optimised existing technology, managed technology transfer, and devel- oped and commercialised new casthouse technologies. He remains active in research with a current focus on ingot cavity control and inclusion removal. His work on direct-chill and ingot casting of aluminum and magnesium has been awarded both internationally and within Australia. He is regularly invited to give training courses, participate in in-house innovation workshops, and conduct R&D program reviews around the world. He has four patents, has published two book chapters and more than 50 conference and journal papers, and has co-authored a book on DC casting of light metals. He is a member of the TMS Aluminum Committee and was editor of Light Metals 2014.

Ultrasonic Processing of Liquid and Solidifying Alloys

Dmitry G. Eskin received his Engineering and Ph.D. degrees from Moscow Institute of Steel and Alloys (Technical Univer- sity, Russia) in 1985 and 1988, respectively. After that, he worked as a senior scientist in the Baikov Institute of Metallurgy (Russian Academy of Sciences) with a main research focus of alloy development, heat treatment, and metal processing of aluminum alloys. In 1999–2011, he was Senior Scientist and Fellow in Materials innovation institute and since 2008 also held a position of Associate Professor in Delft University of Tech- nology (The Netherlands), where he conducted fundamental and applied research on solidification processing of metallic mate- rials, with major contributions to direct-chill casting. In 2011, he joined Brunel University London (UK) as professor in Solidi- fication Research. His current research concerns fundamentals and application of ultrasonic cavitation to melt processing. He is a well-known specialist in physical metallurgy and solidification processing of light alloys and author and co-author of more than 250 scientific papers, 7 monographs, and a number of patents. Among his books are Multicomponent Phase Diagrams: Applications for Commercial Aluminum Alloys (2005), Physical Metallurgy of Direct-Chill Casting of Aluminum Alloys (2008), Direct-Chill Casting of Light Alloys: Science and Technology (2013), and Solidification Processing of Metallic Alloys Under External Fields (2018). He has been a member of TMS since 2000, an organizer of a number of TMS symposia, and a regular speaker at TMS Annual Meetings. xxxii Program Organizers

TMS-DGM Symposium on Lightweight Metals: A Joint US-European Symposium on Challenges in Light Weighting the Transportation Industry

Eric Nyberg is the former Director of Programmes at Brunel University London, for the Brunel Centre for Advanced Solidification Technology (BCAST). He joined BCAST in 2016 to lead the development of research programs with international partners. Prior to this, he worked for 24 years at the Pacific Northwest National Laboratory (PNNL), most recently as chief engineer, materials research and development. The US Department of Energy (DOE) recognized Nyberg with the 2016 DOE Vehicle Technologies Office Special Recognition Award. He also holds three US patents and an R&D 100 Award and has authored or co-authored more than 50 technical publications. He earned both his bachelor’s and master’s degrees in materials science and engineering from Washington State University in Pullman, Washington. A TMS member since 1990, Nyberg was awarded the Light Metals Division (LMD) Distinguished Service Award in 2012. He has been engaged in LMD and TMS functional committees, including the Magnesium Committee Chair (Chair, Vice-Chair, and Secretary), the LMD Council (Vice-Chair), and the Program Committee (Magnesium Committee representative). He has also edited the Magnesium Technology Symposium proceedings and co-edited Essential Readings in Magnesium Technology (2014).

Wim H. Sillekens is Materials Science Coordinator in the Directorate of Human and Robotic Exploration Programs of the European Space Agency (ESA), and in that capacity oversees ESA’s microgravity research program on materials science using such platforms as the International Space Station. He obtained his Ph.D. from Eindhoven University of Technology, The Netherlands, on a subject relating to metal-forming tech- nology. Since then, he has been engaged in aluminum and magnesium research, among others on hydromechanical forming, recycling/refining, (hydrostatic) extrusion, forging, magnesium-based biodegradable implants, and most recently on light metal matrix nanocomposites and grain-refined mate- rials. His professional career includes positions as a postdoc researcher at his alma mater and as a research scientist/project leader at the Netherlands Organization for Applied Scientific Research (TNO). International working experience includes a placement as a research fellow at MEL (now AIST) in Tsu- kuba, Japan. He has (co)-authored a variety of publications (about 150 entries to date). Other professional activities include an involvement in association activities (among others, as the lead organizer of TMS Magnesium Technology 2011), inter- national conference committees, and as a peer reviewer of research papers and proposals. In 2017, he received the TMS Light Metals Division Distinguished Service Award. Program Organizers xxxiii

Jürgen Hirsch is a Senior Consultant for Hydro Aluminium Rolled Products R&D Bonn; Professor at the Institute of Physical Metallurgy & Metal Physics (IMM), RWTH Aachen University; CTO of HoDforming GmbH Düsseldorf; Lec- turer IUL at Technische Universität TU Dortmund; Guest Professor at Central South University, Changsha, China; and Remote Researcher at Samara National Research University, Russia. He is a member of the board of the German Society for Material Science (DGM), where he served as president in 2015-2016, and is head of FA “Aluminium”. He is also a member of the EUMAT EU platform steering committee and a member of the ICAA international committee, where he served as president from 2004 to 2016. He completed his Dr.-Ing. in material science and engi- neering at the IMM Institute of Physical Metallurgy & Metal Physics at the RWTH Aachen University in 1985. In 1988, he began work at Alcoa Technical Center (R&D) in Pittsburgh, USA, as a senior engineer. In 1991, he took a position as senior scientist at VAW Aluminium AG/Bonn (F&E), where he served as Head of Department for Rolling. This organization changed to Hydro Aluminium/Bonn (R&D) in 2002. In 2017, he became a consultant for “Aluminium—Metallurgy, Pro- cessing and Application”. He has authored more than 200 technical publications and articles and has edited several books on aluminum.

Norbert Hort is the head of the Magnesium Processing Department at the Magnesium Innovation Centre (MagIC) within the Helmholtz-Zentrum Geesthacht, Geesthacht, Ger- many. Concurrently, he is Lecturer at Leuphana University, Lüneburg, Germany. He studied Materials Sciences at Claus- thal University of Technology (CUT), Germany, where he has been involved in magnesium research since the early 1990s. In 1994, he obtained his university degree in engineering. He obtained his Ph.D. in materials sciences in 2002 from CUT. During 1994–1999, he worked as a researcher at the Institute of Materials Sciences (CUT), and he joined the MagIC in 2000. At MagIC, he is responsible for the development of new creep resistant alloys, biodegradable implant materials, and grain refinement and castability of magnesium alloys. This also covers in situ observations of solidification behavior using synchrotron diffraction and tomography. He is co-author of more than 190 peer reviewed journal articles and more than 220 contributions to conference proceedings. In recent years, he was involved in the organization of Magnesium Technology symposia at TMS Annual Meetings (2012–2014, 2018). Additionally, he was member of the organizing committees of Magnesium Alloys and their Applications (2009, 2012, 2015, 2018), LightMat (2013, 2017), Thermec (2013, 2016, 2018), Euromat 2017, IMA annual meetings (2013, 2014), and the conference “Light Metal Technologies 2011”. Since 2009, he has been Chairman of the technical committee “Magnesium” of the German Society of Materials (DGM). Aluminum Committee 2018–2022

Chairperson Olivier Martin, Rio Tinto Alcan, Saint Jean, France

Vice Chairperson Corleen Chesonis, Metal Quality Solutions, LLC, Pennsylvania, USA

Past Chairperson Arne P. Ratvik, SINTEF, Trondheim, Norway

Director-at-Large Barry A. Sadler, Net Carbon Consulting Pty Ltd, Victoria, Australia

Secretary Stephan Broek, Hatch Ltd, Ontario, Canada

JOM Advisor Pascal Lavoie, Quebec, Canada

Light Metals Division Chair Alan A. Luo, The Ohio State University, Ohio, USA

Members-at-Large Through 2019

Marc Dupuis, GeniSim Inc, Quebec, Canada Bingliang Gao, Northeastern University, Shenyang, China

Members Through 2019

John V. Griffin, ACT LLC, New Jersey, USA Margaret M. Hyland, Victoria University of Wellington, Wellington, New Zealand Pascal Lavoie, Quebec, Canada Hans-Werner Schmidt, Outotec GmbH, Oberursel, Germany Alan David Tomsett, Pacific Aluminium, Queensland, Australia

Members Through 2020

Angelique N. Adams, Alcoa Inc, Tennessee, USA Stephen Broek, Hatch Ltd, Ontario, Canada Mohamed I. Hassan Ali, Masdar Institute of Science and Technology, Abu Dhabi, UAE Phil Black, Victoria, Australia Edward McRae Williams, Arconic, Pennsylvania, USA

xxxv xxxvi Aluminum Committee 2018–2022

Members Through 2021

Arne P. Ratvik, SINTEF, Trondheim, Norway

Members Through 2022

Mark Badowski, Hydro Aluminium Rolled Products, Bonn, Germany Xian-An Liao, Elkem, Ontario, Canada Linus Perander, Outotec Gmbh & Co Kg, Stokke, Norway Xiyu Wen, University of Kentucky, Kentucky, USA