Aluminium Cast House Technology XII
Selected, peer reviewed papers from the 12th International Conference and Exhibition, on Aluminium Cast House Technology, September 11-14, 2011, Melbourne, Australia
Edited by:
A.Prasad, J.A. Taylor and J.F. Grandfield Table of Contents
Preface v
Sponsors, Trade Exhibitors and Committees vi
Chapter 1: Markets and Cast House Layouts Improving Casthouse Throughput Using Discrete-Event Modelling B. Gunn and Y. Fray man 3
Chapter 2: Controlling Melt Loss
A Historical Perspective on Dross Processing R.D. Peterson 13
The Approach to Zero Waste from Smelter and Secondary Dross Processing D.J. Roth 24
Preserving Metal Units Utilising the Latest Generation of Aluminium Dross Press A. Peel, J. Herbert, R. Connaughton and H. Cotton 33
Crucible Fluxing with Hycast RAM- Effect on Metal Quality and Operational Cost T. Haugen, I.K. Steen, E. Myrbostad and A. Hakonsen 44
SPH Modeling of the Effect of Crucible Tipping Rate on Oxide Formation M. Prakash, P.W. Cleary and J.A. Taylor 54
Oxidation of Rolled and Flash Anodized 3000 Aluminum in Air, Nitrogen, Oxygen, and Carbon Dioxide Atmospheres D. Stevens, A. Kvithyld and T.A. Engh 63
Chapter 3: Furnaces and Refractories
A Historical Perspective of Aluminium Casthouse Furnace Developments P. Whiteley 73
Improved Monolithic Materials for Lining Aluminium Holding and Melting Furnaces - Roof, Upper Walls and Flue A. Wynn, J. Coppack, T. Steele and G. Latter 80
Phosphate Bonded Monolithic Refractory Materials with Improved Hot Strengths as a Potential Replacement for Phosphate Bonded Bricks J. Decker 90
Cost Savings in the Cast House through Optimizing Furnace Operation, Staff Training and Associated Variables J.T. Grayson 104
Thermocouple Protection Tube Options for Aluminium Casthouses P. Herd and J. Chen 112
The Challenges to Supply New Casthouse Furnaces in a Modern Aluminium Smelter Project M. Unitt, G. Guest, S. Williams and G. Proffitt 122
Chapter 4: Safety
Can the Aluminium Industry Learn from another Industry's Catastrophe? A.W. Lowery and T. Bateman 133 X Aluminium Cast House Technology XII
Chapter 5: Melt Quality and Treatment Increasing Cast House Throughput through "In-Spec First Time" G. Girard, M. Bishop, P. Austen and L. Swain 141 Control and Removal of Impurities from Al Melts: A Review M.A. Dewan, M.A. Rhamdhani, J.B. Mitchell, C.J. Davidson, G.A. Brooks, M. Easton and J.F. Grandfield 149
Development of a Fused Magnesium Chloride Containing Refining Flux Based on a Ternary System J.H. Courtenay 161
Recent Results with New Filter Technologies Based on the Principle of Multi Stage Filtration with Grain Refiner Added in the Intermediate Stage J.H. Courtenay, F. Reusch and S. Instone 169 Automatic Control of Molten Metal Flow for Improving Casting Performance T. Jarlsmark, J. Strombeck, M. Terner and J. Wilkins 179
Chapter 6: Direct Chill Casting
The Development of Alsim - a Modelling Tool for Direct Chill Casting, Twin Roll Casting, Wheel and Belt Casting and Chain Conveyor Casting D. Mortensen, H.G. Fjasr, D. Lindholm, M. Rudshaug and E.A. Serheim 187
Aluminum Ingot Thermal Stress Development Modeling of the Wagstaff* EpsilonTM Rolling Ingot DC Casting System during the Start-up Phase B. Zhang and C. Shaber 196
Mold and Casting Table Maintenance Management System at Aluar: A Key to Quality Billets and Saving Costs L.S. Batalla, O.A. Godoy and M.V. Canullo 208
Hot Tearing in Al-Mg-Si Alloys with Minor Additions of Cu or Mn L. Sweet, J.A. Taylor, M.J. Couper and M.A. Easton 217
Chapter 7: Ingot and Continuous Casting Implementation of CASTfill Low-Dross Pouring System for Ingot Casting V. Nguyen, P. Rohan, J.F. Grandfield, A. Levin, K. Naidoo, K. Oswald, G. Girard, B. Harker and J. Rea 227
3D Thermo-Mechanical Modelling of Wheel and Belt Continuous Casting J.F. Grandfield, S. Dablement, H.G. Fjasr, D. Mortensen, M. Lee, V. Nguyen and G. Savage 235
Chapter 8: Alloys and Heat Treatment
Design of Secondary Alloy Compositions for High Performance Aluminium Pressure Diecastings R. Lumley 247
The Effect of Calcium on the Rolling Behaviour and Hot Tensile Properties of AA5182 D.A. Doutre and P.A. Wycliffe 256 The Metallurgy of Homogenisation B. Rinderer 264 Effect of Homogenisation Parameters on Dissolution and Precipitation in Aluminium Alloy AA7150 L.J. D.K. P.A. Wang, Xu, Rometsch, S.X. Gao, Y. Zhang, Z.B. He, M.J. Couper and B.C. Muddle 276
Index Keyword 283 Author Index 285