Light Metals 2014 1st Edition John Grandfield 3319481444 9783319481449

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• ISBN 10: 3319481444
• ISBN 13: 9783319481449
• Author: John Grandfield

The Light Metals symposia are a key part of the TMS Annual Meeting & Exhibition, presenting the most recent developments, discoveries, and practices in primary aluminum science and technology. Publishing the proceedings from these important symposia, the Light Metals volume has become the definitive reference in the field of aluminum production and related light metal technologies. The 2014 collection includes papers from the following symposia: •Alumina and Bauxite •Aluminum Alloys: Fabrication, Characterization and Applications •Aluminum Processing •Aluminum Reduction Technology •Cast Shop for Aluminum Production •Electrode Technology for Aluminum Production •Light-metal Matrix (Nano)-composites

Table of contents:

1. Evolution of the Technology for the Production of Alumina from Bauxites
2. Approaches to the Processing of Jamaican Bauxite with High Goethite Content
3. Improvement of Processing Characteristics of High Carbonate and High Silica Diasporic Bauxite by Enr
4. New High-Performance Crystal Growth Modifiers to Improve Alumina Trihydrate Quality and Yield
5. Process Control
6. Votorantim Metals – CBA Alumina Refinery Precipitation Modeling
7. Value of Systems Integration to Optimize Operation in Alumina Refineries
8. Study of Influences on the Bauxite Moisture and Solids in Filtrate in the Hyperbaric Filters through
9. Increased Operational Flexibility in CFB Alumina Calcination
10. Increasing Extraction Efficiency Using a Closed Grinding Circuit
11. Cost Reduction/Alumina Recovery
12. A Review of Two Phase Flow Modeling and Its Applicability to the Bayer Process
13. Pipeline Scaling Prevention and Removal Methods in Bayer Digestion Process
14. Using of Siliconate-Type Polymers as Inhibitor of Scaling at Aluminate Liquors Heating and Evaporati
15. Crystal Structure and Alumina Leaching Property of Na2O Doped C12A7
16. Decomposition Property of γ-2CaO·SiO2 during Leaching Process of Calcium Aluminate Slag
17. Effect of Calcium/Aluminium Ratio on Crystal Structure and Al2O3 Leaching Property of 12CaO-7Al2O3
18. Multi-Steps Carbonation Treatment of Calcified Slag of Red Mud
19. Non-Bayer Process
20. Tests on Comprehensive Recovery of Iron Minerals and Bauxite from High Iron Diasporic Bauxite by Med
21. The Influence of the Mineral Composition of Low-Grade Aluminum Ores on Aluminum Extraction by Acid L
22. Dry Sintering of Nepheline – A New More Energy Efficient Technology
23. A Study on Sintering Process Optimization of Alumina Attraction from Fly Ash
24. Effect of Pressure on Alumina Extraction from Low-Grade Bauxite by Acid-Leaching Method
25. Extraction of Alumina from Coal-Derived Pyrite Flotation Tailing by Pre-Desilication–Bayer Process
26. Extracting Alumina from Low Grade Bauxite with Ammonium Bisulfate Leaching
27. Hydrochemical Method of Low-Quality Raw Materials Processing to Alumina
28. Waste Recovery
29. The Enexal Bauxite Residue Treatment Process: Industrial Scale Pilot Plant Results
30. Sustainability and Bauxite Deposits
31. Valorization of Alumina Red Mud for Production of Geopolymeric Bricks and Tiles
32. Study of Alternative Technologies for Residue Disposal (Red Mud)
33. Economic Analysis of Producing Alumina with Low-Grade Bauxite (Red Mud) by Calcification-Carbonizati
34. Recovery of Titanium Oxide from Undigested Sand of an Indian Alumina Refinery and Preparation of Val
35. Aluminum Alloys: Development, Characterization and Applications
36. Development and Application
37. AMAG 6XXX Series Alloys for Chassis Application in the Automotive Industry
38. Heat Treating of High Pressure Die Cast Components: Challenges and Possibilities
39. Influence of the Chemical Composition on the Ductility of an AlSiCuZnFe Recycling Foundry Alloy
40. Assessment of Hot Cracking during TIG Welding of B206 Aluminum Alloy
41. Influence of Microstructure on the Folding Behavior of Crash Relevant Aluminum Extrusion Parts
42. Effect of TiC Powder Addition on the Grain Refinement Response of B319 Aluminium Alloy
43. Properties of AlZn10Si8Mg Alloys for High Performances Application
44. Processing, Texture and Formability
45. An Experimental and Modeling Investigation on High-Rate Formability of Aluminum
46. Influence of Chemical Composition and Process Parameters on Mechanical Properties and Formability of
47. High Strength Aluminum Brazing Sheets for Condenser Fins of Automotive Heat Exchangers
48. High-Temperature Processes Occurring during Homogenization of AA6082 Aluminum Alloy
49. Solutioning and Aging Behavior
50. A Study of the Artificial Ageing on the Low Temperature Creep of AlMgSi (AA6201) Wires
51. Precipitates in Long Term Aging Al 5083 Alloy
52. Effect of Modified Aging Treatments on the Tensile Properties, Quality Indices and Fatigue Life of C
53. Effect of Vanadium Additions on the Structure of Aluminium (Al99.5) and 6xxx Aluminium Alloys
54. Aluminum Tailor-Welded Blanks for High Volume Automotive Applications
55. Corrosion and Fatigue
56. A New Approach for Evaluation of Fatigue Life of Al Wire Bonds in Power Electronics
57. Long and Small Fatigue Crack Growth in Aluminum Alloys
58. Alumina Silica Brick Corrosion by Different Aluminium Alloys
59. Effect of Salt Solution Corrosion on Tensile Properties of Vacuum High Pressure Die Cast A356 Alloy
60. Effect of the Thermo-Mechanical Treatment on IGC Susceptibility of AA 5083 Alloy
61. Material Characterization and Modeling
62. Role of Ni and Zr in Preserving the Strength of 354 Aluminum Alloy at High Temperature
63. Stress-Strain Curves of Pure Aluminum and Al-4.5mass%Cu Alloy in Semi-Solid State
64. Modeling Texture Evolution of Pure FCC Alloy during Annealing
65. Microstructure and Mechanical Properties of 3003 Aluminum Alloy with Mg and Ni Addition
66. Lightweight Construction for Electric Mobility Using Aluminium
67. Emerging Technologies
68. Deformation of Open-Cell Microcellular Pure Aluminum Investigated by the Acoustic Emission Technique
69. The Research on Process of Impact Factors of Hard Anodic Oxidation for 6061 Aluminum Alloy
70. Using Scrap in Recycling Alloys for Structural Applications in the Automotive Industry
71. Residual Stress Analysis in Semi-Permanent Mold Engine Head Castings
72. Tensile and Shear Mechanical Properties in a Thermo-Mechanical-Electrical Processed Spot Weld
73. Development of High-Strength and Highly Ductile Hypo-Eutectic Al-Si Alloys by Nano-Refining the Cons
74. Anodization and Optical Appearance of Sputter Deposited Al-Zr Coatings
75. Poster Session
76. Friction Coefficients on Compression Testing of AA6060 and 42CrMo4 with Different Lubrication Condit
77. Effect of Tin on the Corrosion and Electrochemical Behavior of Al-Zn-Mg Alloy in Sea Water
78. Interface Evolution in the Process of Fabricating Aluminum Foam Sandwiches
79. Alloy AlZn9 Casted in the Process of Rapid Solidification and Consolidated in the Process of Plastic
80. Aluminum Processing
81. Rolling & Twin Roll Casting
82. Evolution of Microstructure and Texture during Severe Cold Rolling and Annealing of Al-2.5% Mg and A
83. Dynamic Simulation of Internal Logistics in Aluminum Downstream Manufacturing
84. Influence of the Twin-Roll Casting Parameters on the Microsegregation in Thin Strips of the Aluminiu
85. Determination of Aluminum Rolling Oil and Machinery Oil Residues on Finished Aluminum Sheet and Foil
86. Extrusion & Miscellaneous Processes
87. A Numerical and Experimental Study of Homogenization of Al-Si-Mg Alloys
88. Effect of Mg2Si Phase on Extrusion of AA6005 Aluminum Alloy
89. Analysis of the Evolution and Deformation of Pore Morphology during Compression
90. Aluminum Reduction Technology
91. Potline Operations – Cell Operations
92. Cell Electrical Preheating Practices at DUBAL
93. DUBAL Cell Voltage Drop Initiatives Towards Low Energy High Amperage Cells
94. Startup of Shut-Down Pots – Problems and Solutions to Improve Results
95. Thermal Events of the Early Life of an Aluminum Electrolysis Cell
96. Regulation System to Improve Quality of the Metal Sucked during Tapping Operation
97. Key Success Factors Deploying a Manufacturing Excellence Solution (MESALTM) in Rio Tinto Alcan
98. Cell Design and Performance – Cathodes and Anodes Joint Session with Electrode Technology
99. Influence of the Cathode Surface Geometry on the Metal Pad Current Density
100. On the Influence of MHD Driven Convection on Cathode Wear
101. Effect of Innovative Cathode on Bath/Metal Interface Fluctuation in Aluminum Electrolytic Cell
102. Simulation and Optimization of Cathode Current Distribution to Reduce the Horizontal Current in the
103. Numerical Simulation of Full Life Cycle Cathode Assembly Performances for Design Optimization
104. Bar to Block Contact Resistance in Aluminum Reduction Cell Cathode Assemblies
105. Anode Rod to Beam Contact
106. Towards Decreasing Energy Consumption of Aluminum Reduction by Using Anodes with Holes and Channels
107. Environment I
108. Comparing Different Measurement Approaches to Characterize All PFC Emissions
109. Anode Effect Phenomena during Conventional AEs, Low Voltage Propagating AEs & Non-Propagating AEs
110. Monitoring of Continuous PFC Formation in Small to Moderate Size Aluminium Electrolysis Cells
111. At-Line Analysis of Polycyclic Aromatic Hydrocarbons in Aluminium Primary Production
112. Raw Gas Particles and Depositions in Fume Treatment Facilities in Aluminium Smelting
113. The Nature of Particles and Fines in Potroom Dust
114. Predictive Tools in Evaluating Re-Entrainment of Exhausted Particulate in Different Ventilator Confi
115. Economic and Environmental Alternative for Destination of Spent Pot Lining from Primary Aluminum Pro
116. Fundamentals – Chemistry
117. Improving XRD Analysis for Complex Bath Chemistries – Investigations and Challenges Faced
118. Al2O3-Na3AlF6 Man-Made Ledge Composites for Aluminum Electrolysis Cells
119. Structural Characterisation and Thermophysical Properties of the Side Ledge in Hall-Héroult Cells
120. The Melting Behaviour of Aluminium Smelter Crust
121. Key Physical Properties of Smelter Grade Alumina
122. Modeling the Behavior of Alumina Agglomerate in the Hall-Héroult Process
123. Wetting Characteristics of Cryolite-Based Melts on Spinels Substrate
124. Environment II
125. Abart CDS – A New Compact Multi-Pollutant Pot Gas and Alumina Handling System
126. Development on Electrolytic Cell Gas Cooling
127. 15 Years of GTC Operation at ALDEL: Long-Term Assessment of GTC Performance
128. Pot Gas Cooling Technologies
129. Modelling HF Generation: The Role of Ambient Humidity
130. Online Monitoring of Aluminium Primary Production Gas Composition by Use of Fourier-Transform Infrar
131. Fundamentals – Modeling
132. On the Prediction of the Crust Evolution inside Aluminum Electrolysis Cells
133. An Improved Finite Element Model for Thermal Balance Analysis of Aluminum Electrolysis Cells
134. A Modelling of Heat Losses in Aluminium Reduction Cell with Slotted Anodes
135. AP60 Cell Start-Up: Thermal Electrical Mechanical Quarter Cell Model
136. A Numerical Approach for the Design of Anode Beam Mechanical Systems
137. MHD Stability for Irregular and Disturbed Aluminium Reduction Cells
138. Revised Benchmark Problem for Modeling of Metal Flow and Metal Heaving in Reduction Cells
139. Dynamic Simulation of Cell Voltage Resonance Effect in Aluminum Electrolysis Cell
140. Analysis of the MHD Instabilities in Reduction Cells with Lyapunov Method
141. Potline Operations – Equipment
142. A Novel Design Criterion for Alumina Feeders in Aluminium Electrolysis Cells
143. Non-Linear Behavior of a Metallic Foam for the Reduction of Energy Losses at Electrical Contacts in
144. Influence of Heat Source Cooling Limitation on ORC System Layout and Working Fluid Selection: The Ca
145. Concept and Design of DUBAL Pot Start-Up Fuses
146. A Novel Heat Recovery Technology from an Aluminum Reduction Cell Side Walls: Experimental and Theore
147. On-Line Monitoring of Anode Currents: Experience at TRIMET
148. Startup and Tuning of Material Distribution System at Aluminium Smelter in Qatar
149. Fundamentals – Electrochemistry and New Processes
150. Mass Transfer Reactions Near the Cathode during Aluminium Electrolysis
151. Current Efficiency in Aluminium Reduction Cells: Theories, Models, Concepts, and Speculations
152. Effect of Current Density and Phosphorus Species on Current Efficiency in Aluminum Electrolysis at H
153. A Concept for Electrowinning of Aluminium Using Depolarized Gas Anodes
154. Investigations into Innovative and Sustainable Processes for the Carbothermic Production of Gaseous
155. A CFD-PBM Coupled Model Predicting Anodic Bubble Size Distribution in Aluminum Reduction Cells
156. Simulation of Anode Bubble: Volume of Fluid Method
157. EAF Carbothermic Co-Reduction of Alumina and Silica for the Direct Production of Al-Si Master Alloy
158. Cell Design and Performance
159. Preparation and Start-Up of Arvida Smelter, AP60 Technological Center
160. Industrial Running of the 530kA Potline in North-Western China
161. The End of an Era for Søderberg Technology in North and South America
162. Successful Start-Up of World Largest Greenfield Smelter
163. Potline Operations – Control
164. Understanding and Managing Alumina Quality Fluctuations to Minimise Impact on Cell Performance and M
165. Developing a New Process Indicator Based on the Relationship Between an Electrolysis Cell Impurity B
166. New Generation Control for Daily Aluminium Smelter Improvement Generation 3 Process Control for Potl
167. Current Status of Research and Development of Automatization and Intellectuality for Plants of Alumi
168. Statistical Evaluation and Modeling of the Link between Anode Effects and Bath Height, and Implicati
169. Cast Shop for Aluminum Production
170. Macrosegregation and DC Casting
171. Mechanisms and Control of Macrosegregation in DC Casting
172. Modelling of Micro- and Macrosegregation in Multicomponent Aluminium Alloys Accounting for Secondary
173. Macrosegregation Modelling of DC-Casting Including Grain Motion and Surface Exudation
174. A New DC Casting Technology for Extrusion Billets with Improved Surface Quality
175. An Innovative Automated Surface Inspection of DC Cast Billets
176. Impact of Cooling Water Composition on Heat Transfer in Ingot Casting
177. Neutron Diffraction Measurement of As-Cast Residual Stresses in AA7050 Rolling Plate Ingots: Influen
178. Recycling/Cast Shop
179. Life Cycle Assessment of Secondary Aluminium Refining
180. A Material Flow Model for Impurity Accumulation in Beverage Can Recycling Systems
181. The Viability of a “Voluntary Refund-Deposit System” for Aluminum Can Recycling in the U.S
182. Oxide Skin Strength Measurements on Molten Aluminum – Manganese Alloys with and without Salt on Surf
183. Oxidation of Manganese-Containing Aluminum Alloys
184. Development of a Sampling Device for Furnace Dross
185. Grain Refinement/Solidification
186. Grain Refinement of Aluminium Alloys: Recent Developments in Predicting the As-Cast Grain Size of Al
187. A Comparison of the Effects of Al-Ti-B Type Grain Refiners from Different Makers on Pure Aluminum
188. Improved Grain Refinement of AA6060 Extrusion Billets
189. On the Performace of a Novel Grain Refiner in Hyper-Eutectic Al-Si Cast Alloys
190. Analysis of Boron Treatment for V Removal Using AlB2 and AlB12 Based Master Alloys
191. The Effect of Trace Levels of Ni and V on the Microstructure and Properties of Four Common Aluminum
192. Evaluation of Functional Properties of the Rapidly Solidified Cast AlSi30 Alloy as a Material for Tr
193. The Near-Rapid Solidification Behavior of AA1070 Aluminum Alloy
194. Furnaces and Energy
195. Computational Analysis of Thermal Process of a Regenerative Aluminum Melting Furnace
196. Electromagentic Stirring in Melting Furnaces – A Critical Evaluation
197. Sampling Tool for In-Depth Study of Furnace Processes
198. Transient Properties of Refractory Castable with Hydraulic Binders
199. A Novel Method of Online Measurement to Develop Specific Heating-Up Procedures for Industrial Furnac
200. Metal Treatment
201. 20 Years of LiMCA Utilization in the Aluminum Industry: A Review of the Technology Development and A
202. Clean Aluminum Processing: New Avenues for Measurement and Analysis
203. Metallurgical Performance of Salt and Chlorine Fluxing Technologies in Casting Furnaces
204. Metal Cleanliness Evaluation of Reusable Ceramic Foam Filters
205. Parallel Laboratory and Industrial Scale Aluminium Filtration Tests with Al2O3 and SiC Based CFF Fil
206. New Developments of the I-60 SIR Melt Refining Unit
207. A New Vacuum Degassing Process for Molten Aluminum
208. General Cast Shop
209. Development and Demonstration of a Molten Metal Cooling Trough to Improve Casthouse Performance
210. Commissioning and Start-Up of Ingot Casting Machines in the Biggest Integrated Aluminum Complex in t
211. Preventing Explosions in Maintenance Pits Under Furnaces
212. The Effect of Magnesium Supply on the Quality of Aluminum Melts
213. Effects of Microstructure and Defects on Tensile and Fracture Behavior of a HPDC Component: Potentia
214. Thermal Parameters Analysis during Directional Solidification of Al-Cu Eutectic Alloys
215. Electrode Technology for Aluminum Production
216. Anode Raw Materials
217. Impurity Level Distribution in GPC and CPC and Impact on Anode Properties
218. Determination of Contact Angle from Raw Material Properties Using Linear Multivariable Analysis
219. Use of Coal Tar Pitch Coke for Producing Prebaked Electrodes
220. Characterization of Dry Aggregates in Carbon Anodes by Image Analysis
221. Paste Plant Operations
222. Characterization of Packing Ability of Coke Particles
223. Texture Analysis of Anode Paste Images
224. High Temperature Compression Test to Determine the Anode Paste Mechanical Properties
225. Viscoplastic Modeling of the Green Anode Forming Process
226. Characterization of Homogeneity of Green Anodes through X-Ray Tomography and Image Analysis
227. Field Experience with the Buss Kneader Type KX: Highest Quality and Throughput Targets Attained
228. Maximizing Green Anode Slots Height through a Rigorous Methodology and Finite Elements Modeling
229. High Performance of “Eolios” Pitch Fume Treatment System
230. Bake Furnace Design and Operation
231. Improving Fuel Gas Injection in Anode Baking Furnace
232. Anode Baking Furnace Firing System Lean Engineering
233. Effect of Heating Rate on the Crack Formation during Baking in Carbon Anodes Used in Aluminum Indust
234. Structured Approach to Modernization of Fume Treatment Centers
235. Upgrade of an Existing Fume Treatment Plant at Aluar to Cope Higher Production in the New Open Type
236. Anode Quality and Performance
237. An Approach to Help Control Air Permeability of Pre-Baked Anodes
238. Optimising Anode Performance in DUBAL Reduction Cells
239. Paste Production and Its Perfomance in Søderberg Smelters
240. Study of Manufacturing Technology for High Quality Anodes
241. Understanding Anode Overpotential
242. Cathode Materials and Wear
243. Room Temperature Creep Behaviour of Ramming Paste Baked at Different Temperatures
244. Characterisation of the Material Behaviour of Cathode Steel Collector Bar at High Temperatures and L
245. Cartography and Chemical Composition of the Different Deposits in the Hall-Heroult Process
246. Interaction of Sodium Vapor and Graphite Studied by Thermogravimetric Analysis
247. N-SiC Side Lining – Variations of Materials Structure
248. Rodding Operation and Anode Electrical Connections
249. Improving Energy Efficiency at Albras: A Case Study in the Rodding Shop
250. ARTS – Anode & Rod Tracking System – A New Tool for Optimization of Anode Performance
251. Anode Rodding Basics
252. Anode Electrical Resistance Measurements: Learning and Industrial On-Line Measurement Equipment Deve
253. Automated Crack Detection Method Applied to CT Images of Baked Carbon Anode
254. Development of a New Methodology to Measure Contact Pressure along a Thermo-Electro-Mechanical Inter
255. Rodding in Hall-Héroult Cells: An FEA Model that Predicts Room Temperature Mechanical Properties an
256. Temperature Fitting Method for Predicting Equidistant Voltage Drop of Anode Rod in Aluminum Reductio
257. Inert Anodes, Cathode Design and Alternative Processes
258. Effect of La on the Electrolysis Performance of 46Cu-25Ni-19Fe-10Al Metal Anode
259. Evaluation of a Pre-Oxidation Treatment for Limiting Electrolyte Penetraton in Cu-Ni-Fe Anode during
260. Inert Anodes: An Update
261. Investigating the Corrosion Behaviors of Fe-Ni-Cr Anode Material for Aluminum Electrolysis
262. The Metal Phase Selection of 10NiO-NiFe2O4-Based Cermet Anodes for Aluminum Electrolysis
263. Study on the Anode and Cathode Configuration of Aluminum Reduction Cell
264. Study on Cathode Structure Optimization of Aluminum Reduction Cell
265. Light-Metal Matrix (Nano)-Composites
266. Microstructure-Property Relationships I
267. Effect of Process Control Agent on the Microstructure and Mechanical Behavior of an Aluminum and B4C
268. Microstructure and Damping Properties of Ultra Fine Grained Al Wires Reinforced by Al2O3 Nanoparticl
269. Elevated Temperature Deformation Behavior of High Strength Al-Cu-Mg-Ag Based Alloy Reinforced by TiB
270. Microstructure-Property Relationships II: Modeling and Advanced Characterization
271. Understanding the Role of Nanodispersions on the Properties of A390 Hyper-Eutectic Al-Si Cast Alloy
272. Phase Formation and Mechanical Properties of Al-Mg-Mn-Ti-B-Zr-Sc Composite Material
273. Physico-Mechanical and Electrical Properties of Aluminum-Based Composite Materials with Carbon Nanop
274. Contactless Acoustic Wave Generation in a Melt by Electromagnetic Induction
275. Brownian Motion Effects on the Particle Settling and Its Application to Solidification Front in Meta
276. X-Ray Tomography and Small-Angle Neutron Scattering Characterization of Nano-Composites: Static and
277. Emerging Processes
278. The Physical-Mechanical Properties of Aluminum Nanocomposites Produced by High Energy Explosion Impa
279. Processing of Metal Matrix Composites under External Fields and Their Application as Grain Refiner
280. Grain Refinement and Nanoparticle Dispersion Using Traveling Magnetic Field
281. Nanoparticles Distribution and Mechanical Properties of Aluminum-Matrix Nano-Composites Treated with
282. Manufacturing of Nano-Surface AA7075 Composites by Friction Stir Processing
283. In-Situ Synthesis and Novel Additions
284. Novel Ultrafine-Grained Aluminium Metal Matrix Composites Prepared from Fine Atomized Al Powders
285. The Structure, Phase Composition and Mechanical Properties of Hot Pressed Metal Matrix Nanocomposite
286. Mechanical Properties of Aluminium-Based Nanocomposite Reinforced with Fullerenes
287. The Effect of Mechanically Exfoliated Graphene Dispersion on the Mechanical Properties of Aluminum/G
288. Development of Al/C60 Composites with Nano-Network Structures

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