Williams Light Metals 2016

1. Auflage 2016
ISBN: 978-3-319-48251-4
Verlag: Springer International Publishing
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 983 Seiten, eBook

Reihe: The Minerals, Metals & Materials Series

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 2016 collection includes papers from the following symposia: 1.Alumina and Bauxite
2.Aluminum Alloys, Processing, and Characterization
3.Aluminum Reduction Technology
4.Cast Shop Technology
5.Electrode Technology
6.Strip Casting

Zielgruppe

Professional/practitioner

Autoren/Hrsg.

Williams, Edward

Inhaltsverzeichnis

1;Cover;1
2;Half Title;2
3;Title Page;4
4;Copyright Page;5
5;Table of Contents;6
6;Preface;18
7;About the Editor;19
8;About the Organizers;20
9;Committee Members;24
10;Alumina & Bauxite Bauxite and Alternative Raw Materials;27
10.1;An Improved Lime Sinter Process to Produce Al?O? from Low-Grade Al-Containing Resources;28
10.2;Investigation of Flotation Behaviors of Refractory High-Silica Bauxite;33
10.3;Study on Effective Extraction of Al and Fe from High-Iron Bauxite through “Calcification-Carbonization” Method;37
10.4;Ways to Improve of Aluminum Content Raw Material Treatment by Sintering Method;41
10.5;Extraction of Aluminium by Autoclave Hydrochloric Acid Leaching of Boehmite-Kaolinite Bauxite;45
10.6;FT-IR, XPS and Density Functional Theory Study of Adsorption Mechanism of Sodium Formate onto Goethite or Hematite;51
11;Digestion;58
11.1;Effect of Different Silica Mineral Compositions on the Digestion Results in Bayer Process;59
11.2;Effect of Lime Addition during Digestion on Stability of Digested Liquor of Diasporic Bauxite;64
11.3;Influence Factors of Stirring Speed of Self-Stirring Tubular Reactor Used in Bauxite Digestion Process;69
11.4;Leaching Kinetics for Recovering Alumina from Waste Tricalcium Aluminate Generated after Filtration of Bayer's Liquor;74
11.5;Industrial Implementation Characteristics of Aluminates Liquor Low-Temperature Desilication Technology;80
11.6;Study on the Influence of Chemical Additives during the Digestion of Bauxite;84
12;Precipitation and Innovation;89
12.1;Going Far (Floating Alumina Refinery);90
12.2;Sustaining Capital of Alumina Refinery Projects – Important but Unloved;96
12.3;Reaction Behavior and Conversion of Anatase in Alumina Production Process with Calcification-Carbonization Method;99
12.4;Alkalinity Precipitation Measurement on Carbonation of Bauxite Residue;105
12.5;Extraction of Alumina from the Magnetic Separation Tailings Derived from Reductive Roasting of Bauxite Residue;110
12.6;Research on Activated Alumina Obtained by Spray Pyrolysis Method;116
13;Aluminum Alloys, Processing and Characterization Alloy Development and Applications;121
13.1;Characterization of Near Net-Shape Castable Rare Earth Modified Aluminum Alloys for High Temperature Application;122
13.2;On the Effect of Alloying Element Range on the Mechanical Properties of Recycled Aluminium Alloy EN AB-46000;126
13.3;Phase and Thermal Stability Analysis of Al-Fe-V-Si-Y Alloys after Solidification at Intermediate Cooling Rates;132
13.4;Microstructure and Phase Evolution in A201 Alloys with Additions of Silicon;138
13.5;High Temperature Creep Evolution in Al-Si Alloys Developed for Automotive Powertrain Applications: A Neutron In-Situ Study on hkl-Plane Creep Response;142
14;Corrosion Resistance;148
14.1;Influencing Intergranular Corrosion via Surface Treatment;149
14.2;Mechanical Characterization and Corrosion Testing of X608 Al Alloy;154
14.3;Simultaneous Improvement of Mechanical and Corrosion Properties of Aluminum Alloys;160
15;Plasticity Behavior;166
15.1;New Methodology to Determine Stable Texture Components under Cold Rolling in FCC Metals;167
15.2;Recrystallization in Al-Mg Alloys after Hot Compression;170
15.3;Large Strain Cyclic Simple Shear Behavior of Aluminum Extrusions: An Experimental and Numerical Study;175
15.4;Quasi and Dynamic Compression of ECAP Processed AA 6082;181
15.5;Study on Hot Sizing and Creep-Ageing Behavior of Al-Cu-Mn Cast Alloy;186
16;Solidification;191
16.1;Grain Refinement Mechanism of Aluminum by Al-Ti-B Master Alloys;192
16.2;The Microstructures and Mechanical Properties of Al-5Mg-1.4Mn Alloy Cast under Near-Rapid Cooling;197
16.3;Effect of the Shape of Solid Particles on the Distribution of Particles in JIS AC4CH (A356) Aluminum Alloy Semi-Solid High-Pressure Die Casting;203
16.4;A High Strength Aluminium Alloy for High Pressure Die Casting;209
17;Thermal Mechanical Processing;213
17.1;Precipitation of Al3Zr Dispersoids during Homogenization of Al-Zn-Cu-Mg-Zr Alloys;214
17.2;Application of Secondary Shear Effects in the Extrusion Machining Process to Explore Recrystallization Mechanics during Conventional Extrusion of 7050 Aluminum;220
17.3;Large Strain Extrusion Machining on 6013 Aluminum Alloy;226
17.4;Effect of Extrusion Ratio on Mechanical Properties of Al-20Si Produced by Spray Deposition and Continuous Extrusion Technique;231
18;Precipitation Behavior;235
18.1;The Influence of Low Temperature Clustering on Strengthening Precipitation in Al-Mg-Si Alloys;236
18.2;Synthesis of Al-TiC Nanocomposites by an In-Situ Gas-Liquid Method;243
18.3;Orientation Relationships of Precipitates with the Matrix in an Aluminum Quasicrystalline Alloy;253
19;Joining Technologies;257
19.1;Important Considerations for Laser Marking an Identifier on Aluminum;258
20;Poster Session;262
20.1;Corrosion Resistance of Different Aluminum Alloys in Ethanol;263
20.2;Refinement of Primary Silicon Crystals by Novel Al-ZnS Master Alloy in Solidification of Hypereutectic Al-Si Alloys;267
20.3;Effects of Alloying Elements on Microstructure, Mechanical Properties and Formability of Al-Si-Fe-Cu-Mn Based Alloys for Micro-Channel Tube of Heat Exchanger;270
21;Aluminum Reduction Technology Cell Technology & Design;274
21.1;Conception of “Dream Cell” in Aluminium Electrolysis;275
21.2;The Impact of the Cavity on the Top Heat Losses in Aluminum Electrolysis Cells;281
21.3;Rio Tinto AP44 Cell Technology Development at Alma Smelter;287
21.4;Hydro’s Cell Technology Path towards Specific Energy Consumption below 12 kWh/kg;293
21.5;The Successful Implementation of DUBAL DX+ Technology at EMAL;298
22;Investigations and Design Using Computer Modelling;303
22.1;Alumina Dissolution Modeling in Aluminium Electrolysis Cell Considering MHD Driven Convection and Thermal Impact;304
22.2;Numerical Investigation on the Impact of Anode Change on Heat Transfer and Fluid Flow in Aluminum Smelting Cells;309
22.3;On the Importance of Field Validation in the Use of Cell Thermal Balance Modeling Tools;314
22.4;Sideledge Facing Metal in Aluminium Electrolysis Cells: Freezing and Melting in the Presence of a Bath Film;320
22.5;Modelling of Metal Flow and Metal Pad Heaving in a Realistic Reference Aluminum Reduction Cell;326
23;Fundamentals in Chemistry I;332
23.1;Characterization of Bubble Behavior in Aluminum Reduction Cells;333
23.2;Elimination of Lithium from Aluminium Electrolyte by Acid Leaching Method;339
23.3;Impact of the Heat Flux on Solidification of Cryolite Based Bath;344
23.4;Investigation of Sodium Sulfate Additions into Cryolite-Alumina Melts;350
23.5;Polyvalent Impurities and Current Efficiency in Aluminium Cells: A Model Concerning Electrochemical Short Circuiting;356
23.6;Sodium in Aluminum Metal of Operating Prebake Cells: Confirmation and New Findings;362
23.7;The Performance of Aluminium Electrolysis in a Low Temperature Electrolyte System;368
23.8;The Role of Key Impurity Elements on the Performance of Aluminium Electrolysis – Current Efficiency and Metal Quality;373
24;Fundamentals in Chemistry II;379
24.1;Alcoa STARprobe™ – Update in Further Development for Measuring Cryolite Properties;380
24.2;Analysis and Visualization of Aluminum Reduction Cell Noise Based on Wavelet Transform;386
24.3;Study on Effect of Al-O-C Compound in Alumina Carbothermal Reduction;392
24.4;The Impact of Alumina Quality on Current Efficiency and Energy Efficiency in Aluminum Reduction;399
24.5;Sideledge Facing Metal in Aluminium Electrolysis Cells: Preliminary Modelling Study of Bath Film Formation;405
24.6;Pilot Test of Aluminum Electrolysis by the NiFe?O?-M Inert Anodes;411
24.7;Thermodynamic Analysis and Dynamic Simulation on Carbothermic Chlorination Reaction of Al?O under Vacuum;414
25;Environment I;420
25.1;Design, Start-Up and Performance of Four Gas Treatment Centers for Ma’aden Aluminium;421
25.2;Management and Performance of the Largest Gas Treatment Centre at EMAL Potline during Major Shutdown of Main Exhaust Fans;426
25.3;Compact GTC Design: Reducing Footprint and Overall Steel Weight;432
25.4;Technology for Removal of Sulphur Compounds from Gases Generated during Aluminum Production;436
25.5;Sustainable Practices in Spent Potliner - An Industrial Ecology Approach;440
25.6;The LCL&L Process: A Sustainable Solution for the Treatment and Recycling of Spent Potlining;446
25.7;Development, Proof of Concept and Industrial Pilot of the New CHAC Scrubbing Technology: An Innovative and Efficient Way to Scrub Sulfur Dioxide;451
25.8;Aluminerie de Bécancour Conditioning Tower Replacement;457
26;Materials & Equipment;462
26.1;Alumina Handling in the Smelter – From Port to Pot;463
26.2;Recent Developments in Hyper-Dense Phase Alumina Handling Systems;469
26.3;The Challenge to Supply Consistent Alumina Quality to All Pots on Increasingly Longer and Higher Capacity Potlines;475
26.4;Design and Demonstration of an Improved Automated Pot Tapping Method and Equipment;480
26.5;Evolution of Crust Breaker Control for DX+ and DX+ Ultra Technologies;485
26.6;SiC in Electrolysis Pots: An Update;489
27;Environment II;492
27.1;Assessing the Role of Smelter Grade Alumina Porosity in the HF Scrubbing Mechanism;493
27.2;The Competitive Adsorption of HF and SO? on Smelter Grade Alumina;498
27.3;Evaluation of Gas Composition from Laboratory Scale Electrolysis Experiments with Anodes of Different Sulphur Content;503
27.4;Sustainable Reduction of Anode Effect and Low Voltage PFC Emissions;507
27.5;QCL-Based Perfluorocarbon Emission Monitoring;511
27.6;Using Artificial Neural Network to Predict Low Voltage Anode Effect PFCs at the Duct End of an Electrolysis Cell;515
27.7;Anode Effect Initiation during Aluminium Electrolysis in a Two-Compartment Laboratory Cell;521
28;Smelter Operation & Energy Management;527
28.1;Enhancing Production Performance by Optimization All Resources at PT Inalum (Persero);528
28.2;New Assisted Gauging System: Another Step to Reduce Variation on Low ACD Operation;532
28.3;A Novel Method for Processing Sodium Reduction Skimming Station Residue;535
28.4;The 'Virtual Battery' – Operating an Aluminium Smelter with Flexible Energy Input;539
28.5;Understanding the Basic Requirements of the Anode Set Modifier;545
28.6;Reduction Operating Experience on Power Shading at Maaden;550
28.7;Effect of Carbon Dust on the Electrical Resistivity of Cryolite Bath;554
29;Process Control in Reduction;559
29.1;Detection of Local Cell Conditions Based on Individual Anode Current Measurements;560
29.2;Dynamic Response of Cryolitic Bath and Influence on Cell Heat and Mass Balance with Large Scale Potline Power Shifts;566
29.3;Simulations on the Bath Chemistry Variables Using Neural Networks;571
29.4;Technology Research on Decreasing the Aluminum Surface Waves and Reducing the Cathode Voltage Drop in Aluminum Electrolysis Cell;577
29.5;Hall-Heroult Cell Simulator: A Tool for the Operation and Process Control;581
29.6;Studies on Anode Pre-Heating Using Individual Anode Signals in Hall-Héroult Reduction Cells;587
30;Cast Shop Technology: An LMD Symposium in Honor of Wolfgang Schneider Direct Chill Casting;594
30.1;35 Years of Contributions to Cast Shop Research and Development – Honoring Prof. Dr. Wolfgang Schneider;595
30.2;Effect of Liquid Metal Distribution on the Flow Field and Macrosegregation during Direct Chill Casting of Aluminum Alloy 7050;603
30.3;Aluminum Billets D.C. Casting: Level-Pour vs. Fall-Pour: A Techno-Historical Approach;609
30.4;Hot Tearing in DC Casting Ingot of 7XXX Aluminum Alloys;613
30.5;Initial Development of Micro-Shrinkage Crack during Early Stages of Direct Chill Casting of Al-4.5% Cu Alloy;619
30.6;Successful Implementation of a New Rolling Slab Casting Technology, AFM, within Hydro;625
30.7;Uncertainty Propagation in Numerical Modeling of Direct Chill Casting;629
30.8;The Study Conditions Occurrence of Hot Tearing in the Billets Alloy EN AW6060 Produced with the Process ofDirect Chill Casting;635
31;General Cast Shop;641
31.1;Weibull Analysis for the Repeatability of Die Castings Made by an Al-Mg-Si-Mn Alloy;642
31.2;Thermo-Mechanical Properties of Wrought Aluminium Alloys Produced from Scrap Mixing;647
31.3;History and Development of Slag and Dross Pressing;653
31.4;Testing PPE for Molten Aluminum Splash Resistance;657
32;Alloying and Grain Refinement;663
32.1;Grain Refinement of Self-Hardening Aluminum Alloys;664
32.2;Modification of Eutectic Si and Refinement of Eutectic Grain in Al-Si-Mg Alloys by CrB? and Sr Addition;670
32.3;Modification of Macrosegregation Patterns in Rolling Slab Ingots by Bulk Grain Migration;674
32.4;Effect of High Intensity Ultrasonic Treatment on the Microstructure, Corrosion and Mechanical Behaviour of AC7A Aluminum Alloy;679
32.5;Mechanism of Zirconium Poisoning Effect on TiB? Inoculation in Aluminium Alloys;683
32.6;Study of Manganese Dissolution in Aluminum Melts;688
32.7;Ultrasonic Grain Refining of Continuous Cast Aluminum: Microstructure and Properties;694
33;Furnaces and Energy Efficiency;698
33.1;Aluminum Casting Furnace Energy Efficiency: Recent Improvements in Rio Tinto Aluminium Casthouses;699
33.2;Case Study on Round-Top Fire Rates;705
33.3;Increasing Holding Furnace Capacity from 30 to Be 40 Tons Molten Aluminium through Modification of Lining Design;708
33.4;Furnace Modeling for Efficient Combustion Gas Circulation;712
33.5;Furnace Pressure Control Technology for Fuel Efficiency;717
33.6;Calculated Aluminum Oxidation Rates during Rotary Furnace Melting through Flue Gas Analysis – Part Two;721
33.7;On the Cast House Exergy Management;726
34;Degassing and Solidification Defects;730
34.1;Design of Square Induction Coils for the Electromagnetic Priming of Ceramic Foam Filters;731
34.2;Assessment of Active Filters for High Quality Aluminium Cast Products;737
34.3;Numerical Simulation of Degassing Phenomena in Direct Chilled Casting Process under External Static Magnetic Field on Flow Pattern in Slab Mold;742
34.4;The Problem of Cavities in Open Mold Conveyor Remelt Ingots;748
34.5;Theory and Practical Application of Ultrasonic Degassing at J. W. Aluminum;753
34.6;TiB? Particle Detection in Liquid Aluminum via Laser Induced Breakdown Spectroscopy;759
35;Metal Treatment and Metal Quality;764
35.1;Inline Melt Treatment for Low to Medium Metal Flow Rates;765
35.2;Effect of Soaking Treatment on the Microstructure and Wear Behavior of the Ultrasonic Melt-Treated B390 Hypereutectic Al-Si Alloy;769
35.3;Influence of Oxidation on Contact Angle between Liquid Aluminum and Al?O?;774
35.4;Optimization of the Ultrasonic Processing in a Melt Flow;780
35.5;A Comparison of Cold and Hot PoDFA Procedure for Particle Monitoring in Liquid Aluminium;784
35.6;Assessment of Settling Behavior of Particles with Different Shape Factors by LiMCA Data Analysis;790
35.7;Modeling of Inclusion Behavior in an Aluminum Induction Furnace;796
36;Electrode Technology Electrode Materials and Characterization;803
36.1;Characterization of Carbon Anode Materials by Image Analysis;804
36.2;Electrochemical Reactivity and Wetting Properties of Anodes Made from Anisotropic and Isotropic Cokes;810
36.3;Study of the Wetting of Coke by Different Pitches;816
36.4;Quantification of Sodium Present in Dry Aggregates and Anodes;822
36.5;Interfacial Boundary between Carbon Anodes and Molten Salt Electrolyte;827
36.6;Measurement of the Electric Current Distribution in an Anode;833
37;Joint Session with Aluminum Reduction;839
37.1;Cathode Wear in Electrowinning of Aluminum Investigated by a Laboratory Test Cell;840
37.2;Copper Bars for the Hall-Héroult Process;846
37.3;Modeling Gravity Wave in 3D with Openfoam in an Aluminum Reduction Cell with Regular and Irregular Cathode Surfaces;852
37.4;Porous Carbon Anodes for the Supply of Methane during Electrowinning of Aluminium;858
37.5;Creep Behavior and Change of Porous Structure of Graphite Cathode Material in NaF-AlF?-Al?O? Melt under External Pressure;864
37.6;Uneven Cathode Wear in Aluminium Reduction Cells;869
37.7;Effect of Cathode Collector Copper Inserts on the Hall-Héroult Cell MHD Stability;875
38;Electrode Baking and Assembly;881
38.1;Anode Baking Furnace Fluewall Design Evolution: A Return of Experience of Latest Baffleless Technology Implementation;882
38.2;Effect of Heating Rate during Baking on the Properties of Carbon Anodes Used in Aluminum Industry;887
38.3;Empirical Modeling of the Baking Furnace to Predict Baked Anode Properties;892
38.4;In Situ Investigation of the Behavior of Anode Assemblies;898
38.5;Low Resistance Anode Assembly Using Steel Stubhole Conductors across the Cast Iron to Carbon Interface;904
38.6;Upgrade of the Firing and Control System at Egyptalum for Dual Fuel Firing;909
39;Electrode Operations and Control;915
39.1;MIREA: An On-Line Quality Control Equipment Integration in an Operational Context;916
39.2;Journey towards World-Class Operational Effectiveness at DUBAL (EGA Jebel Ali) Paste Plant;922
39.3;The Startup and the Operation Performance of the Twin Green Anode Plant at Maaden Aluminium Smelter in Saudi Arabia;928
39.4;Simulation-Based Decision Support in Cathode Re-Lining Facility Design;934
40;Strip Casting of Light Metals Strip Casting Process;941
40.1;Twin-Roll Casting of Carbon Fiber-Reinforced and Glass Fiber-Reinforced Aluminum Strips;942
40.2;Productivity Improvements in Industrial Twin-Roll Casting by Heat Loss Analysis along the Process Chain;948
40.3;Development and Numerical Simulation of a Compound Belt Casting Process;952
41;Strip Casting: Properties;957
41.1;Crystallographic Texture Development of As-Cast 3105 Alloy Produced by St/Cu Shell Pair;958
41.2;Annealing Curve of 3105 Alloy Produced by Twin Roll and Belt Casting Method;964
41.3;Effect of As-Cast Strip Thickness and Reduction Prior to Soft Annealing on the Formability of Twin-Roll Cast 5754 Sheets;969
42;Author Index;974
43;Subject Index;979

Über Autor(innen)

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