Light Metals 2016 (eBook)

Edward Williams (Herausgeber)

eBook Download: PDF

2016 | 1st ed. 2016
XXVI, 1053 Seiten
Springer International Publishing (Verlag)
978-3-319-48251-4 (ISBN)

Infos

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

The Minerals, Metals & Materials Society (TMS) is a member-driven international professional society dedicated to fostering the exchange of learning and ideas across the entire range of materials science and engineering, from minerals processing and primary metals production, to basic research and the advanced applications of materials. Included among its nearly 13,000 professional and student members are metallurgical and materials engineers, scientists, researchers, educators, and administrators from more than 70 countries on six continents. For more information on TMS, visit www.tms.org.

Inhalt

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

Produkt-Details

• Erscheint lt. Verlag: 20.12.2016
• Reihe/Serie: The Minerals, Metals & Materials Series
• Reihe/Serie: The Minerals, Metals & Materials Series
• Zusatzinfo: XXVI, 1053 p.
• Verlagsort: Cham
• Sprache: englisch
• Themenwelt: Technik ► Bauwesen
• Themenwelt: Technik ► Maschinenbau
• Schlagworte: aluminum alloys • aluminum reduction • cast shop • electrode technology • Light Metals
• ISBN-10: 3-319-48251-3 / 3319482513
• ISBN-13: 978-3-319-48251-4 / 9783319482514