Light Metals 2020 (eBook)

Preface 5
Contents 6
About the Editor 20
Program Organizers 21
Aluminum Committee 2019–2023 24
Part I Alumina and Bauxite 26
1 Impacts of Mineralogy on Soluble Phosphorus Concentrations During Low Temperature Processing of Jamaican Bauxites 27
2 Effects of the Granular Properties of Bauxite Pisolithes on the Solid/Liquid Separation in Liquid Fluidized Beds of Classifiers 36
3 Mineralogical Assessment of the Solid Phase Obtained on Leaching of Brazilian Red Mud 45
4 Low-Quality Aluminum-Containing Raw Materials: Experience, Problems and Prospects 50
5 Inhibition of Kaolinite Dissolution in Bayer Liquor Through Lithium Addition 57
6 Ionic Effect of NaCl and KCl on the Flotation of Diaspore and Kaolinite Using Sodium Oleate as Collector 64
7 Quantifying the Effect of Seeds on Gibbsite Crystallization—Mathematical Modelling of Particle Size Distribution 71
8 Experimental Study on Flow Field Characteristics in Seed Precipitation Tank and Influence on Physical Properties of Al(OH)? Products 78
9 Application of Advanced Oxidative Process for Organic Compounds Removal from Bayer Liquor 84
10 A Review of Comprehensive Utilization of High-Iron Red Mud of China 89
11 Conversion Behavior of Iron-Containing Minerals in the Process of Dissolving High-Iron Bauxite by Starch Hydrothermal Method 96
12 Disc Magnetic Separator Applied to the Extraction of Magnetite in Bauxite Residue 109
13 Recovery of Iron from High-Iron Bayer Red Mud by Smelting Reduction 116
14 Bayer Process Towards the Circular Economy—Metal Recovery from Bauxite Residue 122
15 Bayer Process Towards the Circular Economy—Soil Conditioners from Bauxite Residue 131
16 Brazilian Bauxite Residue Physical–Chemical Characterization and Acidic Neutralization Potential 139
17 Effect of Concentrations and Pressures of CO? on Calcification–Carbonation Treatment of Bauxite Residue 148
18 Comprehensive Utilization of Red Mud Through the Recovery of Valuable Metals and Reuse of the Residue 153
19 A Review of Research on Alumina Extraction from High-Alumina Fly Ash and a New Method for Preparing Alumina by Electrotransformation 160
20 Effect of Sodium Alkali Concentration on Calcification–Carbonization Process 167
Part II Aluminum Alloys, Processing and Characterization 175
21 Stress Characterization of Bore-Chilled Sand Cast Aluminum Engine Blocks in As-Cast and T7 Condition with Application of Neutron Diffraction 176
22 Molecular Dynamics Simulations of the Solidification of Pure Aluminium 181
23 Nanoindentation and Cavitation-Induced Fragmentation Study of Primary Al?Zr Intermetallics Formed in Al Alloys 191
24 In Situ Neutron Diffraction Solidification Analyses of Rare Earth Reinforced Hypoeutectic and Hypereutectic Aluminum–Silicon Alloys 197
25 Influence of TiB? Particles on Modification of Mg?Si Eutectic Phase in Al–Zn–Si–Mg–Cu Cast Alloys 202
26 A Statistical Analysis to Study the Effect of Silicon Content, Surface Roughness, Droplet Size and Elapsed Time on Wettability of Hypoeutectic Cast Aluminum–Silicon Alloys 208
27 Aluminum Trace Elements Analyses Using Epsilon 1 Meso EDXRF Technique 217
28 Effect of Cooling Rate During Solidification of Aluminum–Chromium Alloy 227
29 Effects of Si on the Electrical Conductivity, Microhardness, Microstructure and Hot Tearing of Al–0.8Fe–0.5Mg–0.4Ni Alloys 233
30 The Efficacy of Replacing Metallic Cerium in Aluminum–Cerium Alloys with LREE Mischmetal 239
31 Effects of Sc and Y on the As-Cast Microstructure of AA6086 245
32 Ternary Interactions and Implications for Third Element Alloying Potency in Al–Ce-Based Alloys 250
33 Development and Analysis of Al7075 Alloy Materials Using Press and Sinter Processing 256
34 Formation of Rare Earth Intermetallics in Al–Cu Cast Alloys 264
35 Retrogression Forming and Reaging of AA7075-T6 Alclad to Produce Stampings with Peak Strength 270
36 High Cycle Fatigue Properties of the Zr-Modified Al–Si–Cu–Mg Alloy at Elevated Temperatures 276
37 Effect of Mo on Elevated-Temperature Low-Cycle Fatigue Behavior of Al-Si 356 Cast Alloy 284
38 State Parameter-Based Simulation of Temperature- and Strain Rate Dependent Flow Curves of Al-Alloys 290
39 Coarsening-Resistance of a Severely Deformed Al-0.2 Wt% Sc Alloy 295
40 The Effect of Modified Strain-Induced Melt Activation (Modified SIMA) Process on the Microstructure and Mechanical Properties of Al-7Si Alloy 300
41 Effect of Mg on Flow Behavior of Al–Mg Alloys and Its Constitutive Modeling Using Finite Element Analysis 306
42 Influence of Thermal Treatment and Design Parameters on the Fatigue Life of Automotive Control Arm Fabricated from A357 Semi-solid Alloy 312
43 The Formation of Al?(Fe, Mn) Phase in Die-Cast Al–Mg Alloys 320
44 Spark Plasma Sintering of Graphene Nanoplatelets Reinforced Aluminium 6061 Alloy Composites 324
45 Effects of Mn and Mo Micro-additions on Al–Zr–Sc–Er–Si Mechanical Properties 335
46 Nanotreating High-Zinc Al–Zn–Mg–Cu Alloy by TiC Nanoparticles 341
47 Microstructure and Mechanical Response of an Artificially Aged Al–Mg–Si Alloy: Experiments and Modeling 347
48 Effect of Zn Additions on the Mechanical Properties of High Strength Al–Si–Mg–Cu Alloys 354
49 Utilization of 3D Printed Materials in Expendable Pattern Casting Process 361
50 Hemming Evolution of 6xxx Aluminum Alloys in the Course of Natural Aging Following the Continuous Annealing 368
51 The Effect of Deformation Mode and Microstructure on the IGC Susceptibility of Al–Mg–Si–Cu Alloys for Automotive Applications 375
52 Evolution of Grain Refinement in AA5083 Sheet Metal Processed by ECAP 385
53 Mechanical and Microstructural Behavior of Dissimilar AA2014-T6 and AA7075-T6 Aluminium Alloys Joined by Friction Stir Welding 393
54 High Strength Nanotreated Filler Material for TIG Welding of AA6061 403
55 Optimization of Thermo-Mechanical Processes of Continuous Casting Products Using High Magnesium Aluminum Alloys in Automotive Industry Applications 409
56 Plastic Flow of AA6013-T6 at Elevated Temperatures and Subsequent Reaging to Regain Full Strength 423
57 Influence of Chemical Composition and Pre-deformation on the Age-Hardening Response of Al-Mg-Si Alloys 429
58 Hot Deformation and Die-Quenching of 6000-Series Alloys—The Effect of Quench-Interruption Temperature 435
59 Descriptors and Predictors: New Tools for the Predictive Modelling of Production Paths and the Properties of Aluminum-Based End-Products 442
60 Effect of Extrusion Parameters on Microstructural and Mechanical Properties of EN AW 6063 448
61 Simulation Study on Equal Channel Right Angular Extrusion Process of Aluminum Alloy 6061 456
62 Characterization of Dynamic Material Property of AlSi10 Mg Aluminum Alloy Under High Strain Rate Compressive Loading 463
63 Current Efficiency for Direct Production of an Aluminium–Titanium Alloy by Electrolysis in a Laboratory Cell 468
64 Corrosion Inhibition Effect of Aloe Saponaria Gel on the Corrosion Resistance of Aluminum 475
65 Experimental Investigation of MgAl?O? Spinel Formation in Oxidation of Al–Mg Alloys 483
66 Impact of Dispersion Hardening by Alumina Nano Particles on Mechanical Properties of Al 1100 488
67 Investigation of Temperature Variation During Friction Drilling of 6082 and 7075 Al-Alloys 494
68 Study on the Anti-EMF of Al-Er Master Alloy Prepared by Er?O? as Erbium Source 501
Part III Aluminum Reduction Technology 506
69 Comparison Between Different Laminated Aluminum Busbars Expansion Joints in Terms of Mechanical Performance and Relative Costs 507
70 Demo Retrofit Study of a Chinese Inspired Cell Technology 517
71 Mass Transport by Waves on the Bath Metal Interface in Electrolysis Cell 532
72 Numerical Investigation of Flow Field Effect on Ledge Shape in Aluminum Reduction Cell by Coupled Thermo-Flow Model 539
73 Study of Heat Distribution Due to ACD Variations for Anode Setting 549
74 Anodic Incident Detection through Multivariate Analysis of Individual Anode Current Signals 557
75 Fault Detection and Diagnosis of Alumina Feeding System Using Individual Anode Current Measurement 565
76 Change of Anode Operation Pattern from Single to Double Staircase at Albras 572
77 An Advanced Nonlinear Control Approach for Aluminum Reduction Process 578
78 Model Based Approach for Online Monitoring of Aluminum Production Process 588
79 Predictive Analytics for Enhancing Productivity of Reduction Cells 594
80 Restart of Shutdown Pots: Troubles, Solutions and Comparison with Normal Pots to Improve Results 601
81 Electrochemical Behaviour of Cu-Al Oxygen-Evolving Anodes in Low-Temperature Fluoride Melts and Suspensions 613
82 Alumina Concentration Measurements in Cryolite Melts 622
83 The Influence of Polarisation on the Wetting of Graphite in Cryolite-Alumina Melts 630
84 Oxidation Study of Zinc Sulfite on the Removal of Sulfur Dioxide from Aluminum Electrolysis Flue Gas by Zinc Oxide 642
85 Electrolysis of Low-temperature Suspensions: An Update 648
86 Adapting Modern Industrial Operation Parameters in a Standardized Laboratory Cell for Measuring Current Efficiency for Aluminium Deposition: Unexpected Challenges and Lessons Learned 659
87 Aluminium Smelter Crust—Phase Distribution and Structure Analysis of Top Zone Layer 666
88 Influence of Anode Cover Material Particle Size Composition on Its Physical Property and Insulation Performance 675
89 Lab Scale Experiments on Alumina Raft Formation 681
90 Mass- and Heat Transfer During Dissolution of Alumina 686
91 The Rate of HF Formation During Addition of Alumina to NaF-AlF? Melts 694
92 Validation of the Gravimetric Method to Properly Follow Alumina Dissolution in Cryolitic Bath 702
93 Development of a Mathematical Model to Simulate Raft Formation 710
94 Efficient Alumina Handling 718
95 Status Analysis of Particle Size Distribution and Attrition Index of the Smelter Grade Alumina 726
96 The Effect of Hard Scale Deposition on the Wall Heat Flux of a Cold Finger 732
97 The Application of Intelligent Breaking and Feeding Technology for Aluminium Reduction Pot 741
98 Reducing the Carbon Footprint: Aluminium Smelting with Changing Energy Systems and the Risk of Carbon Leakage 748
99 Measurement System for Fugitive Emissions in Primary Aluminium Electrolysis 757
100 Validation of QCL CF? Gas Analyzer for Sensitivity and Selectivity 766
101 A Laboratory Study of the HF Generation Potential of Particulate Fluorides from Cell Emissions 773
102 Method Development to Estimate Total Low Voltage and High Voltage PFC Emissions 780
103 Update on SO? Scrubbing Applied in Primary Aluminium Smelters 788
104 Optimization of a Gas Treatment Center Equipped with Extended Surface Bag Filters 799
105 Update on the Abart Gas Treatment and Alumina Handling at the Karmøy Technology Pilot 807
106 The Australian Energy Crisis, Its Impact on Domestic Aluminium Smelting and Potential Solutions 813
107 Recycling of the Flue Gas from Aluminium Electrolysis Cells 825
108 Utilization of Waste Heat for Pre-heating of Anodes 833
109 Toward Minimizing the of Co-evolution of PFC Emission in EGA Smelter 839
110 Development and Application of GP500+ Energy Saving Aluminum Reduction Cell 849
Part IV Cast Shop Technology 857
111 Hands-Free Casting at AMAG Casting GmbH—It Is Possible! 858
112 User-Friendly Surveillance Tools to Prevent Bleed-Out During Cast Start 865
113 Beryllium Reduction Potential in AlMg Cast Alloys 873
114 Accurate Real-Time Elemental (LIBS) Analysis of Molten Aluminum and Aluminum Alloys 881
115 Industrial Verification of Two Rotor Fluxing in Large Crucibles 886
116 Dynafeed: An Improved Crucible Transfer System 889
117 Metal Transfer from Furnace to Furnace—A Case Study 894
118 Heavily Loaded Areas in Aluminum Melting Furnaces and Possible Refractory Solutions 900
119 Mold Shape Control for Direct Chill Ingot Casting 908
120 Continuous Monitoring of Butt Curl Development During DC Casting—Development and Application 913
121 Constellium’s Mould Technology for Al Alloy Slab DC Casting 922
122 Fluid Flow Analyses and Meniscus Behavior During the Horizontal Single Belt Casting (HSBC) of Aluminum Alloy AA6111 Strips 930
123 Effect of Water Flow Distribution on the Performance of Aluminium Small-Form Ingot Chains 938
124 Small Scale Oxidation Experiments on AlMg Alloys in Various Gas Fired Furnace Atmospheres 944
125 Study of the Oxidation of an Al-5Mg Alloy in Various Industrial Melting Furnace Atmospheres 951
126 Batscan™, Constellium In-melt Ultrasonic Inclusion Detector: Industrial Performance 957
127 Benchmark and Practical Application of State of the Art Hydrogen Monitoring 965
128 Molten Aluminum Quality Evaluations for Thin Foil Products 972
129 Industrial Verification of One- and Two-Chamber Siphon Degassing 980
130 Evaluation of CFF and BPF in Pilot Scale Filtration Tests 984
131 Dynaprime Filtration Technology Experience at Alcoa Baie-Comeau 993
132 Improving Ultrasonic Melt Treatment Efficiency Through Flow Management: Acoustic Pressure Measurements and Numerical Simulations 1002
133 Impact of TiB? Particle Size Distribution on Grain Refining Effectiveness 1009
134 Effect of Nucleant Particle Size Distribution on the Grain Refining Efficiency of 7xxx Alloys 1015
135 Impact of Transition-Metal Elements on Grain Refiner Performance in AA6061 1021
136 Application Ultrasonic Technology Processing for Aluminum Treatment While Casting Slabs on Industrial Equipment of UC RUSAL 1028
137 Influence of Liquid Jet Stirring and In-Situ Homogenization on the Intermetallics Formation During DC Casting of a 6xxx Al Alloy Rolling Ingot 1034
138 Digital Manufacturing for Foundries 4.0 1040
139 Integrating Fluid Simulation with Virtual Die Casting Machine for Industry 4.0 and Operator Training 1047
140 Numerical Simulation of Wire Rod Casting of AA1370 and AA6101 Alloys 1053
141 Influence of Nozzle Shape on Near-Surface Segregation Formation During Twin-Roll Casting of Aluminum Strips 1060
142 Effect of Ultrasonic Treatment on the Eutectic Phase and Cu Content in the Al Matrix of Large-Scale 2219 Al Alloy Ingot 1066
143 Influence of Alloying Additives on the Electrochemical Behavior of Cast Al-5Zn Alloys 1073
144 Thermal Analysis and Microstructure of Al-12%Si-2.5%Cu-0.4%Mg Cast Alloy with Ce and/or La Rare Earth Metals 1077
145 Numerical Simulation of Temperature Field in 6061 Aluminum Alloy Vertical Twin-Roll Casting Process 1084
Part V Cast Shop Technology: Recycling and Sustainability Joint Session 1092
146 Constellium R& D Approach in Recycling, From Lab to Industrial Scale
147 Representative Sampling, Fractionation and Melting of Al-Scrap 1103
148 Recycling of Aluminium from Mixed Household Waste 1111
149 An Assessment of Recyclability of Used Aluminium Coffee Capsules 1121
150 Fractional Solidification for Purification of Recycled Aluminium Alloys 1130
151 A Rapid Method of Determining Salt Flux Melting Point and Composition 1139
152 Recovery of Aluminium Metal Using Ultrasonic Technique and Production of Al–Si Hypereutectic Alloys from 6063 Alloy’s Black Dross Using Silicon Lumps and Flux 1148
153 Automatic Skimming Procedure for Reducing Aluminium Losses and Maintaining the Uniform Quality of the Molten Metal 1157
154 Evaluation of the Effect of CO? Cover Gas on the Rate of Oxidation of an AlMgSi Alloy 1161
Part VI Electrode Technology for Aluminum Production 1168
155 The Development of Anode Shape, Size and Assembly Designs—Past, Present and Future Needs 1169
156 10 Years of Anode Research and Development: Alcoa and Université Laval Experience 1179
157 Carbon Anode Raw Materials—Where Is the Cutting Edge? 1181
158 Solids Flow Considerations and Their Impact in Smelter Carbon Plant Operations and Product Quality 1184
159 How to Improve the Environmental Efficiency of the Hall-Heroult Process While Producing and Using Carbon Anodes 1189
160 Trends in Anode Carbon Production Projects 1192
161 Development of a Soft Sensor for Detecting Overpitched Green Anodes 1194
162 Diffusion Measurements of CO? Within Carbon Anodes for Aluminium Smelting 1201
163 Testing of SERMA Technology on Industrial Anodes for Quality Control for Aluminum Production 1207
164 Modelling of Gas Injection on Anode Baking Furnace and Application to Operations 1214
165 Higher Baking and Production Levels in Anode Baking Furnaces and Associated Challenges 1221
166 Major Reconstruction of Central Casing of Open Top Baking Furnace with a View to Increase Its Lifespan and Reduce the Total Costs Comparing to Full Reconstruction 1228
167 Regulation and Management of Anode Baking Furnace Production Cycle During Green Anode Crisis 1236
168 Sustainable Spent Pot Line Management Guidance 1243
169 Purification of Graphite by Thermal Vacuum Treatment of Spent Potlining 1249
170 The LCL& L Process: A Sustainable Solution for the Treatment and Recycling of Spent Pot Lining
171 Experimental Study on the Collecting Agent for Spent Potlining Flotation Index Optimization 1261
172 Environmental Benefits of Using Spent Pot Lining (SPL) in Cement Production 1269
173 Characteristic Analysis of Hazardous Waste from Aluminum Reduction Industry 1279
174 Energy Saving in Hall–Héroult Cell by Optimization of Anode Assembly Design 1285
175 High Temperature Creep Behaviour of Carbon-Based Cathode Material for Aluminum Electrolysis 1296
176 Redesigning of Current Carrying Conductor—The Energy Reduction Initiative in Low Amperage Hall-Héroult Cell 1301
177 Ready-to-Use Cathodes for the Hall-Héroult Process 1309
178 Mechanism Understanding of Sodium Penetration into Anthracite Cathodes: A Perspective from Diffusion Coefficients 1317
179 Anhydrous Carbon Pellets—An Engineered CPC Raw Material 1327
180 Influence of Particle Shape and Porosity on the Bulk Density of Anode Grade Petroleum Coke 1337
181 An EXAFS and XANES Study of V, Ni, and Fe Speciation in Cokes for Anodes Used in Aluminum Production 1345
182 Additive Selection for Coal Tar Pitch Modification in Aluminium Industry 1347
183 Charcoal and Use of Green Binder for Use in Carbon Anodes in the Aluminium Industry 1356
184 Correction to: Effect of Concentrations and Pressures of CO? on Calcification–Carbonation Treatment of Bauxite Residue 1366
Author Index 1367
Subject Index 1373