Light metals 2015 : proceedings of the symposia sponsored by the TMS Alumnium Committee at the TMS 2015 Annual Meeting & Exhibition, March 15-19, 2015, Walt Disney World, Orlando, Florida, USA

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 2015 collection includes papers from the following symposia: 1. Alumina and Bauxite 2. Aluminum Alloys: Fabrication, Characterization and Applications 3. Aluminum Processing 4. Aluminum Reduction Technology 5. Cast Shop for Aluminum Production 6. Electrode Technology for Aluminum Production 7. Strip Casting of Light Metals Front Matter....Pages i-xxviii Front Matter....Pages 1-1 Theory and Practice of Bauxite X-Ray Sorting....Pages 5-10 Roasting Pretreatment of High-Sulfur Bauxite with Low-Median Grade in Chongqing China....Pages 11-14 Improving Characterization of Low Grade Elburz Bauxite to Be Utilized in Jajarm Alumina Plant....Pages 15-20 Bauxite Beneficiation Modifying Factors: A Case Study....Pages 21-25 A Novel Self-Stirring Tubular Reactor Used in Bauxite Digestion Process....Pages 29-34 Study on the Prediction Model of Heat Transfer Coefficient during Tube Digestion....Pages 35-38 Research on Digestion Behavior of Sulfur in High-Sulfur Bauxite....Pages 39-43 The Impact of Sulphate and Carbonate on the Performance of Siliconate-Type Polymers as Inhibitor of Scaling....Pages 45-47 Fuzzy Technology Application in a Bauxite Digestion Unit....Pages 49-53 Research of the Mineral Fouling Composition and Removal Method in Bauxite Digestion Process....Pages 55-58 Synergistic Effect of C12A7 and CA on Alumina Leaching Property Under Low Calcium/Aluminum Ratio....Pages 59-62 CFD Simulations of a Large-Scale Seed Precipitation Tank Stirred with Multiple Intermig Impellers....Pages 65-68 Recovering Waste-Heat and Water from Alumina Calciner Gas....Pages 69-71 Smelter Grade Alumina Quality in 40+ Year Perspective: Where to from Here?....Pages 73-78 Alumina Calcination: A Mature Technology Under Review from Supplier Perspective....Pages 79-84 Numerical Simulation on Carbonation Reactor of Calcified Residue....Pages 85-90 Improved Efficiency of Red Mud Processing through Scandium Oxide Recovery....Pages 93-96 Modern Technologies for Difficult to Filter Substances in Alumina Refinery....Pages 97-101 Bauxite Beneficiation Reject Dewatering and Disposal....Pages 103-106 Complex Additives on the Basis of Red Mud for Intensification of Iron-Ore Sintering and Pelletizing....Pages 107-111 Front Matter....Pages 1-1 Utilization of the Smartdiver to Improve Control of Settlers, Washers and Tailings Thickeners....Pages 113-117 Preparation of Zeolite 4A by Using High-Alumina Coal Fly Ash....Pages 121-126 Study of Filtration and Washing of Residue After HCL Leaching of Kaolin Clay....Pages 127-130 Energy in Alumina Refining: Setting New Limits....Pages 131-136 Sustainability and Alumina Refinery Design....Pages 137-142 Study on the Production of Ceramic Glass from Calcium-Silica Residue....Pages 143-145 Preparation of Pseudo-Boehmite by Using High-Alumina Coal Fly Ash....Pages 147-151 Front Matter....Pages 153-153 The Influence of Microchemistry and Processing Conditions on the Softening Behavior of Cold-Rolled Al-Mn-Fe-Si Alloys....Pages 157-162 Effects of Zr and V Micro-Alloying on Activation Energy during Hot Deformation of 7150 Aluminum Alloys....Pages 163-167 Microstructure Evolution in Al-Mg Alloys during and after Hot Deformation....Pages 169-172 The Effect of Vanadium Addition on Structure and Material Properties of Heat Treated 6XXX Series Aluminium Alloys....Pages 173-178 Mechanical Properties of Al-(8, 10)%Zn-2%Mg-2%Cu Base Alloys Processed with High-Pressure Torsion....Pages 179-182 Influence of Solution Heat Treatment Temperature in the Final Properties of AA6201 Drawn Wire....Pages 183-187 Primary Crystallisation of Intermetallic Compounds in the Al-Ni-Fe-Mn-Si System in Relation to Foundry Alloys Based on an Aluminium-Nickel Eutectic....Pages 189-194 Process Development for Stamping A-Pillar Covers with Aluminum....Pages 197-201 Development of an Accelerated Ageing Test on an Al-Si-Cu-Mg Alloy for Aeronautics....Pages 203-208 Mechanical and Thermal Properties of Rheocast Telecom Component Using Low Silicon Aluminium Alloy in As-Cast and Heat-Treated Conditions....Pages 209-214 Aluminum High Pressure Vacuum Die Casting Applications for the Multi Material Lightweight Vehicle Program (MMLV) Body Structure....Pages 215-221 Warm Forming of AA7075-T6 with Direct Electrical Resistance Heating....Pages 223-227 Influence of Heat Treatment Parameters on the Metallurgical Quality of EN AW 7068 Extruded Bars....Pages 229-235 Front Matter....Pages 153-153 Scrap-Intensive Wrought Aluminum Alloys of Standard Quality....Pages 237-242 Deformation and Failure of an Al-Mg Alloy Investigated Through Multiscale Microstructural Models....Pages 245-249 Load/Displacement and Energy Dissipation Performances of Aluminum and Magnesium Extrusions Subjected to Quasi-Static and Dynamic Loading under Axial Crush and Cutting Deformation Modes....Pages 251-256 Estimation of Heat Transfer Coefficient in Squeeze Casting of Wrought Aluminum Alloy 7075 by the Polynomial Curve Fitting Method....Pages 257-261 Statistical and Thermodynamic Optimization of Trace-Element Modified Al-Mg-Si-Cu Alloys....Pages 265-270 The Influence of Cooling Rate and Alloying Elements on the Microstructure Refinement of Al-5Fe Alloy....Pages 271-275 An Alternative Eutectic System for Casting Aluminum Alloys I. Casting Ability and Tensile Properties....Pages 277-281 An Alternative Eutectic System for Casting Aluminum Alloys II. Modification of the Eutectic Morphology....Pages 283-287 Role of Solidification Conditions in Determining the Microstructure of Al-Si Cast Alloys....Pages 289-296 Microstructure and Tensile Data of a Very Ductile as Cast Al-21%Si-1.5% Ba Hyper-Eutectic Alloys....Pages 297-299 Grain Refinement Behavior of Al-Zn-Si Alloy by Inoculation in Hot-Dip Coating....Pages 301-306 Evaluation of Forming Limit Diagram of Aluminum Alloy 6061-T6 at Ambient Temperature....Pages 309-314 Characterizing and Modeling the Deformation of AA5182 for Hot Blank — Cold Die (HB-CD) Stamping....Pages 315-320 The Portevin-Le Châtelier Effect in a Rheocast Al-Si-Cu Alloy....Pages 321-325 High-Rate Formability of High-Strength Aluminum Alloys: A Study on Objectivity of Measured Strain and Strain Rate....Pages 327-331 The Surface Necking Forming Mechanism in an AA6016 Automotive Sheet during Bending....Pages 333-337 Hydrogen Visualization in the Deformed Microstructure of Al-Zn-Mg Base Alloys....Pages 341-345 Investigation of the Structural Stability of Nanostructured Al-5.7wt.%-Ni Mechanically Alloyed Eutectic Alloy Powders....Pages 347-351 A Comprehensive Study on the Effect of Retrogression and Re-Aging on the Properties of Aluminium Alloy Conforming to AA 7049 Specification....Pages 353-357 Effects of Different Temper and Aging Temperature on the Precipitation Behavior of Al 5xxx Alloy....Pages 361-365 Front Matter....Pages 153-153 Influence of Temperature on Natural Aging Kinetics of AA6061 Modified with Sn....Pages 367-371 Use of Nano-Structured Silanols on the Solidification of Aluminum-Silicon Based Casting Alloys....Pages 375-377 Study on Inhibitors of Copper and Copper-Nickel Alloy in LiBr Solution....Pages 381-385 The Influence of Alloying Additions on Interaction of Aluminum Alloys with Aqueous Media....Pages 387-391 Effect of Titanium on Dross Formation in Hot-Dip 55%Al-Zn-Si-La Bath....Pages 393-396 Nickel Coatings with Submicrometric Hard Ceramic Particles on Aluminum Alloys....Pages 397-401 The Effect of Cooling Rate and Cerium Melt Treatment on Thermal Analysis Parameters and Microstructure of Hypoeutectic Al-Si Alloy....Pages 403-407 Front Matter....Pages 409-409 Prioritizing Water Contaminants’ Impact on Heat Transfer in Casting Aluminum Ingots....Pages 413-418 Optimization of Isothermal Hot Rolling Parameters Using ANSYS and LS-DYNA....Pages 419-421 Direct Flame Impingement: A New Oxy-Fuel Based Technology for Continuous Annealing of Aluminium Strip....Pages 423-425 Aluminum Surface Texturing by Means of Laser Interference Metallurgy....Pages 427-429 Novelis High-Speed can End Coating Line — Operational Results....Pages 431-436 Theoretical and Experimental Studies of a Thermal Regenerator for Heat Recovery in Aluminum Melting Furnaces....Pages 439-443 Strain Analysis during the Symmetric and Asymmetric Rolling of 7075 Al Alloy Sheets....Pages 445-449 Results in Production of an Improved Grain Refinement Practise for 6XXX Extrusion Billets....Pages 451-455 Structural Studies on the Evolution of Texture in Heavily Wire Drawn and Subsequently Annealed Pure Al Metal....Pages 457-461 Use of Vaporizing Foil Actuator for Impact Welding of Aluminum Alloy Sheets with Steel and Magnesium Alloys....Pages 463-468 Microstructure Evolution of AA3003 Aluminum Alloys Enhanced by Zirconium Addition Studied by Electron Microscopy....Pages 469-474 Front Matter....Pages 475-475 Simulation and Measurements on the Flow Field of 600KA Aluminum Reduction Pot....Pages 479-482 CHINALCO 600KA High Capacity Low Energy Consumption Reduction Cell Development....Pages 483-487 Front Matter....Pages 475-475 Development History and Performance of Dubal DX+ Demonstration Cells....Pages 489-494 Arvida Aluminum Smelter — AP60 Technological Center, Start-Up Performance and Development of the Technology....Pages 495-498 From D18 to D18+: Progression of Dubal’s Original Potlines....Pages 499-504 World’s Longest Potline Start-Up at EMAL....Pages 505-510 Technology Research on Aluminum Reduction Cell Pre-Stressed Shell....Pages 511-515 Investment Advantages of the Establishing of Aluminium Clusters....Pages 517-520 Use of the Life Cycle Assessment Methodology to Support Sustainable Aluminum Production and Technology Developments....Pages 523-528 Comparative Analysis of the Environmental Impacts of Aluminum Smelting Technologies....Pages 529-534 Variability Analysis of Total Fluoride Concentrations from Two Reduction Cell Technologies in a Primary Aluminum Smelter....Pages 535-538 Anode Effect Reduction at Nordural — Practical Points....Pages 539-543 Studies on Background PFC Emission in Hall-Héroult Reduction Cells Using Online Anode Current Signals....Pages 545-550 Non Anode Effect PFCS: Measurement Considerations and Potential Impacts....Pages 551-555 Effect of Operational Parameters on the Behavior of Phosphorus and Sulfur in Aluminum Reduction....Pages 559-564 Chemical Characterization and Thermodynamic Investigation of Anode Crust Used in Aluminum Electrolysis Cells....Pages 565-570 Non-Intrusive Freeze Layer Detection Method in an Aluminum Reduction Cell....Pages 571-576 Monitoring Local Alumina Dissolution in Aluminum Reduction Cells Using State Estimation....Pages 577-581 Study on the Dissolution of Alumina in Cryolite Electrolyte Using the See-Through Cell....Pages 583-588 Production of Al-Sc Alloy by Electrolysis of Cryolite-Scandium Oxide Melts....Pages 589-593 Horizontal In-Duct Scrubbing of Sulfur-Dioxide from Flue Gas Exhausts....Pages 597-601 Impact of Potroom Work Practices on Roofline Fluoride Emissions and Wet Scrubber Efficiency....Pages 603-605 Front Matter....Pages 475-475 Mobile Monitoring System for Potroom Roof HF Emissions....Pages 607-611 Impact of Operational Practices and Cell Hooding on Total Fluoride Emissions in the Aluminium Smelter Plant of Aluar....Pages 613-615 Solution to Reduce Fluoride Emissions from Anode Butts....Pages 617-622 Start-Up of the Ozeos Gas Treatment Center (GTC) for RTA AP60....Pages 623-625 Treatment of Gas Emissions in Potrooms....Pages 627-630 Possible Use of 25 MW Thermal Energy Recovered from the Potgas at Alba Line 4....Pages 631-636 Behavior of Powders on the Surface of a Liquid....Pages 639-642 Development of a Mechanized Bath Sampling Method....Pages 643-647 Impact of Variable Bath Chemistry and Wetting on Gas Bubble Flow in Aluminium Electrolysis Cells....Pages 649-654 Study of the Structure and Thermophysical Properties of the Side Ledge in Hall-Héroult Cells Operating with Modified Bath Composition....Pages 655-659 The Performance of Aluminium Electrolysis in Cryolite Based Electrolytes Containing LiF, KF and MgF2....Pages 661-664 Wetting Between Carbon and Cryolitic Melts. Part I: Theory and Equipment....Pages 665-670 Wetting Between Carbon and Cryolitic Melts. Part II: Effect of Bath Properties and Polarisation....Pages 671-676 External Potshell Insulation: A Multi-Usage Tool in Low Power Operation....Pages 679-684 In-Depth Analysis of Lining Designs for Several 420 kA Electrolytic Cells....Pages 685-690 Energy Savings Using a Different Anode Rod Design....Pages 691-694 New ECL Embedded Service Robot: towards an automated, efficient and green smelter....Pages 695-697 An Innovative Pot Ramming Machine....Pages 699-704 Primary Aluminium Production: Is Automation the Key to New Success?....Pages 705-707 Bath Treatment Plant Process and Technology Trends....Pages 709-713 Front Matter....Pages 475-475 Standard Development Work in ISO Technical Committee 226 “Materials for the Production of Primary Aluminium”....Pages 715-720 On-line Monitoring of Individual Anode Currents to Understand and Improve the Process Control at Alouette....Pages 723-728 High Frequency Measurements of Current through Individual Anodes: Some Results from Measurement Campaigns at Hydro....Pages 729-734 Frequency Response Analysis of Electrolysis Cell Voltage Signals during the Alumina Feed Cycles....Pages 735-740 Experiments on Measurement of Online Anode Currents at Anode Beam in Aluminum Reduction Cells....Pages 741-745 Investigation of Cathode & Collector Bar Modification on Thermal Balance of a Low Amperage Cell....Pages 747-752 Trading Current or Resistance for Metal Depth to Maintain Ledge....Pages 753-755 Reduction in Power Consumption at UC RUSAL’s Smelters 2012–2014....Pages 757-762 Aspects of Change Management and Process Management at Some Smelters....Pages 763-768 3D Coupled MHD and Thermo-Electrical Modelling Applied to AP Technology Pots....Pages 771-775 A Model Based Study of Cell Electrical Preheating Practices at DUBAL....Pages 777-782 Mathematical Modelling of Hall-Héroult Pot Instability and Verification by Measurements of Anode Current Distribution....Pages 783-788 Bubble Flow in a Static Magnetic Field....Pages 789-793 The Impact of Bubble-Bubble Interaction on Anodic Gas Release: A Water Model Analysis....Pages 795-800 Observation of Anodic Bubble Behaviors Using Laboratory Scale Transparent Aluminium Electrolysis Cells....Pages 801-806 Impact of Copper Inserts in Collector Bars....Pages 807-812 In-Situ Formation of Slots in Søderberg Anodes....Pages 815-820 Non-linear Stability Analysis of Cells Having Different Types of Cathode Surface Geometry....Pages 821-826 The Influence of Cathode Shape on Current Density and Metal Heave in 300 kA Aluminum Reduction Cell....Pages 827-830 Detailed Model of Electrochemical Cathode Wear in Hall-Héroult Cells....Pages 831-836 Front Matter....Pages 475-475 ELECTROSLAG WELDING (ESW): A New Option for Smelters to Weld Aluminum Bus Bars....Pages 837-842 The Resistibility of Semi-Graphitic Cathode to Alkali Metal (K and Na) Penetration....Pages 843-848 The Status and Development Trends of Carbon Cathode Materials in China....Pages 849-854 Front Matter....Pages 855-855 On Liquid Metal Wetting of Casting Rings for DC Casting....Pages 859-863 Thermal Stress Prediction in AA5182 Rectangular Ingots....Pages 865-870 Macrosegregation during Direct Chill Casting of Aluminum Alloy 7050....Pages 871-875 Experimental Observations of Macrosegregation in DC Casting of Rolling Slab Ingots....Pages 877-882 Development and Demonstration of a Flexible Ingot Mould Filling System....Pages 883-886 Developing a Do-It-Yourself Excel Model of a Reverberatory Side-Well Aluminum Melting Furnace....Pages 889-894 Numerical Modeling of Heat Transfer in a Full Scale Industry Furnace....Pages 895-900 Rotary Flux Injector (RFI): Recent Development Towards an Autonomous Technology....Pages 901-904 Truths and Falsehoods of Molten Metal Explosions in the Aluminium Industry....Pages 905-907 Calculated Aluminum Oxidation Rates during Rotary Furnace Melting Through Flue Gas Analysis....Pages 909-914 CFD Comparison of Immersed Heater and Open Fire Burner Designs for Casting Furnaces....Pages 915-920 Recent Progress with Development of a Multi Stage Filtration System Employing a Cyclone....Pages 923-927 Effect of Electromagnetic Fields on the Priming of High Grade Ceramic Foam Filters (CFF) with Liquid Aluminum....Pages 929-935 Practical Use of the MetalVision Ultrasonic Inclusion Analyzer....Pages 937-942 Ultrasonic Degasing and Processing of Aluminum Part II....Pages 943-948 An Investigation on Permeability of Ceramic Foam Filters (CFF)....Pages 949-954 Assessment of Modification Level in EN AC-46000 Aluminum Casting Alloys Using Thermal Analysis and Microscopic Evaluation....Pages 955-960 Front Matter....Pages 855-855 A New Kind of Al-5Ti-0.3C Master Alloy and Its Refining Performance on 6063 Alloy....Pages 961-964 Study of Particle Settling and Sedimentation in a Crucible Furnace....Pages 967-972 Improvements in LiMCA Technology: Introducing the LiMCA III....Pages 973-978 Molten Metal Treatment Improvements at JW Aluminum Used as a Method to Guarantee Metal Quality....Pages 979-982 The Influence of Melt Charge Materials on Molten Metal Quality at JW Aluminum....Pages 983-986 SiC Particle Detection in Liquid Aluminum via Laser Induced Breakdown Spectroscopy....Pages 987-990 Development of a LiMCA Methodology for the Measurement of Inclusions at Different Depths in Molten Aluminium....Pages 991-996 Deformation of the Aluminum Bath Surface in an Induction Melting Furnace....Pages 999-1004 History and Future of Dross Processing....Pages 1005-1009 Recycling of Aluminum A380 Machining Chips....Pages 1011-1015 Production and Certification of Metallic Certified Reference Materials for the Analysis of Aluminium Alloys....Pages 1017-1022 Recycling of Automotive Wrought Alloys....Pages 1023-1028 Front Matter....Pages 1029-1029 Pilot Anode Testing of Alternative Binder and CPC Raw Materials....Pages 1033-1038 Calcined Petroleum Coke Density Separation Process: Solution to Maintain Anode Quality with Degrading Coke Density....Pages 1039-1044 New Developments of Anode Coke Grinding Using a Vertical Mill Technology....Pages 1045-1048 Effects of Mixing Parameters and Pores of Cokes on Pitch Absorption in Making Carbon Anode Pastes....Pages 1049-1053 Real-Time Measurement of Coke Aggregate Size and Vibrated Bulk Density Using Image Texture Analysis....Pages 1055-1060 Anode Aggregate Bulk Density Determinations Using a Y-Blender....Pages 1061-1065 A Size-Dependent Thermodynamic Model for the Carbon/Hydrogen/Sulfur System in Coke Crystallites: Application to the Production of Pre-Baked Carbon Anodes....Pages 1067-1072 Traceability of Raw Materials in Silos in an Anode Plant....Pages 1073-1078 Front Matter....Pages 1029-1029 A Dynamic Process Model for Predicting the Performance of Horizontal Anode Baking Furnaces....Pages 1081-1086 Environmental and Operating Benefits of a New Fume Treatment System at a Restarted Anode Plant....Pages 1087-1092 Successful Start-Up of Firing Control System at Vlissingen....Pages 1093-1096 Quality Control via Electrical Resistivity Measurement of Industrial Anodes....Pages 1097-1102 Xelios Vibrocompactors Performance and Reliability....Pages 1103-1107 Baking Furnace Rebuild Strategy at DUBAL to Improve Productivity....Pages 1109-1114 Description and Applications of a 3D Mathematical Model for Horizontal Anode Baking Furnaces....Pages 1115-1120 Evaluating the Crack Resistance of Carbon Anodes: Implementation of a Measurement System for Tensile Strength and Fracture Toughness....Pages 1123-1128 Comparison of Linear Multivariable, Partial Least Square Regression, and Artificial Neural Network Analyses to Study the Effect of Different Parameters on Anode Properties....Pages 1129-1134 Factors Influencing Baked Anode Properties....Pages 1135-1140 Spatial Methods for Characterising Carbon Anodes for Aluminium Production....Pages 1141-1146 Air and CO2 Reactivity of Carbon Anode and Its Constituents: An Attempt to Understand Dusting Phenomenon....Pages 1147-1152 Effects of Coke Types and Calcining Levels on the Properties of Bench-Scale Anodes....Pages 1153-1156 Effects of Current Density and Temperature on Anode Carbon Consumption in Aluminum Electrolysis....Pages 1157-1161 Anode Stub 3D Inspection System....Pages 1165-1168 Determination of the Microstructural Creep Properties of Cast Iron Connector at High Temperatures for the Prediction of the Thermo-Mechanical Behavior of Anodic Assemblies....Pages 1169-1173 Development of a New Approach to Increase the Electrical Performance of Anodic Assemblies....Pages 1175-1180 On the Evolution of Steel Stub Thermo-Physical and Thermo-Mechanical Properties during Operational Stage of Anodic Assemblies....Pages 1181-1186 Influence of Partial Substitution of Cu by Various Elements in Cu-Ni-Fe Alloys on Their High-Temperature Oxidation Behavior....Pages 1187-1191 Study on the Bubble Behavior and Anodic Overvoltage of NiFe2O4 Ceramic Based Inert Anodes....Pages 1193-1197 Front Matter....Pages 1029-1029 Application of Grey Relational Analysis for Corrosion Rates of Inert Anodes in Aluminum Electrolysis....Pages 1199-1204 Front Matter....Pages 1205-1205 The Importance of Heat Removal for Productivity in Industrial Twin Roll Casting of Aluminium....Pages 1209-1213 A Single Roll Caster Equipped with a Scraper....Pages 1215-1218 Effect of Casting Parameters on Microstructure, Recrystallization Behaviour and Final Material Properties of Twin-Roll Cast 1050 Alloy....Pages 1219-1223 Comparison of Twin-Roll Casting and High-Temperature Roll Bonding for Steel-Clad Aluminum Strip Production....Pages 1225-1230 Casting of Clad Strip by a Twin Roll Caster....Pages 1231-1234 High Strength Aluminum Alloy Sheets Fabricated by Twin Roll Casting for Automobile Application....Pages 1235-1240 Modelling of the Twin Roll Casting Process Including Friction....Pages 1243-1247 Effect of Cu Addition on the Microstructural Constituents and Mechanical Properties of Twin Roll Cast AlFeMnSi Alloys....Pages 1249-1254 Improvement of Corrosion Resistance in Modified 3003 Aluminum Alloys Produced by Twin Roll Casting under Different Casting Parameters....Pages 1255-1259 Back Matter....Pages 1261-1272