Light Metals 2023

Preface
Contents
About the Editor
Program Organizers
Aluminum Committee 2022–2026
Part I 60 Years of Taking Aluminum Smelting Research and Development from New Zealand to the World: An LMD Symposium in Honor of Barry J. Welch
1 What Makes TMS Special? Let Us Consider a Case Study in Volunteer Excellence: Barry J. Welch
2 Meeting the Requirements of Potline Customers: The Largely Unmet Challenges Set by Barry Welch to Carbon Anode Producers
3 The Need to Respect the Interlink Between Science, Physics, and Cell Design in an Environmentally Responsible Manner: The Next Big Challenge for Aluminium Smelting
4 Anode Quality Optimisation: Industry Learnings from the Research Supervised by Barry Welch
5 Process Recovery to Unlock Power Efficiency Improvement at BSL
6 A Smart Individual Anode Current Measurement System and Its Applications
7 Light Metals Research at the University of Auckland
8 Impact of Aluminium Reduction Cell Parameters on Feeder Hole Condition
9 A Dynamic Coupled Mass and Thermal Model for the Top Chamber of the Aluminium Smelting Cells
10 Following Alumina Dissolution Kinetics with Electrochemical and Video Analysis Tools
11 Monitoring Cell Conditions and Anode Freeze Dissolution with Model-Based Soft Sensor After Anode Change
12 EGA’s First Holistic Mobile Application for Smelter Operations
13 Testing Feeding Alumina in Three Channels in a Wide Cell
14 A Pragmatic Model for Bath Temperature Evolution During Alumina Feeding
15 A New Strategy for Transient Heat Transfer Models with Phase Change for the Aluminum Electrolysis Industry
16 A Discussion on Thermal Impact of Anode Change in Aluminum Reduction Cell
17 Development and Deployment Measures in PLC-Based Pot Control System at Low Amperage Aluminium Reduction Cell
Part II Alumina and Bauxite
18 Process Simulation with Tertiary Cyclone for Kaolinite Removal from Amazonian Bauxite
19 Granulometry Impact on Digestion Efficiency and Cost-Economics in Alumina Refinery for East Coast Bauxite (India)
20 Effect of Thermal Activation Temperature on Pre-desilication of Low-Grade Bauxite
21 Application of Repeatability and Reproducibility Analysis in the Determination of Available Alumina and Reactive Silica in Bauxites
22 Zero Waste Alumina Production
23 Statistical Modelling of Operating Parameters on Bauxite Slurry Hyperbaric Filtration
24 Reduction of GHG Emissions and Increase Operational Reliability Using Immersed Electrode Boiler in an Alumina Refinery
25 Steam Grid Stability Using Advanced Process Control and Real Time Optimization in an Alumina Refinery
26 Effects of Impurities on the Boiling Point of Bayer Liquor
27 Effects of Different Precursors on the Preparation of β″-Al₂O₃
28 Determination of Unit Cell Parameters of α-Alumina Reference Material
29 Improvement Seminars: Continuous Improvement and People’s Engagement to Support Sustainability
30 Turning Bauxite Residue to Metal Adsorption Materials Through a Low-Cost Approach
31 Hematite and Anatase Conversion to Magnetic Phases During Reductive Re-digestion of Gibbsitic Bauxite Residue
32 Digestion Efficiency Improvement of Gibbsite-Boehmite Bauxite
33 Decanter Centrifuge for Dewatering Bauxite Tailings
Part III Aluminum Alloys, Characterization, and Processing
34 Comparison of TiB2 and TiC Grain Refiners’ Impact on Surface Quality, Edge Cracking, and Rolling Performance of AA5182 DC-Cast Ingot
35 The Influence of Crystallographic Texture Gradients on the Deformation Response of Aluminum Extrusions
36 Mechanical Properties, Microstructures, and Textures of Cold Rolling Sheets Made from a Low-cost Continuous Cast Al-1.5Cu Alloy with Potential Application in Auto Sheets
37 Challenges in the Production of 5754 Automotive Alloy Sheet via Twin Roll Casting Route
38 Fabrication of Bright-Rolled Aluminum Suitable for Design Elements in the Automotive Industry
39 Effects of Aging Conditions on Fracture Characteristics of Al–Mg–Si Alloys
40 Evaluation of EN AW 3003 Aluminium Alloy Homogenization with Specific Electrical Resistivity Measurement
41 The Effect of Octagonal Ingot Shape on AA6xxx Hot Rolling Performance
42 The Low-Carbon Production of Wrought Aluminum Alloys Based on Post-consumer Scrap
43 Reduce Inclusion Level Study in Aluminum Slab Products 3XX and 5XX
44 Effect of Iron and Manganese Content on Microstructure and Mechanical Properties of AlSi11 Alloy in Wheels Produced by LPDC-Process
45 Shear Assisted Processing and Extrusion of Unhomogenized Aluminum Alloy 6063 Castings with High Iron Content
46 Solutionization via Severe Plastic Deformation: Effect on Natural Aging in an Al–Mg–Si–(Mn) Alloy
47 Manufacture of Nano-to-Submicron-Scale TiC Particulate Reinforced Aluminium Composites by Ultrasound-Assisted Stir Casting
48 Effect of Mn Content on Quench Sensitivity of 6082 Alloys
49 Characterization of Aluminum Conductors Steel Reinforced in Overhead Transmission Lines
50 Mechanical and Electrical Properties of Permanent Steel Mold Cast Eutectic Al-1.8Fe Alloy
51 Effects of the Friction Stir Welding Sliding and Sticking Mechanisms on the Microhardness, Texture, and Element Concentration
52 Experimental Investigation of the Effect of High-Temperature Shot Peening on the Surface Integrity of 7010-T7452 Aluminum Alloy
53 Quality Assessment and Features of Microdrilled Holes in Aluminum Alloy Using Ultrafast Laser
54 Surface Characterization Methods to Evaluate Adhesive Bonding Performance of 6xxx Automotive Alloys
55 Investigation of Resistance of Intergranular Attack for Various Heat Treated 2011 Alloys After Hard Anodizing
56 Fundamental Study on Modified Solidification of 1370 and ALSI7 with and without Commercial Grain Refiners
57 Improving the Mechanical Properties of Cast Aluminum via Ultrasonication-Induced Microstructural Refinement
58 Microstructural Changes on a Ternary Al–Cu–Si Eutectic Alloy with Different Pre-heated Mold Temperatures
59 Nanoparticle-Enhanced Arc Welding of Aluminum Alloys
60 Phase Equilibria in Al–Fe Alloys
61 Secondary Phase Refinement in Molten Aluminum via Low Power Electric Current Processing
62 Fluidity and Microstructural Analysis of Al–Ni Alloys with Varied Ni Concentrations
63 Effect of Ti Addition on the Microstructure and Mechanical Properties of Hypo-Eutectic and Eutectic Al–Si Alloys
64 Compatibility Study of Polymeric Binders for Aluminum Binder Jet Parts
65 Material Evaluation Framework of Additive Manufactured Aluminum Alloys for Space Optical Instruments
66 Comparison of Additively Manufactured and Cast Aluminum A205 Alloy
67 The Role of Ti and B Additions in Grain Refinement of Al–Mn Alloy During Laser Additive Manufacturing
68 AMAG CrossAlloy®—A Unique Aluminum Alloy Concept for Lightweighting the Future
69 Effect of Alloying Elements on Corrosion Resistance of Quench-Free Al–Ca Alloys for HPDC
70 Influence of Increased Cu and Fe Concentrations on the Mechanical Properties of the EN AB-42100 (AlSi7Mg0.3) Aluminum Alloy
71 Temperature Dependence of Lattice Misfit in Determining Microstructural Evolution of High Temperature High Strength Aluminium Alloys—A 3D Phase-Field Study
72 Microstructure and Mechanical Properties of an Al-Mn-Si Alloy Microalloyed with Sn
73 Innovative Approaches in Development of Aluminium Alloys for Packaging Industry
74 The Role of Microstructure on Strength and Fracture Anisotropy Effects in Al–Mg–Si Extrusion Alloys
75 Comparison of Experimental Test and Finite Element Simulations of Car Crash Boxes Manufactured with Different Aluminum Alloys
76 Exploring Semi-solid Deformation of Al–Cu Alloys by a Quantitative Comparison Between Drained Die Compression Experiments and 3D Discrete Element Method Simulations
77 The Role of Through-Thickness Variation of Texture and Grain Size on Bending Ductility of Al–Mg–Si Profiles
78 Anisotropy of Tearing Behavior in AA7075-T6 Sheet at 200 °C
79 Evaluating the Earing Amount of Materials Under Various Chemical Composition and Heat Treatment Processes with Finite Element Simulations of Cup Drawing Tests
80 Effect of Al-3Ti-1B-1.5Ce Refiner on Microstructure and Mechanical Properties of A356 Aluminum Alloy
81 Effect of Al-Ti-B Refiner on Microstructure and Properties of A356 Alloy by Continuous Rheo-Extrusion
82 Effect of Annealing Process on Recrystallization Microstructure and Properties of 1235D Aluminum Alloy Sheet
83 Effect of Thermal Treatment (T5) on Microstructure and Tensile Properties of Vacuum High Pressure Die Cast Al–Si–Mg Alloy
84 Numerical Simulation of Flow of Liquid in Molten Pool of Twin-roll Casting Rolling 5182 Aluminum Alloy Strip
85 Study of the Solidification Behavior and Homogenization Heat Treatment of the Investment-Cast Al–Cu Foams: Experimental and Modelling Investigations
Part IV Aluminum Industry Emissions Measurement, Reporting, and Reduction
86 The Way Towards Zero Carbon Emissions in Aluminum Electrolysis
87 Individual Pot Sampling for Low-Voltage PFC Emissions Characterization and Reduction
88 Determination of PFC with Canister Sampling and Medusa GC–MS Analysis in Comparison to General IPCC Estimation Methods
89 Heavy Metal Emissions through Particulate Matter from Aluminium Electrolysis
90 Verification of Open-Path Dust Laser for Continuous Monitoring of Diffuse Emissions
91 Characterization of Industrial Hydrocarbon Samples from Anode Baking Furnace Off-Gas Treatment Facility
Part V Aluminum Reduction Technology
92 CFD Modelling of Solidification and Melting of Bath During Raft Formation
93 Experimental Investigation of the Alumina Cloud During Alumina Injections in Low- and High-Temperature Conditions
94 Fundamental Mass Transfer Correlations Based on Experimental and Literature Data
95 Potential of Production Al–Si Green Alloys in AP18 Aluminium Reduction Cell
96 Effect of Sulfur Content of Carbon Anode on Measuring Current Efficiency of Aluminum Electrolytic Cell by Gas Analysis Method
97 KF Content on Physical and Chemical Properties of Aluminum Electrolysis Electrolyte
98 Fundamentals of Pot Ventilation in Aluminum Smelters
99 Evaluation of Methodologies for Assessment of SO₃ Concentration in Industrial Off-Gas
100 Mathematical Modelling of the Desulfurization of Electrolysis Cell Gases in a Low-Temperature Reactor
101 Improvements to a Mathematical Model Used to Reproduce the Wave and Stream at the Bath-Metal Interface and Assess Their Impact on the Movement of Alumina Rafts
102 Numerical Investigation of Thermal, Electrical, and Mechanical Behaviour of Aluminium Cell During Preheating Phase
103 Simplified 3D MHD Model for Quick Evaluation of Aluminium Electrolysis Cell Design
104 Achieving Low Pot Failure Rate at Aditya Aluminium
105 Dissimilar Results in Restarting Two Different Potlines
106 Restart of Albras’ Potline 2—Improving Performance and Changing Paradigms
107 Application of Cell Retrofit in GP320 Aluminum Reduction Cell Line
108 The Expanded Industrial Pilot of SAMI’s NCCT+ Technology
109 The SY500 Pot Technology Development
110 Preheat, Start-Up and Early Operation of DX+ Ultra Pots at 500 kA
Part VI Aluminum Waste Management and Utilization
111 Recovery of Value Added Products from Bauxite Residue
112 Current Status and Proposed Economic Incentives for Higher Utilization of Bauxite Residue to Enhance Sustainability of the Aluminum Industry
113 Aluminium Bahrain (Alba) SPL Sustainable Solution from Landfill to Valuable Feedstock “HiCAL30”
114 Valorization of Treated Spent Potlining in Cement Industry
115 Aluminum Recycling and Recovery of Other Components from Waste Tetra Pak Aseptic Packages
Part VII Cast Shop Technology
116 Electromagnetic Priming of Filtration Systems: Pyrotek EM-DF
117 Automated Metal Cleanliness Analyzer (AMCA): Digital Image Analysis Phase Differentiation and Benchmarking Against PoDFA-Derived Cleanliness Data
118 Automated Image Analysis of Metallurgical Grade Samples Reinforced with Machine Learning
119 Characterization of Low- and High Mg-Containing Aluminum White Dross Using Deterministic Image Analysis of EPMA Scans
120 Assessment of Separation and Agglomeration Tendency of Non-metallic Inclusions in an Electromagnetically Stirred Aluminum Melt
121 Microalloying of Liquid Al–Mg Alloy Studied In-Situ by Laser-Induced Breakdown Spectroscopy
122 Hydrogen Absorption of Aluminum-Magnesium Melts from Humid Atmospheres
123 Influence of Cryolite Content on the Thermal Properties and Coalescence Efficiency of NaCl–KCl Salt Flux
124 Oxidation Study of Al–Mg Alloys in Furnace Atmospheres Using Hydrogen and Methane as Fuel
125 Towards the Efficient Recycling of Used Beverage Cans: Numerical Study and Experimental Validation
126 A Novel Green Melt Technology for Aluminum Alloys
127 MagPump
128 Recycling of Aluminum from Aluminum Food Tubes
129 Recent Studies Using HR-TEM on the Fundamental Mechanism of Nucleation of a-Aluminum on TiB₂ in TiB D High-Efficiency Grain Refiners
130 A Cellular Automaton Model for Qualifying Current Grain Refiners and Prescribing Next-Generation Grain Refiners for Aluminium Alloys
131 Modelling Contactless Ultrasound Treatment in a DC Casting Launder
132 Numerical Analysis of Channel-Type Segregations in DC Casting Aluminum Slab
133 Effect of Casting Variables on Mechanical Properties of Direct Chill Cast Aluminium Alloy Billets
134 Stability of SiC and Al₂O₃ Reinforcement Particles in Thermomechanical Processed Direct Chill Cast Al MMnCs
135 TRC Combi Box: A Compact Inline Melt Treatment Unit for Continuous Casting
136 CFD Modeling of Thin Sheet Product Using the Horizontal Single Belt Casting Method
137 Numerical and Experimental Investigation of Twin-Roll Casting of Aluminum–Lithium Strips
138 Segregation Mechanisms and Their Effects on the Aluminium Flat Rolled Products (Sheet/Foil) Produced by Twin Roll Casting Technology
139 Novel Methods for Roll Texturing: EDT and Sandblast Applications for Aluminium Twin-Roll Cast and Cold Rolling
140 Characterization of 8006 Aluminium Alloy Casted by TRC Technology with Steel–Steel and Copper–Copper Roll Pairs
141 Tailoring the As-Cast Microstructure of Twin-Roll Cast AA3105 Alloy Produced by St/Cu Shell Pair
142 Designing a Safe Casthouse
143 Operations Assisting and Predictive Maintenance Tools in Cast Houses: Examples from AMAG Casting
144 Counter-Gravity Casting of Al Alloys: Microstructure and Properties
145 Defect Minimisation in Vacuum-Assisted Plaster Mould Investment Casting Through Simulation of High-Value Aluminium Alloy Components
Part VIII Electrode Technology for Aluminum Production
146 Partial Replacement of Coke with Biocoke: Effect of Biocoke Production Temperature on Anode Quality
147 Method for Calcined Petroleum Coke Evaluation to Improve the Anode Quality
148 Influence of Crusher Type and Particle Shape on the Bulk Density of Blended Shaft and Hearth Calcined Anode Grade Petroleum Coke
149 Managing Green Petroleum Coke Properties Variations on Prebaked Anodes Quality in Aluminium Bahrain “Alba”
150 Development of an Iron Aluminide Coating for Anticorrosion Protection of Anodic Pins
151 New Methods to Determine PAH Emission Dynamics During Electrode Mass Processing
152 Investigation of the Stacking Effects on the Electrical Resistivity of Industrial Baked Anodes
153 New Generation Anode Baking Furnace: Use of Prefabrication for Additional Conversions at Bell-Bay Plant
154 AHEX Full Scale Experiences at TRIMET Aluminium SE
155 Inline Modal Detection System of Anodes and Cathodes Measuring Cracks and Physical Properties
Part IX Scandium Extraction and Use in Aluminum Alloys
156 Investigations into Optimized Industrial Pilot Scale BR Leaching for Sc Extraction
157 Solvent Extraction of Scandium from Titanium Process Solutions
158 State of the Art Technologies for Scandium Recovery, Purification, and Aluminum-Scandium Alloy Production
159 FEA Materials—Aluminum Scandium Master Alloy Production Technology
160 Scandium Master Alloy Production Via Sulfidation and Vacuum Aluminothermic Reduction
161 European Scandium for a Lighter and Greener Future
162 Formation of Al₃Sc Dispersoids and Associated Strengthening
163 Use of Sc to Improve the Properties of AA5083 Cast and Rolled Products
164 Efficiency of Sc for Strengthening and Formability Improvement of 5XXX BIW Sheets
165 Effect of Sc and Zr Additions on Dispersoid Microstructure and Mechanical Properties of Hot-Rolled AA5083
166 Effect of Cooling Rate on W-Phase Formation in Al-Cu-Sc Alloys
167 Solute Clustering During Natural Ageing in Al-Cu-(Sc)-(Zr) Alloys
168 Effect of Zr and Sc on Intermetallic Morphology and Hardening of an Al–Fe Alloy
169 Effect of Sc, Zr, and Other REE on the 1XXX Conductive Aluminum Alloy Properties
170 Developing Al-Zr-Sc Alloys as High-Temperature-Resistant Conductors for Electric Overhead Line Applications
171 The Development of New Aluminum Alloys for the Laser-Powder Bed Fusion Process
172 Sustainable Scandium Recovery Method from Metallic 3D Printing Powders
173 New Aluminium–Scandium Welding Wires for Additive Manufacturing
174 Comparative Study of Al-Mg-Ti(-Sc-Zr) Alloys Fabricated by Cold Metal Transfer and Electron Beam Additive Manufacturing
175 Dissolution and Development of Al₃(Sc, Zr) Dispersoids in Structures Produced Via Wire Arc Additive Manufacturing
Author Index
Subject Index