Pulling together information previously scattered throughout numerous research articles into one detailed resource, Physical Metallurgy of Direct Chill Casting of Aluminum Alloys connects the fundamentals of structure formation during solidification with the practically observed structure and defect patterns in billets and ingots. The author examines the formation of a structure, properties, and defects in the as-cast material in tight correlation to the physical phenomena involved in the solidification and the process parameters.
The book draws on the author’s advanced research to provide a unique application of physical metallurgy to direct chill (DC) casting technology. He examines structure and defect formation— including macrosegregation and hot tearing. Each technology-centered chapter provides historical background before reviewing current developments. The author supports his conclusions with computer simulation results that have been correlated with highly progressive experimental data. He presents a logical system of structure and defect formation based on the specific features of the DC casting process. He also demonstrates that the seemingly controversial results reported in literature are, in fact, caused by the different ratio of the same mechanisms.
Compiling recent results and data, the book discusses the fundamentals of solidification together with metallurgical and technological aspects of DC casting. It gives new insight and perspective into DC casting research.
Table of Contents
Direct Chill Casting: Development of the Technology
Solidification of Aluminum Alloys
Effect of Cooling Rate and Melt Temperature on Solidification of Aluminum Alloys
Microsegregation in Aluminum Alloys
Solidification Reactions and Phase Composition
Effect of Alloy Composition on Structure Formation: Grain Refinement
Solidification Patterns and Structure Formation during Direct Chill Casting
Shape and Dimensions of the Billet Sump
Solidification Rate and Cooling Rate during DC Casting
Effects of Process Parameters on the Formation of Grain Structure
Effect of Process Parameters on the Amount of Nonequilibrium Eutectics
Effect of Process Parameters and Alloy Composition on the Occurrence of Some Casting Defects
Mechanisms of Macrosegregation
Effects of Process Parameters on Macrosegregation during DC Casting
Effect of Composition on Macrosegregation. Macrosegregation in Commercial Aluminum Alloys
Thermal Contraction during Solidification
Mechanical Properties of Semi-Solid Alloys
Mechanisms and Criteria for Hot Tearing
Effects of Process Parameters on Hot Tearing during DC Casting