Light Metals 2019

1548 Pages·2019·133.114 MB·English

by  Corleen Chesonis

19
Edited by
CORLEEN CHESONIS
The Minerals, Metals & Materials Series
Corleen Chesonis
Editor
Light Metals 2019
123
Editor
Corleen Chesonis
Metal Quality Solutions,LLC
Avonmore,PA,USA
ISSN 2367-1181 ISSN 2367-1696 (electronic)
TheMinerals, Metals& Materials Series
ISBN978-3-030-05863-0 ISBN978-3-030-05864-7 (eBook)
https://doi.org/10.1007/978-3-030-05864-7
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Preface
ItismyhonortopresenttheLightMetals2019proceedingsandtowelcomeyoutotheTMS
2019AnnualMeetingandExhibitioninSanAntonio.Ihopethatbeingthesecondwomanto
edit this respected publication is an indication of increasing and ongoing inclusion and
diversity in the light metals community. TMS has always been welcoming to me, both as a
woman and as a chemical engineer rather than a metallurgist.
Thealuminumindustryhascontinuedtochangeinthepastyearwiththeannouncementof
Elysis,ajointventuretoscaleupandcommercializearevolutionarysmeltingtechnologythat
emitsoxygenandeliminatesgreenhousegases.Ifsuccessful,thistechnologycouldhelpsolve
one of the major challenges of our industry and our world. In the meantime, a number of
manufacturers have introduced certified low-carbon products and products made with 100%
recycled metal. No matter what smelting technology is used in the future, recycling, reduced
energy consumption, and lower environmental impact will continue to be important to our
industry.
These proceedings reflect an incredible effort by all the authors and their organizations in
conducting their research and preparing the manuscripts that are published here. I would like
to thank all of them for their work; their contributions continue to make Light Metals the
pre-eminent annual publication for technical information on aluminum production processes.
As in the past, this volume contains research and development papers on aluminum pro-
cessesorganizedintothetraditionalLightMetalssymposia:AluminaandBauxite;Aluminum
Alloys, Processing, and Characterization; Aluminum Reduction Technology; Cast Shop
Technology;andElectrodeTechnologyforAluminumProduction.Italsoincludestwospecial
symposia for 2019: Ultrasonic Processing of Liquid and Solidifying Alloys and Scandium
Extraction and Use in Aluminum Alloys. We are honored to also have included papers on
aluminum processing from two joint symposia: REWAS 2019: Cast Shop Recycling Tech-
nologies and the TMS-DGM Symposium on Lightweight Metals: A Joint US-European
Symposium on Challenges in Light Weighting the Transportation Industry. This last sym-
posium is the result of a Memorandum of Understanding between TMS and the German
Materials Society (DGM).
I would like to thank the subject chairs and symposium organizers for all of their hard
work: Sébastien Fortin, Hiromi Nagaumi, Marc Dupuis, Pierre-Yves Menet, Lorentz Petter
Lossius, Nigel Ricketts, John Grandfield, Dmitry Eskin, Mertol Gökelma, Eric Nyberg, Wim
Sillekens, Norbert Hort, and Jürgen Hirsch. I also appreciate the guidance of the previous
editors,OlivierMartinandArneRatvik.Finally,mysincerethankstoallthewonderfulstaffat
TMS who guided us through the production of these proceedings.
Corleen Chesonis
v
Contents
Part I Alumina & Bauxite: Bayer Process and Non-conventional Processing
Advances in Beneficiation of Low-Grade Bauxite . . . . . . . . . . . . . . . . . . . . . . . . 3
Lala Behari Sukla, Archana Pattanaik and Debabrata Pradhan
Leaching Kinetics of Thermally-Activated, High Silica Bauxite. . . . . . . . . . . . . . 11
Hong Peng, Steven Peters and James Vaughan
Rheological Improvements in Alumina Industry Clarification Circuits . . . . . . . . 19
Lawrence J. Andermann Jr., Adrian Mullins, Cameron Smyth and Clive Roscoe
Improving the Reliability of Fluidized Bed Alumina Calciners by Suitable
Refractory Lining Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Mariana A. L. Braulio, José R. Cunha, Austin J. Maxwell, Dean Whiteman
and Victor C. Pandolfelli
Valorization of Bauxite Residue: A Challenge that Leads to a Mentality
Shift and Eventually Innovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Yiannis Pontikes
Synchronous Desulfurization and Desilication of Low-Grade and High-Sulfur
Bauxite by a Flotation Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Wencui Chai, Guihong Han, Yanfang Huang, Yijun Cao and Jiongtian Liu
Preparing Alumina by an Electrolytic Method from Sulfuric Acid Leachate
of Coal Fly Ash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Yuan Shi, Kai-xi Jiang, Ting-an Zhang and Guo-zhi Lv
Part II Alumina & Bauxite: Bauxite Residue: Management and Valorization
Use of Two Filtration Stages for Bauxite Residue . . . . . . . . . . . . . . . . . . . . . . . . 47
Roberto Seno Jr., Rodrigo Aparecido Moreno and Heri Cristine Nakamura
Environmental Friendly Transformation of the First and Oldest Alumina
Refinery in the World . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Laurent Bonel, Philippe Clerin and Laurent Guillaumont
Accelerating Bauxite Residue Remediation with Microbial Biotechnology. . . . . . 69
T. C. Santini, K. Warren, M. Raudsepp, N. Carter, D. Hamley, C. McCosker,
S. Couperthwaite, G. Southam, G. W. Tyson and L. A. Warren
Simulation and Experiment Study on Carbonization Process of Calcified Slag
with Different Ventilation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Guanting Liu, Liu Yan, Xiaolong Li, Weihua Sun, Zimu Zhang and Ting’an Zhang
An Ecological Approach to the Rehabilitation of Bauxite Residue. . . . . . . . . . . . 87
Elisa Di Carlo and Ronan Courtney
vii
viii Contents
Quantitative X-Ray Diffraction Study into Bauxite Residue
Mineralogical Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
John Vogrin, Harrison Hodge, Talitha Santini, Hong Peng and James Vaughan
Technospheric Mining of Rare Earth Elements and Refractory Metals
from Bauxite Residue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
John Anawati and Gisele Azimi
Migration of Iron, Aluminum and Alkali Metal Within Pre-reduced-Smelting
Separation of Bauxite Residue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Jian Pan, Siwei Li, Deqing Zhu, Jiwei Xu and Jianlei Chou
Part III Aluminum Alloys, Processing and Characterization: Aluminum
Alloy Development
Influence of Amine Additives on the Electrodeposition of Aluminum
from AlCl -Dimethyl Sulfone Electrolytes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3
S. A. Salman, Sangjae Kim, Kensuke Kuroda and Masazumi Okido
Determination of the Intermetallic a-Phase Crystal Structure in Aluminum
Alloys Solidified at Rapid Cooling Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Joseph Jankowski, Michael Kaufman, Amy Clarke, Krish Krishnamurthy
and Paul Wilson
Comparison of the Effects of B C and SiC Reinforcement in Al-Si Matrix
4
Alloys Produced via PM Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Yavuz Kaplan, Engin Tan, Hakan Ada and Sinan Aksöz
The Effects of Manganese (Mn) Addition and Laser Parameters
on the Microstructure and Surface Properties of Laser Deposited
Aluminium Based Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
O. S. Fatoba, S. A. Akinlabi and E. T. Akinlabi
Understanding the Role of Cu and Clustering on Strain Hardening
and Strain Rate Sensitivity of Al-Mg-Si-Cu Alloys. . . . . . . . . . . . . . . . . . . . . . . . 143
M.Langille,B.J.Diak,F.DeGeuser,G.Guiglionda,S.Meddeb,H.Zhao,B.Gault,
D. Raabe and A. Deschamps
Production of the AA2196-TiB MMCs via PM Technology . . . . . . . . . . . . . . . . 153
2
Engin Tan, Yavuz Kaplan, Hakan Ada and Sinan Aksöz
Retrogression-Reaging Behavior in Aluminum AA6013-T6 Sheet . . . . . . . . . . . . 159
Katherine E. Rader, Jon T. Carter, Louis G. Hector Jr. and Eric M. Taleff
Part IV Aluminum Alloys, Processing and Characterization: Microstructures
and Mechanical Properties of Aluminum Alloys
Advanced Characterization of the Cyclic Deformation and Damage Behavior
of Al-Si-Mg Cast Alloys Using Hysteresis Analysis and Alternating Current
Potential Drop Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Jochen Tenkamp, Kevin Bleicher, Sven Klute, Karin Chrzan, Alexander Koch
and Frank Walther
3-D Microstructural Distribution and Mechanical Analysis of HPDC
Hypereutectic Al-Si Alloys via X-Ray Tomography. . . . . . . . . . . . . . . . . . . . . . . 177
J. Wang and S. M. Xiong
Conditions for Retrogression Forming Aluminum AA7075-T6 Sheet. . . . . . . . . . 187
Katherine E. Rader, Matthew B. Schick, Jon T. Carter, Louis G. Hector Jr.
and Eric M. Taleff
Contents ix
Influence of Silicon Phase Particles on the Thermal Conductivity
of Al-Si Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Wenping Weng, Hiromi Nagaumi, Xiaodong Sheng, Weizhong Fan, Xiaocun Chen
and Xiaonan Wang
Influence of Microstructure Development on Mechanical Properties
of AlSi7MgCu Alloy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Davor Stanić, Zdenka Zovko Brodarac and Letian Li
Fabrication and Characterization of Open Cell Aluminum Foams
by Polymer Replication Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Ceren Yagsi and Ozgul Keles
Hot and Cold Rolling Behavior of AA5083 Aluminium Alloy . . . . . . . . . . . . . . . 217
S. Das, Shiwani Meena and R. Sarvesha
Part V Aluminum Alloys, Processing and Characterization: Behavior
of Casting Alloys
Study on Tensile Behavior of High Vacuum Die-Cast AlSiMgMn Alloys. . . . . . . 227
Haidong Zhao, Fei Liu, Chen Hu, Runsheng Yang and Fengzheng Sun
The Effect of Manganese and Strontium on Iron Intermetallics in Recycled
Al-7% Si Alloy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
James Mathew and Prakash Srirangam
The Effect of Thermo-Mechanical Processing on the Microstructure
and Mechanical Properties of Modified SIMA Treated Al-7Si Alloy . . . . . . . . . . 241
Chandan Choudhary, K. L. Sahoo and D. Mandal
Elevated-Temperature Low-Cycle Fatigue Behaviors of Al-Si 356 and 319
Foundry Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
S. Chen, K. Liu and X.-G. Chen
High Conductivity Al-Si-Mg Foundry Alloys—Market, Production,
Optimization and Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Takeshi Saito, Petter Åsholt, Leonhard Heusler, Thomas Balkenhol
and Kjetil R. Steen
Influence of Die Soldering on Die Erosion and Soldering Layer Between
Al Melts and Die in Al-Si-Fe Alloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Jong Min Kim, Jeong IL Youn and Young Jig Kim
Part VI Aluminum Alloys, Processing and Characterization:
Simulations and Studies of Processing
Coupled Fluid Flow and Heat Transfer Analysis of Ageing Heat Furnace . . . . . 279
Mircea Popa, Ioan Sava, Marin Petre, Cătălin Ducu, Sorin Moga,
Alexandra-Valerica Nicola and Constantin-Nicușor Drăghici
The Influence of the Distance Between the Plate and the Top Nozzles During
the Soft Quenching Process of the 6061 Aluminium Alloy Plates. . . . . . . . . . . . . 285
Gheorghe Dobra, Ioan Sava, Carmen Nicoleta Stănică, Marin Petre, Cătălin Ducu,
Sorin Moga and Cristian Nicușor Florescu
Numerical Investigation on the Motion of Free-Floating Crystals During DC
Casting of Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Qipeng Dong, Hiromi Nagaumi, Haitao Zhang, Tianpeng Qu and Jingkun Wang
x Contents
Numerical Modelling, Microstructural Evolution and Characterization
of Laser Cladded Al-Sn-Si Coatings on Ti-6Al-4V Alloy . . . . . . . . . . . . . . . . . . . 305
O. S. Fatoba, E. T. Akinlabi, S. A. Akinlabi and M. F. Erinosho
The Influence of Quenching and Stretching Process Conditions of Aluminium
Alloy Plates on Residual Stresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Gheorghe Dobra, Ioan Sava, Cristian Theodor Stanescu, Cătălin Ducu, Sorin Moga,
Decebal Dorin Bălășoiu and Dan Ion Păun
Characteristics of Surface Properties of Aluminum Flat Products Related
with Different Annealing Temperature and Cleaning Properties . . . . . . . . . . . . . 323
Emel Çalışkan, Sadık Kaan İpek, Ahmet Seisoğlu, Erdem Güler and Ali Ulus
Comparative Electrochemical and Intergranular Corrosion-Resistance Testing
of Wrought Aluminium Alloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Varužan Kevorkijan, Lucija Skledar, Marko Degiampietro, Irena Lesjak
and Teja Krumpak
NatureofGrainBoundaryPrecipitatesandStressCorrosionCrackingBehavior
in Al 7075 and 7079 Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Ramasis Goswami
Part VII Aluminum Alloys, Processing and Characterization:
Characterizations and Applications of Aluminum Alloys
Effect of Homogenization on Al-Fe-Si Centerline Segregation of Twin-Roll Cast
Aluminum Alloy AA 8011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Sooraj Patel and Jyoti Mukhopadhyay
Effect of Mg and Si Content in Aluminum Alloys on Friction Surfacing
Processing Behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Jonas Ehrich, Arne Roos and Stefanie Hanke
Mechanical Properties Evolution for 8xxx Foil Stock Materials by Alloy
Optimization—Literature Review and Experimental Research . . . . . . . . . . . . . . 365
Erik Santora, Josef Berneder, Florian Simetsberger and Martin Doberer
Effects of Zr Additions on Structure and Microhardness Evolution
of Eutectic Al-6Ni Alloy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Chanun Suwanpreecha, Phromphong Pandee, Ussadawut Patakham,
David C. Dunand and Chaowalit Limmaneevichitr
Microstructure and Mechanical Properties of an Al-Zr-Er High Temperature
Alloy Microalloyed with Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
A. R. Farkoosh, David Dunand and David N. Seidman
Effect of Nickel Foil Thickness on Microstructure and Microhardness
of Steel/Aluminium Alloy Dissimilar Laser Welding Joints . . . . . . . . . . . . . . . . . 385
Xiaonan Wang,XiamingChen,WenpingWeng,Hiromi Nagaumi andJingzheZhou
ResidualStressCharacterizationforMarineGearCasesinAs-CastandT5Heat
Treated Conditions with Application of Neutron Diffraction . . . . . . . . . . . . . . . . 395
Joshua Stroh and Dimitry Sediako
Microstructural and Dry Sliding Friction Studies of Aluminum Matrix
Composites Reinforced PKS Ash Developed via Friction Stir Processing. . . . . . . 401
R. S. Fono-Tamo, Esther Titilayo Akinlabi and Jen Tien-Chien
Contents xi
Part VIII Aluminum Alloys, Processing and Characterization: Casting
and Solidification
ComparisonofDiversifiedCastingMethodsonMechanicalandMicrostructural
Properties of 5754 Aluminum Alloy for Automotive Applications . . . . . . . . . . . . 409
Ali Ulaş Malcıoğlu, Çisem Doğan and Canan İnel
The Effect of High Speed Direct Chill Casting on Microstructure
and Mechanical Properties of Al-Mg-Si-Fe Alloy. . . . . . . . . . . . . . . . . . . . . . . . . 417
Haitao Zhang, Dongtao Wang, Jianzhong Cui, Hiromi Nagaumi and Weizhong Fan
Multi-Component High Pressure Die Casting (M-HPDC): Temperature
Influence on the Bond Strength of Metal-Plastic-Hybrids Manufactured
by M-HPDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Patrick Messer, Arthur Bulinger, Uwe Vroomen and Andreas Bührig-Polaczek
On Microstructures, Textures and Formability of AA6xxx Alloy Sheets
from DC and CC Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Xiyu Wen, Randall Bowers and Shridas Ningileri
PrototypingofaHighPressureDieCastAl-SiAlloyUsingPlasterMoldCasting
to Replicate Corresponding Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . 435
Toni Bogdanoff, Ehsan Ghassemali, Martin Riestra
and Salem Seifeddine
Reduction of Aluminium Ingot Cooling Time in DC Casting Process . . . . . . . . . 443
Josée Colbert and André Larouche
ImpactoftheMainCastingProcessParametersonFloatingCrystalsinAlAlloy
DC-Cast Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Mousa Javidani, Martin Fortier and Josée Colbert
Part IX Aluminum Alloys, Processing and Characterization: Poster
Session I—Development of Aluminum Alloy Processing
Effect of Cu Addition on the Microstructure, Mechanical and Thermal
Properties of a Piston Al-Si Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Suwaree Chankitmunkong, Dmitry G. Eskin and Chaowalit Limmaneevichitr
Effects of Sc and Zr Addition on Microstructure and Mechanical Properties
of Al-3Cu-2Li Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Yang Wang, Zheng Li and Ruizhi Wu
Effects on Microstructure Evolution of Al-9Si-0.3Mg Alloy by
Pyrometallurgically Produced Sr Master Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . 481
İbrahim Göksel Hizli and Derya Dışpınar
Microstructure Characterization and Properties of Cast Al-Si-Fe-Zn Alloys
with High Thermal Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
Chun Zou, Gu Zhong, Chu Qiu and Xinghui Gui
Effects of Ag on the Microstructures and Mechanical Properties
of Al-Mg Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
Haitao Zhang and Bo Zhang
Part X Aluminum Alloys, Processing and Characterization: Poster
Session II—Characterizations of Aluminum Alloys
The Preparation Methods and Application of Aluminum Foam . . . . . . . . . . . . . 501
Xia Duan, Zhiwei Dai, Rong Xu, Ronghui Mao and Binna Song