Melt Conditioned Direct Chill (MC-DC) Casting of AA-6111 Aluminium Alloy Formulated from Incinerator Bottom Ash (IBA)

Al-Helal, Kawther; Lazaro-Nebreda, Jaime; Patel, J. S.; Scamans, G. M.; Fan, Z.

doi:10.3390/recycling4030037

Cited by 9 publications

(3 citation statements)

References 16 publications

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“…This rotor-stator type technology has been tested as a multi-purpose device for degassing, grain refinement, metal matrix composite casting and industrial casting processes such as direct chill casting and twin roll casting. 10 Because of its advantages in chemical and thermal homogenization, HSMC technology can be used for microstructure control, especially morphological control of Fe-rich intermetallic phases. By dispersing naturally existing oxide particles and enhancing their wettability in the melt, they can act as heterogeneous nuclei during solidification.…”

Section: Introductionmentioning

confidence: 99%

Fe-Rich Intermetallic Formation and Mechanical Properties of Recycled AA6111 Alloy Strips Produced by Melt Conditioning Twin Roll Casting

Al-Helal

Patel

Fan

2020

JOM

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The impact of high shear melt conditioning on the morphology and distribution of Fe intermetallic compounds was investigated in the processing of recycled AA6111 alloy by the twin roll casting process. The optical and scanning electron microscope (SEM) micrograph studies were carried out on twin roll casting (TRC) and melt conditioning twin roll casting (MC-TRC) samples. The microstructural analysis showed fine and uniformly distributed Fe-rich intermetallic phases for MC-TRC strips compared with the TRC strips. There was a significant improvement in the mechanical properties of MC-TRC strips after applying melt conditioning. The as-cast MC-TRC samples showed 18.7%, 19.2% and 9.8% increases in elongation, yield strength and ultimate tensile strength, respectively, in the longitudinal direction, while in the transverse section, the MC-TRC samples showed 32.3%, 2.2% and 3.8% increases in elongation, yield strength and ultimate tensile strength, respectively.

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Section: Introductionmentioning

confidence: 99%

Fe-Rich Intermetallic Formation and Mechanical Properties of Recycled AA6111 Alloy Strips Produced by Melt Conditioning Twin Roll Casting

Al-Helal

Patel

Fan

2020

JOM

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“…The α-Al15 (Fe, Mn)3Si2 intermetallics in cast Al-Mg-Si-Mn alloys have body-centered cubic structure and can appear in different morphologies, such as star-like, hexagonal, or dendritic crystal, depending on Mn/Fe ratio. Compact shape is preferable to provide acceptable tensile properties of the final product [20,21]. The β-AlFeSi phase exhibits a plate-like morphology that can lead to local crack initiation and induces surface defects on the final cast material.…”

Section: Wt% Cu Mg Si Fe Mn Ni Zn Pb Sn Ti Cr Al Zorba Ingotmentioning

confidence: 99%

High-Shear De-Gassing and De-Ironing of an Aluminum Casting Alloy Made Directly from Aluminum End-of-Life Vehicle Scrap

et al. 2021

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High-shear melt conditioning (HSMC) technology was used for degassing and de-ironing of an aluminum alloy recovered from the Zorba cast fraction of the non-ferrous scrap from shredded end-of-life vehicles. The results showed that the recovery of aluminum alloys from the Zorba cast fraction was more than 80%. High-shear melt conditioning improved the degassing process during melt treatment in comparison with the adding of degassing tablets. The efficiency of the de-ironing process using HSMC increased by up to 24% after, increasing the Mn content to 0.8% in the melt. Adding Mn to Zorba melt enhanced the de-ironing process and eliminated the formation of β-AlFeSi intermetallic particles, which have a detrimental effect on both the mechanical and corrosion properties of the alloy.

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“…The main target of this research has been the extraction of metallic fractions from waste and scrap sources to facilitate its reuse in industrial applications. Recycling of Al-alloys has an economic and environmental benefit as the processing of secondary aluminum from recycled resources consumes 2.8 kWh/kg while the production of the primary Al requires about 45 kWh/kg of energy [1].…”

Section: Introductionmentioning

confidence: 99%

Melt Conditioned Direct Chill (MC-DC) Casting and Extrusion of AA5754 Aluminium Alloy Formulated from Recycled Taint Tabor Scrap

et al. 2020

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The melt conditioned direct chill (MC-DC) casting process has been used to produce billets and extruded planks of AA5754 alloy formulated from 100% recycled Taint Tabor scrap aluminum. The billets were homogenized and then extruded into flat planks. Optical metallography of the MC-DC cast billets showed equiaxed refined grains in comparison to conventional direct chill (DC) cast and direct chill grain refined (DC-GR) cast billets formulated from the same Taint Tabor scrap. Microstructural evaluation of the extruded planks showed extensive peripheral coarse grain (PCG) for the DC, DC-GR and MC-DC cast planks. The 2 mm and 1 mm MC-DC cast planks produced after cold rolling and heat treatment showed a fully recrystallized microstructure at 380 °C and 300 °C for 10 min respectively with an improvement in mechanical properties over DC-GR cast and similarly processed planks. The as-extruded MC-DC cast planks tensile tested in the transverse direction showed 34% elongation and 213 MPa ultimate tensile strength. These tensile results showed 5.8% higher elongation and 1.2% higher ultimate tensile strength compared with the DC-GR planks after applying high shear melt conditioning.

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Melt Conditioned Direct Chill (MC-DC) Casting of AA-6111 Aluminium Alloy Formulated from Incinerator Bottom Ash (IBA)

Cited by 9 publications

References 16 publications

Fe-Rich Intermetallic Formation and Mechanical Properties of Recycled AA6111 Alloy Strips Produced by Melt Conditioning Twin Roll Casting

Fe-Rich Intermetallic Formation and Mechanical Properties of Recycled AA6111 Alloy Strips Produced by Melt Conditioning Twin Roll Casting

High-Shear De-Gassing and De-Ironing of an Aluminum Casting Alloy Made Directly from Aluminum End-of-Life Vehicle Scrap

Melt Conditioned Direct Chill (MC-DC) Casting and Extrusion of AA5754 Aluminium Alloy Formulated from Recycled Taint Tabor Scrap

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