Light Metals 2023

The Light Metals symposia at the TMS Annual Meeting & Exhibition present the most recent developments, discoveries, and practices in primary aluminum science and technology. The annual Light Metals volume has become the definitive reference in the field of aluminum production and related light metal technologies. The 2023 collection includes contributions from the following symposia: · 60 Years of Taking Aluminum Smelting Research and Development from New Zealand to the World: An LMD Symposium in Honor of Barry J. Welch · Alumina & Bauxite · Aluminium Industry Emissions Measurement, Reporting & Reduction · Aluminium Waste Management & Utilisation · Aluminum Alloys, Characterization and Processing · Aluminum Reduction Technology · Cast Shop Technology · Electrode Technology for Aluminum Production · Scandium Extraction and Use in Aluminum Alloys 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