Conference proceeding
Preventative metal treatment through advanced melting
SHAPING CASTING: THE JOHN CAMPBELL SYMPOSIUM, pp.31-40
01 Jan 2005
Featured in Collection : UN Sustainable Development Goals @ Drexel
Abstract
Conventional aluminum melting results in a deterioration of metal quality due to in-situ melt oxidation, exposure of molten metal to products of combustion, and from separation of the oxide envelope that surrounds the charge media. Peak melt surface temperatures in reverberatory melting can exceed 2000 degrees F. This results in an increase in oxidation rate by a factor of 64, compared to a bulk temperature of 1350 degrees F. Additionally, the dew point of typical products of combustion is equivalent to saturated air at 75 degrees F, further exacerbating oxidation and establishing a high partial pressure of monatomic hydrogen. Such melting processes depend on downstream remedial metal treatment for removal of consequential inclusions and dissolved 14 hydrogen. An advanced melting process has been developed under the support of the US Department of Energy Office of Industrial Technology, with the objectives of minimizing specific melting energy and melt loss. This has been accomplished. In addition, it has been found that dissolved hydrogen level, are maintained at exceptionally low values during melting, with a freedom from visible supernatant oxides, using ingot charge material. Importantly, the maximum temperature that the melt is exposed to is 40 degrees F higher than bulk temperature, thus minimizing melt oxidation. Further, the melt is not exposed to products of combustion that results in a further reduction of oxides and dissolved hydrogen. The melting process also includes an integral flotation device to separate surface oxides and remove any dissolved hydrogen introduced by the charge media. Metal treatment has now become implicitly preventative through the use of advanced melting (Isothermal Melting). This paper considers the implication of various melting parameters on molten metal quality, and provides a perspective on cause-effect relationship through phenomenological and quantitative analysis. Source to charge heat transfer and intra-charge secondary heat transfer is considered in the context of impact on metal quality. This analysis clearly demonstrates the detrimental impact that conventional melting methods can have on metal quality. Preventative metal treatment, through advanced melting methods, represents a paradigm shift in aluminum melt preparation methodology.
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Details
- Title
- Preventative metal treatment through advanced melting
- Creators
- C E EckertT MeyerM KinoszR Mutharasan
- Contributors
- M Tiryakioglu (Editor)P N Crepeau (Editor)
- Publication Details
- SHAPING CASTING: THE JOHN CAMPBELL SYMPOSIUM, pp.31-40
- Conference
- SHAPING CASTING: THE JOHN CAMPBELL SYMPOSIUM
- Publisher
- Minerals, Metals & Materials Soc
- Number of pages
- 10
- Resource Type
- Conference proceeding
- Language
- English
- Academic Unit
- Chemical and Biological Engineering
- Identifiers
- 991019174011304721
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InCites Highlights
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- Web of Science research areas
- Metallurgy & Metallurgical Engineering