Selected, peer reviewed papers from the international conference, organised by the CAST CRC, on behalf of the aluminium industry. It was held from 13 – 16 September, 2009 on the Gold Coast, Queensland, Australia

Aluminium Cast House Technology: Eighth Australasian Conference

Surface Tension Forces in Gas Pressurized VDC Casting 195 P.W. Baker and J.F. Grandfield A Total Business Cost Approach 205 Brett T. Aisen and Lachlan J. Massey Optimising Pit Recoveries on 6XXX Extrusion Billet 213 David Latter CAST HOUSE SAFETY Casthouse Safety in 2001 223 John E. Jacoby Improving Safety Performance in an Aluminium Casthouse 233 Barry Taylor CONTINUOUS CASTING An Assessment of the Design of a Gautschi Mould Using Finite Element Analysis 247 Philip Clausen and Geoff Whan Horizontal Direct Chilled (HDC) Casting Technology for Aluminium and Requirements to Metal Cleanliness 253 Franz Niedermair Aspects of Heat Transfer During Production of Remelt Ingot Using Chain Casters 263 J.F. Grandfield, T.T. Nguyen, G. Redden and J.A. Taylor Twin-Belt Casting Technology Update (abstract only) 273 W. Szczypiorski Improving Horizontal Direct Chill Casting 275 Ali A. Dawood HEAT TREATMENT Effect of Homogenisation Temperature and Time on Billet Microstructure and Extruded Properties of Alloy 6061 287 M.J. Couper, M. Cooksey and B. Rinderer Effect of Homogenization on Small Diameter Billets - An Extruder's Experience 297 Hua-Tian Tan and Callistus Hing-Chih Lee Control of Wire Rod Physical Properties Like Ultimate Tensile Strength and Elongation by Close Monitoring of Rolling Energy Input 305 S.D. Chouharia, P.S. Gambhir and M. Dash MAGNESIUM CASTING Aluminium and Magnesium: Equipment and Process Comparison 319 Paul McGlade and Nigel Ricketts RECYCLING Recycling of Contaminated Aluminium Scrap - A Responsible Approach 331 Richard J. Evans REFRACTORY Cast House Refractories - Selection & Evaluation 343 Robert C. Flann PROCESS CONTROL Advances in On-Site Alloy Analysis and Identification (abstract only) 357 Keith Watson Automation Primer for Supervisors and Operators 359 Peter R. Whiteley Author

ONE OF A FOUR-BOOK COLLECTION SPOTLIGHTING CLASSIC ARTICLES Original research findings and reviews spanning all aspectsof the science and technology of casting Since 1971, The Minerals, Metals & Materials Society haspublished the Light Metals proceedings. Highlighting some ofthe most important findings and insights reported over the pastfour decades, this volume features the best original researchpapers and reviews on cast shop science and technology for aluminumproduction published in Light Metals from 1971 to 2011. Papers have been divided into ten subject sections for ease ofaccess. Each section has a brief introduction and a list ofrecommended articles for researchers interested in exploring eachsubject in greater depth. Only 12 percent of the cast shop science and technology papersever published in Light Metals were chosen for this volume.Selection was based on a rigorous review process. Among the papers,readers will find landmark original research findings and expertreviews summarizing current thinking on key topics at the time ofpublication. From basic research to industry standards to advancedapplications, the articles published in this volume collectivelyrepresent a complete overview of cast shop science and technology,supporting the work of students, researchers, and engineers aroundthe world.

Aluminium is a well established modern lightweight engineering and functional material with a unique combination of specific properties like strengh, formability, durability, conductivity, corrosion resistance, etc. It is present in many intelligent solutions in established markets like building, transport, packaging, printing, and many others, in our fast moving modern society. The various aluminium alloys can be processed quite efficiently in large quantities by conventional fabrication routes, as well as in special sophisticated forms and material combinations for highly innovative high–tec solutions and applications. This book contains latest information about all these aspects in form of the refereed papers of the II th International Conference on Aluminium Alloys "ICAA", where world–wide experts from academia and engineers from industry present latest results and new ideas in fundamental as well as applied research. Since 22 years the ICAA series provides scientists and engineers with a complete overview over the latest scientific and technological developments, featuring profound technology–based overviews and new innovative perspectives. This book is a reference for the scientific community as well as for the aluminium industry working on aluminium alloy development, processing and application issues. It gives a global perspective on the current focus of international research with emphasis on in–depth understanding of specific properties and applications of conventional and advanced aluminium alloys.

No pyrometallurgical smelter can operate without some form of tapping system. It is the one thing all smelters have in common. This collection discusses this meeting point of the science, technology, and skill involved in this process. The tap-hole design process includes a set of design criteria, which need to be revised as the results of laboratory, computational fluid dynamics (CFD), and time-and-motion studies become available. The tap-hole life cycle is considered in this volume, with authors addressing the requirements for installation and operability as well as for maintenance. Matters such as online monitoring of the tap-hole wear, handling of liquid products, and extraction of fumes are all discussed. Although much has been done to make the tapping process as automatic as possible, tapping of smelters cannot be done without labor. Tap floor operators work in harsh environments where safety is of utmost importance. Selection of suitable personnel and intensive training is required and is discussed in this collection.

Written by leading experts in their respective fields, Solidification and Casting provides a comprehensive review of topics fundamental to metallurgy and materials science as well as indicates recent trends. From an industrial perspective, the book begins with chapters on the casting techniques most commonly used in industry today. It then d