Abstract
The melt conditioned direct chill (MC-DC) casting process has been used for the production of billets of AA-6111 alloy formulated from recycled aluminium derived from incinerator bottom ash (IBA). The billets were homogenised and then extruded into planks. Optical metallography of the MC-DC billets showed equiaxed refined grains in comparison to DC and grain refined (DC-GR) billets formulated from the same scrap source. Microstructure evaluation for the extruded planks showed a less extensive peripheral coarse grain (PCG) for the MC-DC sample.
Highlights
Incineration of waste has been used for many years, and it has become a more and more popular process worldwide as an alternative to landfilling
The high shear melt conditioning process has been applied for the direct chill (DC) casting of an aluminium alloy formulated from the recovered aluminium fraction from incinerator bottom ash
Milver Metals supplied 300 kg of their lion grade (DRYINC© LION +10 mm) aluminium recovered from incinerator bottom ash (IBA)
Summary
Incineration of waste has been used for many years, and it has become a more and more popular process worldwide as an alternative to landfilling. The formation of coarse grain with non-uniform microstructure, chemical segregation, porosity and hot tearing are the most common problems encountered in direct chill casting These defects can result in unacceptable mechanical properties of the final products [9]. For in-situ microstructural control and to overcome solidification defects, melt conditioned direct chill (MC-DC) casting technology has been developed at BCAST Rotor-stator based shearing has been used successfully for the grain refinement, degassing, metal-matrix composite casting, and can be viewed as a multi-purpose device that can be used for any industrial casting processes from direct chill casting to twin roll casting [13]. The high shear melt conditioning process has been applied for the direct chill (DC) casting of an aluminium alloy formulated from the recovered aluminium fraction from incinerator bottom ash. Reusing recycled aluminium for the formulation of alloys for industrial applications in the UK provides both significant CO2 savings (less or no primary metal) and major cost savings
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