Hydro Aluminium Research Articles

Impact of long-term liming on sandy soil phosphorus sorption properties

Abstract The static fertilisation experiment conducted in Skierniewice (Central Poland) since 1923 investigates the effect of mineral fertilisation with lime (CaNPK) or without lime (NPK) on the accumulation and release of phosphorus in reference to phosphorus sorption properties in the sandy soil profile. In the case of application of same doses of mineral fertilisers, the content of total phosphorus was higher in NPK than CaNPK soil. Parameters related to sorption capacity and bonding energy from Langmuir and Freundlich model of P sorption were significantly lower in CaNPK than NPK soil profile. This was particularly caused by a lower content of poorly crystallised hydro(oxide) aluminium and iron forms in CaNPK than NPK soil. Higher content of oxide-extractable and bioavailable phosphorus extracted with double lactate solution, dissolved reactive phosphorus in water solution as well as degree of phosphorus saturation in the CaNPK soil profile suggests higher mobility and possibility of occurrence of losses of phosphorus from the profile of limed soil than from acidified soil. Therefore, management of phosphate fertilizers on permanently limed sandy soils requires the optimisation of phosphorus doses to a greater degree corresponding to the actual take-off of the element with crop. An additional finding of the study was evidence of the possibility of re-estimating contents of bioavailable phosphorus and, as a consequence, the degree of phosphorus saturation with Mehlich3 method in strongly acid soil receiving P mineral fertilisers, which can make it difficult to use the test for fertiliser recommendation.

Alternating Current Phosphoric Acid Etching of Aluminium

Alkaline etching is a common pretreatment process for aluminium alloys before anodising or application of organic coating. Removal of the mill-finish surface layer is performed by a simple dipping process, which also gives the matt finish normally required for aesthetic appearance before conventional anodising. Major disadvantage of alkaline treatment is the surface enrichment of the alloying and trace elements more noble than the aluminium substrate by dealloying. This may reduce corrosion resistance and deteriorate the optical properties of the surface. The purpose of this work is to investigate fluoride-free acid etching for aluminium alloys as an alternative to alkaline etching to prevent or reduce heavy metal enrichment, while achieving matt appearance. Alternating current is applied to increase the rate of etching as the dissolution rate of aluminium in acid solutions is slower than in alkaline solutions. The principle is based on anodic oxidation of the heavy metal components, as well as aluminium, during the anodic cycle and removal of the corrosion products and concentration gradients by hydrogen evolution during the cathodic cycle. The materials used for this study were hot-rolled aluminium alloy AA3105 (Si 0.3%, Fe 0.6%, Cu 0.1%, Mn 0.7%, Mg 0.3%) and extrusion AA6060 (Si 0.4%, Fe 0.2%, Cu 0.01%, Mn 0.02%, Mg 0.5%). Phosphoric acid was used as the etching electrolyte. Consumption of aluminium was calculated from weight loss. Appearance was analysed visually and by gloss measurements. SEM was used to study surface microstructure and morphology. Aluminium oxidation rate increased with increasing temperature, current density, electrolyte concentration and etching time. Intermetallic Al-Mn-Fe-Si particles were selectively and rapidly removed by 1 min etching at 80⁰C. In contrast, particles were exposed and remained on the surface by alkaline etching. Matt appearance without visible defects was achieved after 10 min etching at 80⁰C. Presence of phosphorus in thin oxide film formed was determined by glow discharge optical emission spectroscopy (GD-OES). Advantages foreseen of acid-based AC pretreatment over alkaline dip processes in practice are suitability for in-line coil processing, superfluity of the desmutting step, low gloss achievable with reduced metal loss, improved corrosion resistance and adhesion properties. Acknowledgements This work was supported by Hydro Aluminium and The Research Council of Norway.

The Effect of Varying Mixing Temperatures and Baking Level on the Quality of Pilot Scale Anodes—A Factorial Design Analysis

Identifying optimum anode baking level and mixing temperature are important when producing high quality anodes. The effect of varying mixing temperature and baking level were investigated in terms of the resulting apparent anode density, specific electrical resistivity (SER), air permeability, coefficient of thermal expansion (CTE), air reactivity, and CO2 reactivity. Six pilot-scale anodes were prepared at Hydro Aluminium using a single source petroleum coke and <2 mm coke fractions. A coal tar pitch was used with Mettler softening point of 119.1 °C. The aggregate was mixed at 150 °C or 210 °C and baked to a low, medium, or high baking level. A 22 full-factorial design analysis was performed to determine the response of the analyzed properties to the applied mixing and baking temperature. Apparent density, SER, and air permeability were found to be highly dependent on mixing temperature. Apparent density and SER were also slightly affected by baking level. CTE was found to be independent of both baking level and mixing temperature. Air reactivity was found to be mainly dependent on baking level, while CO2 reactivity was dependent on both mixing temperature and baking level.

English and Indian legal perspective on third-party disclosure in arbitration: it is time to assimilate third party into the family of arbitration

Arbitration is recognized as a trustworthy and reliable way of rendering justice. But, there may be instances in which the cases are not decided on sufficiently required amount of evidence and this will tarnish the reputation of arbitration. This is the case when the evidence required in arbitration proceedings is in the possession of a non-party because in this case, if the party to the arbitration cannot narrate the documents with high specification, the English courts will not only refuse to lend its support for disclosure from the third party, but will also express its inability to fulfil the requests made by arbitral tribunal as well as other courts for such disclosure. The gravity of the situation becomes patent in light of the fact that in most of the cases, the party to arbitration is unable to define the documents in the possession of the third party with required particularity and can only describe them broadly with reference to some transaction or event. It becomes imperative to establish with clarity that the arbitrator has the power under English law to order the third party and to suggest guidelines for it to use while deciding the application for third-party disclosure orders. The situation is not much better in India. Despite the clarity in India's legal regime on the issue of third-party disclosure, the law needs improvements. Arbitration Act 1996 (UK), ss 2, 43 and 44 Indian Arbitration and Conciliation Act (1996) English Civil Procedure Rules (1998) English Evidence (Proceedings in Other Jurisdictions) Act (1975) Hague Convention on the Taking of Evidence Abroad in Civil or Commercial Matters (1970) Bharat Aluminium Co. v Kaiser Aluminium Technical Service , Inc, Supreme Court of India (2005) Tajik Aluminium Plant v Hydro Aluminium AS and Ors , England and Wales Court of Appeal (2005) BNP Paribas & Ors v Deloitte & Touche LLP , High Court of Justice of England and Wales (2003) Bhatia International v Bulk Trading BA , Supreme Court of India (2002)

Designing superplastic forming process of a developmental AA5456 using pneumatic bulge test experiments and FE-simulation

Relatively low tooling costs, high design complexity coupled with low forming speeds make the superplastic sheet metal forming process attractive, especially for smaller lot sizes. Due to the relatively small lot size, the effort and budget for designing superplastic forming processes is usually limited (Kappes and Liewald in J Mater Sci Eng B1:472–478, 2011). For this reason the tool design and corresponding pressure profiles in superplastic forming processes are often based on trial and error (Franchitti et al. in 11th international Esaform conference on material forming, 2008; Barnes in J Mater Eng Perform 4:440–454, 2007). Consequently a process chain should be established to design superplastic forming processes accurately and efficiently. This paper deals with the process chain to form an aluminium part superplastically. At the beginning of the process chain, there is a new, developmental aluminium alloy sheet (AA5456, s0 = 1.6 mm) designed for superplastic forming supplied by Hydro Aluminium Rolled Products GmbH. The relevant material parameters of this sheet are then determined via pneumatic bulge testing with and without in situ measurement of strains. Using these experimentally determined parameters superplastic forming process can be simulated by FE modelling (PAM-STAMP 2G). Due to in situ measurement of strains during pneumatic bulging, the comparison of experiment and FE-simulation results over the whole pneumatic bulging process could be done. This comparison shows good correlation for the observed conditions. Furthermore a cylindrical cup was simulated, evaluated via determined isobar Superplastic Forming Limit Curve (at fracture) and finally formed by pneumatic bulging. Material characterisation of the bottom of this cup showed that excessive cavitation was observed as a result of the iron-silicon particles. Superplastic forming of a bracket usually formed out of AA5083 was also simulated using material parameters of AA5456. The simulation was able to show that this part is not able to be manufactured out of AA5456 under these forming conditions, which was confirmed by forming trials performed at ALU-SPF AG.

Sustainability, climate change, and greenhouse gas emissions reduction: Responsibility, key challenges, and opportunities for the aluminum industry

This article contains the transcript from a panel discussion held at the TMS 2008 Annual Meeting on environmental challenges, responsibilities, and opportunities for the primary aluminum industry. A special event at the TMS Annual Meeting in New Orleans in March 2008 was a plenary session sponsored by the TMS Light Metals Division. The purpose was, as given in the title of this article, to discuss “Sustainability, Climate Change, and Greenhouse Gas Emissions Reduction: Responsibility, Key Challenges, and Opportunities for the Aluminum Industry.” The participants came from key leadership of the primary metals groups of the world’s largest aluminum companies; Halvor Kvande from Hydro Aluminium was the program organizer. This session attracted a high number of attendees, with 250–300 present in the audience, and it was among the best-attended events of the TMS 2008 Annual Meeting. The speaker presentations in this session were followed by a panel discussion with the opportunity for the audience to ask questions and provide their comments to the panelists. Because a recap of the session’s roundtable discussion will be of interest to both the attendees and to the community of TMS, a transcript of the discussion is given here. The transcript has been edited slightly to improve its readability, but without altering the content of the questions and answers. Moderating the discussion was James Evans, professor of metallurgy, Sustainability, Climate Change, and Greenhouse Gas Emissions Reduction: Responsibility, Key Challenges, and Opportunities for the Aluminum Industry

AkzoNobel in consortium for research into making chemicals from algae

Many firms are embracing the environmental challenge by implementing incremental changes in their production systems. Nevertheless, radical innovations are also important for achieving sustainability goals. This paper focuses on the technology strategies leading to radical innovations in aluminium production systems. It conceptualizes the radical nature of innovations, and develops a framework for analysing the technology strategies of two aluminium smelters, Aluminium Delfzijl in The Netherlands and Hydro Aluminium in Norway. From the analysis, policy instruments are proposed for a transition towards sustainable aluminium production.

Aluminium cylinder crankcase for V6-diesel engines from Daimler-Chrysler

Based on many years experience in the production of cylinder crankcases, which have been supplied to customers in the European and North American markets since 1994, Hydro Aluminium Alucast GmbH, Dillingen, is now the partner of Daimler-Chrysler for the manufacture of cylinder crankcases for a new V6 diesel engine, volume-produced using the CPS-core package system. The engine replaces the five and six cylinder in-line engines previously used in all Mercedes-Benz models, from the C- to the S-Class. The new power unit, which will also be used in Chrysler vehicles, represents a milestone in the compact lightweight construction of diesel engines.

New polymorph friction-stir-welded aluminium liquid petroleum gas tank

This paper presents the development of the new flexible polymorph liquid-petrol-gas (LPG) tank. Research has been carried out in close collaboration between Renault (France), Hydro Aluminium (Norway), and Witte van Moort (The Netherlands). The term polymorph is used here to describe a complex shape built from different simple forms. This type of tank is specifically designed to be integrated under a vehicle floor and, owing to its flexibility in design, it enables an increased range compared with conventional steel tanks. The new LPG tank is made from aluminium extruded sections, longitudinally joined by applying the friction-stir-welding process and aluminium end closures made by stamping. This allows good mechanical properties and a significant mass reduction.

The role of technology in the global primary aluminum industry today and in the future

A special event at the 2005 TMS Annual Meeting in San Francisco in February 2005 was a plenary session sponsored by the TMS Light Metals Division, the TMS Aluminum Committee, and the Aluminum Association. The purpose was, as stated in the symposium title, to discuss “The role of technology in the global primary aluminum industry, both today and in the future.” The participants were leaders from the primary metals groups of the world’s largest aluminum companies. This global industry session attracted a high number of attendees, with 500 or more leaving standing room only, and it was the best-attended event of the 2005 TMS Annual Meeting. The speaker presentations were followed by a panel discussion with the opportunity for the audience to ask questions and provide their comments to the presenters. While the presentations were generally off-the-record, with neither a proceedings nor distribution of the PowerPoint slides, the authors feel that a recap of the session’s roundtable discussion would be of interest to both the attendees and to the community of TMS. Thus, the transcript of the discussion is given here. The transcript has been edited slightly to improve its readability, but the content of the questions and answers was not altered. The participants were: Cynthia Carroll, president and chief executive offi cer of Alcan Primary Metal Group, Canada; Truls Gautesen, president of Hydro Aluminium Primary Metal, Norway; Wayne Hale, senior vice president of operations, Sual Holding, Russia; Xiangmin Liu, vice president, Aluminum Company of China Limited (Chalco), China; Valery Matvienko, deputy general director, Aluminium Business, Rusal, Russia; Bernt Reitan, executive vice The Role of Technology in the Global Primary Aluminum Industry Today and in the Future

Technology strategies for sustainable metals production systems: a case study of primary aluminium production in The Netherlands and Norway

Many firms are embracing the environmental challenge by implementing incremental changes in their production systems. Nevertheless, radical innovations are also important for achieving sustainability goals. This paper focuses on the technology strategies leading to radical innovations in aluminium production systems. It conceptualizes the radical nature of innovations, and develops a framework for analysing the technology strategies of two aluminium smelters, Aluminium Delfzijl in The Netherlands and Hydro Aluminium in Norway. From the analysis, policy instruments are proposed for a transition towards sustainable aluminium production.

Inertia effects in uniaxial dynamic compression of a closed cell aluminium alloy foam

The dynamic compressive characteristics of a closed cell aluminium alloy foam (manufactured by Hydro Aluminium AS, Norway) have been studied experimentally by using a direct impact technique for a range of velocities up to 210 m s–1. Experimental data on the dynamic initial crushing and plateau stresses are compared for two average cell sizes of approximately 4 and 14 mm. The data reveal significant dynamic enhancements of the initial crushing strengths throughout the range of velocities used. The dynamic plateau stresses are insensitive to impact velocity below the values of 50 and 100 m s–1 for the large and small cell foams respectively. Beyond a critical velocity value of ~ 100 m s–1, the crushing wave front propagates through the foam with shock like characteristics. The inertia effects associated with the dynamic localisation of crushing and the microinertia of the cell wall/edge material on the dynamic strength enhancement are discussed. A one-dimensional shock model based on a rate independent, rigid, perfectly plastic locking idealisation of the nominal stress–strain curve for foams is employed to provide a first order understanding of the various parameters involved in the crushing process. The results of the analyses are seen to predict well the dynamic strength enhancements that are measured experimentally. The sources of discrepancies are highlighted and discussed, as are the limitations and shortcomings of the shock model.

Modeling and simulation of an anode carbon baking furnace

The anode temperature profile in a Hydro Aluminium baking furnace is obtained by solving the three dimensional heat equation. The main heat transfer and chemical processes are taken into account. Due to symmetry, one half of a pit is modeled. Along the gas path, submodels are derived for the under-pit area, pit area and under-lid area. For the gas flow, a stationary model is derived, whereas the heat equations are dynamically solved. The numerical model is derived from the control volume formulation

Does Norwegian industry have different environmental considerations at home than in developing countries?

This article deals with some of the few Norwegian TNCs which are involved in industrial activity in developing countries; Elkem's involvement in carbon production in Brazil, Dyno's glue production in Singapore and Hydro Aluminium's mining and refining of bauxite into alumina in Jamaica. In these industrial cases the environmental issue is probably not a significant factor causing the location of these corporate activities abroad. However, all the industrial processes create environmental hazards. Some of these hazards are managed differently from similar environmental impacts in Norway. This is obvious in spite of the fact that the TNCs referred to in this article all have publicized and signed commitments to have identical environmental standards at home and abroad.

Rapid solidification of aluminium by the Hydro Aluminium process

A proprietary method to produce low-cost particular rapid solidified (RS) material for subsequent precompaction and extrusion is described. Production facilities for both granular production and precompaction/extrusion have been developed and are now available for test runs. At Hydro Aluminium R & D Centre, Sunndalsøra, a pilot plant for production of RS needles with annual capacity of up to 200 tons is operable. Cooling rates averaging as high as 10 3–4 K/s can be achieved, and recent work on alloy development offers improved properties with respect to fatigue- and mechanical-strength and rigidity at both room- and elevated temperatures. These property profiles and corresponding total production process cost estimates for RS aluminium show promise for future exploitations both in the low-cost high-volume automotive and the nonautomotive market.