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direct chill ingot casting

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Published: 01 December 2004
Fig. 18 Transverse cross section of 5052 as-cast direct chill rolling ingot—corner of 64 × 152 cm (25 × 60 in.) slice. Width shown is 13.5 cm (5.3 in.). Etchant: mixed acid More
Image
Published: 01 December 2004
Fig. 11 Feather crystals in an alloy 3003 ingot cast by the direct-chill semicontinuous process. Growth twins in the crystals. Polarized light. Barker's reagent. Original magnification 50×. Source: Ref 4 More
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006485
EISBN: 978-1-62708-207-5
..., and particle ingot and powder. It describes the molten metal processing and ingot casting process in terms of open-mold casting and direct chill process. The article examines the continuous processes that provide commercial alternatives to conventional ingot casting. It reviews the postsolidification processes...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005286
EISBN: 978-1-62708-187-0
... by downstream manufacturing processes. This article starts with a review of the different forms of ingot and the molten-metal processing techniques involved in ingot casting. It then describes the open-mold casting and direct chill (DC) ingot casting processes. The process variations and solidification...
Series: ASM Handbook
Volume: 9
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.hb.v09.a0003727
EISBN: 978-1-62708-177-1
... ). Fig. 10 Longitudinal section through a 75 mm (3 in.) diam alloy 1100 ingot, direct-chill cast without grain refiner. Center of section contains fan-shaped zones of feather crystals. Tucker's reagent. Actual size. Source: Ref 4 Fig. 11 Feather crystals in an alloy 3003 ingot cast...
Image
Published: 01 December 2004
Fig. 35 Bleed bands normal to the casting direction on the surface of a direct-chill semicontinuous cast ingot of alloy 3003. Unpolished. One-fourth actual size. Source: Ref 25 More
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005216
EISBN: 978-1-62708-187-0
... pressure. This is termed exudation and results in even higher positive macrosegregation at the surface. In direct chill casting of aluminum ingots, this macrosegregation can be so severe that the exuded surface layer must later be removed by scalping the ingot. Fig. 4 Inverse segregation in an A1...
Image
Published: 01 December 2004
Fig. 31 Variation in copper concentration across a 600 mm (24 in.) thick direct-chill semicontinuous cast ingot of 2124 alloy. Source: Ref 4 More
Image
Published: 01 December 2004
Fig. 34 Section through an alloy 7075 ingot (edge at right), direct-chill semicontinuous cast. Etchant: dilute Keller's reagent. Original magnification 250×. Source: Ref 4 More
Image
Published: 01 December 2004
Fig. 38 Cross section through a 75 mm (3 in.) diam alloy 1100 ingot, direct-chill cast. Center cracks at arrow. Etchant: Tucker's reagent. Actual size. Source: Ref 4 More
Image
Published: 01 December 2004
Fig. 9 Cross section of a 150 mm (6 in.) diam ingot of alloy 6063 direct-chill semicontinuous cast. (a) Without grain refiner. (b) With grain refiner. Tucker's reagent. Actual size. Source: Ref 4 More
Image
Published: 01 December 2004
Fig. 36 Section through a 305 mm (12 in.) diam alloy 2024 ingot, direct-chill semicontinuous cast. Coarse dendrites and copper and magnesium constituents agglomeration in the surface layer. As-polished. Original magnification 25×. Source: Ref 4 More
Image
Published: 01 December 2004
Fig. 10 Longitudinal section through a 75 mm (3 in.) diam alloy 1100 ingot, direct-chill cast without grain refiner. Center of section contains fan-shaped zones of feather crystals. Tucker's reagent. Actual size. Source: Ref 4 More
Image
Published: 01 December 2004
Fig. 30 Microstructure at a midthickness location. Direct-chill semicontinuous cast 610 × 1372 mm (24 × 54 in.) 2124 alloy ingot. Etchant: (a) 0.5% HF. (b) Copper and magnesium microsegregation (revealed by electron probe microanalysis) across the dendrites. Source: Ref 4 More
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005295
EISBN: 978-1-62708-187-0
... become equiaxed toward the center of the ingot. Fig. 11 Sketch of ingot structures showing chill zone, columnar zone, and equiaxed zone. Source: Ref 4 Fig. 12 Constitutional supercooling in alloy solidification. Source: Ref 5 The structures in continuous casting are identical...
Book Chapter

By Samuel M. Purdy
Series: ASM Handbook
Volume: 9
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.hb.v09.a0003750
EISBN: 978-1-62708-177-1
... cross section of a direct chill cast rolling ingot alloy 5052 (A1-2.5 Mg-0.25 Cr). It was etched in Poulton's reagent (etchant 2 in Table 4 ). In this case, very little grain refiner was added, resulting in a structure containing columnar surface grains in the chill zone and massive twin columnar...
Series: ASM Handbook
Volume: 22B
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.hb.v22b.a0005525
EISBN: 978-1-62708-197-9
... of more complicated casting processes (e.g., Ref 13 , 51 , 52 ). One example is direct chill casting, a semicontinuous process in which molten aluminum enters the top of a water-cooled mold, is cooled, and forms a solid ingot drawn out below ( Fig. 2 ). The molten aluminum begins to solidify...
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0009012
EISBN: 978-1-62708-185-6
... costs. A slice of an EMC ingot of aluminum-magnesium alloy 5182 was purchased from a company that was casting the alloy by EMC. Visual inspection of the ingot clearly showed superior surface finish relative to conventional -chill-cast (DC) ingots. In addition, metallographic evaluation revealed...
Series: ASM Handbook
Volume: 2
Publisher: ASM International
Published: 01 January 1990
DOI: 10.31399/asm.hb.v02.a0001077
EISBN: 978-1-62708-162-7
... a roughening on the drag surface of the casting as zinc liquid is drawn up into the casting. Both a reduction in underside shrinkage and a sound casting can be ensured when chills are used to promote directional solidification and to increase the solidification rate. The addition of rare earth elements has...
Series: ASM Handbook Archive
Volume: 12
Publisher: ASM International
Published: 01 January 1987
DOI: 10.31399/asm.hb.v12.a0000601
EISBN: 978-1-62708-181-8
..., was made by vacuum induction melting, chill casting, and swaging. Heat treatment: recrystallize for 30 min at 850 °C (1560 °F), austenitize for 1 h at 1100 °C (2010 °F), air cool. Sample was tensile tested at 700 °C (1290 °F) and an initial strain rate of 1.1× 10 −6 /s. Test was interrupted other 12 h...