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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
... Abstract When a heat of steel is melted and refined, it is necessary to solidify it into useful forms for further processing or final use. Ingot casting remains the preferred method for certain specialty, tool, forging, and remelted steels. This article discusses the methods, equipment...
Abstract
When a heat of steel is melted and refined, it is necessary to solidify it into useful forms for further processing or final use. Ingot casting remains the preferred method for certain specialty, tool, forging, and remelted steels. This article discusses the methods, equipment, and theory for pouring, solidifying, and stripping steel ingots. It describes two basic types of pouring methods, top pouring and bottom pouring, and provides information on equipment such as hot tops, ingot molds, and stools. The design of the ingot is dictated by the application and type of steel involved. The article concludes with information on the applications of solidification simulation.
Book Chapter
Aluminum Alloy Ingot Casting and Continuous Processes
Available to PurchaseBook: 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
... Abstract Ingot casting is the vital conduit between molten metal provided by primary production and recycling and the manufacture of aluminum and aluminum alloy products. A number of ingot casting processes have been developed to ensure the soundness, integrity, and homogeneity required...
Abstract
Ingot casting is the vital conduit between molten metal provided by primary production and recycling and the manufacture of aluminum and aluminum alloy products. A number of ingot casting processes have been developed to ensure the soundness, integrity, and homogeneity required 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 in the DC process are summarized. The article explains continuous processes, namely, twin-roll strip casting, slab casting, and wheel-belt processes. It concludes with information on postsolidification processes, including stress relief and scalping, and a discussion of safety practices for ingot casting.
Book Chapter
Aluminum Alloy Ingot Casting and Continuous Processes
Available to PurchaseSeries: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006485
EISBN: 978-1-62708-207-5
... Abstract Ingot casting is the vital conduit between molten metal provided by primary production and recycling, and the manufacture of aluminum and aluminum alloy products. This article discusses various ingot forms, such as remelt ingot, billets, ingots for rolling, fabricating ingot...
Abstract
Ingot casting is the vital conduit between molten metal provided by primary production and recycling, and the manufacture of aluminum and aluminum alloy products. This article discusses various ingot forms, such as remelt ingot, billets, ingots for rolling, fabricating ingot, 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 in terms of stress relief, homogenization, and scalping. The article concludes with a discussion on safety limited to ingot casting.
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Grain structures of an ingot casting showing the regions of chill, columnar...
Available to PurchasePublished: 01 December 2008
Fig. 9 Grain structures of an ingot casting showing the regions of chill, columnar, and equiaxed grains
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Cross section through an alloy 1100 ingot cast by the Properzi (wheel-and-b...
Available to PurchasePublished: 01 December 2004
Fig. 7 Cross section through an alloy 1100 ingot cast by the Properzi (wheel-and-belt) method showing columnar grains growing perpendicularly to the faces of the mold. Tucker's reagent. Original magnification 1.5×. Source: Ref 4
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Feather crystals in an alloy 3003 ingot cast by the direct-chill semicontin...
Available to PurchasePublished: 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
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Manganese sulfides in (a) a billet of ingot-cast type 303 stainless steel a...
Available to Purchase
in Metallography and Microstructures of Stainless Steels and Maraging Steels[1]
> Metallography and Microstructures
Published: 01 December 2004
Fig. 6 Manganese sulfides in (a) a billet of ingot-cast type 303 stainless steel and (b) a bar of continuously cast 303 stainless steel
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Eight typical conditions of commercial steel ingots, cast in identical bott...
Available to PurchasePublished: 01 December 1998
Fig. 19 Eight typical conditions of commercial steel ingots, cast in identical bottle-top molds, in relation to the degree of suppression of gas evolution. The dotted line indicates the height to which the steel originally was poured in each ingot mold. Depending on the carbon and, more
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Eight typical conditions of commercial steel ingots, cast in identical bott...
Available to Purchase
in Classification and Designation of Carbon and Low-Alloy Steels
> Properties and Selection: Irons, Steels, and High-Performance Alloys
Published: 01 January 1990
Fig. 2 Eight typical conditions of commercial steel ingots, cast in identical bottle-top molds, in relation to the degree of suppression of gas evolution. The dotted line indicates the height to which the steel originally was poured in each ingot mold. Depending on the carbon and, more
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Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005296
EISBN: 978-1-62708-187-0
... Abstract The purpose of continuous casting is to bypass conventional ingot casting and to cast to a form that is directly rollable on finishing mills. The use of this process has resulted in improvement in yield, surface condition, and internal quality of product when compared to the ingot-made...
Abstract
The purpose of continuous casting is to bypass conventional ingot casting and to cast to a form that is directly rollable on finishing mills. The use of this process has resulted in improvement in yield, surface condition, and internal quality of product when compared to the ingot-made material. This article outlines the advantages of steel continuous casting, along with its developments and challenges for improvement. It provides a general description of the continuous casting process and the design and layout of a continuous casting steelmaking facility. It reviews process enhancements such as near-net shape casting, tundish metallurgy, and pouring stream protection. The article discusses the use and capabilities of different molds for steel continuous casting, including thin-wall tube-type molds, solid molds, and plate molds. The article explains the methods for enhancing productivity and improving quality in steel continuous casting. It evaluates the applications of horizontal continuous casting in casting steel. The article concludes by outlining priorities for future development such as enhanced control systems and automation.
Book Chapter
Alloy and Temper Designation Systems for Aluminum and Aluminum Alloys
Available to PurchaseSeries: ASM Handbook
Volume: 2
Publisher: ASM International
Published: 01 January 1990
DOI: 10.31399/asm.hb.v02.a0001058
EISBN: 978-1-62708-162-7
... designations. It also tabulates the grade designations and compositions of wrought and cast aluminum and aluminum alloys. The article provides information on cross-referencing of aluminum wrought and ingot/cast products according to composition, per the Aluminum Association, Unified Numbering System (UNS...
Abstract
A four-digit numerical designation system is used to identify wrought aluminum and aluminum alloys. In addition to providing a detailed account of the temper designation system for aluminum and aluminum alloys, this article describes wrought and cast aluminum and aluminum alloy designations. It also tabulates the grade designations and compositions of wrought and cast aluminum and aluminum alloys. The article provides information on cross-referencing of aluminum wrought and ingot/cast products according to composition, per the Aluminum Association, Unified Numbering System (UNS) and International Organization for Standardization (ISO) standards.
Book Chapter
Failures Related to Hot Forming Processes
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006835
EISBN: 978-1-62708-329-4
... of wrought products. The article addresses the types of flaws or defects that can be introduced during the steel forging process itself, including defects originating in the ingot-casting process. Defects found in nonferrous forgings—titanium, aluminum, and copper and copper alloys—also are covered...
Abstract
The primary purpose of this article is to describe general root causes of failure that are associated with wrought metals and metalworking. This includes a brief review of the discontinuities or imperfections that may be common sources of failure-inducing defects in the bulk working of wrought products. The article addresses the types of flaws or defects that can be introduced during the steel forging process itself, including defects originating in the ingot-casting process. Defects found in nonferrous forgings—titanium, aluminum, and copper and copper alloys—also are covered.
Book Chapter
Steelmaking Practices and Their Influence on Properties
Available to PurchaseSeries: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003091
EISBN: 978-1-62708-199-3
... of various steel manufacturing processes, such as ingot casting, continuous casting, and hot rolling. It provides an outline of specialized processing routes of producing ultralow plain carbon steels, interstitial-free steels, high strength low-alloy steels, ultrahigh strength steels, stainless steels...
Abstract
This article presents a detailed account on the process flow, composition, alternative sources, and the advancement of ironmaking, steelmaking and secondary steelmaking practices. Some steels, such as bearing steels, heat-resistant steels, ultrahigh strength missile and aircraft steels, and rotor steels have higher quality requirements and tighter composition control than plain carbon or ordinary low-alloy steels. The production of special-quality steels requires vacuum-based induction or electric remelting and refining capabilities. The article explores the types and characteristics of various steel manufacturing processes, such as ingot casting, continuous casting, and hot rolling. It provides an outline of specialized processing routes of producing ultralow plain carbon steels, interstitial-free steels, high strength low-alloy steels, ultrahigh strength steels, stainless steels, and cold-rolled products, and briefly explains the analytical techniques for liquid steels.
Image
Backscattered scanning electron micrographs showing the morphology of cells...
Available to PurchasePublished: 01 December 2004
Fig. 32 Backscattered scanning electron micrographs showing the morphology of cells and dendrites within the cross section of the columnar grains in Ti-46Al-2W-0.5Si directionally solidified ingots cast in alumina molds. B 2 particles (ordered β phase). Ceramic Al 2 O 3 particle (C
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Book Chapter
Solidification Structures of Aluminum Alloys
Available to PurchaseSeries: ASM Handbook
Volume: 9
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.hb.v09.a0003727
EISBN: 978-1-62708-177-1
...% Mg, 6.56% Zn, 0.03% Cr, 0.09% Fe, 0.05% Mn, 0.01% Ni, 0.06% Si, 0.018% Ti, 0.10% Zr, balance aluminum. Source: Ref 3 Grain Structure Grain size is a readily observed feature of aluminum alloy ingots and castings. For solid-solution type alloys, mechanical properties are highly dependent...
Abstract
The most common aluminum alloy systems are aluminum-silicon, aluminum-copper, and aluminum-magnesium. This article focuses on the grain structure, eutectic microstructure, and dendritic microstructure of these systems. It provides information on microsegregation and its problems in casting of alloys. The article also illustrates the casting defects such as macroporosity, microshrinkage, and surface defects, associated with the alloys.
Image
Macrostructure of as-cast aluminum ingot. Transverse section shows outer ch...
Available to PurchasePublished: 01 January 1986
Fig. 5 Macrostructure of as-cast aluminum ingot. Transverse section shows outer chill zone and columnar grains that have grown perpendicularly to the mold faces. Etched using Tucker's reagent. 1.5×
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Image
Macrostructure of a continuous-cast copper ingot. (a) Spider cracks reveale...
Available to PurchasePublished: 01 January 1986
Fig. 6 Macrostructure of a continuous-cast copper ingot. (a) Spider cracks revealed using dye-penetrant inspection. Transverse section at top; longitudinal section at bottom. (b) Same ingot, etched using Waterbury's reagent. Cracks are not revealed. Both approximately 0.5×
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Published: 01 January 1986
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As-cast Al-7Si ingots showing the effects of grain refinement. (a) No grain...
Available to PurchasePublished: 01 December 2008
Fig. 3 As-cast Al-7Si ingots showing the effects of grain refinement. (a) No grain refiner. (b) Grain refined. Both etched using Poulton's etch; both 2×. Courtesy of W.G. Lidman, KB Alloys, Inc.
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Image
Two margash-form zinc alloy ingots for feeding die casting alloy to the hol...
Available to PurchasePublished: 01 December 2008
Fig. 2 Two margash-form zinc alloy ingots for feeding die casting alloy to the holding furnace. Note the hole that accepts a hook that slowly lowers the metal into the furnace. Source: Courtesy of Allied Metal Company, Chicago, IL
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