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Meeting 2022 TMS Annual Meeting & Exhibition
Symposium Cast Shop Technology
Presentation Title Energy resilient foundries: The "Small is beautiful" projects
Author(s) Mark Jolly, Konstantinos Salonitis, Emanuele Pagone, Michail Papanikolaou, Prateek Saxena
On-Site Speaker (Planned) Konstantinos Salonitis
Abstract Scope Applying the concept of "small is beautiful" into a conservative relatively low technology manufacturing sector where the "economies of scale" argument has been used to build ever more so-called efficient process lines is a major challenge. The energy efficiency of the casting process has only been investigated in a limited fashion. The two “Small is Beautiful” projects aimed to introduce a new concept into foundries with regards the use of their resources. The new philosophy, "small is beautiful", starts by encouraging the use of high-quality feedstock, only melting what is required and only when it is required. Recycling of internal scrap is not necessarily acceptable but an aim for higher yields is. Applying counter gravity casting methods to improve yield and give enhanced quality is encouraged as is the recovery low grade heat from solidification. The present paper discusses the research undertaken and the key findings from the two projects.
Proceedings Inclusion? Planned: Light Metals
Keywords Sustainability, Aluminum, Modeling and Simulation

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

Adaptive tempering in high pressure die casting through prediction functions
Advances in Ingot and Billet Quench Measurement
Al-Mg-Cu cast alloys: Correlation of bifilm index and Porosity studies with mechanical behavior and microstructure evaluation
Aluminium melting process optimization with SmartMelt, a digital tool for real-time operational guidance
Aluminothermic Reduction of Sulfides via Reactive Vacuum Distillation
Aluminum Melt Cleanliness Analysis based on Direct Comparison of Computationally Segmented PoDFA Samples and LiMCA Results
Analytical, numerical and experimental investigations of transient heat conduction in launder during casting process.
Are Molten Metal Explosions Declining?
Assessment of a neural network based approach for application as a digital twin in billet DC casting.
Casthouse furnace tending: a new approach thanks to custom robotics
Chlorine free degas system for aluminum slab casting and its effect on sheet products
Continuous chemical analysis of molten aluminum
Control pin refractory reaction in high magnesium aluminium-melts
Dew Point Monitoring and Alarm System for Meltable Storage
Digital Twin for design and optimization of DC casting lines
Distributed Temperature and Gap Measurements at the Metal-Mold Interface during Aluminum Casting using Optical Fiber Sensors
Effect of flow management on ultrasonic melt processing in a launder upon DC casting
Effect of heat treatment on mechanical properties of Er, Dy and Eu modified A356 Alloy
Effects of Casting Temperature and Iron Content on the Microstructure of Hypoeutectic A380 Aluminum Alloy
Energy resilient foundries: The "Small is beautiful" projects
Evaluation of Breathability of Molten Metal PPE Fabrics
Fluidity and microstructural investigations of cast eutectic Al-Ni alloys for electric vehicle body manufacture
Heat Treatment of Mg-Containing Aluminum Alloys 5182 and 6016 in an Oxidizing Atmosphere with 4 % CO2
Impact of ingot size on rolling ingot metallurgy
Microalloying to inhibit oxidation of Al-Mg alloys
Microstructural modification of a high-pressure die-cast A380 alloy through friction stir processing and its effect on mechanical properties
Modeling of structural parameters during the casting of slabs of aluminum alloys 1xxx, 3xxx, 5xxx, 8xxx series at the RUSAL Pilot Casting Center
Modelling of Al-Mg-Cu light cast alloys behaviors via Finite Element methods with correlation of bifilm index and Xray Studies
Numerical and experimental investigation of heat transfer in the solidification-deformation zone during twin-roll casting of aluminum strips
Performance of Regular and Modified Ceramic Foam Filters (CFFs) during Aluminium Melt Filtration in a Pilot Scale Setup
Predicted back-meniscus stability for the horizontal single belt casting (HSBC) with single impingement feeding system
Quality Defects Metallurgical Root Cause Analysis for Aluminium Thin Foil Production
Quantitative Assessment of LPDC Process Parameters on Die Temperatures
Short- and long-term aluminum filtration trials with carbon-bonded alumina filters
The Effect of the Holding Time on the Microstructure of Gd-containing AlSi7Mg Alloys
The Great Debate - High vs Low Water Direct Chill Casting Pits - Which is safer.
The local squeeze technology for challenging aluminium HPDC automotive components
The Origins of Wagstaff Inc. Part 1- Two Emerging Technologies Collide
The Origins of Wagstaff Inc. Part 2- Aggressive R&D
TRC D&F - A compact inline melt treatment unit for continuous casting

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