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Meeting 2025 TMS Annual Meeting & Exhibition
Symposium Melt Processing, Casting and Recycling
Presentation Title In Situ Observations of the Nucleation and Growth of Al-Si-Fe-Mn Intermetallics in Model Aluminium Alloys
Author(s) Eliane Farhi, Georges Salloum-Abou-Jaoude, Silvère Akamatsu, Philippe Jarry, Christine Nardin, Sabine Bottin-Rousseau
On-Site Speaker (Planned) Eliane Farhi
Abstract Scope In order for the aluminum industry to reduce its scope 3 carbon footprint, the share of pre- and post-consumer scrap in recycling must be significantly increased. This leads to higher Fe and Si impurities, increasing the volume fraction of Al-Fe-Si intermetallics (IMs), causing a decrease in final formability properties. The understanding of the physical phenomena governing nucleation and growth of Al-Fe-Si IMs remains limited due to the absence of direct observations. We present an in situ experimental study using directional-solidification with real-time optical observations in thin samples of model Al-Fe-Si-Mn based alloys. We capture the nucleation and growth of IM crystals under well-controlled solidification parameters. Chemical analysis (EDX) is used to identify the different IM phases predicted by thermodynamic models. For the first time, we show direct evidence of a morphological transition from divorced growth of faceted IM crystals in the liquid to coupled αAl-Fe_IM growth in this type of alloys.
Proceedings Inclusion? Planned: Light Metals
Keywords Solidification, Aluminum, Other

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

Application of Digital Twins for Complete DC-Casting Lines
BATSCAN – A Breakthrough for Industrial Inclusion Measurement in Aluminium Casthouses
Development of Numerical Model of Plasma Burner for Primary Aluminium Casthouses
Dynamics of Hydrogen in Aluminium in Contact with Humid Atmosphere
In Situ Observations of the Nucleation and Growth of Al-Si-Fe-Mn Intermetallics in Model Aluminium Alloys
Investigating the Castability of Recycling AZ91 Machining Chips Through Shape Casting
Investigation of Al6(Fe, Mn) Intermetallics Formation on AA8006 Aluminum Alloy Produced by Twin-Roll Casting at Different Solidification Conditions
Investigation of the Effect of Lacquered and Delacquered Scrap on Casting Impurities for Recycling Efficiency
Liquid Composition Analysis of Wrought Aluminum Alloys Using Laser-Induced Breakdown Spectroscopy (LIBS) for Industrial Furnace Applications
Modeling and Simulation of Cold Hearth Continuous Casting of Titanium Alloys
On the Influence of Oxide Layer Formation and Alloying in the Mg Vapor Pressure for Ternary Dilute Al-Mg Alloys
Optimizing Solid and Liquid Loading Times in Aluminium Melting Furnaces: Enhancing Efficiency and Process Control with SmartMelt Technology
Oxidation of Aluminium Melts in Dry and Moist Atmospheres
Removal Efficiencies of Hydrogen and Inclusions in a Combined Filter with De-Gassing and CFF
Removal of Metallic Impurities from Aluminum Alloy Using Gravity Sedimentation Technique
Removal of Zn and Other Volatile Elements from Molten Al by Vacuum Refining
Review of Recent Catastrophic Molten Metal Explosions and Their Causes
Sedimentation of Inclusions In Melts of Aerospace Structural Aluminium Alloy Castings: A Sustainable Approach
Smart Sensors for Additive Manufacturing and Aluminum Foundry 4.0 Initiatives
The Effect of Nucleating Particle Agglomerates on Grain Refiner Efficiency of 7xxx Aluminium Alloys
The Relationship Between Casting Thickness and Surface Quality of 8079 Alloy Foils in Twin-Roll Casting
ThermaSiC Coating for Applications in Contact with Molten Aluminum
Tracking Primary Al3Ti and Al3Zr Phase Formation in Liquid Aluminum Alloys Using LIBS
Ultra-Short Process for Producing Pure Nickel Casting Strip

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