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Meeting 2025 TMS Annual Meeting & Exhibition
Symposium Melt Processing, Casting and Recycling
Presentation Title Review of Recent Catastrophic Molten Metal Explosions and Their Causes
Author(s) Alex W. Lowery
On-Site Speaker (Planned) Alex W. Lowery
Abstract Scope Since the year 2000, one or more casthouses in our industry have been destroyed by a catastrophic molten metal explosion(s). Workers have been killed and injured. Companies have been shuttered because of the loss of production. Many of these explosions have not been reported to the Aluminium Association’s Molten Metal Incident Reporting Program. Thus, our industry is unaware of the root causes of these explosions and cannot take the necessary action through engineering control or revised training to prevent recurrence. This project will review a number of these catastrophic casthouse explosions. Providing root cause analysis where previously there were none publicly. Since the year 2000, catastrophic explosions have been occurring and many incidents’ root causes have not been shared within our industry. Companies who fail to share the root causes of Force 3 explosions unknowingly place other companies and our entire industry at risk of experiencing the same fate.
Proceedings Inclusion? Planned: Light Metals
Keywords Aluminum,

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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