Alloys & Billet Process (BP)

John D. Lee, Logemann Brothers Company; University of Arizona Department of Engineering Capstone Sponsor, USA

Logemann, a leading U.S. supplier of scrap processing equipment to the metal fabrication industry for over 140 years, proposes a collaborative study with the University of Arizona engineering capstone program and key aluminum foundry partners to evaluate how scrap aluminum bale density impacts remelt efficiency and sustainability metrics. Bale density will be tested as a controllable input variable during the remelt process. The study will measure its influence on yield, dross generation, carbon emissions, energy consumption, and transportation efficiency. Controlled trials across multiple density levels will support development of a density-yield performance curve and quantify the return on density optimization. By partnering with remelt operators, the project aims to define an industry standard for optimal bale density. The findings will inform best practices for scrap preparation across the secondary aluminum supply chain, with global relevance for extrusion, rolling, and casting operations seeking to reduce costs and carbon footprint.

Evangelos Giarmas, Anastasia Kotsiaridi, Stavros Arvanitis, Alumil S.A., Production Division; Helen Kamoutsi and Gregory Haidemenopoulos, Department of Mechanical Engineering, University of Thessaly, Greece

This study explores sustainable manufacturing of 6060 aluminum alloy by increasing Copper (Cu) and Zinc (Zn) alloying content, emphasizing recycled aluminum use in casting process. Strategies to boost scrap utilization during remelting include furnace and burner upgrades and impurity removal through sorting lines. The research examines how recycling content affects energy consumption, dross formation, CO₂ emissions, and alloy composition, emphasizing the need to expand tolerance limits for Cu and Zn to improve recyclability. Three alloy compositions were assessed: a primary alloy with minimal Cu (0.01%) and Zn (0.02%), and two scrap-based variants with higher Cu (0.017%, 0.028%) and Zn (0.034%, 0.06%) plus excess Silicon (Si). Mechanical tests, grain size analysis, and corrosion resistance evaluations including filiform corrosion and acetic salt spray were conducted. Results show increased Cu and Zn, with excess Si, enhance tensile strength without notably affecting corrosion resistance or anodizing behavior. The findings support sustainable alloy design without compromising performance.

Myrsini Ntemi, Ilias Gialampoukidis, Stefanos Vrochidis, and Ioannis Kompatsiaris, CDXi solutions; Evangelos Giarmas and Anastasia Kotsiaridi, Alumil Group, Greece

Advanced aluminum recycling demands precise insight into scrap melting and dross behavior, yet existing monitoring relies on operator interpretation. We introduce a cost-efficient machine learning framework that transforms a single heat-resistant camera into a source of quantitative furnace intelligence. Real-time semantic segmentation and spatiotemporal inference models estimate scrap volume and surface roughness dynamics to determine delacquering progression with objective accuracy. In parallel, dross coverage and formation rate are continuously quantified to support proactive impurity control and yield stability. The system also identifies operational actions and hazardous heat zones, enabling safer, more consistent interventions. All indicators are integrated into actionable decision support tools that help operators optimize reload timing, avoid excess dross generation, reduce furnace idle periods, and preserve molten aluminum quality. The framework has been validated in a full-scale industrial recycling furnace, demonstrating significant measurable efficiency improvements and emission reductions in real-world production environments.

Eli Harma and Paul Sanders, Michigan Technological University, USA

Alloy 6005A has a recrystallized microstructure due to low dispersoid concentration, which enhances formability but reduces strength. Modifying 6005A alloy to maintain the fibrous microstructure by replacing Mn and Cr with Sc and Zr to produce a finer dispersion of Al3Sc-Zr dispersoids could improve strength without impacting formability. To examine the effect of dispersoid type on hot deformation, four alloys were tested through compression testing and extrusion: baseline 6005A without dispersoid formers, 6005A with Mn and Cr dispersoids, 6005+ with Sc and Zr replacing Mn and Cr and increased Cu, and 6005++ with increased Sc and Zr additions and similar Cu. The 6005++ alloy had the highest flow stress under all conditions, a non-recrystallized extruded microstructure, and texture components of copper, brass, and S. This resulted in the highest mechanical properties, with a yield strength (YS) of 304MPa, ultimate tensile strength (UTS) of 326MPa, and 12.5% ductility.

Veerendra R, Jindal Aluminium Ltd., India

Titanium Boron Aluminum (TiBAl) rod is commonly used during the casting of aluminum alloys to prevent crack formation and refine the grain size. At the incoming inspection stage, it is essential to verify the composition of TiBAl, which typically contains Titanium (5%) and Boron (1%). However, due to the non-availability of Certified Reference Material (CRM) samples with such high concentrations of Ti and B, we are currently unable to conclusively determine the acceptability of the measured compositions. CRM samples with these elevated levels are not readily available in the market. To overcome this limitation, we have developed a method for the in-house preparation of secondary reference samples, which will be subsequently certified through 2-3 independent testing laboratories. This will help to ensure consistent and accurate assessment of TiBAl composition, thereby enhancing the quality of output of the log casting process.

Nick Parson and Jerome Fourmann, Rio Tinto, Canada

There is a growing demand for extrusion billet with an increased recycled content using both pre and post consumer scrap. Recycling can lead to increases in impurity elements of which iron is typically the most significant in terms of quantity and effect on the extruded product. This paper examines the effect of iron content on the ingot structure of AA6063, the role of casting technology and ingot diameter and the interrelation with extrudability and finishing response.

Ali Elashery, Norwegian Univeristy of Science and Technology (NTNU), Norway; X-G. Chen, University of Quebec; and Nick Parson, Rio Tinto, Canada

Zirconium is widely used as a dispersoid forming addition to Al-Zn-Mg general extrusion alloys such as AA7003 and aerospace alloys such as AA7150. Although some AA6XXX alloy specifications include a Zr addition these are the exception and additions of manganese and chromium are more widely used. This paper examines the dispersoid distributions formed in Al-Mg-Si-Zr compositions with varying silicon contents subjected to a range of homogenization treatments. Finally, the effects of single and combined additions of Mn and Zr on the extruded microstructure and properties of an AA6082 composition are compared.

Giovanni Battino, Presezzi Extrusion S.p.A., Italy

This abstract presents an advanced aluminum melting process integrating an automatic scrap charging system with a permanent magnet stirrer controlled by artificial intelligence. The automatic scrap charger enables optimized and continuous feeding of aluminum scrap, minimizing thermal losses, oxidation, and operator dependency. Melt homogenization is achieved through a Presezzi’s patented permanent magnet stirrer whose operating parameters are dynamically adjusted by an AI algorithm embedded in a high-temperature industrial camera installed on the melting furnace. The vision-based system monitors bath surface behavior and scrap dissolution, enabling real-time optimization of stirring intensity and flow patterns. In addition, the process is supported by SPARK (Smart Platform for Assistance Resources and Knowledge), an AI-based assistance tool providing remote troubleshooting and maintenance support through contextual analysis of alarms and operational data. The combined use of automation, AI-driven process control, and intelligent assistance improves thermal uniformity, melting efficiency, process stability, and overall plant reliability.

Alex Lowery, Wise Chem LLC, USA

Many companies are blind to the hazards associated with loading and unloading trucks. They only become aware of this hazard when an incident occurs at their workplace. There is a gap in the literature on this hazard that has resulted in many workplaces operating with a hidden hazard on their premises. This paper will explain common pitfalls that result in workers being injured and killed during the unloading and loading of trucks. This paper will provide case studies on how workplaces mitigate this hazard. In addition, this paper will review the proper load securement on flatbed trailers that also injure and kill. Workplaces’ failure to see an obvious hazard in the loading and unloading of trucks as well the proper load securement on trucks will continue to injure and kill workers until our industry places a spotlight on this hazard.

Jostein Røyset, Eva Mørtsell and Ulf Tundal, Hydro Aluminium Research and Technology Development; Eila Bergene, Department of Physics, Norwegian University of Science and Technology (NTNU); and Trond Furu, Norsk Hydro, Corporate Technology Office, Norway

Within the Al-Mg-Si alloys there is a tendency to lower ductility with increasing Mg and Si content, for extruded and age-hardened profiles this is particularly evident when the profiles have been air-cooled after extrusion. The reduction in ductility can be countered by small additions of Mn and Cr. It is assumed that the beneficial effect of Mn and Cr is due to the dispersoids formed during homogenization, but it has not been well understood. The present work sums up several studies of base-alloys where the Mn and Cr content has been increased to increase the ductility. The alloys were laboratory cast and extruded, and the extruded profiles were either air-cooled or water quenched. Characterization has been done with mechanical testing, light microscopy, scanning electron microscopy and transmission electron microscopy. It seems that the role of dispersoids is at least twofold; reducing intergranular fracture and influencing the development of the crystallographic texture.

Jostein Røyset, Martha Indriyati, Eva Mørtsell and Ulf Tundal, Hydro Aluminium Research and Technology Development, Norway

In the 6005A alloys the added Mn and Cr forms dispersoids during homogenization. When added in sufficient amount one achieves a fibrous grain structure after extrusion, but this also makes the billet much harder to extrude. Therefore, one should seek to add only as much Mn and/or Cr as necessary to achieve the desired microstructure. Also, the effects of Mn and Cr are not identic, and it is not straightforward to determine whether to use Mn, Cr, or a combination of the two. Six alloys with various contents of Mn and/or Cr were studied. Casting and extrusion were on laboratory scale. Two profile types were extruded, one for comparing the maximum extrusion speed before tearing, and one for determining mechanical properties. Profile samples were examined in light microscope and by tensile testing. The results provide a sound basis for optimizing the Mn and Cr contents in these types of alloys.

Seif Badawy, Yahya Mahmoodkhani and Steve Coates, Signature Aluminum Canada Ltd., Canada

Inverse segregation is the accumulation of alloying elements in the skin of direct chill-cast aluminum billets at concentrations higher than in the bulk, driven by convection, feeding flow, and shrinkage-induced movement during solidification. This study examines the relationship between inverse segregation severity and billet skin thickness, with emphasis on alloy chemistry, casting speed, and cooling practice. Increased inverse segregation is shown to produce thicker, more highly alloyed surface layers that increase scrap rate during extrusion. Through experimental trials and simulation, the study correlates skin thickness to extrusion recovery, demonstrating that it directly reduces recovery and increases cost per unit length extruded. Even small reductions in inverse segregation can significantly decrease skin thickness, improving yield without compromising press performance. The results highlight DC casting control as a critical upstream lever for improving extrusion recovery, reinforcing the importance of integrated casting-extrusion process optimization for modern aluminum extrusion operations.

Emrah Ozdogru, Isik Kaya, Aybars Guven, Aleyna Gumussoy and Hilal Colak, Tri Metalurji, Turkey

The 6063-aluminum billet alloy has been widely used in production of profiles. Homogenization is an essential process for having a good extrudability and high-quality end product. Homogenization process gives a homogeneous microstructure by reducing micro segregation and well-designed intermetallic phases. However, If the iron level is so high, especially in the high recycle content aluminum billet, the AlFeSi phase formation and their behaves during homogenization is different than the primary aluminum billet due to the complex AlFeSi formation. Making an identification of AlFeSi based phases is one of the most important stages for understanding the phase transformation in homogenization process. In this study, microstructural assessment has been applied to the AlFeSi phases for setting the homogenizing cycle and pointing out the importance of the high recycled content aluminum billet production.

Tanju Çeliker, Harun Uslu, İlhan Karabiyik and İrfan Eker, ONAT Aluminyum SAN. TİC. A.S., Turkey

This study investigates the influence of secondary aluminum content on the chemical composition, inclusion characteristics, microstructure, mechanical properties, and process stability of EN AW 6082 alloy for automotive extrusion. Billets containing varying proportions of secondary aluminum were produced under controlled casting conditions. Particular attention was given to Mg-Si-Mn balance, impurity accumulation, especially Fe, and the formation of Fe-rich intermetallic phases together with non-metallic inclusions originating from recycled input. Increasing secondary content intensified impurity sensitivity and inclusion-related heterogeneity, promoting β-AlFeSi phase formation when critical Fe levels were exceeded and reducing ductility. However, optimized compositional control and melt treatment practices mitigated inclusion defects and preserved target mechanical properties within industrially acceptable limits. The results demonstrate that high secondary aluminum utilization in 6082 alloy is feasible when elemental impurities and melt cleanliness are carefully controlled, supporting low-carbon and circular aluminum production without compromising structural performance.

Jostein Røyset, Eva Mørtsell and Ulf Tundal, Hydro Aluminium Research and Technology Development; Hedda Øye and Randi Holmestad, Norwegian University of Science and Technology (NTNU); Sigurd Wenner and Calin Marioara, SINTEF Materials and Nanotechnology, Norway; and Helen Weykamp, Hydro Aluminium Metals, USA

The effects of Ti and V additions to a 6005-aluminum alloy were investigated with respect to corrosion susceptibility and cooling rate from extrusion. Both Ti- and V-containing alloys exhibited a significant improvement in intergranular corrosion resistance. The depth of intergranular corrosion was substantially reduced by the addition of either element, with Ti showing the strongest effect. Crush-, bend-, and tensile testing demonstrated that the Ti- and V-modified alloys performed comparably. The beneficial effect was most pronounced at slow cooling rates, where both Ti and V increased the bend angle significantly. Peritectic elements such as Ti and V segregate to the centers of dendrite arms during solidification, leading to Ti/V banding during extrusion. These bands were confirmed by optical- and electron microscopy in addition to energy-dispersive X-ray spectroscopy. The hardening precipitates formed during artificial aging were quantified and characterized by transmission electron microscopy and were unaffected by Ti or V additions.

Endre Hennum, Jon Møretrø and Ulf Tundal, Hydro Aluminium AS, Norway

This work compares recrystallized and non‑recrystallized Al‑Mg‑Si extrusions for crash applications. Two alloys with identical yield strength but different grain structures were subjected to bending and quasi‑static axial and lateral compression tests after quenching at different rates after solution heat treatment. The recrystallized alloy shows excellent bendability transverse to the extrusion direction at high quench rates but suffers from strong anisotropy and reduced ductility as quench rate decreases, which limits performance in lateral compression. The non‑recrystallized alloy displays lower anisotropy and better bendability along the extrusion direction. Although it loses yield strength more rapidly with slower quenching, it retains ductility more effectively, giving improved performance particularly in lateral compression. Overall, the results indicate that non‑recrystallized alloys may be advantageous for certain lateral side‑crush applications.

David Roth, GPS Global Solutions, USA

Dross processing has moved forward significantly since the 1960s when it was common to take materials directly to the land fill. The industry has shifted from preserved aluminum being in the 20% range to current processing systems preserving and recovering maximum amounts of aluminum in the 60 - 70% range. Also, for the first time there are multiple processes that recover aluminum and produce by products for sale and eliminate land filling of a salt cake material. This paper will detail the historical development and today’s current implementation of all of the commercial dross processing systems used in the aluminum industry.

Alex Poznak, Martha Indriyati and Ole Runar Myhr, Hydro Aluminium Research and Technology Development; and Trond Furu, Norsk Hydro, Corporate Technology Office, Norway

Extruded profiles that retain a fibrous, unrecrystallized grain structure can offer significant performance benefits for structural applications, including higher strength and improved damage tolerance. The tendency for an alloy to recrystallize is strongly dependent on the dispersoid density (controlled by Mn, Cr content and homogenization practice), as well as the extrusion process (e.g. temperature, speed, and reduction ratio). Alloys with insufficient recrystallization resistance become sensitive to extrusion process variation, which can cause grain structure to become the limiting factor in extrusion speed. Increased recrystallization resistance, however, typically comes at the cost of reduced extrudability due to increased flow stress and deformation heating. The present work examines this balance through extrusion trials coupled with through-process microstructure modelling. The results highlight how alloy and homogenization can be strategically matched to an extrusion process to optimize extrudability while stabilizing a fibrous grain structure.

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