This open access book covers novel techniques and materials for removing inclusions in metallic melts, resulting in significant improvements to the purity, quality, and materials properties of the cast metal product. It looks at an entirely new generation of intelligent filter materials and filter systems with functionalized surfaces for removing solid and liquid inclusions such as deoxidation products, sulfides, and nitrides carbide from metallic melts. This collection of contributed chapters addresses the overarching goal of the production of lightweight structures and high-demand construction materials within an overall substantially cleaner and more sustainable global supply chain. The chapters cover a diverse array of topics ranging in scope from the development of ceramic foam filters, to in-situ x-ray and optical characterization techniques, as well as advanced modelling of 3D-printed filter structures. Additionally, the book features a number of contributions directly transferable to industrial applications related to the clean metal casting technologies of aluminium and steel alloys.
Carbon-bonded filter materials and filter structures with active and
reactive functional pores for steel melt filtration.- In-situ
high-temperature microscopy on the interaction of exogenous non-metallic
particles with endogenous particles in molten steel.- New insights in the
aluminum melt filtration.- Thermodynamic assessment as a tool for modeling
interactions at the interface between ceramic filter and melt.- Structural
and thermodynamic properties of filter materials: A Raman and DFT
investigation.- Microstructure of filter constituents and non-metallic
inclusions and their interaction at high temperatures.- Using SPS/FAST to
facilitate interface reactions and to establish reaction mechanisms.- Dealing
with Fe in secondary Al-Si cast alloys including metal melt filtration.-
Influence of reactive filter materials on castings quality in aluminum
casting.- Filtration of magnesium.- Qualitative and quantitative X-ray
tomography of filter macrostructures and functional components.- Metal melt
filtration in a water-based model system using a semi-automated pilot plant:
experimental methods, influencing factors, models.- Modelling and Pore-Scale
Simulation of Fluid Flow and Particle Transport inside Open-cell Foam Filters
for Metal Melt -Filtration.- Characterisation of Heat Transport and Diffusion
Processes during Metal Melt Filtration-Microprocesses of agglomeration,
heterocoagulation and particle deposition of poorly wetted surfaces in the
context of metal melt filtration and their scale up.- Modeling and evaluation
of the chemo-thermo-mechanical behavior of filter materials and filter
structures.- Reactive cleaning and active filtration in continuous steel
casting.- Virtual Prototyping of 3D Printed Metal Melt Filters: An HPC-based
Workflow and Software Tool Chain.- Registration of filtration efficiency of
active or reactive filter in contact with steel melt in a steel casting
simulator.- Decopperization by utilization of filter and the thermophysical
propertiesof low content of Fe-Cu alloys.- Interactions between molten iron
and carbon bonded ceramics.- High-temperature strength and form stability of
compact and cellular carbon bonded alumina.- Determination of the
temperature-dependent fracture and damage properties of ceramic filter
materials from small scale specimen.- Influence of internal defects on the
fatigue life of steel and aluminium alloys in the VHCF range.- Analysis of
detrimental inclusions in steel and aluminum.- Numerical and statistical
modelling in the identification of positions of non-metallic inclusions in
steel samples based on thermography data from ultrasonic fatigue testing.-
Effect of non-metallic inclusions on the temperature and strain
rate-dependent strength, deformation and toughness behavior of high-strength
quenched and tempered steel.- Influence of filter structure and casting
system on filtration efficiency in aluminium mould casting.- Filtration of
non metallic impurities (dross) specifically occurring in cast iron with
nodular graphite.- Cleanness of molten steel active and reactive,
exchangeable filter systems for the continuous casting of steel.- Numerical
simulation of continuous steel casting regarding the enhancement of the
cleanliness of molten steel.- Precipitation of iron-containing intermetallic
phases from aluminum alloys by metal melt filtration.- Functionalized
feeders, hollowware, spider bricks and starter casting tubes for increasing
the purity in steel casting processes.- Increasing cleanliness of Al-melts by
additon of ceramic fibers.
Christos Aneziris has been a professor of Ceramics at the Technische Universität Bergakademie Freiberg, Germany since 2001. His major field of research includes fundamental and applied aspects of modern refractories in advanced metallurgy processing routes. His current research spans the areas of iron and steel clean technology and casting up to advanced casting of non ferrous low and high temperature materials, refractories in energy applications as well as non conventional processing routes of metal and ceramic matrix fine- and coarse-grain composite materials, and porous materials. He is speaker of the collaborative research center of the German Research Foundation (DFG) Multifunctional Filter systems; a contribution to Zero Defect materials, deputy speaker of the collaborative research center TRIP Matrix Composites and speaker of the Priority Program Refractory Initiation for Reduction of Emissions. Christos Aneziris has been a full member of the Saxon Academy ofSciences and Humanities in Leipzig since 2009 and the German Academy of Technical Science (ACATECH) since 2011. Since 2012 he is a member of the review board of the German Research Foundation (DFG) in the field of Ceramic and Metallic Sintered Materials and since 2014 member of the board of the Federation of International Refractory Research and Education - FIRRE. He has been serving as a member of the board of the German Ceramic Society since 2003 and in 2017 he was elected Fellow of the European Ceramic Society. In 2018 he became member of the World Academy of Ceramics and distinguished life member of the UNITECR organization.
Horst Biermann has been head of the Institute of Materials Engineering at the Technische Universität Bergakademie Freiberg, Germany, as University Professor for Materials Engineering since 2000. There, he was Dean of the Faculty of Materials Science and Technology for 10 years. He studied Materials Science at the University of Erlangen-Nurembergand received his doctorate and habilitation. His fields of work include plasticity and fatigue as well as surface engineering with about 350 publications as author or co-author. Since 2008 he has been speaker of the Collaborative Research Centre SFB 799 "TRIP-Matrix-Composite - Design of tough, transformation-reinforced composites and structures based on Fe-ZrO2" funded by the German Research Foundation (DFG). In his career to date, he has received several awards, including the Gerhard-Hess Prize of the German Research Foundation in 1997 and the "Breakthrough" Prize of the German Society for Materials Science in 2012. Since 2012 he has been a full member of the Academy of Sciences and Literature, Mainz, and since 2015 a full member of the Saxon Academy of Sciences and Humanities in Leipzig.
