Analysis of Distribution of Nonmetallic Inclusions in Aluminum DC-Cast Billets and Slabs

Inclusion distribution was studied in commercial aluminum DC-cast billets and slabs using a newly developed deep-etching method. Analyses revealed a nonuniform distribution of nonmetallic inclusions across billet diameters and lengths, and also across slab thicknesses and widths. In as-cast billets, more inclusions were found at the beginning and end of the billet length; more were present near the cross-section center than near the surface. In slabs, inclusions were located mostly within 13 mm of the surface and in a band between the centerline and the surface. Few inclusions were found 60 to 100 mm from the slab surface or at the centerline. In addition, comparing slab quality after casting using three types of ceramic foam filters (CFFs; i.e., 30 ppi, 50 ppi, and 50 ppi + HF) revealed significant differences in inclusion size, number, and distribution. Casting slabs using a finer pore-size filter (50 ppi) reduced the number of non-metallic inclusions greatly. The inclusion distribution patterns observed in the solidified slabs are discussed in terms of melt flow during casting.