Completed R&D Projects

The following projects have completed their research and development of improved processes and technologies for the Aluminum Industry of the Future. Project fact sheets for each project are available as Adobe PDFs. Download Adobe Reader.

Efficient Melting Technologies

Degassing of Aluminum Alloys Using Ultrasonic Vibrations (PDF 76 KB)
Final Report: June 2006 (PDF 2.1 MB)
Detection and Removal of Salts from Molten Aluminum Alloys (PDF 81 KB)
Final Report: August 1999 (PDF 4.6 MB)
Energy Conserving Tool for Combustion Dependent Industries (PDF 93 KB)
Energy-Efficient Isothermal Melting of Aluminum (PDF 403 KB)
Gas Fluxing of Aluminum (PDF 110 KB)
High-Efficiency, High-Capacity, Low-NOx Aluminum Melting Using Oxygen-Enhanced Combustion (PDF 88 KB)
High-Efficiency, Low-Dross Combustion System (PDF 86 KB)
Improving Energy Efficiency in Aluminum Melting (PDF 213 KB)
Modeling Optimization of Direct Chill Casting to Reduce Ingot Cracking (PDF 96 KB)
Final Report: June 2006 (PDF 5.3 MB)
Molten Aluminum Treatment by Salt Fluxing with Low Environmental Emissions (PDF 165 KB)
Prevention of Molten Aluminum-Water Explosion (PDF 79 KB)
Recycling Aluminum Salt Cake (PDF 80 KB)
Final Report: February 2000 (PDF 795 KB)
Reduction of Oxidative Melt Loss (PDF 131 KB)
Final Report: February 2006 (PDF 10.3 MB)
Selective Adsorption of Salts from Molten Aluminum (PDF 78 KB)
Spray Rolling Aluminum Strip (PDF 93 KB)
Final Report: May 2006 (PDF 2.8 MB)

Forming Technologies

Calculation Methods for Extruded Aluminum Design-Integrated Numerical Methods and Design Provisions for Aluminum Structures (PDF 107 KB)
Combined Experimental and Computational Approach for the Design of Mold Surface Topography (PDF 135 KB)
Final Report: September 2005 (PDF 2.8 MB)
Continuous Severe Plastic Deformation Processing of Aluminum Alloys (PDF 210 KB)
Coolant Characteristics and Control in Direct Chill Casting (PDF 131 KB)
Development of Integrated Methodology for Thermo-Mechanical Processing of Aluminum Alloys (PDF 101 KB)
Development of a Rolling Process Design Tool for Use in Improving Hot Roll Slab Recovery (PDF 187 KB)
Effects of Casting Conditions and Composition on Microstructural Gradients in Roll Cast Aluminum Alloys (PDF 78 KB)
Effects of Impurities on the Processing of Aluminum Alloys (PDF 71 KB)
Energy-Efficient Manufacturing of Superior Aluminum Extrusions (PDF 203 KB)
Evaluation & Characterization of In-Lined Annealed Continuous Cast Aluminum Sheet (PDF 456 KB)
Final Report: August 2005 (PDF 4.5 MB)
Reduction of Annealing Times for Energy Conservation in Aluminum Processing (PDF 115 KB)
Final Report: August 2005 (PDF 23.9 MB)
Structural Factors Affecting Formability of Continuous Cast Aluminum Alloys (PDF 239 KB)
Surface Behavior of Aluminum Alloys Deformed Under Various Processing Conditions (PDF 238 KB)
Textures in Aluminum Alloy (PDF 207 KB)
Final Report: July 2003 (PDF 593 KB)
Two-Phased Model for the Hot Deformation of High Alloyed Aluminum (PDF 100 KB)

ITP Crosscutting Applications

CFCC Immersion Tube (Continuous Fiber Ceramic Composites) (PDF 191 KB)
Development of an Innovative Energy Efficient High Temperature Natural Gas and Fired Services (Chemicals) (PDF 89 KB)
Forced Internal Recirculation Burner (Combustion) (PDF 96 KB)
NOx Emission Reduction by Oscillating Combustion (Combustion) (PDF 74 KB)
Dynamic Expert Control for Oxy Fuel Performance (Glass) (PDF 4.9 MB)
Advanced Intermetallic Alloy Development (Industrial Material of the Future) (PDF 206 KB)
Nickel Aluminide Heat Trays and Furnace Fixtures (Industrial Material of the Future) (PDF 260 KB)
Rotary Burner Demonstration (Petroleum) (PDF 97 KB)
Intelligent Extruder (Sensors and Controls) (PDF 622 KB)
Laser-Based Ultrasonic System (Sensors and Controls) (PDF 741 KB)
Sensors Fusion for Intelligent Process Control (Sensors and Controls) (PDF 164 KB)
Thermal Imaging Control of Furnace and Combustors (Sensors and Controls) (PDF 318 KB)
Centrifugally Cast Nickel Aluminide Transfer Rolls for Steel (Steel) (PDF 260 KB)
Energy Saving Light Weight Refractory (Steel) (PDF 105 KB)
Measurement of Melt Constituents with LIBS (Steel) (PDF 118 KB)

Primary Aluminum Production

Aluminum Carbothermic Technology (PDF 108 KB)
Final Report: December 2004 (PDF 2.5 MB)
Inert Metal Anodes for Primary Aluminum Production (PDF 100 KB)
Numerical Modeling of Transient Melt Flow Sand Interface Instability in Aluminum Reduction Cells (PDF 102 KB)
Advanced Anodes and Cathodes Utilized in Energy-Efficient Aluminum Production Cells (PDF 78 KB)
Final Report: May 2002 (PDF 5.2 MB)
Development of a Novel Non-Consumable Anode for Electrowinning Primary Aluminum (PDF 86 KB)
Final Report: December 2003 (PDF 547 KB)
Inert Metal Anode Life in Low-Temperature Aluminum Reduction (PDF 92 KB)
Intelligent Potroom Operation: Improved Control of Aluminum (PDF 495 KB)
Final Report: July 2003 (PDF 1.7 MB)
Potlining Additives (PDF 90 KB)
Final Report: August 2004 (PDF 1.6 MB)
Wettable Ceramic-Based Drained Cathode Technology for Aluminum Electrolysis Cells (PDF 82 KB)
Final Report: December 2002 (PDF 355 KB)
Wetted Cathodes for Low-Temperature Aluminum Smelting (PDF 139 KB)
Final Report: September 2002 (PDF 2.6 MB)

Alternative Reduction Technologies

Low-Temperature Reduction of Alumina Using Fluorine Containing Ionic Liquids (PDF 148 KB)

Advanced Hall Heroult Cells

Microwave-Assisted Electrolyte Cell with Inert Anode and Wetted Cathodes (PDF 89 KB)

Technologies Developed by Small Businesses and Inventors, funded by Inventions and Innovation

Development of a Composite Reinforced Aluminum Conductor (Inventions and Innovation) (PDF 85 KB)
Filtering Molten Metal (Inventions and Innovation) (PDF 123 KB)
Novel Ceramic Composition for Hall Heroult Cell Anode Application (Inventions and Innovation) (PDF 399 KB)
Reflective Aluminum Chips (Inventions and Innovation) (PDF 198 KB)
Titanium Matrix Composite Tooling Material for Enhanced Manufacture of Aluminum Die Casting (Inventions and Innovation) (PDF 96 KB)

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