Assessment of melt cleanliness in A356.2 aluminium casting alloy using the porous disc filtration apparatus technique: Part II Inclusion analysis

The data obtained on inclusion types and concentrations has been analysed in the present part in terms of their effect on filtration time and fluidity (measured by the length of solidified metal in quartz tubes). The dross, i.e., the oxide layer that formed on the surface of the molten metal, was carefully collected and its mass determined; then it was examined in a scanning electron microscope equipped with an energy-dispersive X-ray system. The results show that inclusions are not the only parameter to be considered. More importantly, it is Al2O3 (films or particles), which seems to be the deciding factor. It is found, however, that it is quite difficult to separate the individual role of each parameter using the porous disc filtration apparatus (PoDFA) technique, i.e., sampling, without disturbing the molten metal. Sampling would introduce undesirable oxides into the PoDFA crucible, resulting in an artificial increase in the filtration time. Increasing the holding periods of the molten metal increases the quantity of dross. In all cases, the skimmed dross is wet, i.e., it contains an appreciable amount of molten metal. The main types of oxides in the dross are MgO, MgAl2O4, Al4C3 and Al2O3. This revised version was published online in November 2006 with corrections to the Cover Date.