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Rule 1. Provide a Good Quality Melt

Immediately prior to casting, the melt shall be prepared and treated if necessary using the best current practice. The aim is to provide a melt at the correct temperature, correct chemistry and with low residual levels of dissolved gas and inclusions. Inclusions, particularly oxide films, are reintroduced into the liquid metal by poor handling, such as pouring from furnaces and ladles prior to casting. Procedures to avoid such reintroduction of damage need to be introduced.

The figure below shows the hydrogen solubility in aluminum and two of its alloys, illustrating the abrupt fall in solubility on solidification.

The chart below shows mechanical property regimes for an Al-4.5 Cu - 1.5 Mg alloy in filtered and unfiltered conditions [Hedjazi et al. (1975)].

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