Implementation of CASTfill Low-Dross Pouring System for Ingot Casting


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Producing low-dross ingots has been a long-term goal in aluminium cast houses. The patented CASTfill technology [1] is a low-dross and high-productivity pouring system developed to fulfil this demand. This paper describes the research methods used during the development of CASTfill; now in service at Boyne Smelters Limited (BSL) since August 2009. The importance of combining scientific modelling and testing procedures with process operability, maintainability and durability to ensure the success of new technology in a production facility is also highlighted. Ingot assessments showed that the latest CASTfill design greatly reduced dross generated during mould filling. Improved ingot packaging and reduced variation of ingot weights were also observed as the results of a more tranquil flow of molten aluminium through CASTfill and its uniquely modular design.



Edited by:

A.Prasad, J.A. Taylor and J.F. Grandfield






V. Nguyen et al., "Implementation of CASTfill Low-Dross Pouring System for Ingot Casting", Materials Science Forum, Vol. 693, pp. 227-234, 2011

Online since:

July 2011




[1] CAST CRC, Ingot Casting Apparatus and Method, PCT/AU2005/001025, WO2006/005131, EP1781435B1.

[2] J. Grandfield, P. Rohan, V. Nguyen, K. Oswald, M. Prakash and P. Cleary, in: Aluminium Cast House Technology 2005, edited by J. Taylor, I. Bainbridge and J. Grandfield (2005), pp.137-144.

DOI: 10.1002/9781118787304.ch24

[3] M. Barkhudarov and G. Wei, in: Modeling of Casting, Welding and Advanced Solidification Processes – XI, edited by C-A Gandin & M. Bellet, TMS (2006), pp.71-78.

[4] V. Nguyen, P. Rohan, J. Grandfield, K. Naidoo, and K. Oswald, in: Jim Evans Honorary Symposium, edited by B.Q. Li, B.G. Thomas, L. Zhang, F.M. Doyle and A. Campbell, TMS (2010), pp.123-130.

[5] FLOW-3D: Computational Modeling Power for Scientists and Engineers, Flow Science Inc, report FSI-87-00-01 (1987).

[6] J. F. Grandfield, T.T. Nguyen, P. Rohan and V. Nguyen, in: Solidification Processing 2007, edited by Howard Jones (2007), pp.507-511.

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