Strong churning technique produces more uniformly structured large aluminum casts

Industrial aluminum slabs are typically produced by blending small amounts of copper or manganese in a reservoir of molten aluminum that is rapidly cooled, a process known as direct-chill casting. Variations in the way these elements solidify can yield uneven results that weaken the final product, with castings sometimes ending on the scrap heap. Controlling the distribution of strengthening elements to aluminum throughout a casting is thus key to reducing waste and improving product reliability.