Hydrogen gas porosity

Hydrogen gas porosity is an aluminium casting defect under the form of a porosity or void in an aluminium casting caused by a high
level of hydrogen gas (H2) dissolved in the aluminium atliquid phase. Because the solubility of hydrogen in solid aluminium is much
smaller than in liquid aluminium, when the aluminium freezes, the dissolved hydrogen gas creates porosity in solid aluminium.

Aluminum smelters and aluminumfoundries want to produce high quality aluminum and shape castings with minimum porosity
. This
can be obtained by reducing the amount of hydrogen in the liquid aluminium alloy
.

Contents
The hydrogen problem
Direct hydrogen measurement
Hydrogen analyzer
Operation principle
References

The hydrogen problem

Hydrogen forms whenever molten aluminium comes into contact with water vapor, and easily dissolves into the melt. The gas tends
to come out of the solution and forms bubbles when the melt solidifies.

The detrimental effects arising from the presence of an excess of dissolved hydrogen in aluminium are numerous. Hydrogen causes
porosity in aluminum products leading to many casting defects, reduced mechanical properties like fatigue and lower corrosion
resistance. Several methods are used to reduce the amount of dissolved hydrogen from the melt, such as furnace fluxing prior to the
[1] during the casting process.
casting process or using in-line degasing equipment

Direct hydrogen measurement

An on-line method of measuring hydrogen in aluminum is then required to characterize and optimize the process, which helps ensure
the quality of outgoing products and monitors the performance of these degassing processes. Traditional laboratory methods, such as
hot extraction, are too expensive for routine quality assurance, and too slow for effective process control. The Reduced Pressure Test
(RPT) is often used on the foundry floor. The RPT is a semi-quantitative method with limited accuracy that provides an indication of
the hydrogen level.

Hydrogen analyzer
A hydrogen analyzer[2] can be used for direct measurement of hydrogen in liquid aluminium. Direct monitoring of hydrogen is
possible using an on-line quantitative measurement technology based on a closed-loop gas recirculation method though a porous
ceramic probe.

[3]
Since its introduction in 1989, this gas recirculation method has been increasingly used by major aluminum producers.

Operation principle
The closed loop recirculation is a proven method of directly monitoring hydrogen in
molten aluminium. A small volume of carrier gas, usually nitrogen, is brought in
contact with the melt by means of an immersed probe, and is continuously
recirculated in the closed loop until its hydrogen content reaches equilibrium with
the vapor pressure of H2 in the melt. The H2 concentration in the gas is measured
and converted into a reading of the gas concentration in the metal. This method is
fast, reproducible and accurate, and can be used “on-line” on the cast shop floor
.

The amount of H2 in the gas loop of the instrument is determined by a thermal

conductivity sensor, which provides high reproducibility and a broad measurement
range.

Hydrogen Gas Analyser

References
1. Bernd Prillhofer, Holm Böttcher, DEVELOPMENT AND PRACTICAL PERFORMANCE CH
ARACTERISTICS OF A
NEW IMPELLER FOR METAL TREATMENT IN CASTING/HOLDING FURNACES, LightMetals 2009, The Minerals,
Metals & Materials Society
2. Peter D. Waite, IMPROVED METALLURGICAL UNDERSTANDING OF THE ALCAN COMPACT DEGASSER, Light
Metals 1998, The Minerals, Metals and Materials Society
, 1998, pp 791-796
3. In Situ Hydrogen Measurements in Liquid Al-Si foundry Alloys, Florence Paray
, McGill University

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