Has Recent Advances in Direct Chill Casting Made Us Less Safe?

Abstract

The frequency and severity of molten metal explosions in our industry has increased over the past decade. This paper considers if recent technology advances in direct chill casting processes resulted in our industry downplaying this hazard. Through analysis of past research studies, molten metal incident reporting data and review of the recent explosion that destroyed the Noranda Aluminium cast house. The causes of molten metal explosions are considered and explored. I argue that recent molten metal explosions could have been prevented if the past research studies’ conclusions were adopted as best practices.