Semi-continuous direct-chill (DC) casting holds a prominent position in commercial aluminium alloy processing, especially in production of large sized ingots.Macrosegregation, which is the non-uniform chemical composition over the length scale of a casting, is one of the major defects that occur during this process. The fact that macrosegregation is essentially unaffected by subsequent heat treatment (hence constitutes an irreversible defect) leaves us with little choice but to control it during the casting stage. Despite over a century of research in the phenomenon of macrosegregation in castings and good understanding of underlying mechanisms, the contributions of these mechanisms in the overall macrosegregation picture; and interplay between these mechanisms and the structure formation during solidification are still unclear. This review attempts to fill this gap based on the published data and own results. The following features make this review unique: results of computer simulations are used in order to separate the effects of different macrosegregation mechanisms. The issue of grain refining is specifically discussed in relation to macrosegregation. This report is structured as follows. Macrosegregation as a phenomenon is defined in the Introduction. In Part 2, direct-chill casting, the role of process parameters and the evolution of structural features in the as-cast billets are described. In Part 3, macrosegregation mechanisms are elucidated in a historical perspective and the correlation with DC casting process parameters and structural features are made. The issue of how to control macrosegregation in direct-chill casting is also dealt with in Part 3. In Part 4, the effect of grain refining on macrosegregation is introduced, the current understanding is described and the contentious issues are outlined. The review is finished with conclusion remarks and outline for the future research.

Duplex grain structure consisting of coarse-cell and fine-cell dendritic grains is frequently found in the central portion of direct-chill cast billets and ingots. Coarse-cell grains are usually considered as free-floating grains settled to the bottom of the billet sump. These grains are assumed to be solute-lean and contribute to the negative centerline segregation. In this paper the contribution of coarse-cell and fine-cell grains to macrosegregation is for the first time studied experimentally by direct measurements of their composition. It is shown that the coarse-cell, floating grains are depleted of solute and the areas of their accumulation contribute to the negative macrosegregation. The areas of fine-cell grains can be either enriched in solute or be close to the nominal composition. It is argued that their composition results from the interplay between thermo-solutal and shrinkage-induced flows. The roles of casting speed and grain refining are also under scrutiny in this paper.

Lithium is an effective, well-established treatment for bipolar disorder (BD). However, the mechanisms of its action, and reasons for variations in clinical response, are unclear. We used neural precursor cells (NPCs) and lymphoblastoid cell lines (LCLs), from BD patients characterized for clinical response to lithium (using the “Alda scale” and “NIMH Retrospective Life chart method”), to interrogate cellular phenotypes related to both disease and clinical lithium response. NPCs from two biologically related BD patients who differed in their clinical response to lithium were compared with healthy controls. RNA-Seq and analysis, mitochondrial membrane potential (MMP), cell viability, and cell proliferation parameters were assessed, with and without in vitro lithium. These parameters were also examined in LCLs from 25 BD patients (16 lithium responders and 9 non-responders), and 12 controls. MMP was lower in both NPCs and LCLs from BD; but it was reversed with in vitro lithium only in LCLs, and this was unrelated to clinical lithium response. The higher cell proliferation observed in BD was unaffected by in vitro lithium. Cell death was greater in BD. However, LCLs from clinical lithium responders could be rescued by addition of in vitro lithium. In vitro lithium also enhanced BCL2 and GSK3B expression in these cells. Our findings indicate cellular phenotypes related to the disease (MMP, cell proliferation) in both NPCs and LCLs; and those related to clinical lithium response (cell viability, BCL2/GSK3B expression) in LCLs.

The addition of grain refiners during industrial direct chill (DC) casting of aluminum billets promotes formation of smaller equiaxed grains with obvious advantages. However, the role of grain refining in the extent of macrosegregation in DC cast Al alloys is still unclear. This is particularly evident in the case of commercial aluminum alloys with various alloying elements. In this work, the structure and associated macrosegregation patterns in DC cast AA 2024 (Al–Cu–Mg) aluminum alloy billets were studied at different casting speeds. The concentration profiles of Cu and Mg, measured along the billet diameter, showed an expected negative segregation in the center and close to the surface. The severity of segregation increases at a higher casting speed. On the other hand, grain refining does not seem to have any dramatic effect on the macrosegregation patterns. The experimental results are correlated with microstructural observations such as grain size and morphology and the occurrence of “floating” grains across the cross-section of the billet.

Direct-chill (DC) cast billets 192 mm in diameter of an Al-Cu-Mg alloy were examined in detail with the aim to reveal the effects of grain refining (GR) and casting speed on structure, ''floating'' grains, and centerline macrosegregation. Experimental results show that grain size and dendrite arm spacing (DAS) tend to coarsen toward the billet center with a local refinement DAS in the center. In GR billets, grain size does not change much with the cooling rate, casting speed, and grain refiner amount. Coarse-DAS (floating) grains are observed around the billet axis regardless of GR and the amount of Ti, though their amount is significantly higher in GR billets. Macrosegregation profiles show a negligible influence of GR, while the effect of casting speed is large. The concept of solute-depleted floating grains contributing to the centerline macrosegregation is substantiated by microsegregation measurements, which show that, independent of GR, coarse dendrite branches have a depleted concentration plateau in contrast to the fine dendrite arms.