Fundamental experimentation and theoretical modeling for prevention of molten aluminum-water steam explosions in casting pits

Explosive interactions between molten aluminum and water are being studied with a focus on fundamentals to determine what causes robust-enough triggers for explosion onset, to determine the extent of protection provided from various coatings and to develop a novel methodology for prevention. The workscope includes experimentation and mathematical modeling of the interactions between molten metals and water at various different coated and uncoated surfaces. Phenomenological issues related to surface wettability, gas generation from coatings, charring of coatings, inertial constraint, melt temperature, water temperature, external shocks are being investigated systematically to gage their relative impact on triggerability of surface-assisted steam explosion. The steam explosion triggering studies (SETS) facility was designed and constructed as a rapid-turnaround, cost-effective, and safe means to address these phenomenological issues and to derive quantitative, practically-fundamental data for situations covering melt masses relocating over submerged surfaces ranging from a few grams to {approximately} 1,000 kg. Initial testing has provided insightful results which are very consistent with empirical field observations taken over the past 40 years. This paper provides the scientific basis of the technical approach for design and operation of the SETS facility, along with key results and insights from tests conducted so far