A molten aluminum metal filter system having a holding tank operable to receive a molten metal, a filter device to filter the molten metal, a pump operable to continuously recirculate the molten metal through the filter device, and a casting device to receive a filtered molten metal from the filter device. The filter device includes a chamber, an inlet channel operable to convey the molten metal into the chamber, and an outlet channel operable to convey unused filtered molten metal out of the chamber and back into the holding tank. Removeable filter elements are disposed in series within the inlet channel. The removable filter elements are configured to remove inclusions above a determined diameter size from the molten metal. The filter device includes at least one nozzle operable to direct an inert gas flow to blanket the molten metal and a heating element.

A molten aluminum metal filter system having a holding tank operable to receive a molten metal, a filter device to filter the molten metal, a pump operable to continuously recirculate the molten metal through the filter device, and a casting device to receive a filtered molten metal from the filter device. The filter device includes a chamber, an inlet channel operable to convey the molten metal into the chamber, and an outlet channel operable to convey unused filtered molten metal out of the chamber and back into the holding tank. Removeable filter elements are disposed in series within the inlet channel. The removable filter elements are configured to remove inclusions above a determined diameter size from the molten metal. The filter device includes at least one nozzle operable to direct an inert gas flow to blanket the molten metal and a heating element.

Method of casting aluminum alloy ingot including lithium, including: preparing at least two molten aluminum based alloys in separate furnaces, first alloy with composition A free from lithium as purposive alloying element, and second alloy with composition B including lithium as purposive alloying element; transferring the first alloy via metal conveying trough from the furnace to a casting station; initiating casting an ingot and casting the first alloy to required length L1 in the casting direction; subsequently transferring the second alloy via metal conveying trough from the furnace to the casting station while simultaneously stopping transfer of the first alloy to the casting station; casting the second alloy from an end surface of the cast first alloy at length L1 to an additional required length L2 in the casting direction; cropping the cast ingot at a bottom thereof at a length greater than of equal to cast length L1.

Method of casting aluminum alloy ingot including lithium, including: preparing at least two molten aluminum based alloys in separate furnaces, first alloy with composition A free from lithium as purposive alloying element, and second alloy with composition B including lithium as purposive alloying element; transferring the first alloy via metal conveying trough from the furnace to a casting station; initiating casting an ingot and casting the first alloy to required length L1 in the casting direction; subsequently transferring the second alloy via metal conveying trough from the furnace to the casting station while simultaneously stopping transfer of the first alloy to the casting station; casting the second alloy from an end surface of the cast first alloy at length L1 to an additional required length L2 in the casting direction; cropping the cast ingot at a bottom thereof at a length greater than of equal to cast length L1.

A molten aluminum metal filter system having a holding tank operable to receive a molten metal, a filter device to filter the molten metal, a pump operable to continuously recirculate the molten metal through the filter device, and a casting device to receive a filtered molten metal from the filter device. The filter device includes a chamber, an inlet channel operable to convey the molten metal into the chamber, and an outlet channel operable to convey unused filtered molten metal out of the chamber and back into the holding tank. Removeable filter elements are disposed in series within the inlet channel. The removable filter elements are configured to remove inclusions above a determined diameter size from the molten metal. The filter device includes at least one nozzle operable to direct an inert gas flow to blanket the molten metal and a heating element.

A molten aluminum metal filter system having a holding tank operable to receive a molten metal, a filter device to filter the molten metal, a pump operable to continuously recirculate the molten metal through the filter device, and a casting device to receive a filtered molten metal from the filter device. The filter device includes a chamber, an inlet channel operable to convey the molten metal into the chamber, and an outlet channel operable to convey unused filtered molten metal out of the chamber and back into the holding tank. Removeable filter elements are disposed in series within the inlet channel. The removable filter elements are configured to remove inclusions above a determined diameter size from the molten metal. The filter device includes at least one nozzle operable to direct an inert gas flow to blanket the molten metal and a heating element.

A molten metal filtration apparatus is provided. The apparatus includes a filter chamber having a floor, a metal inlet, a metal outlet, and a wall surface adapted to be partitioned by at least one filter element having an open cell structure characterized by a plurality of interconnected voids. The filter element partitions the filter chamber. At least one heater device is provided at an elevation within the filtration chamber that is equal to or below the filter element.

A molten metal filtration apparatus is provided. The apparatus includes a filter chamber having a floor, a metal inlet, a metal outlet, and a wall surface adapted to be partitioned by at least one filter element having an open cell structure characterized by a plurality of interconnected voids. The filter element partitions the filter chamber. At least one heater device is provided at an elevation within the filtration chamber that is equal to or below the filter element.