Abstract: Methods of treating spent pot lining (SPL) and bauxite residue are disclosed. The treatment processes are capable of producing a ferrosilicon alloy, an off-gas, and/or a byproduct material resulting in the safe disposal of SPL and bauxite residue. The treatment processes may be continuously carried out in an electric arc furnace at a temperature in the range of from about 1500° C. to about 2200° C. and for a period of from about 15 to about 100 minutes.

Abstract: A method of producing aluminum castings which includes the steps of casting a molten alloy, contacting the surface of the molten alloy with a humidified atmosphere and solidifying the alloy. The method is particularly suited for aluminum-magnesium alloys such as AA 5XXX and 7XXX series alloys. In addition to reducing the thickness of the surface oxide layer formed during casting, the method also provides improved surface quality of cast products and reduces subsequent remedial re-work or scalping. An improved aluminum-magnesium cast alloy product is also disclosed.