In a lubricant composition suitable for use in the manufacture of aluminum
alloys comprising a lubricant base, the improvement wherein the lubricant
composition further comprises: an effective amount of water, surfactant,
and a high viscosity organic material having a low vapor pressure. It is
believed that this mixture provides a method for uniformly distributing
the surface oxide at the meniscus for casting applications and increasing
meniscus stability. Uniform distribution of the oxide and increased
stability at the meniscus reduces vertical fold formation that can lead
to cracks in the aluminum ingot. In addition, the mixture promotes
uniform heat transfer around the mold. Uniform heat transfer around the
mold allows the solidifying aluminum alloy to stay in contact with the
mold longer and form stronger ingot shells. A process for continuous or
semi-continuous casting of aluminum alloys via the use of this lubricant
composition is also disclosed.