Aluminum Association Molten Metal Incident Report 2024

The Aluminum Association has published its Annual Molten Metal Incident Report, which tracks explosion and injury events reported worldwide in aluminum melting and casting operations. In 2024, there were 141 reported incidents, down from 156 in 2023 and well below the record high of 198 in 2022. Notably, two severe Force 3 explosions occurred internationally during billet steady-state casting, resulting in seven fatalities, one serious injury, and multiple minor injuries.

While overall incident counts have trended downward compared to the early 2000s, the data shows a concerning increase in Force 2 explosions, which now make up nearly 20% of reported cases. Melting incidents, especially during scrap charging, remain a recurring source of risk, although the overall number of melting explosions in 2024 was at its lowest in over a decade. The report also highlights wet or rusty drain pans as a persistent cause of casting and transfer explosions, accounting for nearly one-fifth of all incidents in those operations.

For nonferrous foundry owners, this report reinforces the importance of rigorous charge preparation, equipment inspection, and continued investment in hazard awareness. Although the industry has made progress in lowering injury rates over time, the severity of recent international incidents demonstrates that vigilance remains essential.

You can read the full 2024 Molten Metal Incident Report and review detailed charts from the Aluminum Association here: Aluminum Association – Health & Safety.