The book draws on the author’s advanced research to provide a unique application of physical metallurgy to direct chill (DC) casting technology. He examines structure and defect formation— including macrosegregation and hot tearing. Each technology-centered chapter provides historical background before reviewing current developments. The author supports his conclusions with computer simulation results that have been correlated with highly progressive experimental data. He presents a logical system of structure and defect formation based on the specific features of the DC casting process. He also demonstrates that the seemingly controversial results reported in literature are, in fact, caused by the different ratio of the same mechanisms. Compiling recent results and data, the book discusses the fundamentals of solidification together with metallurgical and technological aspects of DC casting. It gives new insight and perspective into DC casting research.