International Journal of Minerals, Metallurgy and Materials

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Particle simulation of the failure process of brittle rock under triaxial compression

2010, 17(5): 507-513. doi: 10.1007/s12613-010-0350-4

中文摘要(385) PDF(11) SpringerLink

摘要:
In order to investigate the failure process of brittle rock under triaxial compression through both experimental and numerical approaches, the particle simulation method was used in numerical simulations and the simulated results were compared with those of the experiment. The numerical simulation results, such as fracture propagation, microcrack distribution, stress-strain response, and damage patterns, were discussed in detail. The simulated results under various confining pressures (0–60 MPa) are in good agreement with the experimental results. The simulated results reveal that rock failure is caused by axial splitting under uniaxial compression. As the confining pressure increases, rock failure occurs in a few localized shear planes and the rock mechanical behavior is changed from brittle to ductile. Consequently, the peak failure strength, microcrack numbers, and the shear plane angle increase, but the ratio of tensile to shear microcracks decreases. The damage formation during the compression simulations indicates that the particle simulation method can produce similar behaviors as those observed through laboratory compression tests.

Experimental and theoretical analysis on the procedure for estimating geo-stresses by the Kaiser effect

Yuan-hui Li, Yu-jiang Yang, Jian-po Liu, Xing-dong Zhao

2010, 17(5): 514-518. doi: 10.1007/s12613-010-0351-3

中文摘要(237) PDF(9) SpringerLink

摘要:
Acoustic emission tests of the core specimens retrieved from boreholes at the depth over 1000 m in Hongtoushan Copper Mine were carried out under uniaxial compressive loading, and the numerical test was also done by using the rock failure process analysis (RFPA^2D) code, based on the procedure for estimating geo-stresses by the Kaiser effect under uniaxial compression. According to the statistical damage mechanics theory, the Kaiser effect mechanism was analyzed. Based on these analyses, it is indicted that the traditional method of estimating geo-stresses by the Kaiser effect is not appropriate, and the result is usually smaller than the real one. Furthermore, the greater confining compression in the rock mass may result in a larger difference between the Kaiser effect stresses acquired from uniaxial loading in laboratory and the real in-situ stresses.

Channel effect of the modified powdery mixture of ammonium nitrate and fuel oil

Chun-ping Wu, Lian-sheng Liu, Xu-guang Wang, Yong Liu, Yin-jun Wang

2010, 17(5): 519-525. doi: 10.1007/s12613-010-0352-2

中文摘要(233) PDF(13) SpringerLink

摘要:
The modified powdery mixture of ammonium nitrate and fuel oil (MPANFO) is a new breed of industrial explosives developed years ago in China. As one of the important properties of an industrial explosive, the channel effect of MPANFO was reported in this paper. A series of experiments were conducted to determine the channel effect of MPANFO. The blasthole diameter range was estimated to avoid the channel effect of MPANFO. Three empirical formulae for predicting the detonation length of MPANFO were provided in terms of the channel effect. Experiments and theoretical analysis indicate that the channel effect of MPANFO is very serious. The reason why the channel effect of MPANFO is worse than that of other industrial explosives is explained at a theoretical level. In addition, some properties of MPANFO, such as sympathetic distance, detonation velocity and brisance, are determined.

Estimation of froth flotation recovery and collision probability based on operational parameters using an artificial neural network

Saeed Chehreh Chelgani, Behzad Shahbazi, Bahram Rezai

2010, 17(5): 526-534. doi: 10.1007/s12613-010-0353-1

中文摘要(346) PDF(14) SpringerLink

摘要:
An artificial neural network and regression procedures were used to predict the recovery and collision probability of quartz flotation concentrate in different operational conditions. Flotation parameters, such as dimensionless numbers (Froude, Reynolds, and Weber), particle size, air flow rate, bubble diameter, and bubble rise velocity, were used as inputs to both methods. The linear regression method shows that the relationships between flotation parameters and the recovery and collision probability of flotation can achieve correlation coefficients (R²) of 0.54 and 0.87, respectively. A feed-forward artificial neural network with 3-3-3-2 arrangement is able to simultaneously estimate the recovery and collision probability as the outputs. In testing stages, the quite satisfactory correlation coefficient of 0.98 was achieved for both outputs. It shows that the proposed neural network models can be used to determine the most advantageous operational conditions for the expected recovery and collision probability in the froth flotation process.

Drying and preheating processes of iron ore pellets in a traveling grate

Jun-xiao Feng, Yu Zhang, Hai-wei Zheng, Xiao-yan Xie, Cai Zhang

2010, 17(5): 535-540. doi: 10.1007/s12613-010-0354-0

中文摘要(347) PDF(18) SpringerLink

摘要:
A mathematical model of drying and preheating processes in a traveling grate was presented based on the laws of mass, momentum, heat transfer, and drying semiempirical relations. A field test was systematically carried out in a traveling grate. The effects of pellet diameter, moisture, grate velocity, and inlet gas temperature on the pellet bed temperature were studied. The average relative error between actual measurements and simulations is less than 7.97%, indicating the validity of the model.

Mathematical model of deoxidization with post stirring in a combined blowing converter

Jie Feng, Yan-ping Bao, Xun Wu, Heng Cui

2010, 17(5): 541-545. doi: 10.1007/s12613-010-0355-z

中文摘要(261) PDF(10) SpringerLink

摘要:
Dissolved oxygen in the steel at the terminal of the converter smelting process is the main cause for the formation of oxide inclusions, and the high terminal oxygen content worsens the steel cleanness. However, post stirring in a combined blowing converter can promote the carbon-oxygen reaction in the liquid steel and reduce the dissolved oxygen content at the terminal of the converter smelting process. Thus, the mathematical model of deoxidization in the post stirring process was obtained, and the rationality of which was further verified by industrial tests. Finally, it is concluded that the product of dissolved carbon and oxygen, i.e. w_[C]·w_[O], decreases obviously after adopting the new technique of post stirring in the combined blowing converter.

A thermodynamic model of calculating mass action concentrations for structural units or ion couples in NaClO₄-H₂O and NaF-H₂O binary solutions and NaClO₄-NaF-H₂O ternary solution

Xue-min Yang, Wei-jie Zhao, Han-jie Guo, Qiang Zhang, Jian Zhang

2010, 17(5): 546-557. doi: 10.1007/s12613-010-0356-y

中文摘要(235) PDF(10) SpringerLink

摘要:
A thermodynamic model of calculating mass action concentrations for structural units or ion couples in NaClO₄-H₂O and NaF-H₂O binary solutions and NaClO₄-NaF-H₂O ternary strong electrolyte aqueous solutions was developed based on the ion and molecule coexistence theory (IMCT). A transformation coefficient was needed to compare the calculated mass action concentration and the reported activity, because they were usually obtained at different standard states and concentration units. The results show that transformation coefficients between the calculated mass action concentrations and the reported activities of the same components change in a very narrow range. The transformed mass action concentrations of structural units or ion couples in NaClO₄-H₂O and NaF-H₂O binary solutions agree well with the reported activities. The transformed mass action concentrations of structural units or ion couples in NaClO₄-NaF-H₂O ternary solution are also in good agreement with the reported activities in a total ionic strength range from 0.1 to 0.9 mol/kg H₂O by the 0.1 mol/kg step with different ionic strength fractions of 0, 0.2, 0.4, 0.5, 0.6, 0.8, and 1, respectively. The results indicate that the developed thermodynamic model can reveal the structural characteristics of binary and ternary strong electrolyte aqueous solutions, and the calculated mass action concentrations of structural units or ion couples also strictly follow the mass action law.

Modeling the austenite-ferrite transformation in microalloyed steel P510L

Wan-hua Yu, Lü-ting Xu, Guang-hong Feng, Chun-jing Wu, Cheng Zhou, Hui-feng Wang

2010, 17(5): 558-566. doi: 10.1007/s12613-010-0357-x

中文摘要(215) PDF(10) SpringerLink

摘要:
Based on experimental results, the transformation kinetics and cooling characteristics of low-carbon steel were analyzed and modeled to quantitatively link the operational parameters of a process with the properties. From the continuous cooling transformation results, comparisons of the start temperature of austenite-ferrite transformation among three models were analyzed, and the optimal lnk and n, which are the parameters in the Avrami equation, were determined by applying two regression models at different cooling rates. The transformation kinetics during continuous cooling was determined. Furthermore, reasonable agreements between experimental results and predictions were obtained, which can demonstrate the rationality of the established models.

Toughening mechanisms of a high-strength acicular ferrite steel heavy plate

Zhi-qiang Cao, Yan-ping Bao, Zheng-hai Xia, Deng Luo, Ai-min Guo, Kai-ming Wu

2010, 17(5): 567-572. doi: 10.1007/s12613-010-0358-9

中文摘要(304) PDF(17) SpringerLink

摘要:
An ultra-low carbon acicular ferrite steel heavy plate was obtained with an advanced thermo-mechanical control process-relaxed precipitation controlled transformation (TMCP-RPC) at Xiangtan Steel, Valin Group. The heavy plate has a tensile strength of approximately 600 MPa with a lower yield ratio. The impact toughness of the heavy plate achieves 280 J at -40℃. The fine-grained mixed microstructures of the heavy plate mainly consist of acicular ferrite, granular bainite, and polygonal ferrite. The high strength and excellent toughness of the heavy plate are attributed to the formation of acicular ferrite microstructure. The prevention of blocks of martensite/retained austenite (M/A) and the higher cleanness are also responsible for the superior toughness.

Test research on sticking mechanism during hot rolling of SUS 430 ferritic stainless steel

Jun-xian Liu, Yong-jun Zhang, Jing-tao Han

2010, 17(5): 573-578. doi: 10.1007/s12613-010-0359-8

中文摘要(244) PDF(14) SpringerLink

摘要:
The sticking phenomenon during hot rolling of SUS 430 ferritic stainless steel was investigated by means of a two-disc type high-temperature wear tester. The test results indicate that sticking particles on the surfaces of high chromium steel (HiCr) and high-speed steel (HSS) rolls undergo nucleation, growth, and saturation stages. Grooves on the roll surface generated by grinding provide nucleation sites for sticking particles. The number of sticking particles on the HiCr roll surface is greater than that on the HSS roll surface. The average surface roughnesses (R_a) of HiCr and HSS rolls change from 0.502 and 0.493 μm at the initial stage to 0.837 and 0.530 μm at the saturation stage, respectively. The test further proves that the sticking behavior is strongly dependent on roll materials, and the HSS roll is more beneficial to prevent particles sticking compared with the HiCr roll under the same hot-rolling conditions.

Hydrogen induced cracking of X80 pipeline steel

Chao-fang Dong, Kui Xiao, Zhi-yong Liu, Wen-jing Yang, Xiao-gang Li

2010, 17(5): 579-586. doi: 10.1007/s12613-010-0360-2

中文摘要(316) PDF(13) SpringerLink

摘要:
The hydrogen-induced cracking (HIC) behavior of X80 pipeline steel was studied by means of electrochemical charging, hydrogen permeation tests, tension test, and scanning electron microscopy (SEM). The experimental results indicate that the increase of charging time and charging current density or the decrease of the solution pH value leads to an increase of the hydrogen content in X80 steel, which plays a key role in the initiation and propagation of HIC. It is found that the majority of macro-inclusions within the as-used X80 steel do not constitute a direct threat to HIC except aluminum oxides, which directly or indirectly lead to HIC. The hydrogen trap density at room temperature is estimated to be pretty high, and this is an essential reason why the steel is sensitive to HIC. After hydrogen charging, the elongation loss rate and area reduction of X80 steel decline obviously, taking a noticeable sign of hydrogen-induced plasticity damages. It is demonstrated that the losses of these plastic parameters have a linear relation to the fracture size due to hydrogen.

Precipitation and stability of reversed austenite in 9Ni steel

Yue-hui Yang, Qing-wu Cai, Di Tang, Hui-bin Wu

2010, 17(5): 587-595. doi: 10.1007/s12613-010-0361-1

中文摘要(315) PDF(20) SpringerLink

摘要:
A new method was used to analyze the factors affecting the precipitation of reversed austenite during tempering. The samples were kept at various tempering temperatures for 10 min and their length changes were recorded. Then, the precipitation of reversed austenite which led to the length reduction was shown by thermal expansion curves. The results show that the effects of process parameters on the precipitation of reversed austenite can be determined more accurately by this method than by X-ray diffraction. When the quenching and tempering process is adopted, both the lower quenching temperature and higher tempering temperature can promote the precipitation of reversed austenite during tempering; and when the quenching, lamellarizing, and tempering process is used, intercritical quenching is considered beneficial to the precipitation of reversed austenite in the subsequent tempering because of Ni segregation during holding at the intercritical temperature.

Computational algorithms to simulate the steel continuous casting

A. Ramírez-López, G. Soto-Cortés, M. Palomar-Pardavé, M. A. Romero-Romo, R. Aguilar-López

2010, 17(5): 596-607. doi: 10.1007/s12613-010-0362-0

中文摘要(261) PDF(11) SpringerLink

摘要:
Computational simulation is a very powerful tool to analyze industrial processes to reduce operating risks and improve profits from equipment. The present work describes the development of some computational algorithms based on the numerical method to create a simulator for the continuous casting process, which is the most popular method to produce steel products for metallurgical industries. The kinematics of industrial processing was computationally reproduced using subroutines logically programmed. The cast steel by each strand was calculated using an iterative method nested in the main loop. The process was repeated at each time step (Δt) to calculate the casting time, simultaneously, the steel billets produced were counted and stored. The subroutines were used for creating a computational representation of a continuous casting plant (CCP) and displaying the simulation of the steel displacement through the CCP. These algorithms have been developed to create a simulator using the programming language C++. Algorithms for computer animation of the continuous casting process were created using a graphical user interface (GUI). Finally, the simulator functionality was shown and validated by comparing with the industrial information of the steel production of three casters.

Allowable variation of cold-rolled strip transverse profiles in high tension

Xiao-chen Wang, Quan Yang, Xiao-zhong Du, Zheng-yi Jiang

2010, 17(5): 608-616. doi: 10.1007/s12613-010-0363-z

中文摘要(180) PDF(7) SpringerLink

摘要:
The formation mechanism of the cold-rolled strip shape with high tension was studied. An advanced method to calculate the allowable variation of strip transverse profiles was established by the strip buckling criterion, which can be more properly used in cold rolling. With this method, the aim allowable variation of the product strip transverse profile and the required transverse profile range of incoming strips can be reached. Besides, this method has been successfully applied in a domestic tandem cold mill, and the transverse profile range of incoming strips suggested with this method is more practicable and complete. Consequently, the good performance is acquired.

Microstructural evolution in electroformed nickel shaped-charge liners with nano-sized grains undergone deformation at ultrahigh strain rate

Feng Yang, Chun-hua Li, Sheng-wei Cheng, Lei Wang, Wen-huai Tian

2010, 17(5): 617-623. doi: 10.1007/s12613-010-0364-y

中文摘要(237) PDF(16) SpringerLink

摘要:
Nickel shaped-charge liners with nano-sized grains were prepared by the electroforming technique, and the deformation at ultrahigh strain rate was performed by explosive detonation. The as-formed and post-deformed microstructures of electroformed nickel shaped-charge liners with nano-sized grains were observed by means of transmission electron microscopy, and the orientation distribution of the grains was analyzed by the electron backscattering pattern (EBSP) technique. The melting phenomenon in the jet fragment and the recovery and recrystallization in the slug after plastic deformation at ultrahigh-strain rate were observed in the ultrafine-grained nickel shaped-charge liners. The research evidence shows that dynamic recovery and recrystallization play an important role in plastic deformation at ultrahigh strain rate.

Retrogression characteristics of a novel Al-Cu-Li-X alloy

Zhi-shan Yuan, Zheng Lu, Xiu-liang Wu, You-hua Xie, Sheng-long Dai, Chang-sheng Li

2010, 17(5): 624-628. doi: 10.1007/s12613-010-0365-x

中文摘要(246) PDF(7) SpringerLink

摘要:
Retrogression characteristics of a novel Al-Cu-Li-X alloy of 2A97 were studied by hardness testing, transmission electron microscopy (TEM), and differential scanning calorimetry (DSC). The retrogression treatments of aging at 155℃ for 12 h followed by aging at 220 and 240℃ were chosen by determining the peak temperature of δ' precipitation at 230℃ by DSC. The retrogression treatment at a lower temperature of 220℃ causes the precipitation and coarsening of δ' and θ' phases in the matrix, resulting in an increase in hardness. Retrogression at a higher temperature of 240℃ causes the dissolution and coarsening of δ' and θ' precipitates in the matrix and on the grain boundaries, resulting in a decrease in hardness. Microstructural changes upon retrogression including the appearance of equilibrium precipitates such as T₁, T₂, δ', and θ are confirmed by the selected area electron diffraction and the bright and dark field image analysis.

A Cu-Cr alloy with nano and microscale Cr particles produced in a water-cooled copper mold

Seyyed Mohammd Hossein Hejazi, Fatemeh Majidi, Gholam Hossein Akbari

2010, 17(5): 629-634. doi: 10.1007/s12613-010-0366-9

中文摘要(285) PDF(8) SpringerLink

摘要:
Microstructures have profound effects on the hardness and strength of Cu-Cr alloys. The microstructures of a Cu-Cr alloy cast in a water-cooled copper mold were studied in the present work. The scanning electron microscopy (SEM) results show that there are the copper matrix saturated with chromium, spherical precipitates of chromium separated from liquid phase during cooling before the initiation of solidification, and a eutectic phase in grain boundary areas. To investigate the effect of age-hardening treatment on the microstructures and properties of the material, some samples were subsequently age-hardened in a salt bath and investigated by transmission electron microscopy (TEM). The results show that coherent precipitates with the diameter of 11 nm are detectable in the samples before and after the age-hardening stage. Of course, the volume fraction of coherent precipitates is higher after the aging process.

Deposition behavior of multi-particle impact in cold spraying process

Xiang-lin Zhou, Xiang-kun Wu, Hui-hua Guo, Jian-guo Wang, Ji-shan Zhang

2010, 17(5): 635-640. doi: 10.1007/s12613-010-0367-8

中文摘要(295) PDF(6) SpringerLink

摘要:
In the practical cold-spraying process, a number of particles impact onto a substrate and then form a coating. To study the deformation behavior and multi-particle interactions, single-particle, two-particle, and three-particle impacts were simulated using the AN-SYS/LS-DYNA version 970. A copper coating was prepared and scanning electron microscopy (SEM) was employed to analyze the microstructures of the powders and the coating. Numerical results reveal that the critical deposition velocity is 600 m/s for a copper particle/copper substrate. The particles deform more fully due to multi-particle interactions, such as tamping, interlocking, and extrusion effects. The compression ratio increases from 40% to 70% as a result of the tamping effect. This is beneficial for achieving the cold-sprayed coating. The multi-particle morphology and compression ratio in the experiment are consistent with those of simulation results. Based on these results, the coating of high performance can be prepared through selecting appropriate parameters and suitable pre-treatment processes.

Formation mechanism of an aluminium-based chemical conversion coating on AZ91D magnesium alloy

Wei-ping Li, Xi-mei Wang, Li-qun Zhu, Wen Li

2010, 17(5): 641-647. doi: 10.1007/s12613-010-0368-7

中文摘要(243) PDF(7) SpringerLink

摘要:
An environmentally clean aluminium-based conversion coating on AZ91D magnesium alloy was studied in aluminium nitrate solutions. The morphology, composition, structure, and formation mechanism of the coating were investigated in detail using scanning electron microscopy/energy dispersion spectrometry, X-ray diffraction, transmission electron microscopy, and electrochemical corrosion tests. The results show that the conversion coating is composed of magnesium, aluminium, and oxygen, and shows an amorphous structure. In the initial stage of coating formation, the grain-like nucleus is composed of Al₁₀O₁₅·xH₂O, (Al₂O₃)_5.333, Al₂O₃, AlO(OH), MgAl₂O₄, (Mg_0.88Al_0.12)(Al_0.94Mg_0.06)₂O₄, and (Mg_0.68Al_0.32)(Al_0.84Mg_0.16)₂O₄. The conversion coating formed in the 0.01 mol/L aluminium nitrate solution for 15 min can improve the corrosion resistance of the magnesium alloy greatly. The discussion reveals that the possible formation mechanism for the aluminium-based conversion coating is the reduction reaction on micro-cathodic sites due to the electrochemically heterogeneous magnesium alloy substrate.

Machining studies of die cast aluminum alloy-silicon carbide composites

Thambu Sornakumar, Marimuthu Kathiresan

2010, 17(5): 648-653. doi: 10.1007/s12613-010-0369-6

中文摘要(361) PDF(16) SpringerLink

摘要:
Metal matrix composites (MMCs) with high specific stiffness, high strength, improved wear resistance, and thermal properties are being increasingly used in advanced structural, aerospace, automotive, electronics, and wear applications. Aluminum alloy-silicon carbide composites were developed using a new combination of the vortex method and the pressure die-casting technique in the present work. Machining studies were conducted on the aluminum alloy-silicon carbide (SiC) composite work pieces using high speed steel (HSS) end-mill tools in a milling machine at different speeds and feeds. The quantitative studies on the machined work piece show that the surface finish is better for higher speeds and lower feeds. The surface roughness of the plain aluminum alloy is better than that of the aluminum alloy-silicon carbide composites. The studies on tool wear show that flank wear increases with speed and feed. The end-mill tool wear is higher on machining the aluminum alloy-silicon carbide composites than on machining the plain aluminum alloy.

Development of high volume rice husk ash alumino silicate composites

Ubolluk Rattanasak, Prinya Chindaprasirt, Prasert Suwanvitaya

2010, 17(5): 654-659. doi: 10.1007/s12613-010-0370-0

中文摘要(315) PDF(13) SpringerLink

摘要:
The development of high volume rice husk ash (RHA) alumino silicate composites (ASC) was studied. RHA was used as the source of silica and aluminium in the ASC. The mass ratios of RHA:Al(OH)3 of 70:30 to 99:1 were tested. The results indicate that the obtained ASC mortars are not stable and disintegrate in water. Boric acid was introduced to the mixture to overcome this problem. Stable ASC mortars with high RHA:Al(OH)₃ mass ratios of 90:10 to 97.5:2.5 were obtained with the use of boric acid and 115℃ curing. The compressive strength of the mortar of 20 MPa was gained. The immersion test indicates that high volume RHA ASC mortars show good resistance in 3vol% H₂SO₄ solution, but is slightly less durable in 5wt% MgSO₄ solution.

Preparation and film-growing mechanism of hydrous zirconia coated on TiO₂

Jie Li, Ti-chang Sun, Yong Wang, Li-na Wang, Jing-kui Qu, Tao Qi

2010, 17(5): 660-667. doi: 10.1007/s12613-010-0371-z

中文摘要(223) PDF(7) SpringerLink

摘要:
To overcome the photochemical activity of rutile used as a pigment and improve its durability in application, hydrous zirconia-coated TiO₂ was prepared by the precipitation method. High-resolution transmission electron microscope (HRTEM) and X-ray photoelectron spectroscopy (XPS) were used to characterize the morphology and surface structure of hydrous zirconia-coated TiO₂. The ζ-potential and ultraviolet (UV) absorption of both coated and uncoated rutile were examined. The results show that hydrous zirconia can not only improve the durability but also raise the lightness. A suitable ZrO₂ content of hydrous zirconia-coated TiO₂ is about 1.0wt%, and a dense film on the surface of rutile can be formed with better pigmentary properties. Based on the thermodynamic analysis, the zirconia-coating process and the film growth mechanism were discussed.

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