International Journal of Minerals, Metallurgy and Materials

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Laboratory tests to study the influence of rock stress confinement on the performances of TBM discs in tunnels

N. Innaurato, C. Oggeri, P. Oreste, R. Vinai

2011, 18(3): 253-259. doi: 10.1007/s12613-011-0431-z

中文摘要(271) PDF(9) SpringerLink

摘要:
To clarify some aspects of rock destruction with a disc acting on a high confined tunnel face, a series of tests were carried out to examine fracture mechanisms under an indenter that simulates the tunnel boring machine (TBM) tool action, in the presence of an adjacent groove, when a state of stress (lateral confinement) is imposed on a rock sample. These tests proved the importance of carefully establishing the optimal distance of grooves produced by discs acting on a confined surface, and the value (as a mere order of magnitude) of the increase of the thrust to produce the initiation of chip formation, as long as the confinement pressure becomes greater.

UV/visible spectroscopic analysis of CO³⁺ and CO²⁺ during the dissolution of cobalt from mixed Co-Cu oxidized ores

J. Ndalamo, A. F. Mulaba-Bafubiandi, B. B. Mamba

2011, 18(3): 260-269. doi: 10.1007/s12613-011-0432-y

中文摘要(266) PDF(21) SpringerLink

摘要:
The leaching of cobalt from four-mixed Co-Cu oxidized ores containing cobalt at levels ranging from 0.5wt% to 34wt% was studied and the results has been reported. Conventional dissolution of these oxidized Co-Cu ores with diluted H₂SO₄ and SO₂ as a reducing agent resulted in a substantial improvement in the solution based recovery of cobalt. UV/visible spectroscopic analysis of the leached solutions indicated that the increased cobalt content in the solution was a result of flushing the acidified cobalt leaching solution with SO₂. Furthermore, UV/visible spectroscopy confirmed that as SO₂ was flushed into the acidified leaching solution, Co³⁺ bearing minerals were reduced to the readily soluble Co²⁺ bearing minerals, and this resulted in the increase of total cobalt in the collected solution. The mechanism of the reduction of Co³⁺ to Co²⁺ bearing minerals when SO₂ is flushed during the leaching of mixed Co-Cu oxidized ores, including the stability trends of Co³⁺, Co²⁺, and Cu²⁺ complexes, as shown by their UV/visible spectra, are also discussed.

Sintering characteristics of fluxes and their structure optimization

Gen-sheng Feng, Sheng-li Wu, Hong-liang Han, Luo-wen Ma, Wei-zhong Jiang, Xiao-qin Liu

2011, 18(3): 270-276. doi: 10.1007/s12613-011-0433-x

中文摘要(250) PDF(10) SpringerLink

摘要:
Sintering characteristics of common fluxes and sintering blending ores, such as mineralization capacity, liquid generation capacity, consolidation strength, were examined to master the behavior and effect of fluxes in sintering. Based on fundamental studies, sinter pot tests were carried out to obtain the principles of optimizing the sinter flux structure. The results showed that strong mineralization capacity, liquid phase generation capacity, and consolidation strength were obtained as sintering blending ores combined with the calcareous flux, while relatively poor sintering characteristics were obtained as sintering blending ores combined with the magnesian flux. High reactive quicklime should be used as much as possible in the sintering mixture. It reached better sintering results while quicklime was used instead of limestone and its appropriate proportion in the sintering mixture was around 4wt%. On the premise of ensuring the MgO content, the dolomite amount should be decreased, and the substitution of quicklime for dolomite caused better sintering results. The granularity of serpentine should be refined with a proper size smaller than 2 mm. The application of the divided addition method brought the best sintering performance with 30wt% of quicklime and 70wt% of fuel.

Basic properties of steel plant dust and technological properties of direct reduction

Xue-feng She, Jing-song Wang, Qing-guo Xue, Yin-gui Ding, Sheng-sheng Zhang, Jie-ji Dong, Hui Zeng

2011, 18(3): 277-284. doi: 10.1007/s12613-011-0434-9

中文摘要(220) PDF(10) SpringerLink

摘要:
Basic physicochemical properties of the dust from Laiwu Iron and Steel Co. Ltd. were studied. It is found that C, Zn, K, Na, etc. exist in the fabric filter dust, off gas (OG) sludge, fine ash in converter, and electrical field dust in sinter. Among these, OG sludge gives the finest particle, more than 90% of which is less than 2.51 μm. The dust can lead to a serious negative influence on the production of sintering and blast furnaces (BF) if it is recycled in sintering. The briquette and reduction experimental results showed that the qualified strength could be obtained in the case of 8wt% molasses or 4wt% QT-10 added as binders. Also, more than 75% of metallization ratio, more than 95% of dezincing ratio, as well as more than 80% of K and Na removal rates were achieved for the briquettes kept at 1250℃ for 15 min during the direct reduction process. SEM observation indicated that the rates of indirect reduction and carbonization became dominating when the briquettes were kept at 1250℃ for 6 min.

Cooling process of iron ore pellets in an annular cooler

Jun-xiao Feng, Kai-li Liang, Zhi-bin Sun, Jing-hai Xu, Yong-ming Zhang, Jin-bao Yang

2011, 18(3): 285-291. doi: 10.1007/s12613-011-0435-8

中文摘要(363) PDF(13) SpringerLink

摘要:
A 3-D mathematical model was presented for the cooling process of iron ore pellets based on the laws of mass, momentum, and heat transfer. The flow, pressure, and temperature fields were obtained by numerical simulation with the commercial software FLUENT. In order to verify the model, a mass and energy balance field test was systematically carried out on an annular cooler in Shougang Mining Company. The maximum relative errors of temperature, pressure, and velocity between computational and testing results are 2.87%, -8.11%, and 7.14%, respectively, indicating the validity of the model. Further, the effects of process parameters, such as pellet diameter, bed thickness, air velocity, and temperature, on the pellet bed temperature profiles were studied.

Optimization of flow control devices in a single-strand slab continuous casting tundish

Ning Ding, Yan-ping Bao, Qi-song Sun, Li-feng Wang

2011, 18(3): 292-296. doi: 10.1007/s12613-011-0436-7

中文摘要(307) PDF(13) SpringerLink

摘要:
The optimization of flow control devices in a single-slab continuous casting tundish was carried out by physical modeling, and the optimized scheme was presented. With the optimal tundish configuration, the minimum residence time of liquid steel was increased by 1.4 times, the peak concentration time was increased by 97%, and the dead volume fraction was decreased by 72%. A mathematical model for molten steel in the tundish was established by using the fluid dynamics package Fluent. The velocity field, concentration field, and the residence time distribution (RTD) curves of molten steel flow before and after optimization were obtained. Experimental results showed that the reasonable configuration with flow control devices can improve the fluid flow characteristics in the tundish. The results of industrial application show that the nonmetallic inclusion area ratio in casting slabs is decreased by 32% with the optimal tundish configuration.

Effect of roller shapes on strip buckling in a continuous annealing furnace

Jing Yang, Di Tang, Lan Su, Hai-tao Jiang, Quan Yang

2011, 18(3): 297-302. doi: 10.1007/s12613-011-0437-6

中文摘要(262) PDF(14) SpringerLink

摘要:
The effect of roller shapes on strip buckling in a continuous annealing furnace was focused on. The tensile stress distribution, the transverse compressive stress, and the critical buckling stress of the strip were studied by the finite element method (FEM) when the flat roller, crown roller, single taper roller, and double taper roller were used, respectively. Simulation results show that strip buckling is most likely to occur with the crown roller, then the double taper roller, and finally the single taper roller. Also, strip buckling can not occur when the flat roller is used. Considering strip snaking, the single taper roller and double taper roller are suggested in the continuous annealing furnace. The double taper roller with a better strip snaking-prevention ability should be applied in the sections with high strip temperature, and the single taper roller with a better buckling-prevention ability should be used in the sections with low strip temperature.

Materials databases for the computational materials scientist

Marcel H. F. Sluiter, Darko Simonovic, Emre S. Tasci

2011, 18(3): 303-308. doi: 10.1007/s12613-011-0438-5

中文摘要(324) PDF(11) SpringerLink

摘要:
Until recently, many computational materials scientists have shown little interest in materials databases. This is now changing because the amount of computational data is rapidly increasing and the potential for data mining provides unique opportunities for discovery and optimization. Here, a few examples of such opportunities are discussed relating to structural analysis and classification, discovery of correlations between materials properties, and discovery of unsuspected compounds.

Precipitation behaviors of X80 acicular ferrite pipeline steel

Ai-min Zhao, Yan Wang, Yin-li Chen, Di Tang, Xu-tao Gao, Bi-qiang Zuo

2011, 18(3): 309-313. doi: 10.1007/s12613-011-0439-4

中文摘要(224) PDF(11) SpringerLink

摘要:
The precipitation behaviors of X80 acicular ferrite pipeline steel were investigated by using transmission electron microscopy (TEM) and energy dispersive spectroscopy (EDS). The results show that dendritic precipitates in the as-cast steel slabs precipitate mainly in grain boundaries, and these dendritic precipitates dissolve and re-precipitate to two kinds of carbonitrides: Ti- and Nb-rich (Ti, Nb)(C, N) carbonitrides during reheating. Four types of precipitates mainly exist in the hot rolled plate: Ti-rich carbonitrides resulted from the dendritic carbonitrides undissolved during the reheating process; Ti-rich carbonitrides re-precipitated along austenite grain boundaries during the reheating process; NbC carbides mainly heterogeneously nucleated on the small pre-existing Nb-rich carbonitrides in the hot rolling process; and NbC carbides precipitated on dislocations during hot rolling.

Behaviors of different inhibitors during secondary recrystallization of a grain-orientated silicon steel

Feng-e Cui, Ping Yang, Wei-min Mao

2011, 18(3): 314-319. doi: 10.1007/s12613-011-0440-y

中文摘要(209) PDF(10) SpringerLink

摘要:
The behaviors of different inhibitors including their composition, size, distribution, coalescence and coarsening were experimentally studied. It was observed that during secondary recrystallization of the tested steel, the key inhibition effect was produced by Cu₂S and AlN, but not MnS. With the increase of temperature, the size distributions of AlN and Cu₂S were changed to some extent. However, significant changes in particle size were not observed. The initial temperature of abnormal growth was determined by measuring the evolution of particle sizes and their distribution density during heat treatment. AlN and Cu₂S are the dominant inhibitors and both are necessary, which is verified by calculating the Zener factor.

Corrosion products of reverse crevice corrosion of copper

Lin Lu, Xiao-gang Li

2011, 18(3): 320-324. doi: 10.1007/s12613-011-0441-x

中文摘要(396) PDF(9) SpringerLink

摘要:
Open-circuit potential measurements and Raman spectroscopy were used to investigate the reverse crevice corrosion phenomenon and its corresponding corrosion products. With the aid of these techniques, the existence of reverse-crevice corrosion in copper was verified, i.e., while the surface of a crevice was corrosion free, the outside surface of the copper was attacked. The processes associated with this phenomenon were classified into three phases, and different compositions of the corrosion products were determined. Raman spectra showed that copper and Cu₂O were found in the crevice, while CuO, Cu₂O, and CuCl₂ were the corrosion products on the bold surface. Based on these findings, a hypothesis relating to the three phases of reverse crevice corrosion has been proposed.

Microstructure and properties of laser direct deposited CuNi17Al3Fe1.5Cr alloy

Yong-zhong Zhang, Can Huang, Rui Vilar

2011, 18(3): 325-329. doi: 10.1007/s12613-011-0442-9

中文摘要(297) PDF(8) SpringerLink

摘要:
Thin walls of a copper-base alloy with the nominal composition CuNi17Al3Fe1.5Cr were successfully prepared by laser direct deposition additive manufacturing. The microstructure, as revealed by optical and scanning electron microscopy, indicated that the deposited material was fully dense and with a dendritic microstructure. The dendrites are parallel to the build-up direction, which is also the heat conduction direction during deposition. X-ray diffraction analysis results show that the deposited material is composed of a single phase and a copper-based solid solution. Some precipitate particles of metal silicides were observed in the interdendritic region by scanning electron microscopy. The ultimate tensile strength along the laser scanning direction reaches 735 MPa. The hardness is about Hv_0.1 300.

Processing limit maps for the stable deformation of dieless drawing

Yong He, Xue-feng Liu, Jian-xin Xie, Hong-gang Zhang

2011, 18(3): 330-337. doi: 10.1007/s12613-011-0443-8

中文摘要(269) PDF(8) SpringerLink

摘要:
Tin bronze wires were produced by dieless drawing. The effects of heating power, the distance between cooler and heater as well as feeding speed on the diameter, the temperature field, and the deformation region profile of the wires were investigated. The results indicated that each processing parameter exhibited both lower and upper limits of stable deformation based on the criterion of stable deformation with the diameter fluctuation of ±0.05 mm. Both the temperature and its gradient of the deformation region increased with increasing heating power under stable deformation, but decreased with an increase in feeding speed. As the distance between cooler and heater increased, the temperature of the deformation region increased and the slope of the deformation region profile decreased. The processing limit map of stable deformation exhibited a closed curve and the unstable deformation consisted of wire breakage and diameter fluctuations.

Influence of deformation on precipitation in AZ80 magnesium alloy

Ping Yang, Li-na Wang, Qing-ge Xie, Ji-zhong Li, Hua Ding, Lin-lin Lu

2011, 18(3): 338-343. doi: 10.1007/s12613-011-0444-7

中文摘要(264) PDF(10) SpringerLink

摘要:
Precipitates in the conventionally processed (solution treatment followed by aging) AZ80 alloy are coarse, cellular, and incoherent. They nucleate and grow on the basal planes of the matrix or distribute discontinuously in the alloy. Their unique morphology and undesired distribution make them ineffective for precipitation strengthening. This condition, however, can be modified by applying selected deformation and heat treatment conditions. The effect of deformation and heat treatment on the morphology and distribution of precipitates has been studied. Deformation was introduced by hot extrusion, cold rolling, or equal channel angular pressing (ECAP). The microstructures were characterized using scanning electron microscopy, transmission electron microscopy, and X-ray diffraction. The results showed that cold deformation improved precipitation more significantly than hot deformation, and twinning promoted precipitation more effectively than slip. When ECAP was applied, the Bc-route induced more precipitates than the A-route.

Deformation behavior and microstructural evolution during hot compression of an α+β Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy

Gao-feng Liu, Shang-zhou Zhang, Li-qing Chen, Jian-xun Qiu

2011, 18(3): 344-351. doi: 10.1007/s12613-011-0445-6

中文摘要(296) PDF(9) SpringerLink

摘要:
The effect of processing parameters on the flow response and microstructural evolution of the α+β titanium alloy Ti-6.5Al-3.5Mo-1.5Zr-0.3Si has been studied by conducting isothermal hot compressive tests at a strain rate of 0.01–10 s^-1 at 860–1100℃. The true stress-true strain curves of the sample hot-compressed in the α+β phase region exhibit a peak stress followed by continuous flow softening, whereas in the β region, the flow stress attains a steady-state regime. At a strain rate of 10 s^-1, the alloy exhibits plastic flow instabilities. According to the kinetic rate equation, the apparent activation energies are estimated to be about 674–705 kJ/mol in the α+β region and 308–335 kJ/mol in the β region, respectively. When deformed in the α+β region, the globularization process of the α colony structure occurs, and α dynamic recrystallized microstructures are observed to show bimodal. Dynamic recrystallization can take place in the β region irrespective of starting deformed structures.

Doping effect on thermoelectric properties of nonstoichiometric AgSbTe₂ compounds

Sheng-nan Zhang, Guang-yu Jiang, Tie-jun Zhu, Xin-bing Zhao, Sheng-hui Yang

2011, 18(3): 352-356. doi: 10.1007/s12613-011-0446-5

中文摘要(362) PDF(13) SpringerLink

摘要:
Nonstoichiometric ternary thermoelectric materials Ag_0.84Sb_1.15M_0.01Te_2.16 (M=Ce, Yb, Cu) were prepared by a direct melt-quench and hot press process. The carrier concentration of all the samples increased after doping. Thermoelectric properties, namely electrical conductivity, Seebeck coefficient, and thermal conductivity, were measured from 300 to 673 K. The phase transition occurring at about 418 K representing the phase transition from β-Ag₂Te to α-Ag₂Te influenced the electrical transport properties. The electrical conductivities of Ce and Yb doped samples increased after doping from 1.9×10⁴ to 2.5×10⁴ and 2.3×10⁴ S·m^-1, respectively, at 673 K. Also, at room temperature, the Seebeck coefficient of the Ce doped sample relatively increased corresponding to the high carrier concentration due to the changes in the band structure. However, all the thermal conductivities increased after doping at low temperature. Because of the higher thermal conductivity, the dimensionless figure of merit ZT of these doped samples has not been improved.

Preparation and characterization of in-site regenerated TiO₂-ACFs photocatalyst

Rong Yang, Jian-hua Liu, Song-mei Li

2011, 18(3): 357-363. doi: 10.1007/s12613-011-0447-4

中文摘要(280) PDF(7) SpringerLink

摘要:
In-site regenerated titanium dioxide-activated carbon fibers (TiO₂-ACFs) photocatalyst was prepared by the sol-gel method. Detailed surface and structural characterization of the TiO₂-ACFs photocatalyst was carried out. The photoactivity of TiO₂-ACFs under ultraviolet irradiation was compared with original ACFs and pure TiO₂ by the degradation of methylene blue aqueous solution. The degradation efficiency by the TiO₂ (5wt%)-ACFs sample is much higher than that by TiO₂ and ACFs. The results show that the photocatalysis by TiO₂-ACFs is a six-step process. The adsorption-transfer-photocatalysis rate of TiO₂-ACFs is higher than the adsorption-photocatalysis rate of TiO₂, so the photocatalysis rate of the TiO₂-ACFs system is higher than that of TiO₂ photocatalyst.

Effect of chemical admixtures on properties of high-calcium fly ash geopolymer

Ubolluk Rattanasak, Kanokwan Pankhet, Prinya Chindaprasirt

2011, 18(3): 364-369. doi: 10.1007/s12613-011-0448-3

中文摘要(396) PDF(14) SpringerLink

摘要:
Owing to the high viscosity of sodium silicate solution, fly ash geopolymer has the problems of low workability and rapid setting time. Therefore, the effect of chemical admixtures on the properties of fly ash geopolymer was studied to overcome the rapid set of the geopolymer in this paper. High-calcium fly ash and alkaline solution were used as starting materials to synthesize the geopolymer. Calcium chloride, calcium sulfate, sodium sulfate, and sucrose at dosages of 1wt% and 2wt% of fly ash were selected as admixtures based on concrete knowledge to improve the properties of the geopolymer. The setting time, compressive strength, and degree of reaction were recorded, and the microstructure was examined. The results show that calcium chloride significantly shortens both the initial and final setting times of the geopolymer paste. In addition, sucrose also delays the final setting time significantly. The degrees of reaction of fly ash in the geopolymer paste with the admixtures are all higher than those of the control paste. This contributes to the obvious increases in compressive strength.

A time-saving method to assess the efficiency of corrosion inhibitors by electro osmosis

Chun-lei Geng, Duan Weng

2011, 18(3): 370-376. doi: 10.1007/s12613-011-0449-2

中文摘要(293) PDF(7) SpringerLink

摘要:
The corrosion inhibitor is one of the most important technologies to enhance the durability of steel-reinforced concrete. A kind of time-saving method was developed to assess the inhibitor efficiency by using a 32 V electric field to accelerate chloride ion migration in concrete. Potentiodynamic polarization scanning test was used to evaluate the corrosion states. The comprehensive efficiency of an inhibitor should be assessed in two aspects: resistance to chloride ion permeability and inhibiting efficiency. The specimens with different mixing amount of sodium nitrite and migration corrosion inhibitors were used to verify the accuracy and reliability of this method. The results show the differences in inhibiting efficiency of the inhibitors clearly, indicating the reliability of this time-saving method.

Electrochemical behavior of different shelled microcapsule composite copper coatings

Xiu-qing Xu, Yan-hong Guo, Wei-ping Li, Li-qun Zhu

2011, 18(3): 377-384. doi: 10.1007/s12613-011-0450-9

中文摘要(265) PDF(7) SpringerLink

摘要:
Copper/liquid microcapsule composite coatings with polyvinyl alcohol (PVA), gelatin or methyl cellulose (MC) as shell materials were prepared by electrodeposition. The influence of shell materials on the corrosion resistance of the composite coatings in 0.1 M H₂SO₄ was investigated by means of electrochemical techniques, scanning electron microscopy (SEM), and energy dispersion spectrometry (EDS). The results show that the participation of microcapsules can enhance the corrosion resistance of the composite coatings compared with the traditional copper layer. Based on the analysis of electrochemical test results, the release ways of microcapsules were deduced. Gelatin and MC as the shell materials of microcapsules are easy to release quickly in the composite coating. On the contrary, the releasing speed of PVA microcapsules is relatively slow due to their characteristics.

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2011年第18卷第3期