International Journal of Minerals, Metallurgy and Materials

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Effect and mechanism of siderite on reverse flotation of hematite

Wan-zhong Yin, Dong Li, Xi-mei Luo, Jin Yao, Qian-yu Sun

2016, 23(4): 373-379. doi: 10.1007/s12613-016-1246-8

中文摘要(330) PDF(24) SpringerLink

摘要:
The effects of siderite on reverse flotation of hematite were investigated using micro flotation, adsorption tests, and Fourier transform infrared spectroscopy. The flotation results show that interactions between siderite and quartz are the main reasons that siderite significantly influences the floatability. The interactions are attributed to dissolved siderite species and fine siderite particles. The interaction due to the dissolved species is, however, dominant. Derjaguin-Landau-Verwey-Overbeek (DLVO) theoretical calculations reveal that adhesion on quartz increases when the siderite particle size decreases and that fine particles partly influence quartz floatability. Chemical solution calculations indicate that the dissolved species of siderite might convert the surface of active quartz to CaCO₃ precipitates that can be depressed by starch. The theoretical calculations are in good agreement with the results of adsorption tests and FTIR spectroscopy and explain the reasons why siderite significantly influences reverse flotation of hematite.

Mechanochemical leaching of chalcopyrite concentrate by sulfuric acid

Farhad Khorramshahi Mohammadabad, Sina Hejazi, Jalil Vahdati khaki, Abolfazl Babakhani

2016, 23(4): 380-388. doi: 10.1007/s12613-016-1247-7

中文摘要(275) PDF(14) SpringerLink

摘要:
This study aimed to introduce a new cost-effective methodology for increasing the leaching efficiency of chalcopyrite concentrates at ambient temperature and pressure. Mechanical activation was employed during the leaching (mechanochemical leaching) of chalcopyrite concentrates in a sulfuric acid medium at room temperature and atmospheric pressure. High energy ball milling process was used during the leaching to provide the mechanochemical leaching condition, and atomic absorption spectroscopy and cyclic voltammetry were used to determine the leaching behavior of chalcopyrite. Moreover, X-ray diffraction and scanning electron microscopy were used to characterize the chalcopyrite powder before and after leaching. The results demonstrated that mechanochemical leaching was effective; the extraction of copper increased significantly and continuously. Although the leaching efficiency of chalcopyrite was very low at ambient temperature, the percentages of copper dissolved in the presence of hydrogen peroxide (H₂O₂) and ferric sulfate (Fe₂(SO₄)₃) after 20 h of mechanochemical leaching reached 28% and 33%, respectively. Given the efficiency of the developed method and the facts that it does not require the use of an autoclave and can be conducted at room temperature and atmospheric pressure, it represents an economical and easy-to-use method for the leaching industry.

Comparison of reduction disintegration characteristics of TiO₂-rich burdens prepared with sintering process and composite agglomeration process

Zheng-wei Yu, Guang-hui Li, Chen Liu, Feng Zhou, Zhi-wei Peng, Tao Jiang

2016, 23(4): 389-398. doi: 10.1007/s12613-016-1248-6

中文摘要(238) PDF(13) SpringerLink

摘要:
To reveal the impact of the composite agglomeration process (CAP) on the reduction disintegration properties of TiO₂-rich ironmaking burden for a blast furnace, the reduction disintegration indices (RDIs), mineral constituents, and microstructure of the products prepared by the CAP and the traditional sintering process (TSP) were investigated. The results showed that, compared to the sinter with a basicity of 2.0 prepared by the TSP, the RDI_+6.3 and the RDI_+3.15 of the CAP product with the same basicity increased by 28.2wt% and 13.7wt%, respectively, whereas the RDI_-0.5 decreased by 2.7wt%. The analysis of the mineral constituents and microstructure of the products indicated that the decreasing titanohematite content decreased the volume expansion during reduction. Meanwhile, the decreasing perovskite content decreased its detrimental effect on the reduction disintegration properties. In addition, the higher silicoferrite of calcium and aluminum (SFCA) content improved the strength of the CAP product. Together, these factors result in an improvement of the RDI of the CAP products. In addition, compared to the sinter, the reduced CAP products clearly contained fewer cracks, which also led to mitigation of reduction disintegration.

Research on droplet formation and dripping behavior during the electroslag remelting process

Yu-long Cao, Yan-wu Dong, Zhou-hua Jiang, Hai-bo Cao, Dong Hou, Qian-long Feng

2016, 23(4): 399-407. doi: 10.1007/s12613-016-1249-5

中文摘要(233) PDF(8) SpringerLink

摘要:
A better understanding of droplet formation and dripping behavior would be useful in the efficient removal of impurity elements and nonmetallic inclusions from liquid metals. In the present work, we developed a transparent experimental apparatus to study the mechanisms of droplet formation and the effects of filling ratio on droplet behavior during the electroslag remelting (ESR) process. A high-speed camera was used to clearly observe, at small time scales, the droplet formation and dripping phenomenon at the slag/metal interface during a stable ESR process. The results illustrate that a two-stage process for droplet formation and dripping occurs during the ESR process and that the droplet diameter exhibits a parabolic distribution with increasing filling ratio because of the different shape and thermal state of the electrode tip. This work also confirms that a relatively large filling ratio reduces electricity consumption and improves ingot quality.

Variation and optimization of acid-dissolved aluminum content in stainless steel

Le-chen Zhang, Yan-ping Bao, Min Wang, Chao-jie Zhang

2016, 23(4): 408-416. doi: 10.1007/s12613-016-1250-z

中文摘要(313) PDF(9) SpringerLink

摘要:
As a key step in secondary refining, the deoxidation process in clean stainless steel production is widely researched by many scholars. In this study, vacuum oxygen decarburization (VOD) deoxidation refining in a 40-t electric arc furnace + VOD + ingot casting process was analyzed and optimized on the basis of Al deoxidation of stainless steel and thermodynamic equilibrium reactions between the slag and steel. Under good stirring conditions in VOD, the deoxidation reaction reaches equilibrium rapidly, and the oxygen activity in the bulk steel is controlled by the slag composition and Al content. A basicity of 3–5 and an Al content greater than 0.015wt% in the melt resulted in an oxygen content less than 0.0006wt%. In addition, the dissolved oxygen content decreased slightly when the Al content in the steel was greater than 0.02wt%. Because of the equilibrium of the Si–O reaction between the slag and steel, the activity of SiO₂ will increase while the Si content increases; thus, the Si content should be lowered to enable the formation of a high-basicity slag. A high-basicity, low-Al₂O₃ slag and an increased Si content will reduce the Al consumption caused by SiO₂ reduction.

Kinetics and formation mechanisms of intragranular ferrite in V-N microalloyed 600 MPa high strength rebar steel

Jing Zhang, Fu-ming Wang, Chang-rong Li

2016, 23(4): 417-424. doi: 10.1007/s12613-016-1251-y

中文摘要(191) PDF(7) SpringerLink

摘要:
To systematically investigate the kinetics and formation mechanisms of intragranular ferrite (IGF), isothermal heat treatment in the temperature range of 450℃ to 600℃ with holding for 30 s to 300 s, analysis of the corresponding microstructures, and observation of the precipitated particles were conducted in V-N microalloyed 600 MPa high strength rebar steel. The potency of V(C,N) for IGF nucleation was also analyzed statistically. The results show that the dominant microstructure transforms from bainite (B) and acicular ferrite (AF) to grain boundary ferrite (GBF), intragranular polygonal ferrite (IPF), and pearlite (P) as the isothermal temperature increases from 450℃ to 600℃. When the holding time at 600℃ is extended from 30 s to 60 s, 120 s, and 300 s, the GBF content ranges from 6.0vol% to 6.5vol% and the IPF content increases from 0.5vol% to 2.8vol%, 13.1vol%, and 13.5vol%, respectively, because the ferrite transformation preferentially occurs at the grain boundaries and then occurs at the austenite grains. Notably, V(C,N) particles are the most effective nucleation site for the formation of IPF, accounting for 51% of the said formation.

Mechanism of hot-rolling crack formation in lean duplex stainless steel 2101

Zhi-hui Feng, Jing-yuan Li, Yi-de Wang

2016, 23(4): 425-433. doi: 10.1007/s12613-016-1252-x

中文摘要(360) PDF(20) SpringerLink

摘要:
The thermoplasticity of duplex stainless steel 2205 (DSS2205) is better than that of lean duplex steel 2101 (LDX2101), which undergoes severe cracking during hot rolling. The microstructure, microhardness, phase ratio, and recrystallization dependence of the deformation compatibility of LDX2101 and DSS2205 were investigated using optical microscopy (OM), electron backscatter diffraction (EBSD), Thermo-Calc software, and transmission electron microscopy (TEM). The results showed that the phase-ratio transformations of LDX2101 and DSS2205 were almost equal under the condition of increasing solution temperature. Thus, the phase transformation was not the main cause for the hot plasticity difference of these two steels. The grain size of LDX2101 was substantially greater than that of DSS2205, and the microhardness difference of LDX2101 was larger than that of DSS2205. This difference hinders the transfer of strain from ferrite to austenite. In the rolling process, the ferrite grains of LDX2101 underwent continuous softening and were substantially refined. However, although little recrystallization occurred at the boundaries of austenite, serious deformation accumulated in the interior of austenite, leading to a substantial increase in hardness. The main cause of crack formation is the microhardness difference between ferrite and austenite.

Effects of copper content on the shell characteristics of hollow steel spheres manufactured using an advanced powder metallurgy technique

Hamid Sazegaran, Ali-Reza Kiani-Rashid, Jalil Vahdati Khaki

2016, 23(4): 434-441. doi: 10.1007/s12613-016-1253-9

中文摘要(250) PDF(8) SpringerLink

摘要:
Metallic hollow spheres are used as base materials in the manufacture of hollow sphere structures and metallic foams. In this study, steel hollow spheres were successfully manufactured using an advanced powder metallurgy technique. The spheres’ shells were characterized by optical microscopy in conjunction with microstructural image analysis software, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and X-ray diffraction (XRD). The microscopic evaluations revealed that the shells consist of sintered iron powder, sintered copper powder, sodium silicate, and porosity regions. In addition, the effects of copper content on various parameters such as shell defects, microcracks, thickness, and porosities were investigated. The results indicated that increasing the copper content results in decreases in the surface fraction of shell porosities and the number of microcracks and an increase in shell thickness.

Solidification microstructure formation in HK40 and HH40 alloys

Xian-fei Ding, Dong-fang Liu, Pei-liang Guo, Yun-rong Zheng, Qiang Feng

2016, 23(4): 442-448. doi: 10.1007/s12613-016-1254-8

中文摘要(323) PDF(25) SpringerLink

摘要:
The microstructure formation processes in HK40 and HH40 alloys were investigated through JmatPro calculations and quenching performed during directional solidification. The phase transition routes of HK40 and HH40 alloys were determined as L → L + γ → L + γ + M₇C₃ → γ + M₇C₃ → γ + M₇C₃ + M₂₃C₆→ γ + M₂₃C₆ and L → L + δ → L + δ + γ→ L + δ + γ + M₂₃C₆ δ + γ + M₂₃C₆, respectively. The solidification mode was determined to be the austenitic mode (A mode) in HK40 alloy and the ferritic–austenitic solidification mode (FA mode) in HH40 alloy. In HK40 alloy, eutectic carbides directly precipitate in a liquid and coarsen during cooling. The primary γ dendrites grow at the 60° angle to each other. On the other hand, in HH40 alloy, residual δ forms because of the incomplete transformation from δ to γ. Cr₂₃C₆ carbide is produced in solid delta ferrite δ but not directly in liquid HH40 alloy. Because of carbide formation in the solid phase and no rapid growth of the dendrite in a non-preferential direction, HH40 alloy is more resistant to cast defect formation than HK40 alloy.

Effects of Fe content on the microstructure and properties of CuNi10FeMn1 alloy tubes fabricated by HCCM horizontal continuous casting

Yan-bin Jiang, Jun Xu, Xin-hua Liu, Jian-xin Xie

2016, 23(4): 449-457. doi: 10.1007/s12613-016-1255-7

中文摘要(326) PDF(13) SpringerLink

摘要:
Heating-cooling combined mold (HCCM) horizontal continuous casting technology developed by our research group was used to produce high axial columnar-grained CuNi10FeMn1 alloy tubes with different Fe contents. The effects of Fe content (1.08wt%–2.01wt%) on the microstructure, segregation, and flushing corrosion resistance in simulated flowing seawater as well as the mechanical properties of the alloy tubes were investigated. The results show that when the Fe content is increased from 1.08wt% to 2.01wt%, the segregation degree of Ni and Fe elements increases, and the segregation coefficient of Ni and Fe elements falls from 0.92 to 0.70 and from 0.92 to 0.63, respectively. With increasing Fe content, the corrosion rate of the alloy decreases initially and then increases. When the Fe content is 1.83wt%, the corrosion rate approaches the minimum and dense, less-defect corrosion films, which contain rich Ni and Fe elements, form on the surface of the alloy; these films effectively protect the α-matrix and reduce the corrosion rate. When the Fe content is increased from 1.08wt% to 2.01wt%, the tensile strength of the alloy tube increases from 204 MPa to 236 MPa, while the elongation to failure changes slightly about 46%, indicating the excellent workability of the CuNi10FeMn1 alloy tubes.

Effect of magnesium on the aluminothermic reduction rate of zinc oxide obtained from spent alkaline battery anodes for the preparation of Al–Zn–Mg alloys

Rocio Ochoa, Alfredo Flores, Jesus Torres

2016, 23(4): 458-465. doi: 10.1007/s12613-016-1256-6

中文摘要(326) PDF(18) SpringerLink

摘要:
The aluminothermic reduction of zinc oxide (ZnO) from alkaline battery anodes using molten Al may be a good option for the elaboration of secondary 7000-series alloys. This process is affected by the initial content of Mg within molten Al, which decreases the surface tension of the molten metal and conversely increases the wettability of ZnO particles. The effect of initial Mg concentration on the aluminothermic reduction rate of ZnO was analyzed at the following values: 0.90wt%, 1.20wt%, 4.00t%, 4.25wt%, and 4.40wt%. The ZnO particles were incorporated by mechanical agitation using a graphite paddle inside a bath of molten Al maintained at a constant temperature of 1123 K and at a constant agitation speed of 250 r/min, the treatment time was 240 min and the ZnO particle size was 450-500 mesh. The results show an increase in Zn concentration in the prepared alloys up to 5.43wt% for the highest initial concentration of Mg. The reaction products obtained were characterized by scanning electron microscopy and X-ray diffraction, and the efficiency of the reaction was measured on the basis of the different concentrations of Mg studied.

Growth in solution of hooked Ni–Fe fibers by oriented rotation and attachment approaches

Yong Zhang, Fang Liu, Wei-ze Zhang

2016, 23(4): 466-473. doi: 10.1007/s12613-016-1257-5

中文摘要(255) PDF(7) SpringerLink

摘要:
Inspired by the curved branches of fractal trees, hooked Ni–Fe fibers were grown in situ in Ni–Fe composite coatings on a spheroidal graphite cast iron substrate. These hooked Ni–Fe fibers exhibited inclination angles of about 39°, which was in accordance with the theoretical prediction of 37°. Ni–Fe nanostructures self-assembled to form dendrites and evolved into hooked fibers by an oriented attachment reaction. The orientation rotation of Ni–Fe nanostructures played an important role in the growth of curved hooked Ni–Fe fibers. During sliding wear tests, the volume loss of the spheroidal graphite cast iron substrate was 2.2 times as large as that of the Ni–Fe coating reinforced by hooked fibers. The good load-transferring ability of hooked Ni–Fe fibers led to an improvement in their wear properties during wear tests.

Preparation and electrochemical properties of carbon-coated LiFePO₄ hollow nanofibers

Bin-bin Wei, Yan-bo Wu, Fang-yuan Yu, Ya-nan Zhou

2016, 23(4): 474-480. doi: 10.1007/s12613-016-1258-4

中文摘要(275) PDF(12) SpringerLink

摘要:
Carbon-coated LiFePO₄ hollow nanofibers as cathode materials for Li-ion batteries were obtained by coaxial electrospinning. X-ray diffraction, scanning electron microscopy, transmission electron microscopy, Brunauer–Emmett–Teller specific surface area analysis, galvanostatic charge–discharge, and electrochemical impedance spectroscopy (EIS) were employed to investigate the crystalline structure, morphology, and electrochemical performance of the as-prepared hollow nanofibers. The results indicate that the carbon-coated LiFePO₄ hollow nanofibers have good long-term cycling performance and good rate capability: at a current density of 0.2C (1.0C = 170 mA·g^-1) in the voltage range of 2.5–4.2 V, the cathode materials achieve an initial discharge specific capacity of 153.16 mAh·g^-1 with a first charge–discharge coulombic efficiency of more than 97%, as well as a high capacity retention of 99% after 10 cycles; moreover, the materials can retain a specific capacity of 135.68 mAh·g^-1, even at 2C.

Effect of SrCO₃ addition on the dynamic compressive strength of ZTA

Ali Arab, Roslan Ahmad, Zainal Arifin Ahmad

2016, 23(4): 481-489. doi: 10.1007/s12613-016-1259-3

中文摘要(305) PDF(10) SpringerLink

摘要:
Ceramic parts usually experience dynamic load in armor applications. Therefore, studying the dynamic behaviors of ceramics is important. Limited data are available on the dynamic behaviors of ceramics; thus, it is helpful to predict the dynamic strength of ceramics on the basis of their mechanical properties. In this paper, the addition of SrCO₃ into zirconia-toughened alumina (ZTA) was demonstrated to improve the fracture toughness of ZTA due to the formation of the SrAl₁₂O₁₉ (SA6) phase. The porosity of ZTA was found to be increased by the addition of SrCO₃. These newly formed pores served as the nucleation sites of cracks under dynamic load; these cracks eventually coalesced to form damaged zones in the samples. Although the K IC values of the samples were improved, the dynamic strength was not enhanced because of the increase in porosity; in fact, the dynamic strength of ZTA ceramics decreased with the addition of SrCO₃.

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2016年第23卷第4期

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