International Journal of Minerals, Metallurgy and Materials

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Applications of two electric arc plasma torches for the beneficiation of natural quartz

Yuri-Mikhailovich Grishin, Long Miao, Lev-Alekseevich Borisov, Nikolay-Mikhailovich Serykh, Alexey-Yurievich Kulagin

2019, 26(3): 267-273. doi: 10.1007/s12613-019-1734-8

中文摘要(514) PDF(12) SpringerLink

摘要:
Experimental beneficiation processes of quartz concentrate in arc plasma torches of two different types and electric powers were studied. An emission scanning electron microscope and a universal laser analyzer were used to investigate the structures as well as the size distributions of grains and microparticles. Inductively coupled plasma-mass spectrometry was used to determine the chemical compositions of nonstructural solid-phase mineral impurities in quartz concentrate. Results related to the modified grains' structure and size distribution, the compositions of impurities, and the gas-liquid inclusions in the quartz concentrate were investigated. The total impurities concentrations in the processed grains were found to satisfy the IOTA-STD standard (industry standard for grading high quality fused quartz products). The optimal condition (i.e., the optimal specific plasma enthalpy) for the production of high-purity quartz in arc plasma torches was found to depend on the geological-genetic type and the structural and textural features (i.e., chemical composition and gas-liquid inclusions) of the quartz concentrate.

研究论文

Accelerating leaching of copper ore with surfactant and the analysis of reaction kinetics

Chun-ming Ai, Ping-ping Sun, Ai-xiang Wu, Xun Chen, Chao Liu

2019, 26(3): 274-281. doi: 10.1007/s12613-019-1735-7

中文摘要(724) PDF(35) SpringerLink

摘要:
To solve the problem of low permeability and lower extraction rates of high-mud ores, a surfactant was added as a penetrant to the pregnant leaching solution during column leaching tests. On the basis of the theories of physical chemistry and seepage flow mechanics, the mechanism by which seepage is enhanced under the effects of the surfactant was analyzed. The results show that the action modes of the surfactant were divided into four aspects:changing the wettability of the ore, reducing the viscosity of the leaching solution, adsorbing onto the surface of ore, and enhancing the permeability effect. The findings of column leaching tests demonstrated that permeability was substantially improved by the surfactant. In the later period of leaching, the permeability coefficient was two times higher than that of the control group. Meanwhile, the ore extraction rate increased by approximately 10%. During the leaching process, the surface tension of the solution did not substantially change, and that of the solution with surfactant increased slightly. The kinetics analysis of ore column leaching illustrated that the leaching processes were controlled by both internal diffusion (principal factor) and chemical reaction.

研究论文

Austenite grain growth of medium-carbon alloy steel with aluminum additions during heating process

Zi-yi Liu, Yan-ping Bao, Min Wang, Xin Li, Fan-zheng Zeng

2019, 26(3): 282-290. doi: 10.1007/s12613-019-1736-6

中文摘要(751) PDF(43) SpringerLink

摘要:
In this study, the effects of heating temperature (850-1100℃) and holding time (30-150 min) on the grain growth behavior of austenite in medium-carbon alloy steel were investigated by conducting experiments. The abnormal grain growth and mixed grain structure phenomenon are explained using an equilibrium precipitation phase diagram calculated by Thermo-Calc software package. The AlN particles were observed by field-emission scanning electron microscopy (FESEM), and the amount of AlN precipitations was detected by electron probe microanalysis (EPMA). Based on the research results, it was found that the average grain size of austenite in the test steel increased continuously with the increase of temperature and holding time. Furthermore, the abnormal growth of austenite occurred in the test steel at 950℃, and the heating temperature affected the austenite grain size more significantly. In addition, the decline in the amount of AlN second-phase particle in the test steel, which weakened the "pinning" effect on austenite grain boundaries, resulted in abnormal growth and the development of mixed austenite grain structures. The prediction model for describing the austenite grain growth of medium-carbon alloy steel during heating was established by regression analysis of the experimental data, and the model was verified to be highly accurate.

研究论文

Effect of slag on oxide inclusions in carburized bearing steel during industrial electroslag remelting

Shi-jian Li, Guo-guang Cheng, Zhi-qi Miao, Lie Chen, Xin-yan Jiang

2019, 26(3): 291-300. doi: 10.1007/s12613-019-1737-5

中文摘要(749) PDF(28) SpringerLink

摘要:
Industrial experiments with three types of slags were performed to investigate the effect of slag on oxide inclusions during electroslag remelting (ESR) process. G20CrNi2Mo bearing steel was used as the consumable electrode and remelted using a 2400-kg industrial furnace. The results showed that most inclusions in the electrode were low-melting-point CaO-MgO-Al₂O₃. After ESR, all the inclusions in ingots were located outside the liquid region. When the slag consisted of 65.70wt% CaF₂, 28.58wt% Al₂O₃, and 4.42wt% CaO was used, pure Al₂O₃ were the dominant inclusions in ingot, some of which presented a clear trend of agglomeration. When the ingot was remelted by a multi-component slag with 16.83wt% CaO, a certain amount of sphere CaAl₄O₇ inclusions larger than 5 μm were generated in ingot. The slag with 8.18wt% CaO exhibited greater capacity to control the inclusion characteristics. Thermodynamic calculations indicated that the total Ca and Mg in ingots were attributed from the relics in electrode and strongly influenced by the slag composition. The formation of ingot inclusions was calculated by FactSage^TM 7.0, and the results were basically in accordance with the observed inclusions, indicating that a quasi-thermodynamic equilibrium could be obtained in the metal pool.

研究论文

Relationship between copper content of slag and matte in the SKS copper smelting process

Qin-meng Wang, Song-song Wang, Miao Tian, Ding-xuan Tang, Qing-hua Tian, Xue-yi Guo

2019, 26(3): 301-308. doi: 10.1007/s12613-019-1738-4

中文摘要(710) PDF(25) SpringerLink

摘要:
In the newly developed oxygen-enriched bottom-blowing copper smelting process (also known as the SKS copper smelting process), Cu loss in slag is one of the most concerning issues. This paper presents our research results concerning the relationship between the Cu content of the matte and slag in the SKS process; the results are based on actual industrial production in the Dongying Fangyuan copper smelter. The results show that the matte grade strongly influences Cu losses in slag. The dissolved and entrained losses account for 10%-20% and 80%-90% of the total SKS industrial Cu losses in slag, respectively. With increasing matte grade, the dissolved and entrained Cu losses in the SKS slag both increase continuously. When the matte grade is greater than 68%, the content of Cu in the smelting slag increases much more dramatically. To obtain a high direct recovery of copper, the matte grade should be less than 75% in industrial SKS copper production.

研究论文

Feasibility of aluminum recovery and MgAl₂O₄ spinel synthesis from secondary aluminum dross

Yong Zhang, Zhao-hui Guo, Zi-yu Han, Xi-yuan Xiao, Chi Peng

2019, 26(3): 309-318. doi: 10.1007/s12613-019-1739-3

中文摘要(706) PDF(37) SpringerLink

摘要:
The feasibility of aluminum recovery from secondary aluminum dross by extraction with NaOH solution and the subsequent synthesis of MgAl₂O₄ spinel by sintering the extracted slag were studied. The extraction percentage of soluble aluminum from the dross reached 80% at a temperature of 353 K, liquid-to-solid ratio of 12 mL·g^-1, stirring speed of 300 r·min^-1, and an extraction time of 15 min; the hydrolysis percentage of AlN reached 40% with an extraction time of 30 min. The activation energies of the soluble aluminum and AlN extracted from the dross were 7.15 and 8.98 kJ·mol^-1, respectively, indicating that their kinetics were controlled by outer diffusion without a product layer. The extracted slag was sintered in the temperature range 1373-1773 K; MgAl₂O₄ spinel with a compressive strength as high as 69.4 MPa was produced in the sample sintered at 1673 K for 3 h. This value exceeds the threshold (40 MPa) prescribed by the National Standard for the Magnesia and Magnesia-alumina Refractory Bricks of China (GB/T 2275-2007). These results establish the effectiveness of aluminum recovery from secondary aluminum dross and subsequent MgAl₂O₄ spinel synthesis.

研究论文

Anisotropy in mechanical properties and corrosion resistance of 316L stainless steel fabricated by selective laser melting

Xiao-qing Ni, De-cheng Kong, Ying Wen, Liang Zhang, Wen-heng Wu, Bei-bei He, Lin Lu, De-xiang Zhu

2019, 26(3): 319-328. doi: 10.1007/s12613-019-1740-x

中文摘要(775) PDF(46) SpringerLink

摘要:
The corrosion behavior and mechanical properties of 316L stainless steel (SS) fabricated via selective laser melting (SLM) were clarified by potentiodynamic polarization measurements, immersion tests, and tensile experiments. The microstructural anisotropy of SLMed 316L SS was also investigated by electron back-scattered diffraction and transmission electron microscopy. The grain sizes of the SLMed 316L SS in the XOZ plane were smaller than those of the SLMed 316L SS in the XOY plane, and a greater number of low-angle boundaries were present in the XOY plane, resulting in lower elongation for the XOY plane than for the XOZ plane. The SLMed 316L was expected to exhibit higher strength but lower ductility than the wrought 316L, which was attributed to the high density of dislocations. The pitting potentials of the SLMed 316L samples were universally higher than those of the wrought sample in chloride solutions because of the annihilation of MnS or (Ca,Al)-oxides during the rapid solidification. However, the molten pool boundaries preferentially dissolved in aggressive solutions and the damage of the SLMed 316L in FeCl₃ solution was more serious after long-term service, indicating poor durability.

研究论文

Passivity breakdown of 13Cr stainless steel under high chloride and CO₂ environment

Hui-xin Li, Da-peng Li, Lei Zhang, Ya-wen Wang, Xiu-yun Wang, Min-xu Lu

2019, 26(3): 329-336. doi: 10.1007/s12613-019-1741-9

中文摘要(719) PDF(23) SpringerLink

摘要:
Herein, the effect of high chloride ion (Cl^-) concentration on the corrosion behavior and passive film breakdown of 13Cr martensitic stainless steel under CO₂ environment was demonstrated. The Cl^- concentration was varied from 30 to 150 g/L and cyclic potentiodynamic polarization was conducted to investigate the influence of the Cl^- concentration on the corrosion potential (E_corr), passive breakdown potential (E_pit), and repassivation potential (E_rep). The results of the polarization curves revealed that 13Cr stainless steel is susceptible to pitting under high Cl^- concentration. The passive breakdown potential and repassivation potential decreased with the increase of Cl^- concentration. The semiconducting behavior of the passive film was investigated by Mott-Schottky analysis and the point defect model (PDM). It was observed that the iron cation vacancies and oxygen vacancies were continuously generated by autocatalytic reactions and the higher Cl^- concentration resulted in higher vacancies in the passive film. Once the excess vacancies condensed at the metal/film interface, the passive film became locally detached from the metal, which led to the breakdown of the passive film.

研究论文

Hot-corrosion behavior of Cr₂O₃-CNT-coated ASTM-SA213-T22 steel in a molten salt environment at 700℃

Khushdeep Goyal, Hazoor Singh, Rakesh Bhatia

2019, 26(3): 337-344. doi: 10.1007/s12613-019-1742-8

中文摘要(729) PDF(17) SpringerLink

摘要:
The present work investigates the hot-corrosion behavior of carbon nanotube (CNT)-reinforced chromium oxide coatings on boiler steel in a molten salt (Na₂SO₄-60wt%V₂O₅) environment at 700℃ under cyclic conditions. The coatings were deposited via the high-velocity oxygen fuel process. The uncoated and coated steel samples were subjected to hot corrosion in a silicon tube furnace at 700℃ for 50 cycles. The kinetics of the corrosion behavior was analyzed through mass-gain measurements after each cycle. The corrosion products were analyzed by X-ray diffraction, scanning electron microscopy, and energy-dispersive X-ray analysis techniques. The results revealed that uncoated steel suffered spallation of scale because of the formation of nonprotective Fe₂O₃ scale. The coated steel samples exhibited lower mass gains with better adhesiveness of oxide scale with the steel alloy until the end of exposure. The CNT-reinforced coatings were concluded to provide better corrosion resistance in the hot-corrosion environment because of the uniform dispersion of CNTs in the coating matrix and the formation of protective chromium oxides in the scale.

研究论文

Synthesis of a NiTi₂-AlNi-Al₂O₃ nanocomposite by mechanical alloying and heat treatment of Al-TiO₂-NiO

Reza Beygi, Majid Zarezadeh Mehrizi, Hossein Mostaan, Mahdi Rafiei, Ahmadreza Abbasian

2019, 26(3): 345-349. doi: 10.1007/s12613-019-1743-7

中文摘要(601) PDF(10) SpringerLink

摘要:
The aim of the present study was to investigate the phases formed during ball milling of Al-TiO₂-NiO. For this purpose, a mixture of Al-TiO₂-NiO with a molar ratio of 6:1:1 was used. Characterization of the milled powders by X-ray diffraction, differential thermal analysis, field-emission scanning electron microscopy, and transmission electron microscopy showed the formation of nanocrystalline NiTi₂ along with AlNi. A thermodynamical investigation confirmed that NiO was reduced by Al during ball milling, which consequently promoted TiO₂ reduction and the formation of NiTi₂. Al is capable of reducing NiO either during ball milling or at temperatures above the melting point of Al; by contrast, TiO₂ can be reduced by Al only by milling.

研究论文

Carbon deposition in porous nickel/yttria-stabilized zirconia anode under methane atmosphere

Zhi-yuan Chen, Li-jun Wang, Xiao-jia Du, Zai-hong Sun, Fu-shen Li, Kuo-Chih Chou

2019, 26(3): 350-359. doi: 10.1007/s12613-019-1744-6

中文摘要(673) PDF(10) SpringerLink

摘要:
A commercial solid oxide fuel cell with a Ni/YSZ anode was characterized under a pure methane atmosphere. The amount of deposited carbon increased with an increase in temperature but decreased when the temperature exceeded 700℃. The reactivity of carbon decreased with increasing deposition temperature. Filamentous carbon was deposited from 400 to 600℃, whereas flake carbon was deposited at 700 and 800℃. With increasing temperature, the intensity ratio of the D band over the sum of the G and D bands was constant at the beginning and then decreased with the transformation of the carbon morphology. The crystallite size increased from 2.9 to 13 nm with increasing temperature. The results also indicated that the structure of the deposited carbon was better ordered with increasing deposition temperature. In comparison with pure Ni powders, the interaction between the YSZ substrate and Ni particles could not only modify the carbon deposition kinetics but also reduce the temperature effect on the structure and reactivity variation of carbon.

研究论文

Enhanced elevated temperature wear resistance of Al-17Si-5Cu alloy after a novel short duration heat treatment

Biplab Hazra, Supriya Bera, Bijay Kumar Show

2019, 26(3): 360-368. doi: 10.1007/s12613-019-1745-5

中文摘要(731) PDF(13) SpringerLink

摘要:
The goal of the present study is to improve the elevated temperature wear resistance of an Al-17wt%Si-5wt%Cu alloy (AR alloy) by a novel short duration heat treatment process. The elevated temperature (100℃) dry sliding wear behavior of an AR alloy was studied after microstructural modification using the proposed heat treatment. The study revealed considerable microstructural modifications after the heat treatment and the heat treated alloy was designated as HT (heat treatment) alloy. A higher hardness value was obtained for the HT alloy compared to the AR alloy. Accordingly, the wear rate for the HT alloy was found to be significantly lower compared to the as-cast AR alloy at all applied loads. Accelerated particle pull-out for the AR alloy at elevated temperatures resulted in poor wear behavior for it compared to the HT alloy. On the other hand, the Si particles remained intact on the worn surface of the HT alloy due to the good particle/matrix bonding that resulted from the isothermal heat treatment. Furthermore, the age hardening that occurred in the HT alloy during wear provided additional wear resistance. Thus, the HT alloy at 100℃ exhibited a lower wear rate compared to the AR alloy even at room temperature for all applied loads. This improvement was attributed to microstructural modification upon isothermal heat treatment along with the age hardening effect.

研究论文

Microstructure and finite element analysis of hot continuous rolling of doped tungsten rod

Zheng-jie Shao, Hai-po Liu, Xiao-chun He, Bing Zhou, Yang Li, Shang-zhou Zhang, Meng-jin Li, Shu-jun Li

2019, 26(3): 369-376. doi: 10.1007/s12613-019-1746-4

中文摘要(544) PDF(18) SpringerLink

摘要:
The microstructures of doped tungsten deformed by multi-pass hot continuous rolling were investigated, and the stress and strain fields were simulated by finite element (FE) method. After the continuous rolling, the grains of the tungsten rod were refined, and the microhardness was improved; however, a ring region of abnormal grain growth was present at a distance of about 3/5R (R is the radius of the rod) from the center of the cross section. FE modeling results showed that the equivalent residual strains were minimum around the region of abnormal grain growth; this was due to the release of strain energy by severe plastic deformation, leading a situation where the migration force of grain boundaries was higher than the pinning force of potassium bubbles. By decreasing the initial rolling temperature and rolling speeds, the inhomogeneity of the equivalent residual stain decreased, improving the microstructure uniformity of the doped tungsten.

研究论文

Numerical simulation and experimental verification of a novel double-layered split die for high-pressure apparatus used for synthesizing superhard materials

Zhuo Yi, Wen-zhi Fu, Ming-zhe Li, Rui Li, Liang Zhao, Li-yan Wang

2019, 26(3): 377-385. doi: 10.1007/s12613-019-1747-3

中文摘要(600) PDF(10) SpringerLink

摘要:
Based on the principles of massive support and lateral support, a novel double-layered split die (DLSD) for high-pressure apparatus was designed to achieve a higher pressure-bearing capacity and larger sample cavity. The stress distributions of the DLSDs with different numbers of divided blocks were investigated by the finite element method and compared with the stress distributions of the conventional belt-type die (BTD). The results show that the cylinders and first-layer supporting rings of the DLSDs have dramatically smaller stresses than those of the BTD. In addition, increasing the number of divided blocks from 4 to 10 gradually increases the stress of the cylinder but has minimal influence on the stress of the supporting rings. The pressure-bearing capacities of the DLSDs with different numbers of divided blocks, especially with fewer blocks, are all remarkably higher than the pressure-bearing capacity of the BTD. The contrast experiments were also carried out to verify the simulated results. It is concluded that the pressure-bearing capacities of the DLSDs with 4 and 8 divided blocks are 1.58 and 1.45 times greater than that of the BTD. This work is rewarding for the commercial synthesis of high-quality, large-sized superhard materials using a double-layered split high-pressure die.

勘误

Erratum to: Lithium-ion full cell with high energy density using nickel-rich LiNi_0.8Co_0.1Mn_0.1O₂ cathode and SiO-C composite anode

Azhar Iqbal, Long Chen, Yong Chen, Yu-xian Gao, Fang Chen, Dao-cong Li

2019, 26(3): 386-386. doi: 10.1007/s12613-019-1732-x

中文摘要(420) PDF(12) SpringerLink

摘要:

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2019年第26卷第3期