Search2014 Vol. 21, No. 3
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2014, vol. 21, no. 3, pp.
205-209.
https://doi.org/10.1007/s12613-014-0886-9
Abstract:
Mine dust is classified as one of five natural coal mining disasters because it can harm the health of miners and poses a serious threat to the safety of the coal mine. Therefore, preparation of an effective dust suppression agent is highly desired. To improve the capture efficiency of fine dust, this study examines the dust suppression effects of various combinations of wetting agents, additives, and coagulation agents by using the optimum seeking method to reduce mine dust, particularly respirable particles. The optimal formula is shown to contain 10wt% fatty alcohol polyoxyethylene ether (JFC), 4.96wt% cationic polyacrylamide, and 4wt% calcium chloride. The dust suppression effect can be achieved at 96.1% in 5 min by using the optimal formula.
Mine dust is classified as one of five natural coal mining disasters because it can harm the health of miners and poses a serious threat to the safety of the coal mine. Therefore, preparation of an effective dust suppression agent is highly desired. To improve the capture efficiency of fine dust, this study examines the dust suppression effects of various combinations of wetting agents, additives, and coagulation agents by using the optimum seeking method to reduce mine dust, particularly respirable particles. The optimal formula is shown to contain 10wt% fatty alcohol polyoxyethylene ether (JFC), 4.96wt% cationic polyacrylamide, and 4wt% calcium chloride. The dust suppression effect can be achieved at 96.1% in 5 min by using the optimal formula.
2014, vol. 21, no. 3, pp.
210-215.
https://doi.org/10.1007/s12613-014-0887-8
Abstract:
In this study, we characterized strain F9 and evaluated the interaction between strain F9 and hematite by scanning electron microscopy (SEM), Fourier transform infrared spectrophotometry (FTIR), zeta potential, flotation, and other methods. The results showed that strain F9 belongs to Serratia marcescens. This brevibacterium had CH2, CH3, and hydroxyl groups on its cell wall, which imparted a strong hydrophobic and negative charge. Adsorption of strain F9 reduced the zeta potential of the hematite surface and increased the hydrophobicity of the hematite surface, thereby generating hydrophobic hematite agglomerates. At least four groups on strain F9 interacted with the hematite surface, which contributed to chemical interactions of carboxylic groups and hydrophobic association among hydrophobic hematite particles. The possible use of strain F9 as a bio-collector for hematite flotation was proved.
In this study, we characterized strain F9 and evaluated the interaction between strain F9 and hematite by scanning electron microscopy (SEM), Fourier transform infrared spectrophotometry (FTIR), zeta potential, flotation, and other methods. The results showed that strain F9 belongs to Serratia marcescens. This brevibacterium had CH2, CH3, and hydroxyl groups on its cell wall, which imparted a strong hydrophobic and negative charge. Adsorption of strain F9 reduced the zeta potential of the hematite surface and increased the hydrophobicity of the hematite surface, thereby generating hydrophobic hematite agglomerates. At least four groups on strain F9 interacted with the hematite surface, which contributed to chemical interactions of carboxylic groups and hydrophobic association among hydrophobic hematite particles. The possible use of strain F9 as a bio-collector for hematite flotation was proved.
2014, vol. 21, no. 3, pp.
216-224.
https://doi.org/10.1007/s12613-014-0888-7
Abstract:
We developed a mathematical optimization model coupling chemical compositions and high-temperature characteristics of sintering materials, targeting the best quality and lowest cost. The simplex algorithm was adopted to solve this model. Four kinds of imported iron ores, two kinds of Chinese iron ore concentrates, and two kinds of fluxes were selected to verify both the model and the algorithm. The results confirmed the possibility of considering both chemical compositions and high-temperature characteristics of iron ores in the optimization model. This model provides a technical roadmap to obtain a precise mathematical correlation between the lowest cost and the grade of iron in sinters based on the condition of given raw materials, which can provide a reference to adjust the grade of iron in the sintering process for enterprise.
We developed a mathematical optimization model coupling chemical compositions and high-temperature characteristics of sintering materials, targeting the best quality and lowest cost. The simplex algorithm was adopted to solve this model. Four kinds of imported iron ores, two kinds of Chinese iron ore concentrates, and two kinds of fluxes were selected to verify both the model and the algorithm. The results confirmed the possibility of considering both chemical compositions and high-temperature characteristics of iron ores in the optimization model. This model provides a technical roadmap to obtain a precise mathematical correlation between the lowest cost and the grade of iron in sinters based on the condition of given raw materials, which can provide a reference to adjust the grade of iron in the sintering process for enterprise.
2014, vol. 21, no. 3, pp.
225-233.
https://doi.org/10.1007/s12613-014-0889-6
Abstract:
To achieve high efficiency utilization of Panzhihua vanadium titano-magnetite, a new process of metalizing reduction and magnetic separation based on hot briquetting is proposed, and factors that affect the cold strength of the hot-briquetting products and the efficiency of reduction and magnetic separation are successively investigated through laboratory experiments. The relevant mechanisms are elucidated on the basis of microstructural observations. Experimental results show that the optimal process parameters for hot briquetting include a hot briquetting temperature of 475℃, a carbon ratio of 1.2, ore and coal particle sizes of less than 74 μm. Additionally, with respect to metalizing reduction and magnetic separation, the rational parameters include a magnetic field intensity of 50 mT, a reduction temperature of 1350℃, a reduction time of 60 min, and a carbon ratio of 1.2. Under these above conditions, the crushing strength of the hot-briquetting agglomerates is 1480 N, and the recovery ratios of iron, vanadium, and titanium are as high as 91.19%, 61.82%, and 85.31%, respectively. The new process of metalizing reduction and magnetic separation based on hot briquetting demonstrates the evident technological advantages of high efficiency separation of iron from other valuable elements in the vanadium titano-magnetite.
To achieve high efficiency utilization of Panzhihua vanadium titano-magnetite, a new process of metalizing reduction and magnetic separation based on hot briquetting is proposed, and factors that affect the cold strength of the hot-briquetting products and the efficiency of reduction and magnetic separation are successively investigated through laboratory experiments. The relevant mechanisms are elucidated on the basis of microstructural observations. Experimental results show that the optimal process parameters for hot briquetting include a hot briquetting temperature of 475℃, a carbon ratio of 1.2, ore and coal particle sizes of less than 74 μm. Additionally, with respect to metalizing reduction and magnetic separation, the rational parameters include a magnetic field intensity of 50 mT, a reduction temperature of 1350℃, a reduction time of 60 min, and a carbon ratio of 1.2. Under these above conditions, the crushing strength of the hot-briquetting agglomerates is 1480 N, and the recovery ratios of iron, vanadium, and titanium are as high as 91.19%, 61.82%, and 85.31%, respectively. The new process of metalizing reduction and magnetic separation based on hot briquetting demonstrates the evident technological advantages of high efficiency separation of iron from other valuable elements in the vanadium titano-magnetite.
2014, vol. 21, no. 3, pp.
234-239.
https://doi.org/10.1007/s12613-014-0900-2
Abstract:
In the 20CrMnTi steel production process, the nitrogen content increased by 19 × 10−6 and 29 × 10−6, respectively, during ladle furnace (LF) refining and during the casting process from ladle to tundish. The protective casting is the key to decrease the N content. The results of thermodynamic calculations and a growth kinetics investigation show that TiN formation occurs only when the solidification fraction is greater than 0.533 under the controlled conditions used in this study for the manufacture of 20CrMnTi steel; the radius of TiN particles decreases as the Ti and N contents decrease and as the cooling rate increases. Furthermore, the theory of austenite grains controlled by second-phase particles was analyzed. The elemental analysis results showed that the Ti content was controlled at 0.04wt%–0.06wt% and the N content decreased to 0.005wt%, which satisfy the requirements for grain refinement but can also effectively prevent the precipitation of TiN inclusions in 20CrMnTi steel.
In the 20CrMnTi steel production process, the nitrogen content increased by 19 × 10−6 and 29 × 10−6, respectively, during ladle furnace (LF) refining and during the casting process from ladle to tundish. The protective casting is the key to decrease the N content. The results of thermodynamic calculations and a growth kinetics investigation show that TiN formation occurs only when the solidification fraction is greater than 0.533 under the controlled conditions used in this study for the manufacture of 20CrMnTi steel; the radius of TiN particles decreases as the Ti and N contents decrease and as the cooling rate increases. Furthermore, the theory of austenite grains controlled by second-phase particles was analyzed. The elemental analysis results showed that the Ti content was controlled at 0.04wt%–0.06wt% and the N content decreased to 0.005wt%, which satisfy the requirements for grain refinement but can also effectively prevent the precipitation of TiN inclusions in 20CrMnTi steel.
2014, vol. 21, no. 3, pp.
240-250.
https://doi.org/10.1007/s12613-014-0901-1
Abstract:
By employing a two-dimensional transient thermo-mechanical coupled finite element model for simulating shell heat transfer behaviors within a slab continuous casting mold, we predicted the evolution of shell deformation and the thermal behaviors, including the mold flux film dynamical distribution, the air gap formation, as well as the shell temperature field and the growth of carbon steel solidification, in a 2120 mm × 266 mm slab continuous casting mold. The results show that the shell server deformation occurs in the off-corners in the middle and lower parts of the mold and thus causes the thick mold flux film and air gap to distribute primarily in the regions of 0–140 mm and 0–124 mm and 0–18 mm and 0–10 mm, respectively, from the corners of the wide and narrow faces of the shell under typical casting conditions. As a result, the hot spots, which result from the thick mold flux film filling the shell/mold gap, form in the regions of 20–100 mm from the corners of the wide and narrow faces of the shell and tend to expand as the shell moves downward.
By employing a two-dimensional transient thermo-mechanical coupled finite element model for simulating shell heat transfer behaviors within a slab continuous casting mold, we predicted the evolution of shell deformation and the thermal behaviors, including the mold flux film dynamical distribution, the air gap formation, as well as the shell temperature field and the growth of carbon steel solidification, in a 2120 mm × 266 mm slab continuous casting mold. The results show that the shell server deformation occurs in the off-corners in the middle and lower parts of the mold and thus causes the thick mold flux film and air gap to distribute primarily in the regions of 0–140 mm and 0–124 mm and 0–18 mm and 0–10 mm, respectively, from the corners of the wide and narrow faces of the shell under typical casting conditions. As a result, the hot spots, which result from the thick mold flux film filling the shell/mold gap, form in the regions of 20–100 mm from the corners of the wide and narrow faces of the shell and tend to expand as the shell moves downward.
2014, vol. 21, no. 3, pp.
251-258.
https://doi.org/10.1007/s12613-014-0902-0
Abstract:
A mathematical model has been presented to study the combustion of a single copper concentrate particle with high moisture content. By using the presented model, the effect of particle moisture content on particle temperature, sulfur oxidation, and combustion heat generation has been evaluated. The mineralogical composition of the commonly used concentrate at Khatoonabad flash smelting furnace has been used in this study. It was found that the particle moisture content is removed in the sub-second time range and thus the moisture has marginal impact on the variation of particle temperature and on the reaction rate when the gas temperature is assumed to be constant in the reaction shaft. When a concentrate with high moisture content is charged, the particle size enlargement due to the agglomeration of concentrate particles causes an abrupt fall in the particle reaction rate.
A mathematical model has been presented to study the combustion of a single copper concentrate particle with high moisture content. By using the presented model, the effect of particle moisture content on particle temperature, sulfur oxidation, and combustion heat generation has been evaluated. The mineralogical composition of the commonly used concentrate at Khatoonabad flash smelting furnace has been used in this study. It was found that the particle moisture content is removed in the sub-second time range and thus the moisture has marginal impact on the variation of particle temperature and on the reaction rate when the gas temperature is assumed to be constant in the reaction shaft. When a concentrate with high moisture content is charged, the particle size enlargement due to the agglomeration of concentrate particles causes an abrupt fall in the particle reaction rate.
2014, vol. 21, no. 3, pp.
259-265.
https://doi.org/10.1007/s12613-014-0903-z
Abstract:
Tensile fatigue tests were designed to study the relation between the tangential magnetic memory signal and dislocations. According to experimental results, in the early stage of fatigue, the magnetic signal and the dislocation density rapidly increase; while in the middle stage, the magnetic signal gradually increases, the dislocation density remains steady, and only the dislocation structure develops. On the other hand, in the later stage, the magnetic signal once again increases rapidly, the dislocation structure continues to develop, and microscopic cracks are formed. Analysis reveals that the dislocations block the movement of the domain wall, and the area of dislocation accumulation thus becomes an internal magnetic source and scatters a field outward. In addition, the magnetic memory field strengthens with increasing dislocation density and complexity of the dislocation structure. Accordingly, the dislocation pinning factor related with the dislocation density and the dislocation structure has been proposed to characterize the effect of dislocations on the magnetic memory signal. The magnetic signal strengthens with an increase in the dislocation pinning factor.
Tensile fatigue tests were designed to study the relation between the tangential magnetic memory signal and dislocations. According to experimental results, in the early stage of fatigue, the magnetic signal and the dislocation density rapidly increase; while in the middle stage, the magnetic signal gradually increases, the dislocation density remains steady, and only the dislocation structure develops. On the other hand, in the later stage, the magnetic signal once again increases rapidly, the dislocation structure continues to develop, and microscopic cracks are formed. Analysis reveals that the dislocations block the movement of the domain wall, and the area of dislocation accumulation thus becomes an internal magnetic source and scatters a field outward. In addition, the magnetic memory field strengthens with increasing dislocation density and complexity of the dislocation structure. Accordingly, the dislocation pinning factor related with the dislocation density and the dislocation structure has been proposed to characterize the effect of dislocations on the magnetic memory signal. The magnetic signal strengthens with an increase in the dislocation pinning factor.
2014, vol. 21, no. 3, pp.
266-272.
https://doi.org/10.1007/s12613-014-0904-y
Abstract:
The microstructures and properties of hot-rolled low-carbon ferritic steel have been investigated by optical microscopy, field-emission scanning electron microscopy, transmission electron microscopy, and tensile tests after isothermal transformation from 600℃ to 700℃ for 60 min. It is found that the strength of the steel decreases with the increment of isothermal temperature, whereas the hole expansion ratio and the fraction of high-angle grain boundaries increase. A large amount of nanometer-sized carbides were homogeneously distributed throughout the material, and fine (Ti, Mo)C precipitates have a significant precipitation strengthening effect on the ferrite phase because of their high density. The nanometer-sized carbides have a lattice parameter of 0.411–0.431 nm. After isothermal transformation at 650℃ for 60 min, the ferrite phase can be strengthened above 300 MPa by precipitation strengthening according to the Ashby-Orowan mechanism.
The microstructures and properties of hot-rolled low-carbon ferritic steel have been investigated by optical microscopy, field-emission scanning electron microscopy, transmission electron microscopy, and tensile tests after isothermal transformation from 600℃ to 700℃ for 60 min. It is found that the strength of the steel decreases with the increment of isothermal temperature, whereas the hole expansion ratio and the fraction of high-angle grain boundaries increase. A large amount of nanometer-sized carbides were homogeneously distributed throughout the material, and fine (Ti, Mo)C precipitates have a significant precipitation strengthening effect on the ferrite phase because of their high density. The nanometer-sized carbides have a lattice parameter of 0.411–0.431 nm. After isothermal transformation at 650℃ for 60 min, the ferrite phase can be strengthened above 300 MPa by precipitation strengthening according to the Ashby-Orowan mechanism.
2014, vol. 21, no. 3, pp.
273-278.
https://doi.org/10.1007/s12613-014-0905-x
Abstract:
Low-carbon steel sheets DC04 used in the automotive industry were subjected to cold rolling for thickness reduction from 20% to 89%. The desired thickness was achieved by successive reductions using a rolling mill. The influence of thickness reduction on the microstructure was studied by scanning electron microscopy. Microstructure evolution was characterized by the distortion of grains and the occurrence of the oriented grain structure for high cold work. A mechanism of grain restructuring for high cold work was described. The occurrence of voids was discussed in relation with cold work. The evolution of voids at the grain boundaries and inside the grains was also considered. To characterize the grain size, the Feret diameter was measured and the grain size distribution versus cold work was discussed. The chemical homogeneity of the sample was also analyzed.
Low-carbon steel sheets DC04 used in the automotive industry were subjected to cold rolling for thickness reduction from 20% to 89%. The desired thickness was achieved by successive reductions using a rolling mill. The influence of thickness reduction on the microstructure was studied by scanning electron microscopy. Microstructure evolution was characterized by the distortion of grains and the occurrence of the oriented grain structure for high cold work. A mechanism of grain restructuring for high cold work was described. The occurrence of voids was discussed in relation with cold work. The evolution of voids at the grain boundaries and inside the grains was also considered. To characterize the grain size, the Feret diameter was measured and the grain size distribution versus cold work was discussed. The chemical homogeneity of the sample was also analyzed.
2014, vol. 21, no. 3, pp.
279-288.
https://doi.org/10.1007/s12613-014-0906-9
Abstract:
The 00Cr13Ni5Mo2 supermartensitic stainless steel was first tempered at 570–730℃ for 2 h to observe the microstructure and hardness changes. The tempering temperature was set to 600, 650, and 700℃, which is below, equal to, and above the austenite transformation start temperature, respectively, for each holding period to investigate the effects of tempering time on the structure and properties of the steel. The microstructure of the specimens was examined by optical microscopy and transmission electronic microscopy, and the phase composition was detected by X-ray diffraction. As expected, lath refinement was observed in the steel tempered at 700℃, and the refinement degree significantly depended on the tempering time. Contrary to normal steel softening by tempering, the hardness performance of the steel was significantly enhanced primarily because of the refinement of martensite laths after single-stage intercritical tempering. It is believed that the reverse transformation of martensite (α′) to austenite (γ) is responsible for the refinement.
The 00Cr13Ni5Mo2 supermartensitic stainless steel was first tempered at 570–730℃ for 2 h to observe the microstructure and hardness changes. The tempering temperature was set to 600, 650, and 700℃, which is below, equal to, and above the austenite transformation start temperature, respectively, for each holding period to investigate the effects of tempering time on the structure and properties of the steel. The microstructure of the specimens was examined by optical microscopy and transmission electronic microscopy, and the phase composition was detected by X-ray diffraction. As expected, lath refinement was observed in the steel tempered at 700℃, and the refinement degree significantly depended on the tempering time. Contrary to normal steel softening by tempering, the hardness performance of the steel was significantly enhanced primarily because of the refinement of martensite laths after single-stage intercritical tempering. It is believed that the reverse transformation of martensite (α′) to austenite (γ) is responsible for the refinement.
2014, vol. 21, no. 3, pp.
289-294.
https://doi.org/10.1007/s12613-014-0907-8
Abstract:
The effects of Al-P addition on the microstructure and mechanical properties of as-cast Mg-5%Sn-1.25%Si magnesium alloy were investigated. The results show that the phases of the as-cast alloy are composed of α-Mg, Mg2Sn, Mg2Si, little P, and AlP. The Chinese character shape Mg2Si phase changes into a granular morphology by P addition because AlP can act as a heterogeneous nucleation core for the Mg2Si phase. When 0.225wt% of Al-3.5%P alloy is added, the mechanical properties of the Mg-5%Sn-1.25%Si alloy are greatly improved, and the tensile strength increases from 156 to 191 MPa, an increase of 22.4% compared to the alloy without P addition. When the amount of Al-3.5%P reaches 0.300wt%, a segregation phenomenon occurs in the granular Mg2Si phase, and the tensile strength and hardness decrease though the elongation increases.
The effects of Al-P addition on the microstructure and mechanical properties of as-cast Mg-5%Sn-1.25%Si magnesium alloy were investigated. The results show that the phases of the as-cast alloy are composed of α-Mg, Mg2Sn, Mg2Si, little P, and AlP. The Chinese character shape Mg2Si phase changes into a granular morphology by P addition because AlP can act as a heterogeneous nucleation core for the Mg2Si phase. When 0.225wt% of Al-3.5%P alloy is added, the mechanical properties of the Mg-5%Sn-1.25%Si alloy are greatly improved, and the tensile strength increases from 156 to 191 MPa, an increase of 22.4% compared to the alloy without P addition. When the amount of Al-3.5%P reaches 0.300wt%, a segregation phenomenon occurs in the granular Mg2Si phase, and the tensile strength and hardness decrease though the elongation increases.
2014, vol. 21, no. 3, pp.
295-303.
https://doi.org/10.1007/s12613-014-0908-7
Abstract:
This paper describes the synthesis of Al7075 metal matrix composites reinforced with SiC, and the characterization of their microstructure and mechanical behavior. The mechanically milled Al7075 micron-sized powder and SiC nanoparticles are dynamically compacted using a drop hammer device. This compaction is performed at different temperatures and for various volume fractions of SiC nanoparticles. The relative density is directly related to the compaction temperature rise and indirectly related to the content of SiC nanoparticle reinforcement, respectively. Furthermore, increasing the amount of SiC nanoparticles improves the strength, stiffness, and hardness of the compacted specimens. The increase in hardness and strength may be attributed to the inherent hardness of the nanoparticles, and other phenomena such as thermal mismatch and crack shielding. Nevertheless, clustering of the nanoparticles at aluminum particle boundaries make these regions become a source of concentrated stress, which reduces the load carrying capacity of the compacted nanocomposite.
This paper describes the synthesis of Al7075 metal matrix composites reinforced with SiC, and the characterization of their microstructure and mechanical behavior. The mechanically milled Al7075 micron-sized powder and SiC nanoparticles are dynamically compacted using a drop hammer device. This compaction is performed at different temperatures and for various volume fractions of SiC nanoparticles. The relative density is directly related to the compaction temperature rise and indirectly related to the content of SiC nanoparticle reinforcement, respectively. Furthermore, increasing the amount of SiC nanoparticles improves the strength, stiffness, and hardness of the compacted specimens. The increase in hardness and strength may be attributed to the inherent hardness of the nanoparticles, and other phenomena such as thermal mismatch and crack shielding. Nevertheless, clustering of the nanoparticles at aluminum particle boundaries make these regions become a source of concentrated stress, which reduces the load carrying capacity of the compacted nanocomposite.
2014, vol. 21, no. 3, pp.
304-310.
https://doi.org/10.1007/s12613-014-0909-6
Abstract:
Micro/nano magnesium carbonate pentahydrate (MgCO3·5H2O) with flower-like morphology was synthesized using magnesite as a substrate and potassium dihydrogen phosphate as an additive. The synthesized samples were characterized by scanning electron microscopy, X-ray diffraction, Fourier transform infrared spectroscopy, thermogravimetry and differential scanning calorimetry. The influence of pyrolysis time on crystal morphology was explored. The formation mechanism was investigated on the basis of the characterized results and the crystal structure of MgCO3·5H2O. The results showed that the flower-like MgCO3·5H2O was 1.5–3.0 μm in length and 100–500 nm in diameter and was successfully obtained with a pyrolysis time of 30 min. The formation mechanism of flower-like MgCO3·5H2O is suggested to be the selective adsorption of potassium dihydrogen phosphate on the surface. The process of flower-like crystal growth is as follows: amorphous nanoparticles formation, acicular and rod monocrystal formation, flower-like monocrystal formation, and flower-like polymers (MgCO3·5H2O) crystallization. In the MgCO3·5H2O crystal, the magnesium ion presents two different octahedral coordinations corresponding to Mg(H2O)62+ and [Mg(H2O) (CO32−)2]2−, and the chemical formula of the crystal is Mg(H2O)6 · Mg(H2O)4(CO32−)2.
Micro/nano magnesium carbonate pentahydrate (MgCO3·5H2O) with flower-like morphology was synthesized using magnesite as a substrate and potassium dihydrogen phosphate as an additive. The synthesized samples were characterized by scanning electron microscopy, X-ray diffraction, Fourier transform infrared spectroscopy, thermogravimetry and differential scanning calorimetry. The influence of pyrolysis time on crystal morphology was explored. The formation mechanism was investigated on the basis of the characterized results and the crystal structure of MgCO3·5H2O. The results showed that the flower-like MgCO3·5H2O was 1.5–3.0 μm in length and 100–500 nm in diameter and was successfully obtained with a pyrolysis time of 30 min. The formation mechanism of flower-like MgCO3·5H2O is suggested to be the selective adsorption of potassium dihydrogen phosphate on the surface. The process of flower-like crystal growth is as follows: amorphous nanoparticles formation, acicular and rod monocrystal formation, flower-like monocrystal formation, and flower-like polymers (MgCO3·5H2O) crystallization. In the MgCO3·5H2O crystal, the magnesium ion presents two different octahedral coordinations corresponding to Mg(H2O)62+ and [Mg(H2O) (CO32−)2]2−, and the chemical formula of the crystal is Mg(H2O)6 · Mg(H2O)4(CO32−)2.
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