Search2014 Vol. 21, No. 9
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2014, vol. 21, no. 9, pp.
845-850.
https://doi.org/10.1007/s12613-014-0980-z
Abstract:
Direct reduction is an emerging technology for the utilization of refractory iron ore. With this technology, iron oxides in the ore can be reduced to recoverable elemental iron. The structure of granular aggregates in direct reduction products was investigated by X-ray diffraction (XRD). The results show that iron is mainly generated as a shell in the outer edge of the aggregates. The thermal conductivity of the iron shell is higher than that of other minerals. Thus, minerals close to the iron shell cool faster than those in the inner shells and do not crystallize well. These minerals mainly become stage 2 tailings. Hence the XRD intensity of stage 2 tailings is lower than that of stage 1 tailings. When iron is mainly generated in the interior of the aggregates, the crystallinity of stage 2 tailings will be higher than that of stage 1 tailings. This indicates that the crystallinity of tailings can be used as a marker for the aggregate structure.
Direct reduction is an emerging technology for the utilization of refractory iron ore. With this technology, iron oxides in the ore can be reduced to recoverable elemental iron. The structure of granular aggregates in direct reduction products was investigated by X-ray diffraction (XRD). The results show that iron is mainly generated as a shell in the outer edge of the aggregates. The thermal conductivity of the iron shell is higher than that of other minerals. Thus, minerals close to the iron shell cool faster than those in the inner shells and do not crystallize well. These minerals mainly become stage 2 tailings. Hence the XRD intensity of stage 2 tailings is lower than that of stage 1 tailings. When iron is mainly generated in the interior of the aggregates, the crystallinity of stage 2 tailings will be higher than that of stage 1 tailings. This indicates that the crystallinity of tailings can be used as a marker for the aggregate structure.
2014, vol. 21, no. 9, pp.
851-861.
https://doi.org/10.1007/s12613-014-0981-y
Abstract:
A better understanding of solid-liquid separation would assist in improving the thickening performance and perhaps water recovery as well. The present work aimed to develop an empirical model to study the effects of ore properties on the thickening process based on pilot tests using a column. A hydro-cyclone was used to prepare the required samples for the experiments. The model significantly predicted the experimental underflow solid content using a regression equation at a given solid flux and bed level for different samples, indicating that ore properties are the effective parameters in the thickening process. This work confirmed that the water recovery would be increased about 5% by separating the feed into two parts, overflow and underflow, and introducing two different thickeners into them separately. This is duo to the fact that thickeners are limited by permeability and compressibility in operating conditions.
A better understanding of solid-liquid separation would assist in improving the thickening performance and perhaps water recovery as well. The present work aimed to develop an empirical model to study the effects of ore properties on the thickening process based on pilot tests using a column. A hydro-cyclone was used to prepare the required samples for the experiments. The model significantly predicted the experimental underflow solid content using a regression equation at a given solid flux and bed level for different samples, indicating that ore properties are the effective parameters in the thickening process. This work confirmed that the water recovery would be increased about 5% by separating the feed into two parts, overflow and underflow, and introducing two different thickeners into them separately. This is duo to the fact that thickeners are limited by permeability and compressibility in operating conditions.
2014, vol. 21, no. 9, pp.
862-870.
https://doi.org/10.1007/s12613-014-0982-x
Abstract:
The leaching behavior of a copper flotation concentrate was investigated using ammonium persulfate (APS) in an autoclave system. The decomposition products of APS, active oxygen, and acidic medium were used to extract metals from the concentrate. Leaching experiments were performed to compare the availability of APS as an oxidizing agent for leaching of the concentrate under atmospheric conditions and in an autoclave system. Leaching temperature and APS concentration were found to be important parameters in both leaching systems. Atmospheric leaching studies showed that the metal extractions increased with the increase in APS concentration and temperature (up to 333 K). A similar tendency was determined in the autoclave studies up to 423 K. It was also determined that the metal extractions decreased at temperatures above 423 K due to the passivation of the particle surface by molten elemental sulfur. The results showed that higher copper extractions could be achieved using an autoclave system.
The leaching behavior of a copper flotation concentrate was investigated using ammonium persulfate (APS) in an autoclave system. The decomposition products of APS, active oxygen, and acidic medium were used to extract metals from the concentrate. Leaching experiments were performed to compare the availability of APS as an oxidizing agent for leaching of the concentrate under atmospheric conditions and in an autoclave system. Leaching temperature and APS concentration were found to be important parameters in both leaching systems. Atmospheric leaching studies showed that the metal extractions increased with the increase in APS concentration and temperature (up to 333 K). A similar tendency was determined in the autoclave studies up to 423 K. It was also determined that the metal extractions decreased at temperatures above 423 K due to the passivation of the particle surface by molten elemental sulfur. The results showed that higher copper extractions could be achieved using an autoclave system.
2014, vol. 21, no. 9, pp.
871-877.
https://doi.org/10.1007/s12613-014-0983-9
Abstract:
The dry impact wear behavior of bainite ductile cast iron was evaluated under three different impact loads for 30000 cycles. The strain-hardening effects beneath the contact surfaces were analyzed according to the surfaces’ micro-hardness profiles. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) were used to observe the worn surfaces. The results indicated that the material with the highest hardness was the one continuously cooled at 20°C, which exhibited the lowest wear rate under each set of test conditions. The hardness of the worn surface and the thickness of the hardened layer increased with the increases in impact load and in the number of test cycles. The better wear performance of the sample cooled at 20°C is attributed to its finer microstructure and superior mechanical properties. All the samples underwent the transformation induced plasticity (TRIP) phenomenon after impact wear, as revealed by the fact that small amounts of retained austenite were detected by XRD.
The dry impact wear behavior of bainite ductile cast iron was evaluated under three different impact loads for 30000 cycles. The strain-hardening effects beneath the contact surfaces were analyzed according to the surfaces’ micro-hardness profiles. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) were used to observe the worn surfaces. The results indicated that the material with the highest hardness was the one continuously cooled at 20°C, which exhibited the lowest wear rate under each set of test conditions. The hardness of the worn surface and the thickness of the hardened layer increased with the increases in impact load and in the number of test cycles. The better wear performance of the sample cooled at 20°C is attributed to its finer microstructure and superior mechanical properties. All the samples underwent the transformation induced plasticity (TRIP) phenomenon after impact wear, as revealed by the fact that small amounts of retained austenite were detected by XRD.
2014, vol. 21, no. 9, pp.
878-885.
https://doi.org/10.1007/s12613-014-0984-8
Abstract:
The austenite grain growth behavior in a simulated coarse-grained heat-affected zone during thermal cycling was investigated via in situ observation. Austenite grains nucleated at ferrite grain boundaries and then grew in different directions through movement of grain boundaries into the ferrite phase. Subsequently, the adjacent austenite grains impinged against each other during the α→γ transformation. After the α→γ transformation, austenite grains coarsened via the coalescence of small grains and via boundary migration between grains. The growth process of austenite grains was a continuous process during heating, isothermal holding, and cooling in simulated thermal cycling. Abundant finely dispersed nanoscale TiN particles in a steel specimen containing 0.012wt% Ti effectively retarded the grain boundary migration, which resulted in refined austenite grains. When the Ti concentration in the steel was increased, the number of TiN particles decreased and their size coarsened. The big particles were not effective in pinning the austenite grain boundary movement and resulted in coarse austenite grains.
The austenite grain growth behavior in a simulated coarse-grained heat-affected zone during thermal cycling was investigated via in situ observation. Austenite grains nucleated at ferrite grain boundaries and then grew in different directions through movement of grain boundaries into the ferrite phase. Subsequently, the adjacent austenite grains impinged against each other during the α→γ transformation. After the α→γ transformation, austenite grains coarsened via the coalescence of small grains and via boundary migration between grains. The growth process of austenite grains was a continuous process during heating, isothermal holding, and cooling in simulated thermal cycling. Abundant finely dispersed nanoscale TiN particles in a steel specimen containing 0.012wt% Ti effectively retarded the grain boundary migration, which resulted in refined austenite grains. When the Ti concentration in the steel was increased, the number of TiN particles decreased and their size coarsened. The big particles were not effective in pinning the austenite grain boundary movement and resulted in coarse austenite grains.
2014, vol. 21, no. 9, pp.
886-893.
https://doi.org/10.1007/s12613-014-0985-7
Abstract:
The fabrication of an alumina-metal composite coating onto a carbon steel substrate by using a self-propagating high-temperature synthesis technique was demonstrated. The effects of the type and thickness of the pre-coated layer on the binding structure and surface quality of the coating were systematically investigated. The macrostructure, phase composition, and bonding interface between the coating and the substrate were investigated by scanning electronic microscopy (SEM), X-ray diffraction (XRD), and energy-dispersive X-ray spectrometry (EDS). The diffraction patterns indicated that the coating essentially consisted of α-Al2O3, Fe(Cr), and FeO·Al2O3. With an increase in the thickness of the pre-coated working layer, the coating became more smooth and compact. The transition layer played an important role in enhancing the binding between the coating and the substrate. When the pre-coated working layer was 10 mm and the pre-coated transition layer was 1 mm, a compact structure and metallurgical bonding with the substrate were obtained. Thermal shock test results indicated that the ceramic coating exhibited good thermal shock resistance when the sample was rapidly quenched from 800°C to room temperature by plunging into water.
The fabrication of an alumina-metal composite coating onto a carbon steel substrate by using a self-propagating high-temperature synthesis technique was demonstrated. The effects of the type and thickness of the pre-coated layer on the binding structure and surface quality of the coating were systematically investigated. The macrostructure, phase composition, and bonding interface between the coating and the substrate were investigated by scanning electronic microscopy (SEM), X-ray diffraction (XRD), and energy-dispersive X-ray spectrometry (EDS). The diffraction patterns indicated that the coating essentially consisted of α-Al2O3, Fe(Cr), and FeO·Al2O3. With an increase in the thickness of the pre-coated working layer, the coating became more smooth and compact. The transition layer played an important role in enhancing the binding between the coating and the substrate. When the pre-coated working layer was 10 mm and the pre-coated transition layer was 1 mm, a compact structure and metallurgical bonding with the substrate were obtained. Thermal shock test results indicated that the ceramic coating exhibited good thermal shock resistance when the sample was rapidly quenched from 800°C to room temperature by plunging into water.
2014, vol. 21, no. 9, pp.
894-897.
https://doi.org/10.1007/s12613-014-0986-6
Abstract:
Expulsion is an undesired event during resistance spot welding because the weld quality deteriorates. It is the ejection of molten metal from the weld nugget which usually occurs due to applying a high current for a short welding time. Expulsion has a significant impact on the final yield strength of the weld, thus the detection and characterization of expulsion events is significant for the quality assurance of resistance spot welds. In this study, hardness mapping, using a scanning hardness machine, was used as a quality assurance technique for resistance spot welding. Hardness tests were conducted on a resistance spot welded sample to prepare a hardness map. The test results showed good correlation between the hardness map and metallographic cross sections. The technique also provided further fundamental understanding of the resistance spot welding process, especially regarding the occurrence of expulsion in the nugget.
Expulsion is an undesired event during resistance spot welding because the weld quality deteriorates. It is the ejection of molten metal from the weld nugget which usually occurs due to applying a high current for a short welding time. Expulsion has a significant impact on the final yield strength of the weld, thus the detection and characterization of expulsion events is significant for the quality assurance of resistance spot welds. In this study, hardness mapping, using a scanning hardness machine, was used as a quality assurance technique for resistance spot welding. Hardness tests were conducted on a resistance spot welded sample to prepare a hardness map. The test results showed good correlation between the hardness map and metallographic cross sections. The technique also provided further fundamental understanding of the resistance spot welding process, especially regarding the occurrence of expulsion in the nugget.
2014, vol. 21, no. 9, pp.
898-905.
https://doi.org/10.1007/s12613-014-0987-5
Abstract:
The surfaces of X80 pipeline steel welded joints were processed with a CO2 laser, and the effects of laser heat treatment (LHT) on H2S stress corrosion in the National Association of Corrosion Engineers (NACE) solution were analyzed by a slow strain rate test. The fracture morphologies and chemical components of corrosive products before and after LHT were analyzed by scanning electron microscopy and energy-dispersive spectroscopy, respectively, and the mechanism of LHT on stress corrosion cracking was discussed. Results showed that the fracture for welded joints was brittle in its original state, while it was transformed to a ductile fracture after LHT. The tendencies of hydrogen-induced corrosion were reduced, and the stress corrosion sensitivity index decreased from 35.2% to 25.3%, indicating that the stress corrosion resistance of X80 pipeline steel welded joints has been improved by LHT.
The surfaces of X80 pipeline steel welded joints were processed with a CO2 laser, and the effects of laser heat treatment (LHT) on H2S stress corrosion in the National Association of Corrosion Engineers (NACE) solution were analyzed by a slow strain rate test. The fracture morphologies and chemical components of corrosive products before and after LHT were analyzed by scanning electron microscopy and energy-dispersive spectroscopy, respectively, and the mechanism of LHT on stress corrosion cracking was discussed. Results showed that the fracture for welded joints was brittle in its original state, while it was transformed to a ductile fracture after LHT. The tendencies of hydrogen-induced corrosion were reduced, and the stress corrosion sensitivity index decreased from 35.2% to 25.3%, indicating that the stress corrosion resistance of X80 pipeline steel welded joints has been improved by LHT.
2014, vol. 21, no. 9, pp.
906-912.
https://doi.org/10.1007/s12613-014-0988-4
Abstract:
The densification mechanism of an Fe-based alloy powder containing tiny oxide particles under the synergic multi-field effect of spark plasma sintering (SPS) was investigated. Metallographic microscopy and scanning electron microscopy were used to observe the morphology of samples sintered at different temperatures, and the temperature distribution in an individual spherical powder particle during sintering was calculated in consideration of the influence of plasma, which was qualified and quantified through the analysis of the U-I curve. The plasma was observed to play a substantial role in activating and heating the samples at the very early stage of sintering, whereas the joule-heat effect played a dominant role during sintering. Moreover, the plasma also facilitated the diffusion and migration of materials for neck formation.
The densification mechanism of an Fe-based alloy powder containing tiny oxide particles under the synergic multi-field effect of spark plasma sintering (SPS) was investigated. Metallographic microscopy and scanning electron microscopy were used to observe the morphology of samples sintered at different temperatures, and the temperature distribution in an individual spherical powder particle during sintering was calculated in consideration of the influence of plasma, which was qualified and quantified through the analysis of the U-I curve. The plasma was observed to play a substantial role in activating and heating the samples at the very early stage of sintering, whereas the joule-heat effect played a dominant role during sintering. Moreover, the plasma also facilitated the diffusion and migration of materials for neck formation.
2014, vol. 21, no. 9, pp.
913-918.
https://doi.org/10.1007/s12613-014-0989-3
Abstract:
To enable the use of metallic components in direct methanol fuel cells (DMFCs), issues related to corrosion resistance must be considered because of an acid environment induced by the solid electrolyte. In this study, we report the electrochemical behaviors of metal-fiber-based porous sintered components in a simulated corrosive environment of DMFCs. Three materials were evaluated: pure copper, AISI304, and AISI316L. The environmental factors and related mechanisms affecting the corrosion behaviors were analyzed. The results demonstrated that AISI316L exhibits the best performance. A higher SO42- concentration increases the risk of material corrosion, whereas an increase in methanol concentration inhibits corrosion. The morphological features of the corroded samples were also characterized in this study.
To enable the use of metallic components in direct methanol fuel cells (DMFCs), issues related to corrosion resistance must be considered because of an acid environment induced by the solid electrolyte. In this study, we report the electrochemical behaviors of metal-fiber-based porous sintered components in a simulated corrosive environment of DMFCs. Three materials were evaluated: pure copper, AISI304, and AISI316L. The environmental factors and related mechanisms affecting the corrosion behaviors were analyzed. The results demonstrated that AISI316L exhibits the best performance. A higher SO42- concentration increases the risk of material corrosion, whereas an increase in methanol concentration inhibits corrosion. The morphological features of the corroded samples were also characterized in this study.
2014, vol. 21, no. 9, pp.
919-924.
https://doi.org/10.1007/s12613-014-0990-x
Abstract:
The effect of the microstructure of plates fabricated both in the traditional process, involving casting, hot rolling and cold rolling (HR), and in the novel twin roll casting + cold rolling (TRC) process on the surface quality of presensitized (PS) plates was analyzed by optical microscopy (OM), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDXS). The formation of pores on the surface of the electrolyzed HR plate could be attributed to the presence of approximately 1-μm-sized large Al-Fe precipitates in the HR plate compared to the smaller precipitates in the TRC plate. Moreover, residual graphite lubricants used during the TRC process were entrapped on the surface of the TRC plate during the subsequent rolling process. The entrapped pollutants tended to further deteriorate the formation of pores on the surface of the TRC plate, and no residual carbon was detected on the surface of the HR plate. Furthermore, the surface quality of the TRC plate can be improved by surface cleaning before the cold rolling process, which could dramatically lower the residual graphite on the surface.
The effect of the microstructure of plates fabricated both in the traditional process, involving casting, hot rolling and cold rolling (HR), and in the novel twin roll casting + cold rolling (TRC) process on the surface quality of presensitized (PS) plates was analyzed by optical microscopy (OM), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDXS). The formation of pores on the surface of the electrolyzed HR plate could be attributed to the presence of approximately 1-μm-sized large Al-Fe precipitates in the HR plate compared to the smaller precipitates in the TRC plate. Moreover, residual graphite lubricants used during the TRC process were entrapped on the surface of the TRC plate during the subsequent rolling process. The entrapped pollutants tended to further deteriorate the formation of pores on the surface of the TRC plate, and no residual carbon was detected on the surface of the HR plate. Furthermore, the surface quality of the TRC plate can be improved by surface cleaning before the cold rolling process, which could dramatically lower the residual graphite on the surface.
2014, vol. 21, no. 9, pp.
925-933.
https://doi.org/10.1007/s12613-014-0991-9
Abstract:
The purpose of this study was to investigate the effects of polyelectrolyte multilayer (PEM) coatings on the biological behavior of titanium (Ti) substrates. Collagen type Ι/hyaluronic acid (Col/HA) and chitosan/hyaluronic acid (Chi/HA) multilayer PEM coatings were introduced onto Ti substrates using layer-by-layer assembly. Contact angle instruments and quartz crystal microbalance were used for film characterization. The results obtained showed that both Col/HA and Chi/HA surfaces had high hydrophilicity and promoted cell adhesion in MC3T3-E1 pre-osteoblast and human gingival fibroblast cells. In addition, the synthesis of function-related proteins and gene expression levels in both MC3T3-E1 and fibroblast cells was higher for the Col/HA coating compared with the Chi/HA coating, indicating better cellular response to the Col/HA coating.
The purpose of this study was to investigate the effects of polyelectrolyte multilayer (PEM) coatings on the biological behavior of titanium (Ti) substrates. Collagen type Ι/hyaluronic acid (Col/HA) and chitosan/hyaluronic acid (Chi/HA) multilayer PEM coatings were introduced onto Ti substrates using layer-by-layer assembly. Contact angle instruments and quartz crystal microbalance were used for film characterization. The results obtained showed that both Col/HA and Chi/HA surfaces had high hydrophilicity and promoted cell adhesion in MC3T3-E1 pre-osteoblast and human gingival fibroblast cells. In addition, the synthesis of function-related proteins and gene expression levels in both MC3T3-E1 and fibroblast cells was higher for the Col/HA coating compared with the Chi/HA coating, indicating better cellular response to the Col/HA coating.
2014, vol. 21, no. 9, pp.
934-939.
https://doi.org/10.1007/s12613-014-0992-8
Abstract:
The fabrication of copper (Cu) and copper matrix silicon carbide (Cu/SiCp) particulate composites via the sinter-forging process was investigated. Sintering and sinter-forging processes were performed under an inert Ar atmosphere. The influence of sinter-forging time, temperature, and compressive stress on the relative density and hardness of the prepared samples was systematically investigated and subsequently compared with that of the samples prepared by the conventional sintering process. The relative density and hardness of the composites were enhanced when they were prepared by the sinter-forging process. The relative density values of all Cu/SiCp composite samples were observed to decrease with the increase in SiC content.
The fabrication of copper (Cu) and copper matrix silicon carbide (Cu/SiCp) particulate composites via the sinter-forging process was investigated. Sintering and sinter-forging processes were performed under an inert Ar atmosphere. The influence of sinter-forging time, temperature, and compressive stress on the relative density and hardness of the prepared samples was systematically investigated and subsequently compared with that of the samples prepared by the conventional sintering process. The relative density and hardness of the composites were enhanced when they were prepared by the sinter-forging process. The relative density values of all Cu/SiCp composite samples were observed to decrease with the increase in SiC content.
2014, vol. 21, no. 9, pp.
940-946.
https://doi.org/10.1007/s12613-014-0993-7
Abstract:
The structural parameters of nine Indian coals were determined by X-ray diffraction (XRD) and Raman spectroscopy. The study revealed that the coals contain crystalline carbon of turbostratic structure with amorphous carbon. The stacking height (Lc) and interlayer spacing (d002) of the crystallite structure of the coals ranged from 1.986 to 2.373 nm and from 0.334 to 0.340 nm, respectively. The degree of graphitization was calculated to range from 42% to 99%, thereby confirming the ordering of the carbon layers with the increase in coal rank. An exponential correlation was observed among the aromaticity (fa), the lateral size (La), and the rank (I20/I26), suggesting that the coal crystallites are nanocrystalline in nature. A very strong correlation was observed between the structural parameters (fa, d002, Lc, the H/C ratio, and I20/I26), the volatile matter content, and the elemental carbon content, indicating the structures of coals are controlled by the degree of contact metamorphism. The Raman spectra exhibited two prominent bands: the graphitic band (G) and the first-order characteristic defect band (D). The deconvolution resulted in five peaks: G, D1, D2, D3, and D4. The intense D1 band, which appeared at ~1350 cm−1, corresponds to a lattice vibration mode with A1g symmetry. The D2 mode, which appeared at ~1610 cm−1, arises from the structural disorder as a shoulder on the G band.
The structural parameters of nine Indian coals were determined by X-ray diffraction (XRD) and Raman spectroscopy. The study revealed that the coals contain crystalline carbon of turbostratic structure with amorphous carbon. The stacking height (Lc) and interlayer spacing (d002) of the crystallite structure of the coals ranged from 1.986 to 2.373 nm and from 0.334 to 0.340 nm, respectively. The degree of graphitization was calculated to range from 42% to 99%, thereby confirming the ordering of the carbon layers with the increase in coal rank. An exponential correlation was observed among the aromaticity (fa), the lateral size (La), and the rank (I20/I26), suggesting that the coal crystallites are nanocrystalline in nature. A very strong correlation was observed between the structural parameters (fa, d002, Lc, the H/C ratio, and I20/I26), the volatile matter content, and the elemental carbon content, indicating the structures of coals are controlled by the degree of contact metamorphism. The Raman spectra exhibited two prominent bands: the graphitic band (G) and the first-order characteristic defect band (D). The deconvolution resulted in five peaks: G, D1, D2, D3, and D4. The intense D1 band, which appeared at ~1350 cm−1, corresponds to a lattice vibration mode with A1g symmetry. The D2 mode, which appeared at ~1610 cm−1, arises from the structural disorder as a shoulder on the G band.
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