2012 Vol. 19, No. 2

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Settling characteristics of ultrafine iron ore slimes
Chinthapudi Eswaraiah, Surendra Kumar Biswal, and  Barada Kanta Mishra
2012, vol. 19, no. 2, pp. 95-99. https://doi.org/10.1007/s12613-012-0521-6
Abstract:
The slurry settling characteristics are the most important to design a thickener in process industries. In this work, the iron ore slurry from the screw classifier overflow was used for the settling study. It was observed that the original slurry exhibited a low settling velocity and a turbid supernatant during the settling process. Commercial flocculating agents with anionic, cationic, and nonionic characters were used to improve the settling behavior of suspensions, which were added into the slurry at different ranges of slurry pH values, respectively. The settling results show that the use of flocculants increase the settling rate by several times. Compared with the cationic and nonionic flocculants, the anionic flocculant is more effective in enhancing the slurry settling rate. The small dose of the anionic flocculant is found to be more effective, but the other flocculants are less effective even at higher dosages. The simulation of an industrial thickener was carried out based on the laboratory settling data, and the appropriate design and selection parameters of the industrial thickener were estimated.
Activation pretreatment of limonitic laterite ores by alkali-roasting using NaOH
Qiang Guo, Jing-kui Qu, Tao Qi, Guang-ye Wei, and  Bing-bing Han
2012, vol. 19, no. 2, pp. 100-105. https://doi.org/10.1007/s12613-012-0522-5
Abstract:
Activation pretreatment of Cr-containing limonitic laterite ores by NaOH roasting to remove Cr, Al, and Si, as well as its effect on Ni and Co extraction in the subsequent pressure acid leaching process was investigated. Characterization results of X-ray diffraction (XRD) and scanning electron microscopy/X-ray energy dispersive spectroscopy (SEM/XEDS) show that goethite is the major Ni-bearing mineral, and chromite is the minor one. Experimental results show that the leaching rates of Cr, Al, and Si are 95.6wt%, 83.8wt%, and 40.1wt%, respectively, under the optimal alkali-roasting conditions. Compared with the direct pressure acid leaching of laterite ores, the leaching rates of Ni and Co increase from 80.1wt% to 96.9wt% and 70.2wt% to 95.1wt% after pretreatment, respectively. Meanwhile, the grade of acid leaching iron residues increases from 54.4wt% to 62.5wt%, and these residues with low Cr content are more suitable raw materials for iron making.
Beneficiation of the gold bearing ore by gravity and flotation
Alim Gül, Olgaç Kangal, Ayhan A. Sirkeci, and  Güven Önal
2012, vol. 19, no. 2, pp. 106-110. https://doi.org/10.1007/s12613-012-0523-4
Abstract:
Gold concentration usually consists of gravity separation, flotation, cyanidation, or the combination of these processes. The choice among these processes depends on the mineralogical characterization and gold content of the ore. Recently, the recovery of gold using gravity methods has gained attention because of low cost and environmentally friendly operations. In this study, gold pre-concentrates were produced by the stepwise gravity separation and flotation techniques. The Knelson concentrator and conventional flotation were employed for the recovery of gold. Gold bearing ore samples were taken from Gümüşhane Region, northern east part of Turkey. As a result of stepwise Knelson concentration experiments, a gold concentrate assaying around 620 g/t is produced with 41.4wt% recovery. On the other hand, a gold concentrate about 82 g/t is obtained with 89.9wt% recovery from a gold ore assaying 6 g/t Au by direct flotation.
A method for observing the three-dimensional morphologies of inclusions in steel
Yan-ping Bao, Min Wang, and  Wei Jiang
2012, vol. 19, no. 2, pp. 111-115. https://doi.org/10.1007/s12613-012-0524-3
Abstract:
A method for observing the three-dimensional morphologies of inclusions by deeply eroding a steel sample with a kind of organic solution composed of bromine water, acetone, and HCl (volume ratio, 45:45:10) was introduced. Four different kinds of inclusions in ultra low carbon steel were compared by metallographic observation and erosion observation. The results show that the three-dimensional morphologies of different kinds of inclusions could be observed clearly and simply after erosion. The method is useful for the observation and analysis of inclusions made by deep erosion. It also provides a new way to control and remove inclusions based on the true morphologies of inclusions.
Forming condition and control strategy of ferrite decarburization in 60Si2MnA spring steel wires for automotive suspensions
Chao-lei Zhang, Ya-zheng Liu, Le-yu Zhou, Chao Jiang, and  Jin-fu Xiao
2012, vol. 19, no. 2, pp. 116-121. https://doi.org/10.1007/s12613-012-0525-2
Abstract:
The ferrite decarburization behavior of 60Si2MnA spring steel wires for automotive suspensions, including the forming condition and the influence of heating time and cooling rate after hot rolling, was investigated comprehensively. Also, a control strategy during the reheating process and cooling process after rolling was put forward to protect against ferrite decarburization. The results show that ferrite decarburization, which has the strong temperature dependence due to phase transformation, is produced between 675 and 875℃. The maximum depth is found at 750℃. Heating time and cooling rate after rolling have an important influence on decarburization. Reasonable preheating temperature in the billet reheating process and austenitizing temperature in the heat-treatment process are suggested to protect against ferrite decarburization.
3D finite element simulation of microstructure evolution in blade forging of Ti-6Al-4V alloy based on the internal state variable models
Jiao Luo, Bin Wu, and  Miao-quan Li
2012, vol. 19, no. 2, pp. 122-130. https://doi.org/10.1007/s12613-012-0526-1
Abstract:
The physically-based internal state variable (ISV) models were used to describe the changes of dislocation density, grain size, and flow stress in the high temperature deformation of titanium alloys in this study. The constants of the present models could be identified based on experimental results, which were conducted at deformation temperatures ranging from 1093 K to 1303 K, height reductions ranging from 20% to 60%, and the strain rates of 0.001, 0.01, 0.1, 1.0, and 10.0 s-1. The physically-based internal state variable models were implemented into the commercial finite element (FE) code. Then, a three-dimensional (3D) FE simulation system coupling of deformation, heat transfer, and microstructure evolution was developed for the blade forging of Ti-6Al-4V alloy. FE analysis was carried out to simulate the microstructure evolution in the blade forging of Ti-6Al-4V alloy. Finally, the blade forging tests of Ti-6Al-4V alloy were performed to validate the results of FE simulation. According to the tensile tests, it is seen that the mechanical properties, such as tensile strength and elongation, satisfy the application requirements well. The maximum and minimum differences between the calculated and experimental grain size of primary α phase are 11.71% and 4.23%, respectively. Thus, the industrial trials show a good agreement with FE simulation of blade forging.
Modifying agent selection for Al-7Si alloy by Miedema model
Zhong-wei Chen, Cui-ying Ma, and  Pei Chen
2012, vol. 19, no. 2, pp. 131-135. https://doi.org/10.1007/s12613-012-0527-0
Abstract:
To determine the modifying agents for Al-7Si alloys, microstructure observation and mixing enthalpy analysis using Miedema model for Al-7Si alloy with additions of different rare earth elements were performed, and the effects of rare earth elements on the modification of eutectic silicon morphology were investigated. The results of mixing enthalpy analysis show that these four rare earth elements, La, Sm, Pr, and Ce, which have the large negative mixing enthalpies with Si, can be selected as modifying agents for eutectic silicon morphology. The element with the largest negative mixing enthalpy is Ce. Furthermore, the microstructures indicate that these four elements can effectively modify the eutectic (α)Al-Si crystals in Al-7Si alloy, and the most effective one is also Ce. Differential scanning calorimetry (DSC) results show that the eutectic temperature depressions due to the additions of modifying agents are the important reasons for the modification of eutectic (α)Al-Si crystals.
Research of {0001} crystal orientation for magnesium alloys solidified in a fashion of cellular crystals
Guo-wei Chang, Shu-ying Chen, Qing-chun Li, Xu-dong Yue, and  Yi-hui Qi
2012, vol. 19, no. 2, pp. 136-140. https://doi.org/10.1007/s12613-012-0528-z
Abstract:
The magnesium alloy grew in a fashion of cellular crystals during the process of unidirectional solidification, and the {0001} crystal face orientation in the cast ingot of the magnesium alloy was studied. The theoretical model and methodology were set up, and a corresponding experiment was carried out to verify the theoretical analysis results. The experimental results indicate that the {0001} crystal face of magnesium crystals parallels to the width direction for the thin-plate cast ingot when the magnesium grows in a manner of cellular crystals. The separation angle between the {0001} crystal face of magnesium crystals and the vertical axis line of the cast ingot is about 62° for the circular column cast ingot, which distributes in cone-type. The theoretical analysis results are basically in agreement with the experimental ones of previous literatures and this paper.
Effect of Pd doping on the acetone-sensing properties of NdFeO3
Zhan-lei Wu, Ru Zhang, Ma Zhao, Shao-ming Fang, Zhou-xiang Han, Ji-fan Hu, and  Kai-ying Wang
2012, vol. 19, no. 2, pp. 141-145. https://doi.org/10.1007/s12613-012-0529-y
Abstract:
The acetone-sensing properties of the undoped and Pd doped perovskite-type oxides NdFeO3 were investigated from room temperature to 400℃. The perovskite-type NdFeO3 was synthesized by a sol-gel method, and the dopants Pd with the content from 1wt% to 5wt% were implanted into NdFeO3 nanoparticles by thermal diffusion. X-ray diffraction (XRD) and scanning electron microscopy (SEM) techniques show that NdFeO3 is an orthorhombic structure with the average particle size of about 40 nm. A giant acetone-sensing response of 675.7 is observed when the Pd content in NdFeO3 powders is about 3wt%. The response and recovery time of the sensor to the 5×10-4 acetone gas are 16 and 1 s, respectively. At the same time, it performs a good selectivity to acetone gas and may be a new promising material candidate for the acetone-sensor development.
Effects of crystallization on corrosion behaviours of a Ni-based bulk metallic glass
Sen Liu, Lu Huang, Shu-jie Pang, and  Tao Zhang
2012, vol. 19, no. 2, pp. 146-150. https://doi.org/10.1007/s12613-012-0530-5
Abstract:
The effects of microstructure change on the corrosion behaviours of Ni55Nb20Ti10Zr8Co7 bulk glass-forming alloy were investigated in 1 mol/L HCl and 0.5 mol/L H2SO4 solutions. Different microstructures of the Ni-based alloy were achieved by annealing the bulk glassy rod prepared by copper mould casting. The microstructure, grain size, grain distribution, and phase composition were characterized. Electrochemical behaviours of the Ni-based alloy were revealed by static immersion and anodic potentiodynamic polarization tests. It is indicated that the corrosion behaviours of the Ni-based bulk glass-forming alloy are related to its microstructures, while the fully crystallized alloy exhibits a relatively lower corrosion resistance than those of the amorphous states.
Investigation on the explosive welding mechanism of corrosion-resisting aluminum and stainless steel tubes through finite element simulation and experiments
Guo-fa Sui, Jin-shan Li, Hong-wei Li, Feng Sun, Tie-bang Zhang, and  Heng-zhi Fu
2012, vol. 19, no. 2, pp. 151-158. https://doi.org/10.1007/s12613-012-0531-4
Abstract:
To solve the difficulty in the explosive welding of corrosion-resistant aluminum and stainless steel tubes, three technologies were proposed after investigating the forming mechanism through experiments. Then, a 3D finite element model was established for systematic simulations in the parameter determination. The results show that the transition-layer approach, the coaxial initial assembly of tubes with the top-center-point the detonation, and the systematic study by numerical modeling are the key technologies to make the explosive welding of LF6 aluminum alloy and 1Cr18Ni9Ti stainless steel tubes feasible. Numerical simulation shows that radial contraction and slope collision through continuous local plastic deformation are necessary for the good bonding of tubes. Stand-off distances between tubes (D1 and D2) and explosives amount (R) have effect on the plastic deformation, moving velocity, and bonding of tubes. D1 of 1 mm, D2 of 2 mm, and R of 2/3 are suitable for the explosive welding of LF6-L2-1Cr18Ni9Ti three-layer tubes. The plastic strain and moving velocity of the flyer tubes increase with the increase of stand-off distance. More explosives (R>2/3) result in the asymmetrical distribution of plastic strain and non-bonding at the end of detonation on the tubes.
Left-handed properties of a composite structure with metallic wires in a homogeneous Lorentz medium
Yang Bai, Fang Xu, and  Li-jie Qiao
2012, vol. 19, no. 2, pp. 159-164. https://doi.org/10.1007/s12613-012-0532-3
Abstract:
The electromagnetic properties of a composite structure with metallic wires in a Lorentz medium were studied. The results show that the electromagnetic properties of the medium host influence the plasma resonance of metallic wires and the left-handed character of the composite. The plasma frequency of metallic wires reduces with the rise of permittivity or permeability of the medium host. Also, the negative permeability of the medium can destroy the wires' plasma resonance and prevent the realization of left-handed properties. The high loss of medium permittivity or permeability also inhibits the metallic plasma resonance. The negative influence of the media host on the left-handed properties of the composite structure can be effectively reduced by proper structure design, such as introducing a nonmagnetic medium in the host or using an anisotropic medium.
Kinetics and mechanism of titanium hydride powder and aluminum melt reaction
Ali Rasooli, Mehdi Divandari, Hamid Reza Shahverdi, and  Mohammad Ali Boutorabi
2012, vol. 19, no. 2, pp. 165-172. https://doi.org/10.1007/s12613-012-0533-2
Abstract:
Based on the measurement of the released hydrogen gas pressure (PH2), the reaction kinetics between TiH2 powder and pure aluminum melt was studied at various temperatures. After cooling the samples, the interface of TiH2 powder and aluminum melt was studied. The results show that the 2 H PH2-time curves have three regions; in the first and second regions, the rate of reaction conforms zero and one order, respectively; in the third region, the hydrogen gas pressure remains constant and the rate of reaction reaches zero. The main factors that control the rate of reaction in the first and second regions are the penetration of hydrogen atoms in the titanium lattice and the chemical reaction between molten aluminum and titanium, respectively. According to the main factors that control the rate of reaction, three temperature ranges are considered for the reaction mechanism:(a) 700-750℃, (b) 750-800℃, and (c) 800-1000℃. In the first temperature range, the reaction is mostly under the control of chemical reaction; at the temperature range of 750 to 800℃, the reaction is controlled by the diffusion and chemical reaction; at the third temperature range (800-1000℃), the dominant controlling mechanism is diffusion.
Preparation of high emissivity NiCr2O4 powders with a spinel structure by spray drying
Xu-dong Cheng, Jie Min, Zhen-qi Zhu, and  Wei-ping Ye
2012, vol. 19, no. 2, pp. 173-178. https://doi.org/10.1007/s12613-012-0534-1
Abstract:
Spray-drying was used to produce the high emissivity NiCr2O4 powders with a spinel structure. Preliminary investigations focused on fabricating the high emissivity powders for infrared radiation coatings and finding the relationship between microstructure and emissivity. The NiCr2O4 powders were characterized for composition, microstructure, and infrared emissivity by X-ray diffraction (XRD), scanning electron microscopy (SEM), infrared radiant instrument, and Fourier transform infrared spectra (FT-IR). Thermogravimetry and differential thermal analysis show that the appropriate baking temperature for NiCr2O4 powder preparation is about 1200℃. The emissivity measurement and FT-IR spectra show that, because of the special spinel structure, the NiCr2O4 powders have a high emissivity about 0.91. Spray-drying is a suitable method to produce the high emissivity ceramic powders.
Design and calculation of low infrared transmittance and low emissivity coatings for heat radiative applications
Guang-hai Wang, Yue Zhang, Da-hai Zhang, and  Jin-peng Fan
2012, vol. 19, no. 2, pp. 179-184. https://doi.org/10.1007/s12613-012-0535-0
Abstract:
The infrared transmittance and emissivity of heat-insulating coatings pigmented with various structural particles were studied using Kubelka-Munk theory and Mie theory. The primary design purpose was to obtain the low transmittance and low emissivity coatings to reduce the heat transfer by thermal radiation for high-temperature applications. In the case of silica coating layers constituted with various structural titania particles (solid, hollow, and core-shell spherical), the dependence of transmittance and emissivity of the coating layer on the particle structure and the layer thickness was investigated and optimized. The results indicate that the coating pigmented with core-shell titania particles exhibits a lower infrared transmittance and a lower emissivity value than that with other structural particles and is suitable to radiative heat-insulating applications.