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By Yanhui Liu, Xuewei Lv, Pingsheng Lai, Chenguang Bai

The purpose of this paper is to study the effect of slag basicity on the Si content in stainless steel master alloys prepared by smelting reduction of Fe-Ni-Cr sinters. Theoretical analysis focusing on the gas, slag and alloy phases of the smelting reduction process at 1600°C was carried out by thermodynamic calculation software----FactSage, showing that the increase of CaO within the slag can result in the decrease of Si within the master alloy. Experiments were also carried out in vacuum melting furnace at 1600°C , and chemical analysis method was used to detect Si content in the alloys. When the MgO content is 9.00%, the experimental results were consistent with the calculated values. However, when the MgO content rises up to 14%, the content of Si in the alloy reaches the maximum when SiO2 equals to 22.81%.

Jan 1, 2016

By Sung Wng Kim

The binary antimonide compounds with the skutterudite structure have a potential for thermoelectric applications because of the high carrier mobility, high thermoelectric power, and relatively low thermal conductivity due to the complex crystal structure. However, the room temperature thermal conductivity of these skutterudite materials is as high as about IOW/mK with an estimated 80-90% contribution from the lattice thermal conductivity. Because the lattice thermal conductivity of related ternary skutterudite compounds can be substantially reduced due to the additional phonon scattering, a study of thermoelectric properties of these compounds is of interest. The binary IrSb3, ternary Ir1.xRuxSb3 and Ir(MxSb1.x)3(M=Ge, Sn) compounds were prepared by hot pressing of pre-reacted powders. We have measured the electrical resistivity, thermoelectric power, and thermal conductivity, in a temperature range from room temperature to 973K. The binary IrSb3 compound is found to have P-type electrical properties exhibiting a good Seebeck coefficient (up to 225µV/K around 773K), electrical resistivity(5x10-5Ohm M around 933K), and relatively low thermal conductivity(6W/mK around 950K). The lattice thermal conductivity, K[2] was calculated from the Wiedemann-Franz relationship.

Jan 1, 2002

By Truan-Sheng Lui, Li-Hui Chen, Fei-Yi Hung, Cheng-Yi Chen

"This research used the austempering heat treatment on the SCM435 thin specimen with a type of double loop and obtained the Cr-Mo bainite structure, and then we could further investigate the mechanical properties of SCM435 bainite structure. Experimental data showed the stability of the mechanical properties of specimen with austempering temperature 830°C for 25 minutes was better than that of 15 minutes. The size of austenite grain affected the strength of thin specimen. After austempering at 830°C-25minutes and salt bath at 290°C, the stability of UTS was better than that of salt bath at 310°C and 330°C. The average hardness of all specimens was about more than HRA70. The specimen with austempering at 830°C-25minutes and salt bath at 290°C-30minutes had bigger grain size of austenite and retained y, it also had higher hardness and strength toughness. So, its stability was improved for tensile strength comparing with traditional tempered martensite process.IntroductionSCM435 is a Cr-Mo steel with high strength and high hardness properties, and it has been widely used in machine parts, shafts, gears and strength screw products [1-3]. However, this system often has lower reliability due to the brittleness of high-temperature tempering and quenching inequality. Considering the austempering heat treatment can obtain the uniform bainite structure to improve the temper brittleness, and the austempering heat treatment is a continuous process that it also has efficiency and uniformity. For the thin plate specimens, the mechanical properties of the bainite structure are better than traditional martempering structures."

Jan 1, 2013

By Zhijing Zhang

The management of hazardous wastes is important in a society which is increasingly concerned with environmental issues. Incinerators such as the slagging rotary kiln are widely used in the treatment of hazardous wastes. However, in order to assure a smooth operation of the rotary kiln, the melt should have both a low melting point and high fluidity. In this study, the fluidity of various hazardous waste rotary kiln slags was measured in terms of length of flow using the crucible test technique. It was found that the slags have melting points ranging from 1372 to 1424°C while their fluidities varied from 61-102 mm. The effect of addition of oxides on the fluidity of a slag containing 47 wt% SiO2 was also investigated. For this slag, additions of SiO2 (up to 56 wt%), FeO and Na20 increased fluidity, whereas the addition of CaO and A1203 resulted in lower fluidity values.

Jan 1, 2002

By S. Moussa

The formation of boron-doped nickel aluminides Ni3AI, (76 at. % Ni) from elemental powders by reaction synthesis using reactive sintering was studied. The process involves the mixing of elemental powders of nickel and aluminium with various wt % of boron up to 1 wt % boron. Nickel and Aluminium powders were mixed in the correct proportion to form the intended boron-doped nickel aluminide intermetallic. XRD, SEMI EDS, Image analysis and Archimedes principle; were used to study the effect of Boron addition on the final microstructure, bulk density, average grain size of as reactively-sintered nickel aluminides (boron-doped), compared with no boron addition. The results showed that at greater boron content than 0.3 wt %, a two-phase non-equilibrium microstructure of consisting of NiAI phase in NiJAI matrix was formed that have been primarily retained even after heat treatment for 5 hours at 1000 °C. Boron was present in solid-solution within both the NiAI and the Ni3AI (in greater amounts) phases.

Jan 1, 2001

By Harry Littleton, Jr. Scarber, Wanliang Sun

"The Lost Foam Casting (LFC) process is relatively immature when compared to other casting processes. To make the process more robust, computer modeling is needed to reduce lead times and casting defects. In this study, metal filling of lost foam aluminum castings was visualized using state-of-art real time X-Ray technology. Metal filling of the lost foam casting was simulated using a commercial software package. The result of the computer simulation was compared with the results of the real time X-Ray visualization. Some of the computer simulation results agreed with the real time X-Ray visualization, but some did not. Based on other studies using real time X-Ray technology, new input variables, such as foam density variations, were developed for the computer modeling. With the new variables, modeling of the lost foam casting process becomes more realistic. IntroductionMold filling of the Lost Foam Casting (LFC) process is an important step toward making a quality part. In the LFC process, molten metal is poured against a refractory coated foam pattern surrounded by dry sand. At the pouring temperature of aluminum, the foam pattern is decomposed into 30% (wt) gaseous and 70% (wt) liquid foam pyrolysis products. Existence of the gaseous foam decomposition products significantly increases the back pressure on the metal stream compared with the conventional open cavity sand mold. Entrapment of the liquid pyrolysis products during the metal filling generates many casting defects, such as internal pores, fold and blisters. Existence of these casting defects sometimes seriously degrades the quality of the components manufactured by the LFC process. Understanding and controlling the metal filling of the LFC process will certainly make this process more robust."

Jan 1, 2004

By James T. Skoch

With the ongoing pressure on the secondary aluminum business to limit the amount of waste generated from processing aluminum dross, it becomes very advantageous to preprocess the dross to reduce waste. The advantage of preprocessing is that it significantly reduces the oxides and salt cake generated when melted. Various products can be produced from the oxides for the steel industry. The following paper will demonstrate that removal of oxide fines before melting will result in large volumes of material not being landfilled. We will show that the end result of this technology is to significantly reduce the amount of salt cake sent to a landfill while maximizing the recyclability of the aluminum dross.

Jan 1, 1995

By QIE Jun-mao, DONG Fang, DENG Hao-hua

The DIL402C thermal dilatometer and STA449C thermal analyzer were employed to test the linear expansion and contraction coefficient，CP and DSC curve of 304 stainless steel. The result showed that the linear expansion coefficient range was 20.9700×10-6～21.5712×10-6 and the linear contraction coefficient range was 21.2528×10-6～21.9471×10-6.The linear expansion and contraction coefficient were higher than other steel grade，so the 304 stainless steel belonged to the crack sensitive steel. Because of the crystal phase transformation occurred during the 1000~1400 ℃,the curve of CP fluctuated obviously and the defects of casting blank occurred easily. Chosen 1414℃ as the liquidus temperature of 304 stainless steel based on the analysis results of DSC. The curve of DSC was unsmooth during 1450～1100℃，the crystal phase transformation occurs and thermal stability of slab was inferior.When the initial solidified shell formed in this temperature range,the thickness of the shell would be nonuniform and the surface defects occurred more easily.

Jan 1, 2015

By P. A. Davidson

"We discuss the influence of a static magnetic field on jets, vortices and turbulence. This is particularly relevant to D.C. braking in slab casting. Our main conclusion is that, typically, the magnetic field destroys mechanical energy, via joule dissipation, but is unable to destroy momentum. Rather, it continually rearranges the momentum in such a way that the energy falls.IntroductionIt is well-known that a static magnetic field can suppress motion of a liquid metal. That is to say, movement of the liquid across the magnetic field lines induces a current. This leads to Joule dissipation and the resultant rise in thermal energy is accompanied by a corresponding fall in kinetic energy.This phenomenon has been exploited in a range of metallurgical processes. For example, in the continuous casting of large steel slabs, an intense, static magnetic field is commonly used to suppress motion within the mould. The objective is to keep the free surface of the liquid quiescent, thus avoiding the entrainment of surface debris. In other solidification processes, such as techniques for growing semi-conductor crystals, it is widely believed that natural convection has a detrimental effect on the metallurgical structure of the solid. Again, the imposition of a static magnetic field is seen as one means of suppressing these unwanted motions. Finally, magnetic damping is used in the laboratory measurements of chemical and thermal diffusivities, particularly where solutal or thermal buoyancy can disrupt the measurement technique.In this paper we shall look at the damping of jets, vortices and turbulence. Our aim is to present a unified theoretical framework from which the many published studies may be viewed."

Jan 1, 1999

By Staia. Mariana H.

Thermochemical equilibria of the heterogeneous system Ti-N-H-CI-Fe-Cr-Mo-Ni-Mn-C were calculated by using a commercial software based on the minimization of the free energy. Equilibrium calculations were done for temperatures varying between 800" and l 100°C and an initial molar relationship between reactants, a=NJTiCI,, of 0.1 to 2. The deposition process was considered to occur at atmospheric pressure. The activities of the alloying elements of the stainless steel were considered equal to their molar fractions. It was shown that for the conditions studied the substrate is no inert with respect to the gaseous phase. The existence of liquid chlorides was predicted for temperatures between 800" and 850°C and a ratio between 0.3 and 0.9. The most important metallic chlorides which appears to be present from the calculations in appreciable quantities in the gaseous phase are iron dichloride and manganese dichloride. In the low-temperatures zone and for low initial nitrogen contents, it result that the appearance of the liquid chlorides seems that partially inhibits the production of gaseous HCI. The highest deposition process efficiency calculated is obtained at a temperature 2 900°C and a N2/TiCI, ratios 2 0.7.

Jan 1, 1995

By T. Asahina, M. Nakamura, M. Mabuchi, I. Shigematsu, M. Nakanishi, G. Yamauchi

"Commercial stainless steels (SUS304L and SUS430) were subjected to equal channel angular extrusion (ECAE) at room temperature to a total strain of 2.3 to 9.2. For each type of stainless steel, it was shown that the sample processed by ECAE showed higher room temperature strength than the as-quenched sample. This is probably due to the heavily worked structure. On the other hand, both strength and elongation of the ECAE processed SUS430 were increased by annealing at 773K. It is likely that higher strength is attributed to both the heavily worked structure and fine substructures. It is also likely that higher elongation is attributed to the fine substructures. It is concluded that ECAE is available for improving the room temperature strength of commercial stainless steels.INTRODUCTIONEqual channel angular extrusion ( ECAE ) is a technique that provides the repetitive deformation and allows to high intensity of deformation. With this procedure, a sample is pressed through a channel that has an equal cross section but bent at an angle of ?> [1-2]. Shear strain is introduced when a sample passes through the bending point of the channel. Repetitive processing is feasible because the cross-sectional dimension of a sample has no change during processing. To date, many reports have described that ECAE is available for the fabrication of fine-grained materials [3-14]. On the other hand, an ECAE processed sample can achieve high intensity of deformation through repetitive deformation. According to the equation given by Segal [ 2 ], a strain of about 1 is introduced in each pass through die if the angle ? is 90 deg.It is well known that high tensile strength can be achieved in metallic materials through work hardening [15]. It is also known that metallic materials with fine grain size show high strength [16]. Hence, it is expected that ECAE is available for strengthening method in metallic materials. In the present paper, we will report the mechanical properties of stainless steels processed by ECAE. As samples, SUS304L austenite stainless steel and SUS430 ferritic stainless steel were chosen. Each alloy has a single-phase structure (fee or bee) and shows no phase transformation, so that transformation strengthening cannot be applied. Hence, a heavy cold work such as ECAE may be effective for strengthening of this stainless steel. Annealing was conducted for the ECAE processed SUS430 to vary its microstructure. Then, the effect of annealing on the strength of the ECAE processed SUS430 was also investigated."

Jan 1, 2000

By V. Ramachandran

Under the Resource Conservation and Recovery ACT (RCRA), generators of listed or characteristic hazardous wastes must find satisfactory means for disposal. of wastes. Initially, for many this meant landfills and deep-well injection. Until recently, mining and metallurgical by-products have largely been exempt from RCRA, but now are coming under its jurisdiction. With the increasing closures of landfills, companies in the U.S. such as electroplaters, miners, metallurgical plants and others are turning to recycling as an alternative to treat their wastes. While the cost of recycling has been challenging, the long-term economics prove attractive because recycling interrupts the cradle- to-grave responsibility for the waste generator. The present paper describes the recycling of hazardous wastes at ENCYCLE/TEXAS. Encycle extracts marketable metals from metal-bearing sludges and wastewater using hydrometallurgical processes borrowed from the mining and metallurgical industry.

Jan 1, 1994

By M. Sakamoto, S. Karaswa, Y. Yoneoka, Y. Ohmizo

"The Annaka Refinery has been processing leach residue by Waelz process for 17 years. Recently, the quantity of the leach residue has increased due to a decline in the quality ~f zinc concentrate. Meanwhile, negative factors (e.g. deterioration of water balance due to improved electrolytic power consumption rate) have increased· in the processing of the leach residue.We have implemented various measures in responses to this situation, while striving to increase ·processing capacity and achieve stable operation. AS we have largely completed our assessment of the efficacy of these measures, we report on our recent process improvements.IntroductionWe have been treating leach residue by the Waelz kiln process since 1981. At that time, treatment of only 50,000 tons of leach residue per year was anticipated. However, subsequent process improvements have revised this figure up to 75,000 to 80,000 tons per year.However, today's increased Fe zinc concentrate grade has resulted in increased amounts of leach residue. In addition, improvements have reduced electrolytic power consumption rate of zinc electrolysis, limiting the amount of water that can be used in ·the zinc refining processes and for deaning leach residue. Consequently, we encounter an increasing number of problems and factors adversely affecting leach residue treatment, including increases in water-soluble Zn (WsZn) and. S (S04) in leach residue.To solve these problems, we have taken several measures to ensure long-term continuous operation and treatment of this increased · amount of leach residue. This paper discusses these measures."

Jan 1, 2000

By Martin Brueggemann

In 1993, the El Paso Smelter began operation of the first commercial CONTOP copper smelting furnace. The CONTOP process was chosen for the plant modernization due to its low capital cost and the ease that it could be incorporated into a 100 year old existing smelter. After four years of operation, CONTOP has proved itself to be a reliable copper smelting technology. This paper will discuss a brief start-up history, current operation, and future modifications and improvements.

Jan 1, 1998

By Gabriel Riveros, Ariel Balocchi, Andrzej Warczok, Daniel Smith

Blister copper from converting of copper matte is processed by fire refining prior to electrorefining. The fire refining consists of two steps: copper oxidation with impurities slagging and copper reduction. The classical batch process is carried out in vascular or reverberatory furnaces called anode furnaces. A new process for continuous copper fire refining has been proposed. The copper flows through two reactors in cascade, where is oxidized and reduced. The flow of a liquid copper through a ceramic packed bed increases the surface area and the rate of oxidation as well as the rate of reduction in the packed bed of charcoal. Mathematical modelling allowed for the design of a laboratory scale demonstration installation and industrial-pilot installation in Hernan Videla Lira Smelter (Paipote). The results have demonstrated the process feasibility and flexibility in operation.

Jan 1, 2009

By Valentine A. Chanturiya

A model for development of electric discharges between particles of sulfide minerals (pyrite) under the action of high-voltage nanosecond pulses is proposed. It is shown that through discharges in a layer of pyrite particles lead to energy concentration in small contact regions between particles; the concentrated energy is sufficiently high for local disintegration of mineral complexes.

Jan 1, 2009

By Xuerong Wen

The oxidation behavior of TiAl3 intermetallics was investigated as a hnction of time at 1273K in pure dry oxygen. The oxidation experiments were carried out using TGA method. The oxidation scales were analyzed using SEM, EDS and X-ray diffraction methods. The structures of oxides formed at the different oxidation times were analyzed. The mechanism of oxidation of TiAl3 intermetallics was discussed.

Jan 1, 1998

By Xinli Wang, Matthew Andriese, Jiann-Yang Hwang, Zhiwei Peng, Byoung-Gon Kim

"The microwave reflection loss (RL) of ferric oxide is studied in the temperature range from 297 to approximately 1400 Kat frequencies of 915 and 2450 MHz. It is shown that the maximum microwave absorption with RL of -38.46 and -35.97 dB can be obtained for ferric oxide having thicknesses of 0.03 and 0.01 m at 915 and 2450 MHz, respectively. The maximum absorption peak with RL below -10 dB is in a 250 K temperature range from 723 to 973 Kat 915 MHz, which shifts to the range between 823 and 1073 K at 2450 MHz. This migration is in good agreement with the variation of the dielectric loss tangent of ferric oxide.IntroductionMicrowave irradiation has distinguishing characteristics such as volumetric and selective heating compared with conventional methods, leading to extremely broad applications in materials heating and processing [1-5].The efficiency of microwave heating was found to be dependent on various factors, such as microwave power [6], frequency [7,8], radiation time [8], applicator geometry [8], sample microwave absorption properties and position as well as dimension [9-11 ], etc. Among these parameters, sample dimension plays an important role but is usually neglected by researchers in microwave processing of materials. In fact, although numerous studies have been directed toward the utilization of microwave energy to assist materials heating and processing, few reports were released on the effect of sample dimension [12,13].This is because all aforementioned factors influencing microwave heating generally exert interactive effects to each other during the heating process, making clarification of the effect of sample dimension difficult. Therefore, it is necessary to propose a parameter or concept for quantifying the effect of absorber dimension on microwave heating, increasing heating efficiency."

Jan 1, 2013

By Katsunori Yamaguchi

Secondary materials, that contain relatively high concentrations of platinum group metals, (PGMs) are treated in copper smelting process. The PGMs lost in the slag is increasing with increasing quantities of scrap treated amount. To determine the portion of the PGMs chemically dissolved and that associated with the mechanically trapped matte in the slag will be a key factor to improve the recovery of those metals. An experimental study was carried out to determine the distribution of palladium between the FeOx–SiO2 slag and the liquid Cu2S–FeS matte at 1573 K and a fixed partial pressure of SO2 of 0.1 atm. It was found that the distribution ratios are around 10−3 for platinum and palladium. The distribution ratios show a tendency to increase when the grade of matte is increased above 60 mass% Cu. In addition, the solubility of platinum in FeOx–SiO2 slag equilibrated with a pure palladium and the Pd-Cu alloy was determined at 1573 K and the range of oxygen partial pressure from 10−9 to 10−7 atm. The solubility of palladium in the slag tends to increase with increasing oxygen partial pressure and activity of CuO0.5 in the slag.

By Zhang Chuanfu, Li Shixiong

"In the electrolysis electrodeposition or electroplating of aqueous solution of copper, lead, zinc, nickel, manganese etc, with the increase in cathodic over potential the reducing rate of metal and the cathodic current efficiency increases and the deposit becomes more compact and smooth. According to this principle, a method and equipment of the auto-control of electrolyte quality is invented. The industrial application shows that this method turns the experienced operation into auto-control. The quality and quantity of metal is improved greatly and the consumption of electric energy is reduced.In the electrolysis, electrodeposition or electroplating of aqueous solution of copper, lead, zinc, nickel, manganese etc, usually organic additives are added according to the state of cathodic deposit according to experience. This traditional and experienced operation, often lead to that the quality of additive is not optimum which affects the quality and quantity of metal and increases the consumption of electric energy. To counter the controlling problem of the quantity of additive, the authors have invented a corresponding equipment of the auto-control of electrolyte quality [1], it has found application in industrial practice."

Jan 1, 2000