Search Documents

By E. Kozeschnik

A new model is presented for the simulation of the evolution of precipitates in a multi-component multi-particle multi-phase environment The mathematical formulation as well as the physical background of the model are briefly introduced and its capabilities are discussed on the example of a precipitation sequence in a complex steel. Keywords: Modeling, precipitation kinetics, nucleation, growth, coarsening

Jan 1, 2003

By Zhongming Ren

"A new process of near net shape continuous casting of metal pipe has been put out. The specialty of the process is that no inner core is used. The principle of the process has been presented, and the effect of several factors on the thickness of the pipe has been investigated experimentally and numerically. It is shown that the temperature and the level of the molten metal, cooling intensity of the mold, and the velocity of casting influenced the thickness of the pipe apparently. In order to improve evenness of the thickness of the pipe, the mold was dedicatedly designed, and special methods were taken. By this process, a metallic material like ""bamboo"" was fabricated.IntroductionMetal pipe is a widely used material. Up to now, many processes have been put out to produce the pipe. However, the processes are usually expensive and inefficient. For instance, the welding pipe, which is most widely used, is produced through continuous casting of slab, rolling of the slab into sheet, and welding, with several times of heating and processing. Continuous casting of pipe can not produce small diameter of pipe, which is mostly needed, due to the inner core. Even though. OCC process is novel in fabricating the pipe with small diameter, it is inefficient. In this paper, the no-inner core continuous casting of pipe was proposed. With this process, pipe with small diameter can be produced efficiently. The influence of several parameters on the thickness and evenness of piper wall. With this process, a ""bamboolike"" pipe was fabricated.ExperimentThe experimental apparatus is shown in Fig. I. It is composed of mold, furnace, melt level adjuster, and dummy pipe. In the process, the level of the melt was adjusted at a proper position, then the mold along with the dummy pipe was inserted into the melt in a certain depth. The melt in the mold began solidifying, forming a solid shell. After that, the dummy pipe was pulled upward in a certain speed, drawing the solid shell out of the mold. Thus, a pipe was continuously cast."

Jan 1, 2000

By Di Yang

The influence of high density (104 -105 A/cm2) electric current pulses (70 us duration) and continuous DC (~103 A/cm2) on the flow stress and ductility in tension of a high carbon steel wire were determined at 204°, 427° and 649°C. Electropulsing (100 pulses per second) with an effective current density of 100-200 A/cm2 gave a 10% enhancement in the uniform elongation of the wire at 204°C, but had no effect at 427°C and 649°C. In contrast, continuous DC either had no significant effect on the ductility or gave a decrease. The electropulsing per se decreased the flow stress only slightly at 204° and 427°C, but gave a significant decrease at 649°C. Continuous DC increased the flow stress at all three temperatures. The present results along with those by others suggest that the enhanced ductility by electropulsing and the reduction in flow stress may be further increased by raising the effective current density through increases in either the pulsing frequency, maximum current density of each pulse or pulse duration. This could conceivably increase the reduction per pass during wire drawing or the number of passes between anneals.

Jan 1, 2001

By K. Itagaki, H. Henao

"The experimental study on the phase equilibrium and distribution of minor elements such as chromium and copper between magnesia saturated FeOx-MgO-SiO2 slag and Fe-Ni alloy were carried out under controlled oxygen partial pressure between 10-6-5 and 10-10 using CO and CO2 mixed gas at 1773 and 1873 K.The effect of slag additives such as lime (CaO/SiO2 molar ratio: 1) and alumina (AlO1.5/SiO2 molar ratio: 0.1) on the distribution behavior of the minor elements was also investigated.The value of distribution ratio for chromium, defined by (%Cr in slag)/[%Cr in alloy], is larger than 70 at the pO2 region conducted in the present study for the MgO saturated FeOx-MgO-SiO2 slag at 1773K. These value are almost 4-order higher then that of nickel though the distribution ratio of copper shows similar values with nickel. Analysis of the data indicates that addition of lime in the slag and the increase of temperature reduce the dissolution of chromium into the slag and the addition of aluminum increases the dissolution of chromium into the slag while reduces the dissolution of copper and nickel.IntroductionChromium. is a minor element in a nickel oxide ore but a Japan major component in the secondary material of stainless steel and is also introduced in the Fe-Ni production process due to dissolving bricks of a furnace. Chromium is a concerned matter for the beneficial utilization and disposition of ·slag because Cr6+ is a harmful element. Considering Fe-Ni as an alloy component in steel making, and the demand of high purity nickel, chromium is an -undesirable element that has to be eliminated into slag prior to the steel making, or the production of high temperature refractory alloys. On · the other ·hand chromium is an element of steel alloy for many applications, thus Fe-Ni containing chromium in minor element is desirable in some stainless steel making."

Jan 1, 2000

By K. Narayan Prabhu, W. D. Griffiths

"Heat transfer during the unidirectional solidification of a cast iron alloy against cast iron chills was investigated using an inverse modelling approach. Chills of thickness 100 mm and 10 mm were used, to simulate gravity die cruiting conditions and the use of chills in sand moulds. In both cases transient heat transfer, measured by the interfacial heat flux and heat transfer coeffieient; declined from initially high values in the first few seconds of solidification, to values about an order of magnitude lower which persisted for the remainder of the experiments. In the case of the thin chill it became saturated with heat until it was no longer in a position to extract further heat from ·the casting. These results were interpreted by studying the resistance to heat transfer from the casting offered by the ·casting-chill interface and the chill itself for example, the thermal resistance of the casting-chill interface can be influenced by the deformation of their respective surfaces and their subsequent relationship.IntroductionDie casting cast iron offers several advantages such as energy savings, higher mould yield, and better surface quality over the sand casting process1 • The process is· environmentally' friendly because of the elimination of the sand. However the design and construction of metallic moulds is expensive and a faulty die design may result in a defective casting: A simulation based process design of die castings would enable die designers and solidification modellings to try better designs of dies on the computer and arrive at a cost effective solution more quickly. This has numerous benefits for the die caster, as he would be able to produce sound castings with very short lead times.The success of a solidification model to predict accurately the thermal history and the location of hot, spots inside a solidifying casting depends to a large extent on the heat transfer data prescribed at the metal/mould interface. Many measurements of the heat transfer coeffident (or the heat flux) between a solidifying aluminum alloy and a chill have shown that the heat transfer coefficient is a function of most of the variables of the casting process2 - 8. However heat transfer studies during the solidification of ferrous alloys are rather limited. The high temperatures involved suggest that the contribution due to radiation heat transfer cannot be neglected."

Jan 1, 2000

By M. Z. Sukiennik

A static method for vapor pressure measurement up to 1450 K and above 1 hPa is presented. The method is designed for equilibrium and kinetic studies of metallic systems, including those with a chemical reaction. Application examples are given for determination of activities in condensed phases, and heterogeneous reaction rates and equilibrium constants.

Jan 1, 1993

By Mingchun Lu, Zhijia Liu, Xueqi Zhang, Jianliang Zhang

"In order to solve the problem of shortage of scrap, especially high quality scrap, a new substitute for scrap or DRI has been developed. The decarbonization mechanism of granular pig iron has been analyzed and the technical process and decarbonized granular pig iron have been evaluated in this paper. The research result shows that this new process is superior to direct reduction process in product quality, construction investment, operation flexibility, production efficiency etc. Decarbonized granular pig iron (DGPI) not only can be used as conventional scrap but also can be charged into EAF as high purity .burden equivalent to heavy scrap:IntroductionIn the past years, with the universal application of continuos casting technique in China, the amount of scrap generated inside steelworks has been reducing continually. On the other hand, the EAF steel proportion is increasing and this gives to the obvious change in structure of steel product. At present, the requirement on both scrap quantity and scrap quality is being paid more and more attention. Because China is a country which is devoid of scrap and poor in resource (nature gas and high grade iron ore) for developing direct reduction iron (DRI) so that sponge iron can not be produced cosmically in China and has to be mainly imported. Instead of part of scrap, some cold pig iron in cold state has been charged into EAF in China. However the high carbon content in pig iron has limited its proportion in EAF metal burden. Because the price of pig iron is lower than that of imported DRI in China, the technique of granular pig iron decarboniztion is hopeful to become effective way to produce substitute for scrap or DRI."

Jan 1, 2000

By Michael S. Moats, Jan D. Miller, Wlodzimierz W. Zmierczak

"For many, hydrogen in a pure hydrogen economy would be like natural gas in today’s energy economy. Unfortunately, hydrogen’s physical properties are unsuited to the energy market’s requirements in terms of packaging, storage, transfer, and delivery. In this paper, a hybrid energy economy that packages hydrogen chemically on carbon atoms from various sources including recycled carbon dioxide is introduced and discussed. For this new hybrid energy economy to become a sustainable reality, the ability to recycle carbon dioxide and use hydrogen to create an appropriate energy product, such as dimethyl ether (DME), is needed. DME is recognized as a potential next generation, “beyond-petroleum”, environmentally benign commodity for energy storage and distribution. It is expected that to maximize the sustainability of the proposed hybrid energy economy, “green” hydrogen will be utilized. The “green” hydrogen would be created by the electrolysis of water powered by renewable energy sources, such as solar, wind or geothermal heat.IntroductionWith the growing concerns surrounding trends in global warming and increasing concentrations of “greenhouse” gases, such as CO2 and CH4, efforts to mitigate the emission of these gases from industrial sources are growing. With respect to CO2, the demonstrations of various capture and sequestration methods are underway around the world.The sequestration of CO2 is mainly focused on storing the gas underground or deep in the ocean. The Intergovernmental Panel on Climate Change (IPCC) estimates that 2000 Gtonnes of CO2 can be stored underground in depleted oilfields, un-minable coal beds and other geologic features [1]. Additionally CO2 may be stored at the bottom of the ocean. The lure of storing carbon dioxide in depleted oilfields or un-mineable coal seams is that an economic benefit (enhanced oil or methane recovery) can offset the costs of gas capture, transportation and storage. Unfortunately, all of these storage methods have potential for the release of CO2 or CH4 back into atmosphere or creating environmental damage (mobilizing heavy metals, disrupting deep sea ecology)."

Jan 1, 2008

By Fashina Olugbenga Emmanuel, Ghazali Akeem, Adegbola Adekunle Amos, Omotoyinbo Joseph Ajibade, Olaniran Oladayo

"Modern engineering materials are required to be light weight and corrosion resistant, coupled with high strength and hardness. In this work, Al formed the parent metal and alloyed with 2.03% of Copper by sand casting process. The cast product 2024 was warm worked at various temperatures ranging from 300 to 5600c at 5%, 10%, 15% and 20% deformation respectively and aged accordingly. The results showed that the mechanical properties vis-à-vis hardness, tensile improved with increasing % deformation at a higher temperature. This was due to the progressive close-up of the voids emanated from casting by increasing deformation which is evident from the micrographs. MATLAB was also adopted to generate a model capable of determining the trend of flow of stress at operating temperatures. This was of immense value due to an increasing impact at higher percentage deformation with temperatures. Hence, Al -alloys will find applications in land vehicles, ships, trains, and aircraft, at elevated temperature.INTRODUCTIONThe problem of safe vehicle design with maximum impact energy absorption is a significant subject in structural crash worthiness design [1]. All engineering designs are expected to ensure the safety of users' life. This informed several studies meant to probe the causes of component failures in equipment, vehicles, and aerospace design and decide on appropriate solutions through materials selection techniques. A common example is in the design of crankcases and heads, piston, and cylinder blocks. As with engine blocks, cylinder heads can be made of Cast Iron or Aluminium Alloy. A head made of Aluminium alloy is lighter in weight than if it were made of Cast iron [2]."

Jan 1, 2013

By T. Alboussiere, O. Paireau

"We have designed an experiment to simulate natural convection in a direct-chill aluminium ingot. In this experiment we induce natural convection within a hemisphere filled with liquid-metal (mercury). The device consists of a copper hemispherical bowl closed by a copper plate. The top is maintained at superheat temperature while the boundary is cooled. While the temperature measurements were found using thermocouples, the velocities were obtained using an original technical procedure that relies on MHD properties. By applying a steady local magnetic field, we measure the velocity. The distribution of temperature and velocity can be separated into a thermally stratified core bounded by thermal wall jets. These wall jets greatly influence the degree of macrosegregation in ingots.1. Natural Convection in Aluminium CastingIt is well known that the quality of the final product in aluminium casting depends on the movements within the liquid metal such as forced or thermogravitational convection. Strong buoyancy-driven flows are known to occur in the liquid metal pool of an aluminium ingot caster. These flows have a significant influence on the metallurgical structure of the ingot through the redistribution of heat, fragmented dendrites and segregated material within the pool. Macrosegregation mechanisms depend on favourable temperature and flow distributions in the sump, and these factors will determine the pattern and degree of macrosegregation. Moreover, for many years, the importance of thermally-driven natural convection in casting has been underlined (Cole & Bolling, 1965). In this way, a precise determination of the velocity and temperature fields is required in order to improve understanding of the macrosegregation mechanisms. That is precisely the aim of this paper, which provides experimental data of the flow and the temperature distributions in a natural convection experiment. We intend, with this laboratory experiment, to determine accurately the velocity field, particularly within the thermal boundary layer where the effects of the flows may have an important role in the transport of crystals."

Jan 1, 1999

By Wenying Liu

The effect of aeration on chalcocite heap leaching was studied by analyzing the historical data from two chalcocite heap leach pads located in Chile, one with aeration and the other without aeration. The data showed that the copper leaching kinetics of the aerated heap was greater than that of the unaerated heap within a certain leaching period, after which there was no effect of aeration on the copper leaching kinetics. The total acid consumption per ton of ore processed was higher in the case of aeration, which was supported by the higher pH of the PLS. But the net acid consumption per ton of copper produced was the same in the two cases. Approximately 5% of the total iron added to the unaerated heap was precipitated inside the heap. In contrast, there was no net iron precipitation or generation inside the aerated heap. Bacteria activities were thought to occur even in the unaerated heap, but the extent was much less than in the aerated heap. Given the importance of forced aeration in chalcocite heap bioleaching, mathematical modelling will be applied in the future work to assist the optimization of the aeration system design.

By K. R. Robilliard

An outline is given of the problems facing tlile lead and zinc industry from the viewpoint of the range of residues currently produced from electrolytic zinc, blast furnace and other processes. Smelting approaches available using top submerged lancing technology are discussed and analysed. Pilot plant results for a range of lead and zinc-bearing materials are presented.

Jan 1, 1992

By Reimers. Jan H.

Practically all the world's lead is produced by sintering and blast furnace smelting, or the Imperial Smelting Process which is a variant of the blast furnace process. Increased coke and labour costs and strict lead emission limits have, however, made blast furnace smelting undesirable in most countries. A change-over to other lead smelting processes providing better working conditions and lower emissions is, therefore,. expected to occur once economic conditions improve and the necessary capital expenditures can be justified. The need for new lead smelting processes has long been evident and a number of new processes have been proposed 'and advanced to various stages of development. One of the new processes is already proven on commercial scale, while several others are still being tested on pilot plant scale.

Jan 1, 1983

By Jinrong Zhang

Fresh cyanide solution was treated by near UV light with the assistance of photocatalysts. Cyanide was oxidized mainly to cyanate. Photochemical behavior of the anatase and rutile forms of TiO2 was compared. It is found that anatase has a much higher activity than that of rutile. Bubbling of oxygen in the reactor showed no appreciable increase in cyanide oxidation, implying that the reaction is surface controlling. A very interesting finding in this study is that a natural mineral, ilmenite, can replace chemical titanium dioxide as the photocatalyst. Ilmenite without any treatment did not catalyze the oxidation of cyanide. But, after being roasted at high temperature with oxygen, the oxidation was enhanced dramatically. The mechanisms of photooxidation of cyanide and the roasting of ilmenite are proposed.

Jan 1, 1991

By Nobuaki Sato, Tetsuo Fukasawa, Akira Kirishima

To apply the fluoride volatility process for the treatment of fuel debris formed in the damaged nuclear reactors, study on the fluorination behavior of main constituents, such as fuel and cladding is essential. The mixture of uranium and zirconium oxides is formed under severe conditions such as high temperature and oxidizing atmospheres. In this paper, fluorination and volatilization behavior of uranium and zirconium oxides have been studied by TG-DTA method in the presence of fluorine. From the TG-DTA result of UO2 in F2 atmosphere, the weight gradually increased up to 7% at 350 oC followed by rapid weight decrease with exothermic peak showing the vaporization of uranium as UF6. ZrO2 showed similar fluorination behavior to that of UO2. However, fluorination of UO2-ZrO2 seemed to be suppressed with increasing ZrO2 amount. This may be caused by the formation of solid solution.

Jan 1, 2016

By Kongfang Feng, Fei Ruan, Zhiyu Liu, Jieyu Zhang, Xin Hong, Shaobo Zheng, Jixu Wang, Jinyin Xie

"Mixing phenomena in smelting reduction furnaces with asymmetric side blowing were studied in this paper. Mixing phenomena in a smelting reduction furnace was represented as the mixing time by electrical conductivity measurements. Experiments were performed in a water model under various operating conditions to determine the effects of horizontal angle, radial angle, inserting depth, flow rate of the upper and the lower side nozzle, the included angle between the upper side nozzle, and the lower side nozzle on mixing phenomena in smelting reduction furnace. Comparing mixing time and mixing phenomena, the optimal conditions were obtained for an asymmetric side blowing process.IntroductionIn recent years, many countries have put forward development strategies for saving resources and environment-friendly, the development of various industries had to face its influence for resources and the environment .As we all know, the steel industry is a pillar industry of the global economy, in which ironmaking is an important part of it. In the modern ironmaking process, the blast furnace is regarded as the most important equipment and tool. But with the increasing scarcity of metallurgical coke resources and considering the environmental impact of such processes, metallurgists proposed the concept of smelting reduction. Smelting reduction processes to produce hot metal from iron ore and coal were being developed as a possible alternative to the traditional blast furnace. At present, a number of smelting reduction processes had been developed all over the world, they were mainly included COREX, HISMELT, FINEX, DIOS, etc."

Jan 1, 2012

By L. Yin, R. B. Haber, N. Sobh, D. A. Tortorelli, R. W. Hyland Jr.

"We optimize continuous quench process parameters to produce a desired precipitate distribution in aluminum alloy extrudates. To perform this task, an optimization problem is defined and solved using a standard nonlinear programming algorithm. Ingredients of this algorithm include a cost function, constraint functions and their sensitivities with respect to the process parameters. These functions are dependent on the temperature and precipitate size which are obtained by balancing energy to determine the temperature distribution and by using a reaction-rate theory to determine a discrete precipitate particle size distribution. Both the temperature and the precipitate models are solved via the finite element method. Since we use a discrete particle size model, there are as many as 105 degrees-of-freedom per finite element node. After we compute the temperature and precipitate size distributions, we must also compute their sensitivities. This seemingly intractable computational task is resolved by using an element-by-element discontinuous Galerkin finite element formulation and a direct differentiation sensitivity analysis which allows us to perform all of the computations on a PC.1 IntroductionThis work addresses the need for an integrated design capability that links microstructure evolution to the process parameters. It is motivated by the manufacture of lightweight aluminum-alloy extrusions for use in automotive structures. Aluminum alloys offer obvious benefits, however, care must be taken to manufacture favorable microstructures that ensure acceptable structural performance. For example, the manufacturing process for 6000-series components involves hot extrusion of cast aluminum billets followed by either an air or water quench process. The bill~t's initial grain structure is dramatically altered during extrusion by massive mechanical deformations and recrystallization processes. The microstructure continues to evolve during the quench, as complex chemical processes determine the formation of precipitates. The control of the precipit'ate size distribution is vital. Indeed, large precipitates located on grain boundaries serve as crack initiation sites which adversely effect structural crash· worthiness."

Jan 1, 2000

By Sridhar Seetharuman

Sulfur and oxygen dissolved in nickel and cupronickel melts can be removed as gaseous oxides of sulfur by a vacuum treatment. Presented in this paper is a new matched thermochemical diagram that permits direct evaluation of the equilibrium partial pressure of SO, as a function of temperature over an alloy of specified composition. The matched thermochemical diagram consists of a central plot which shows the integral Gibbs' energy of mixing for the binary system S-O2, at different temperatures. The central plot is flanked on either side by terminal plots of the chemical potentials of oxygen and sulfur, as functions of temperature, for different alloy compositions. By projecting the chemical potentials of oxygen and sulfur from the terminal plots on to the central diagram, the equilibrium pressure of SO2,can be directly read on the nomograms on the central plot at different temperatures. The matched thermochemical diaerams are - useful in assuring the efficiency of vacuum refining.

Jan 1, 1993

By Teruo Tanabe

The hydrogen-absorbing materials are expected to have the following properties at moderate conditions, (a) a large capacity of hydrogen absorption, (b) the absorption rate of hydrogen is large and (c) hydrogen-absorbed materials can easily desorb hydrogen. Thus the three concepts of capacity, rate and reversibility seem to be indispensable to clarify the mechanism of hydrogen absorption by the materials. In this work, the amount of absorbed hydrogen, the absorption rate and the reversibility of hydrogen absorption- desorption reaction were measured for binary R-M systems (R = Y, La, Ce; M = Co, Ni). These experimental results were discussed by the following three physical properties that were calculated by the extended Hückel method, i.e. the density of states unoccupied by electrons, the cohesive energy and the energy fluctuation. The major results are as follows: (a) the amount of absorbed hydrogen increases with the density of states in the energy range between -9 and -4 eV, (b) the R-M compounds of which energy fluctuations are large show a large value of rate of hydrogen absorption, and (c) when the cohesive energy is large, the compound has a tendency not to easily desorb hydrogen, i.e. its reversibility is poor.

Jan 1, 2006

By Olga A. Gomon, Alexey N. Lozhko

The technology of heat treatment for metal frequently includes multiple fast heating and cooling of the products surface. If the product is heavy-weight or long-size, its moving from a zone of cooling to a zone of heating and return require a long time. Other important condition of ensuring qualitative surface at heat treatment is intensification of cooling phase. It is known that turbulization of a flow activates heat exchange and increases efficacy of cooling without increasing volume flow rate of water. Additional difficulty is to ensure the regularity of heating and cooling on length of a product. The technology of cyclic heat treatment of rolling products, at which mobile zone of turbulent heat exchange is formed on the surface of a product, was developed and realized. The submission of water occurs through to face spray systems. Each of the systems has six long-range atomizers, which are located circularly. Two flows of water move towards one another along a surface of a product. When they collide, the right zone of turbulent heat exchange creates heat transfer in this zone of 10-15 time more intensive than on other surface of a product. The effect of moving turbulent zone on length of a product is reached by changing the proportion of volume flow rate of water, which is created by face sprays. The speed of movement for turbulent zone along a surface of a product is chosen so, that the cooling takes place on a small depth only. Then after passing the turbulent zone over a determined site of a surface, its temperature recovers fast owing to hot internal layers. The parameters of process were determined by mathematical simulation of cooling in an installation. The equations for dynamics of movement of collision point of flows, which were received this way, are interesting supplementary products of research. The experiments show that frequency of movement of turbulent zone is an important technological parameter. It defines mechanical properties of a surface and should be chosen depending on a profile of product and metal grade. The results of comparison of mechanical properties of a surface of various rolling products, which were received by developed and conventional technologies, are described in this report. Dependence of regularity of mechanical properties on frequency of movement of turbulent zone is adduced.

Jan 1, 1998