Journal of Alloys and Metallurgical Systems最新文献

The challenge of making sponge iron, or direct reduced iron (DRI), is hard to overstate. These are a key feed for metallurgical operations while iron extraction sets these limits, which include scarcity of metallurgical coke, poor environmental impact, and high production cost. Thus, the non-contact direct reduction process of DRIs has the potential to significantly reduce carbon deposition and CO₂ emission from the ironmaking process. This work produced sponge iron from commercially acquired hematite ore using an alternative reducing agent (i.e. charcoal) under specified isothermal conditions. Comparative analysis of reaction kinetics models including Ginstein−Brounshtein and Shrinking core models was also performed to ascertain the resistances that control the reaction rate for reduction degree up to 98.1%. The reduction kinetics were found to be described by reaction control time and activation energies based on a shrinking core model as the reduction time lasted for 120 min at temperatures 843–1273 K. At temperatures above 973–1073 K, the rate-limiting step was found to be solely an interfacial chemical reaction process, with an apparent activation energy of 196.1 kJ/mol. In addition, a slowing trend was observed for iron ore sample sizes 10–20 mm as a result of ash layer infiltration around the inner-core structure of the DRI metal matrix. The DRI morphological characteristics were performed using Scanning Electron Microscopy (SEM) and Electron Dispersive Spectrometry (EDS) to ascertain the mineralogical and morphological properties of the DRI samples. The XRF analysis confirms that the raw iron ore sample is hematite. Its iron content is 70.04% metallic iron (TFe) which has 83.59% Fe₂O₃ The SEM/EDS image also revealed the presence of micropores on the DRI morphology. This indicates that the reduction ratio and swelling extent rise with the temperature and time. This happens for all DRI sizes. However, the EDS result confirms the presence of gangue elements within the DRI metal matrix and mineralogical structure. The DRI contains very high silicon content up to 33.90%. So, a fluxing experiment is needed using limestone (CaCO₃) or quicklime (CaO) quicklime to remove gangue (silicate, aluminate) from the DRI matrix. At the set reduction temperatures, the largest metallization degree of 93.05% at 1273 K for a reduction time of 120 min was achieved. This showed that the overall reduction process still follows the expected chronological order since the NDR process uses CO gas from preheated charcoal. This makes DRI be produced from raw hematite under non-contact reduction bases. Therefore, the NDR technique offers a viable option for sponge iron production in modern-day iron and steelmaking processes.

Herein, we report the fabrication of graphene nanoplatelets (GNPs) reinforced zinc-copper (ZnCu) matrix composite coatings on a stainless-steel substrate using electro-co-deposition technique. The influence of varying concentrations of GNPs in the acidic electrolyte bath on the microstructure, chemical composition, phase structure, hardness, wear resistance, corrosion resistance, and antibacterial activity of ZnCu/GNPs composite coating was investigated. The microhardness of the ZnCu/GNPs composite coating with a GNPs concentration of 100 mg/L is compared with pure ZnCu coating, which has a 90 % significant enhancement, while (50 mg/L) has 86 %, and (25 mg/L) has 50 %. Also, ZnCu/GNPs composite coating showed a wear loss of 10 mg for 100 mg/L GNPs sample with an increase in microhardness. The bacterial resistance assays were conducted against Escherichia coli (E. coli) and Staphylococcus aureus (S. aureus). The results reveal a notable improvement in the anti-bacterial activity of the ZnCu/GNPs composite coating. The corrosion rate of the ZnCu/GNPs composite coating in 3.5 wt % NaCl solution steadily decreased when the concentration of GNPs in the electrolyte bath was increased to 100 mg/L. These findings hold great potential for various applications, including healthcare settings where preventing healthcare-associated infections is critical, public infrastructure to prolong the lifespan of structures, and marine coatings to protect against corrosion in harsh marine environments.

In this paper the microstructural features of the glass former Fe₆₈Cr₈Mo₄Nb₄B₁₆ coatings are unveiled and related to their electrochemical and tribological responses. The coating was mostly glassy with some embedded borides (M₃B₂, M₂B-tetragonal; M being the metallic elements of the alloy) and ferrite. The tribological behavior of the HVAF coated sample, characterized by a thickness of about 200 µm, ∼6% porosity and a Vickers hardness of 357 HV_0.5, was assessed in a sphere-on-plate configuration, revealing a specific wear rate of approximately 5 ×10⁻⁴ mm³∙N⁻¹m⁻¹. The wear mechanism was dominated by delamination caused by fragile intersplats. The corrosion resistance of HVAF coatings was evaluated in 0.6 M NaCl solution and compared with the results obtained for the crystalline Fe₆₈Cr₈Mo₄Nb₄B₁₆ ingot, produced by melting in an induction furnace, and for the AISI 1020 steel substrate. The HVAF coating showed satisfactory corrosion resistance compared to the carbon steel substrate and the crystalline ingot, with the highest corrosion potential, E_corr, values (−533 mV_SCE) and the lowest corrosion current density, i_corr, (10⁻⁶ A∙cm⁻²) followed by a clear passivation window upon anodic polarization in 0.6 M NaCl solution. Evaluations of HVAF coating showed a higher glassy content compared to the gas-atomized feedstock powders. This suggests that during spraying, certain particles were molten and experienced cooling rates adequate to inhibit crystallization, resulting in the freezing of the supercooled liquid. This phenomenon contributes to the good corrosion resistance observed in the present work and offers an opportunity to enhance the electrochemical behavior of HVAF coatings.

This study aims to observe the residual stress in a substrate and predict stress behavior during the laser deposition process (DED) using finite element analysis (FEA). The residual stress observed on the substrate surface indicated that stress variation during the deposition process increases with proximity to the deposition area, resulting in higher residual stress levels. Additionally, tensile residual stress tends to increase with the height of the deposition area. While variations in the deposition area size influenced the residual stress, consistent stress levels were observed at the same measurement points across different area sizes. The deposition process was simulated using FEA, which confirmed that stress behavior is influenced by melting and solidification cycles. The residual stress levels after cooling aligned well with those observed in actual experiments. Therefore, this study suggests that stress variations can be effectively predicted by simulating the deposition process prior to conducting actual experiments.

The increasing demand and complexities within the manufacturing sector to fabricate composite materials, particularly bimetallic products for the manufacturing industry, have led to the introduction of various joining processes. Notably, explosive welding which is a solid-state welding process has emerged as a highly advantageous technique for the fabrication of composite materials for lighter weight and durable vehicle components. This review aims to provide a comprehensive study of the explosive welding process. The complexities of the explosive welding methodology are explained, incorporating a comprehensive examination of the influence of experimental parameters on the mechanical and microstructural characteristics of the resultant welded composite materials. Additionally, the review consolidates current research pertaining to underwater explosive welding of bimetallic materials and the joining of different configurations using explosive welding. The challenges encountered during the welding process are discussed and solutions proposed by various researchers are presented.

A combination of physical modeling, computational fluid dynamics modeling, and economics with plant trial studies was performed for quality improvement of Special Bar Quality (SBQ) and Oil Country Tubular Goods (OCTG) grade tundish steels. The present study consists of operating parameters like inert gas shrouding, non-isothermal conditions, and flow control devices (FCD) used on the billet product and slab quality. This work uses mathematical modeling using the fluid volume and discrete phase method (DPM) and the standard k-ε turbulence model validated with one-third scale physical water model experiments. A strong correlation between the physical model and computational simulation was found with rejection ratio and inclusion counts. Data about customer demands correlated with operating parameters for proper plant insights with an economic study to predict the cost-related issue. With the incorporation of FCD, the weight of the tundish skull was reduced by 6–10 M USD/year with a simulation studies expenditure of around 200 K. FCD also reduced the customer complaint index (CCI).

Isothermal compression tests were executed on an Al-Mg-Si-Zr-Mn alloy using a Gleeble-3800 thermo-mechanical simulator at temperatures from 400 to 550 °C and strain rates ranging from 1 to 0.001 s⁻¹. By analyzing the flow curves and characterizing the deformed microstructure, this study aimed to gain insights into the hot deformation behavior and hot workability. Utilizing the hyperbolic-sine sinusoidal model, a constitutive equation was derived, revealing an activation energy of hot deformation of 274 kJ/mol. The processing maps were constructed utilizing the dynamic material model, which highlighted the secure range of hot working conditions between 480 to 550 °C and 0.01–0.001 s⁻¹. The softening mechanism observed at relatively low deformation temperatures and high strain rates was primarily dynamic recovery, whereas the safe domain exhibited a combination of dynamically recovered (DRV) and recrystallized (DRX) grain structures. The results of the FEM simulation indicated a non-homogeneous distribution of stress and strain fields, with the highest effective values focused at the center of the sample. Furthermore, the FEM simulation unveiled a clear correlation between the evolution of DRV and DRX and the strain.

An investigation was carried out to assess the suitability of equiatomic ZrNbVTiAl high-entropy alloy (HEA) for biomedical applications. This included microstructural analysis, mechanical property evaluation and in–vivo testing in biological media to examine its cyto-compatibility. The alloy developed a dendritic structure on solidification through arc melting, with BCC –B2 type dendrites separated by inter-dendritic regions rich in Al and Zr. The evolved microstructure and composition matched well with those predicted by the phase field modelling. The HEA also showed a high yield strength (1045 MPa) and moderate elastic modulus (120 GPa) comparable to the commonly used biomedical alloy, Ti-6Al-4 V. Cell culture studies with U2OS Cells showed substantial attachment and growth of healthy osteoblasts to the HEA as well as negligible bio-corrosion after 45 days of exposure. Most importantly, the alloy showed a significantly high tendency of cell attachment than pure Ti and lower magnetic susceptibility (2.55 ×10⁻⁶ cm³/g) than Ti-6Al-4 V alloy indicating its suitability for biomedical applications.

Low cycle fatigue (LCF) and ratcheting experiments were carried out on annealed low-carbon steel at room temperature within a laboratory environment, utilising stress and strain control modes. The annealed low-carbon steel consistently demonstrates a cyclic softening response over its LCF lifespan, across all tested strain amplitudes. Notably, it was observed that ratcheting strain rises while ratcheting life declines with both rising mean stress and stress amplitude. Annealed low-carbon steel, being entirely ferritic and lacking precipitation or substitutional solid solution strengthening or hard phase strengthening, exhibits a restricted ability to withstand or alleviate the accumulation of ratcheting strain, particularly under very low mean stress conditions. In both LCF and ratcheting, significant substructure formation was detected. Nevertheless, there was no discernible difference in substructure formation between LCF and ratcheting when employing electron channelling contrast imaging techniques. The existing mean stress-based fatigue life prediction model has successfully forecasted ratcheting and LCF life within the 10²–10⁵ cycles range. A novel approach utilising modulus is introduced to characterise the cyclic hardening/softening behaviour of alloys in stress and strain-controlled experiments. The cyclic hardening model based on modulus effectively captures the responses observed in cyclic hardening/softening during LCF and ratcheting experiments.

This research explores the tribocorrosion behaviour of 60NiTi alloy, also known as NiTiNOL60, when exposed to a saline environment. Our investigation focuses on understanding the relationship between corrosion and wear rates and assessing surface damage and material degradation. To conduct our experiments, we employed a linear reciprocating ball-on-plate tribometer coupled with electrochemical polarisation using a three-electrode cell configuration to assess the combined effects of corrosion and sliding wear. Surface characterisation was carried out through scanning electron microscopy and energy dispersion spectroscopy, revealing the material to be a Ni-rich 60NiTi alloy, with surface oxidation evident in the electrolyte medium. Our electrochemical findings indicate the occurrence of localised corrosion in both cathodic and anodic regimes, with corrosion pit nucleation, cavities, and cracks being accelerated by reciprocating sliding and corrosion potential. These interactions exposed the material surface to various wear mechanisms, including abrasive, adhesive, oxidative, corrosive, and fatigue processes. This study underscores the significant influence of mechanical properties on the rate of material degradation due to corrosion, while also highlighting the substantial impact of prevailing electrochemical conditions on the rate of mechanical material removal. This paper offers valuable insights for designers working on load-bearing structures in saline environments.