The effects of temperature, pH, and time variations on the protective amount and quality of electroless nickel (EN) deposition on cast aluminium alloy (CAA) substrates were studied. The temperature, pH, and plating time were varied while the surface condition of the substrate was kept constant in acid or alkaline bath. Within solution pH of 5.0–5.5 range, the best quality is obtained in acid solution pH of 5.2. At lower pH (5.0–5.1), good adhesion characterised the EN deposition. Within the range of plating solution pH of 7.0 to 11.5, the highest quantity and quality of EN deposition are obtained on CAA substrate in solution pH of 10.5. It is characterised with few pores and discontinuous metallic EN film. The quantity of EN deposition is time dependent, whereas the adhesion and brightness are not time controlled. The best fit models were developed from the trends of result data obtained from the experiments. The surface morphologies and the chemical composition of the coating were studied using the Jeol JSM-7600F field emission scanning electron microscope.
{"title":"Effect of Processing Parameters on the Protective Quality of Electroless Nickel-Phosphorus on Cast Aluminium Alloy","authors":"O. Ajibola, D. Oloruntoba, B. O. Adewuyi","doi":"10.1155/2015/386347","DOIUrl":"https://doi.org/10.1155/2015/386347","url":null,"abstract":"The effects of temperature, pH, and time variations on the protective amount and quality of electroless nickel (EN) deposition on cast aluminium alloy (CAA) substrates were studied. The temperature, pH, and plating time were varied while the surface condition of the substrate was kept constant in acid or alkaline bath. Within solution pH of 5.0–5.5 range, the best quality is obtained in acid solution pH of 5.2. At lower pH (5.0–5.1), good adhesion characterised the EN deposition. Within the range of plating solution pH of 7.0 to 11.5, the highest quantity and quality of EN deposition are obtained on CAA substrate in solution pH of 10.5. It is characterised with few pores and discontinuous metallic EN film. The quantity of EN deposition is time dependent, whereas the adhesion and brightness are not time controlled. The best fit models were developed from the trends of result data obtained from the experiments. The surface morphologies and the chemical composition of the coating were studied using the Jeol JSM-7600F field emission scanning electron microscope.","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"89611871","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Mill scale is one of waste materials which is produced as a result of hot rolling of steel in all steel companies. On the other hand, mill scale is considered a rich iron source with minimum impurities. This work aims at conversion of mill scale by adjusting smelting processes to produce different valuable products. The smelting processes were carried out using carbothermic reduction in a submerged arc furnace. Two carbonaceous reducing agents and different fluxing materials have been used to adapt optimum smelting process condition. A maximum iron recovery of 83% was obtained by using graphite compared with 76% obtained by using coke. Low sulphur content (≤0.02 wt% S) can be attained by using graphite as a reducing agent in amount that equals or exceeds the stoichiometric molar ratio. By using coke, the highest degree of desulfurization of 97.8% and much lower content of sulphur in the castable metal (0.0028 wt% S) were obtained by controlling the type and quantity of the flux. The results reveal that mill scale waste can be converted into valuable products such as high purity iron as alternative to Sorelmetal used in ductile iron production, low carbon steel, and free cutting steel.
{"title":"Conversion of Mill Scale Waste into Valuable Products via Carbothermic Reduction","authors":"M. Eissa, A. Ahmed, M. El-Fawkhry","doi":"10.1155/2015/926028","DOIUrl":"https://doi.org/10.1155/2015/926028","url":null,"abstract":"Mill scale is one of waste materials which is produced as a result of hot rolling of steel in all steel companies. On the other hand, mill scale is considered a rich iron source with minimum impurities. This work aims at conversion of mill scale by adjusting smelting processes to produce different valuable products. The smelting processes were carried out using carbothermic reduction in a submerged arc furnace. Two carbonaceous reducing agents and different fluxing materials have been used to adapt optimum smelting process condition. A maximum iron recovery of 83% was obtained by using graphite compared with 76% obtained by using coke. Low sulphur content (≤0.02 wt% S) can be attained by using graphite as a reducing agent in amount that equals or exceeds the stoichiometric molar ratio. By using coke, the highest degree of desulfurization of 97.8% and much lower content of sulphur in the castable metal (0.0028 wt% S) were obtained by controlling the type and quantity of the flux. The results reveal that mill scale waste can be converted into valuable products such as high purity iron as alternative to Sorelmetal used in ductile iron production, low carbon steel, and free cutting steel.","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"81683835","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The main objective of the current work is to investigate the influence of different inoculation conditions on the microstructure and mechanical properties of heavy section ductile iron (DI) castings. Inoculation treatment was done via one step and double step treatments with different amounts of inoculants. The mechanical properties of the fabricated samples were evaluated. The best inoculation procedure in terms of graphite nodules characteristics and mechanical properties was double inoculation with 0.8% inoculants added at first and 0.2% in the late inoculation step. The presence of Sb in one of the cast alloys controlled the growth of graphite nodules in these heavy section ductile iron castings; however low impact toughness was recorded. The matrix structure of ductile cast iron showed a significant influence not only on the strength and impact properties but also on the fracture mode during testing.
{"title":"Effect of Processing Parameters on the Mechanical Properties of Heavy Section Ductile Iron","authors":"M. Mourad, S. El-Hadad, M. Ibrahim, A. Nofal","doi":"10.1155/2015/931535","DOIUrl":"https://doi.org/10.1155/2015/931535","url":null,"abstract":"The main objective of the current work is to investigate the influence of different inoculation conditions on the microstructure and mechanical properties of heavy section ductile iron (DI) castings. Inoculation treatment was done via one step and double step treatments with different amounts of inoculants. The mechanical properties of the fabricated samples were evaluated. The best inoculation procedure in terms of graphite nodules characteristics and mechanical properties was double inoculation with 0.8% inoculants added at first and 0.2% in the late inoculation step. The presence of Sb in one of the cast alloys controlled the growth of graphite nodules in these heavy section ductile iron castings; however low impact toughness was recorded. The matrix structure of ductile cast iron showed a significant influence not only on the strength and impact properties but also on the fracture mode during testing.","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"84142275","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In the current study, a factorial design is used to investigate the effect of total iron and silica on the metallurgical performance of different grades of manganese ores. The derived mathematical formulations are applied to estimate the reduction disintegration index (RDI
{"title":"Mathematical Analysis of the Effect of Iron and Silica on the Reduction Performance of Manganese Ores","authors":"S. Ghali, E. Mousa","doi":"10.1155/2015/679306","DOIUrl":"https://doi.org/10.1155/2015/679306","url":null,"abstract":"In the current study, a factorial design is used to investigate the effect of total iron and silica on the metallurgical performance of different grades of manganese ores. The derived mathematical formulations are applied to estimate the reduction disintegration index (RDI","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"86134861","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Induction melting could be a potential fabrication method for aluminum matrix nanocomposites, owing to its characteristics stirring action and rapid heating. In the present work, an induction coil for small scale composite fabrication was designed through geometric, thermal, and electromagnetic analyses. Subsequently, the designed coil was simulated for its thermal efficiency and stirring force using finite element method magnetics software. The designed coil yielded more than 60% of the total energy supplied into thermal efficiency with a stirring force <3 mN, which could be significant for efficient melting and stirring to fabricate the aluminum matrix nanocomposites.
{"title":"On the Designing, Efficiency, and Stirring Force of an Induction Coil for the Processing of Prototype Al Based Nanocomposites","authors":"M. Mansoor, M. Shahid","doi":"10.1155/2014/637031","DOIUrl":"https://doi.org/10.1155/2014/637031","url":null,"abstract":"Induction melting could be a potential fabrication method for aluminum matrix nanocomposites, owing to its characteristics stirring action and rapid heating. In the present work, an induction coil for small scale composite fabrication was designed through geometric, thermal, and electromagnetic analyses. Subsequently, the designed coil was simulated for its thermal efficiency and stirring force using finite element method magnetics software. The designed coil yielded more than 60% of the total energy supplied into thermal efficiency with a stirring force <3 mN, which could be significant for efficient melting and stirring to fabricate the aluminum matrix nanocomposites.","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2014-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"88196627","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Numerical prediction is performed on the reduction of wustite under simulated blast furnace conditions using factorial design approach. Wustite sinter samples with different basicity (0.5, 1.0, and 2.0) are reduced with a gas mixture consisting of 30% CO, 10% H2, 5% CO2, and 55% N2 at 950–1100°C. In all cases, the reduction degree of wustite increased with basicity and temperature. A 23 factorial design is applied to derive a regression model based on the experimental data of acidic (CaO/SiO2 = 0.5) and basic (CaO/SiO2 = 2.0) wustite which is reduced at 950°C and 1100°C for 5 and 35 min. The developed mathematical model is applied to predict the reduction degree of wustite at different basicity (0.5, 1.0, and 2.0), interval of time (5–35 min), and temperatures (950, 1000, 1050°C, and 1100°C). In general, the results of the driven models are found to be in good agreement with the experimental data of reduction of wustite in many cases. The MATLAB program is used to carry out the required calculations.
{"title":"Mathematical Analysis of the Reduction of Wüstite at Different Basicity Using Factorial Design","authors":"E. Mousa","doi":"10.1155/2014/201659","DOIUrl":"https://doi.org/10.1155/2014/201659","url":null,"abstract":"Numerical prediction is performed on the reduction of wustite under simulated blast furnace conditions using factorial design approach. Wustite sinter samples with different basicity (0.5, 1.0, and 2.0) are reduced with a gas mixture consisting of 30% CO, 10% H2, 5% CO2, and 55% N2 at 950–1100°C. In all cases, the reduction degree of wustite increased with basicity and temperature. A 23 factorial design is applied to derive a regression model based on the experimental data of acidic (CaO/SiO2 = 0.5) and basic (CaO/SiO2 = 2.0) wustite which is reduced at 950°C and 1100°C for 5 and 35 min. The developed mathematical model is applied to predict the reduction degree of wustite at different basicity (0.5, 1.0, and 2.0), interval of time (5–35 min), and temperatures (950, 1000, 1050°C, and 1100°C). In general, the results of the driven models are found to be in good agreement with the experimental data of reduction of wustite in many cases. The MATLAB program is used to carry out the required calculations.","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2014-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"82676546","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Nanoindentation test results on different grain sizes of dual phase (DP) steels are used to train artificial neural networks (ANNs). With selection of ferrite and martensite grain size, martensite volume fraction (MVF), and indentation force as input and microhardness, ferrite, and martensite nanohardness as outputs, six different ANNs are trained according to normalized datasets to predict hardness and their tolerances. A graphical user interface (GUI) is developed for a better investigation of the trained ANN prediction. The response of the ANN is analyzed in five case studies. In each case the variation of two input parameters on the output is analyzed when the other input parameters are kept constant. Reliable and reasonable results of ANN predictions are achieved in each case.
{"title":"Artificial Neural Networks Investigation of Indentation Force Effects on Nano- and Microhardness of Dual Phase Steels","authors":"A. Fotovati, J. Kadkhodapour, S. Schmauder","doi":"10.1155/2014/813234","DOIUrl":"https://doi.org/10.1155/2014/813234","url":null,"abstract":"Nanoindentation test results on different grain sizes of dual phase (DP) steels are used to train artificial neural networks (ANNs). With selection of ferrite and martensite grain size, martensite volume fraction (MVF), and indentation force as input and microhardness, ferrite, and martensite nanohardness as outputs, six different ANNs are trained according to normalized datasets to predict hardness and their tolerances. A graphical user interface (GUI) is developed for a better investigation of the trained ANN prediction. The response of the ANN is analyzed in five case studies. In each case the variation of two input parameters on the output is analyzed when the other input parameters are kept constant. Reliable and reasonable results of ANN predictions are achieved in each case.","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2014-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"84272153","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
S. Krishna, S. K. Singh, S. Murty, Ganji Venkata Narayana, A. Jha, B. Pant, K. M. George
A method for the production of Inconel 718 (IN-718) hemispherical domes by closed die hammer forging is proposed. Different combination of operations employed for production are as follows: (i) preforging
{"title":"Closed Die Hammer Forging of Inconel 718","authors":"S. Krishna, S. K. Singh, S. Murty, Ganji Venkata Narayana, A. Jha, B. Pant, K. M. George","doi":"10.1155/2014/972917","DOIUrl":"https://doi.org/10.1155/2014/972917","url":null,"abstract":"A method for the production of Inconel 718 (IN-718) hemispherical domes by closed die hammer forging is proposed. Different combination of operations employed for production are as follows: (i) preforging","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2014-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"91258646","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Metal matrix composites, based on AA6061 reinforced with 60 vol% spherical particles, were produced by gas pressure infiltration and characterized for hardness, impulse excitation modulus, tensile properties (at room temperature and at 250°C), and machining. It was experimentally demonstrated that the novel alumina powder used in the present work does not react with the liquid Mg-containing matrix during the infiltration process. The AA6061 matrix therefore retains its ability to be strengthened by precipitation heat treatment. The latter behaviour combined with the spherical particle shape confers the studied material higher strength and better machinability in comparison with similar composites produced using standard angular alumina particles. The overall features are promising for applications in the aerospace industry, where light and strong materials are required.
{"title":"Aluminium AA6061 Matrix Composite Reinforced with Spherical Alumina Particles Produced by Infiltration: Perspective on Aerospace Applications","authors":"C. Bacciarini, V. Mathier","doi":"10.1155/2014/248542","DOIUrl":"https://doi.org/10.1155/2014/248542","url":null,"abstract":"Metal matrix composites, based on AA6061 reinforced with 60 vol% spherical particles, were produced by gas pressure infiltration and characterized for hardness, impulse excitation modulus, tensile properties (at room temperature and at 250°C), and machining. It was experimentally demonstrated that the novel alumina powder used in the present work does not react with the liquid Mg-containing matrix during the infiltration process. The AA6061 matrix therefore retains its ability to be strengthened by precipitation heat treatment. The latter behaviour combined with the spherical particle shape confers the studied material higher strength and better machinability in comparison with similar composites produced using standard angular alumina particles. The overall features are promising for applications in the aerospace industry, where light and strong materials are required.","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2014-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"77807290","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Three stainless steel grades with different vanadium content were produced in open induction furnace. The base chemical composition of investigated stainless steel has contained 18.48–18.75% Cr, 5.17–5.62% Mn, 2.47–2.58% Mo, and 6.39–6.64% Ni. The vanadium contents of the three stainless steel grades were 0.009%, 0.112%, and 0.189%. The proposed stainless steels were casted at temperatures 1753 K and 1833 K. The nitrogen contents were determined for the produced steel grades at every cast temperature. The determined nitrogen contents were compared with those calculated from the developed equation of Grigorenko and Pomarin. The influence of cast temperature and vanadium content on nitrogen solubility was investigated. Interpretation between experimental and calculated nitrogen content was carried out. Increasing vanadium content and decreasing cast temperature were found to have positive significant effect on the nitrogen solubility. There were great deviations between experimental results and those calculated by Grigorenko and Pomarin equation.
{"title":"Influence of Vanadium and Cast Temperature on Nitrogen Solubility of Stainless Steel","authors":"S. Ghali","doi":"10.1155/2014/528121","DOIUrl":"https://doi.org/10.1155/2014/528121","url":null,"abstract":"Three stainless steel grades with different vanadium content were produced in open induction furnace. The base chemical composition of investigated stainless steel has contained 18.48–18.75% Cr, 5.17–5.62% Mn, 2.47–2.58% Mo, and 6.39–6.64% Ni. The vanadium contents of the three stainless steel grades were 0.009%, 0.112%, and 0.189%. The proposed stainless steels were casted at temperatures 1753 K and 1833 K. The nitrogen contents were determined for the produced steel grades at every cast temperature. The determined nitrogen contents were compared with those calculated from the developed equation of Grigorenko and Pomarin. The influence of cast temperature and vanadium content on nitrogen solubility was investigated. Interpretation between experimental and calculated nitrogen content was carried out. Increasing vanadium content and decreasing cast temperature were found to have positive significant effect on the nitrogen solubility. There were great deviations between experimental results and those calculated by Grigorenko and Pomarin equation.","PeriodicalId":16342,"journal":{"name":"Journal of Metallurgy","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2014-11-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"84111002","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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