Abstract The paper presents the computational studies on the microstructure of WC-Co-Cr coatings deposited by High Velocity Oxy Fuel spraying (HVOF). The study covers the porosity assessment according to ASTM E2109-01 standard, carried out in ImageJ software, in terms of volume porosity, size and shape of the pores. The evaluation was preceded by scanning electron microscope (SEM) observations at magnifications of 2000x and 5000x. Additionally, topography analysis has been performed by confocal laser scanning microscope (CLSM), and the surface roughness Ra was evaluated by the contact method with use of a stylus profilometer. Finally, the influence of porosity was observed for coatings microhardness HV0.3. According to the results, the total closed porosity was found to be in the range of 5.01 vol.% and 5.38 vol.%. The dominated pores in the coatings were of size 0.1-1.0 μm. Studies showed that HVOF process enabled deposition of dense coatings, characterized by homogenous distribution of pores and low roughness.
{"title":"The Effect of Spray Distance on Porosity, Surface Roughness and Microhardness of WC-10Co-4Cr Coatings Deposited by HVOF","authors":"M. Górnik, E. Jonda, M. Nowakowska, L. Łatka","doi":"10.2478/adms-2021-0028","DOIUrl":"https://doi.org/10.2478/adms-2021-0028","url":null,"abstract":"Abstract The paper presents the computational studies on the microstructure of WC-Co-Cr coatings deposited by High Velocity Oxy Fuel spraying (HVOF). The study covers the porosity assessment according to ASTM E2109-01 standard, carried out in ImageJ software, in terms of volume porosity, size and shape of the pores. The evaluation was preceded by scanning electron microscope (SEM) observations at magnifications of 2000x and 5000x. Additionally, topography analysis has been performed by confocal laser scanning microscope (CLSM), and the surface roughness Ra was evaluated by the contact method with use of a stylus profilometer. Finally, the influence of porosity was observed for coatings microhardness HV0.3. According to the results, the total closed porosity was found to be in the range of 5.01 vol.% and 5.38 vol.%. The dominated pores in the coatings were of size 0.1-1.0 μm. Studies showed that HVOF process enabled deposition of dense coatings, characterized by homogenous distribution of pores and low roughness.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"90597315","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}
Abstract This study examined the effect of induction heating on the microstructure and corrosion characteristics of hybrid friction stir welded AISI 410 stainless steel. Five joints have been produced with different friction stir welding parameters like welding speed, spindle speed, plunge depth, and induction power. Their microstructures were evaluated using a scanning electron microscope, and chemical composition was examined using energy-dispersive X-ray spectroscopy (EDX). The rate of corrosion was found out via the weight loss method in a 1 M HCL solution. The hybrid friction stir welding method used for this work is induction assisted friction stir welding; the results show that this method could produce sound AISI 410 stainless steel Joints. The experiment results show that the joint made at a spindle speed of 1150 rpm, welding speed 40 mm/min, plunge depth 0.5 mm, and in-situ heat by induction 480°C show a better corrosion resistance property with a fine grain structure.
{"title":"Assessment of Corrosive Behaviour and Microstructure Characterization of Hybrid Friction Stir Welded Martensitic Stainless Steel","authors":"Dhanesh G. Mohan, S. Gopi, J. Tomków, S. Memon","doi":"10.2478/adms-2021-0025","DOIUrl":"https://doi.org/10.2478/adms-2021-0025","url":null,"abstract":"Abstract This study examined the effect of induction heating on the microstructure and corrosion characteristics of hybrid friction stir welded AISI 410 stainless steel. Five joints have been produced with different friction stir welding parameters like welding speed, spindle speed, plunge depth, and induction power. Their microstructures were evaluated using a scanning electron microscope, and chemical composition was examined using energy-dispersive X-ray spectroscopy (EDX). The rate of corrosion was found out via the weight loss method in a 1 M HCL solution. The hybrid friction stir welding method used for this work is induction assisted friction stir welding; the results show that this method could produce sound AISI 410 stainless steel Joints. The experiment results show that the joint made at a spindle speed of 1150 rpm, welding speed 40 mm/min, plunge depth 0.5 mm, and in-situ heat by induction 480°C show a better corrosion resistance property with a fine grain structure.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"86797625","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}
Abstract Every year hundreds of serious accidents and catastrophic are accompanied by mining sector services as disaster, flooding, and demolition. To reduce the severity of the results such as high death numbers, lost communication inner and out mining, we have to find an easy way to improve communication means during that problems. In this paper, we reach out to fabricate durable, flexible, and wearable chaps, in addition to an easier carrier with highly efficient receiving and sending a signal at 2.4 GHz broad wide band. By doping a bunch of unique conductive metals (silver, copper, and gallium indium alloy) assembled on Graphene, its integration inside Polydimethylsiloxane to be future applicable antenna. Furthermore, we studied the physical and electric properties of a composite including Electrochemical Impedance properties (EIS), cyclic voltammetry (CV), and its thermal stability chip (DSC), as well as, using Transmission electron microscopy (TEM), and, scanning electron microscopy (SEM) techniques to clarify the surface morphology of fabricated materials. In addition to various measurements had been carried out such as Ultraviolet-visible, inductively coupled plasma (ICP) spectroscopy, and Energy-dispersive X-ray spectroscopy (EDX) to reinforce and elucidate the solid-state of ions inside fabricated Antenna. On the other hand, throughout stress-strain for the stretchability of fabricated is expanded to 30% of its original length, in addition to thermal stability reached to 485°C compared to pure PDMS substrate, with enhancing electric conductivity of composite ship.
{"title":"Preparation and Evaluation of Conductive Polymeric Composite from Metals Alloys and Graphene to Be Future Flexible Antenna Device","authors":"Ameen Abdelrahman, F. Erchiqui, M. Nedil","doi":"10.2478/adms-2021-0023","DOIUrl":"https://doi.org/10.2478/adms-2021-0023","url":null,"abstract":"Abstract Every year hundreds of serious accidents and catastrophic are accompanied by mining sector services as disaster, flooding, and demolition. To reduce the severity of the results such as high death numbers, lost communication inner and out mining, we have to find an easy way to improve communication means during that problems. In this paper, we reach out to fabricate durable, flexible, and wearable chaps, in addition to an easier carrier with highly efficient receiving and sending a signal at 2.4 GHz broad wide band. By doping a bunch of unique conductive metals (silver, copper, and gallium indium alloy) assembled on Graphene, its integration inside Polydimethylsiloxane to be future applicable antenna. Furthermore, we studied the physical and electric properties of a composite including Electrochemical Impedance properties (EIS), cyclic voltammetry (CV), and its thermal stability chip (DSC), as well as, using Transmission electron microscopy (TEM), and, scanning electron microscopy (SEM) techniques to clarify the surface morphology of fabricated materials. In addition to various measurements had been carried out such as Ultraviolet-visible, inductively coupled plasma (ICP) spectroscopy, and Energy-dispersive X-ray spectroscopy (EDX) to reinforce and elucidate the solid-state of ions inside fabricated Antenna. On the other hand, throughout stress-strain for the stretchability of fabricated is expanded to 30% of its original length, in addition to thermal stability reached to 485°C compared to pure PDMS substrate, with enhancing electric conductivity of composite ship.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"89089960","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. Sultana, Mehedi Mannan, Md. Jaynal Abedin, Z. Islam, H. Nur, P. R. Samaddar
Abstract Urea formaldehyde (UF) resins are brittle and to improve their tensile properties poly(vinyl alcohol) (PVA) has been used to modify the UF resin. An easy improved procedure was developed to make PVA modified UF resin on the basis of conventional synthesis of UF resin. Prepolymer of UF was mixed with different weight percentages of PVA (1-5%) to synthesize modified UF resin which can be used to make adhesive for forest products. Both UF and modified UF resins were characterized by FTIR, physico-mechanical and thermal properties analyses. Modified UF resin containing 2 wt. % PVA exhibited better results than the UF.
{"title":"Physico-Mechanical and Thermal Properties of Thermoplastic Poly(Vinyl Alcohol) Modified Thermosetting Urea Formaldehyde Resin","authors":"S. Sultana, Mehedi Mannan, Md. Jaynal Abedin, Z. Islam, H. Nur, P. R. Samaddar","doi":"10.2478/adms-2021-0024","DOIUrl":"https://doi.org/10.2478/adms-2021-0024","url":null,"abstract":"Abstract Urea formaldehyde (UF) resins are brittle and to improve their tensile properties poly(vinyl alcohol) (PVA) has been used to modify the UF resin. An easy improved procedure was developed to make PVA modified UF resin on the basis of conventional synthesis of UF resin. Prepolymer of UF was mixed with different weight percentages of PVA (1-5%) to synthesize modified UF resin which can be used to make adhesive for forest products. Both UF and modified UF resins were characterized by FTIR, physico-mechanical and thermal properties analyses. Modified UF resin containing 2 wt. % PVA exhibited better results than the UF.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75706447","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}
Abstract The work presents the results of research on the structure of welded joints in the area of heat affected zone (HAZ). Based on precisely performed metallographic tests, the contribution of individual structural components in the area of welds of pipes welded with the induction method was assessed. The volume fraction of individual structural components in various areas of the heat affected zone, the size of the grain formed in the welding process, as well as its shape coefficients were determined. On the basis of metallographic observations, an attempt was made to describe the course of the pressure induction welding process, taking into account the structural changes, phase changes and the recovering and recrystallization processes taking place in this process.
{"title":"Microstructural Evaluation of the High-Frequency Induction Welded Joints of Low Carbon Steel Pipes","authors":"A. Bunsch, J. Krawczyk, P. Matusiewicz","doi":"10.2478/adms-2021-0022","DOIUrl":"https://doi.org/10.2478/adms-2021-0022","url":null,"abstract":"Abstract The work presents the results of research on the structure of welded joints in the area of heat affected zone (HAZ). Based on precisely performed metallographic tests, the contribution of individual structural components in the area of welds of pipes welded with the induction method was assessed. The volume fraction of individual structural components in various areas of the heat affected zone, the size of the grain formed in the welding process, as well as its shape coefficients were determined. On the basis of metallographic observations, an attempt was made to describe the course of the pressure induction welding process, taking into account the structural changes, phase changes and the recovering and recrystallization processes taking place in this process.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"77422762","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}
W. Zielecki, Katarzyna Burnat, A. Kubit, T. Katrňák
Abstract The paper presents the results of experimental research aimed at determining the possibilities of strengthening structural adhesive joints. Techniques to improve the strength of adhesive joints was to make holes in the front part of the adherends in order to make the joint locally more flexible in the area of stress concentration at the joint edges. The tests were carried out for the lap joints of EN AW-2024-T3 aluminum alloy sheets, which were bonded with Loctite EA3430 epoxy adhesive. Static tests were carried out on the basis of the tensile/shear test. It has been shown that the applied structural modifications allow for an increase in the strength of the joint, in the best variant, an increase in strength of 14.5% was obtained. In addition, it has been shown that making holes in the adherends allows to reduce the spread of strength results.
{"title":"Effect of Holes in Overlap on the Load Capacity of the Single-Lap Adhesive Joints Made of EN AW-2024-T3 Aluminium Alloy","authors":"W. Zielecki, Katarzyna Burnat, A. Kubit, T. Katrňák","doi":"10.2478/adms-2021-0029","DOIUrl":"https://doi.org/10.2478/adms-2021-0029","url":null,"abstract":"Abstract The paper presents the results of experimental research aimed at determining the possibilities of strengthening structural adhesive joints. Techniques to improve the strength of adhesive joints was to make holes in the front part of the adherends in order to make the joint locally more flexible in the area of stress concentration at the joint edges. The tests were carried out for the lap joints of EN AW-2024-T3 aluminum alloy sheets, which were bonded with Loctite EA3430 epoxy adhesive. Static tests were carried out on the basis of the tensile/shear test. It has been shown that the applied structural modifications allow for an increase in the strength of the joint, in the best variant, an increase in strength of 14.5% was obtained. In addition, it has been shown that making holes in the adherends allows to reduce the spread of strength results.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75767532","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}
Abstract Laser surface modification of titanium alloys is one of the main methods of improving the properties of titanium alloys used in implantology. This study investigates the microstructural morphology of a laser-modified surface layer on a Ti13Nb13Zr alloy with and without a carbon nanotube coating deposited by electrophoretic deposition. Laser modification was performed for samples with and without carbon nanotube coating for two different laser powers of 800 W and 900 W and for different scan rates: 3 mm/s or 6 mm/s at 25 Hz, and the pulse duration was 2.25 ms or 3.25 ms. A scanning electron microscope SEM was used to evaluate the surface structure of the modified samples. To observe the heat-affected zones of the individual samples, metallographic samples were taken and observed under an optical microscope. Surface wettability tests were performed using a goniometer. A surface roughness test using a profilograph and a nanoindentation test by NanoTest™ Vantage was also performed. Observations of the microstructure allowed to state that for higher laser powers the surfaces of the samples are more homogeneous without defects, while for lower laser powers the path of the laser beam is clearer and more regular. Examination of the microstructure of the cross-sections indicated that the samples on which the carbon nanotube coating was deposited are characterized by a wider heat affected zone, and for the samples modified at 800 W and a feed rate of 3 mm/s the widest heat affected zone is observed. The wettability tests revealed that all the samples exhibit hydrophilic surfaces and the samples with deposited carbon nanotube coating increase it further. Surface roughness testing showed a significant increase in Ra for the laser-modified samples, and the presence of carbon nanotubes further increased this value. Nanoindentation studies showed that the laser modification and the presence of carbon coating improved the mechanical properties of the samples due to their strength.
{"title":"Microstructure and Mechanical Properties of Laser Surface-Treated Ti13Nb13Zr Alloy with MWCNTs Coatings","authors":"B. Majkowska-Marzec, Joanna Sypniewska","doi":"10.2478/adms-2021-0021","DOIUrl":"https://doi.org/10.2478/adms-2021-0021","url":null,"abstract":"Abstract Laser surface modification of titanium alloys is one of the main methods of improving the properties of titanium alloys used in implantology. This study investigates the microstructural morphology of a laser-modified surface layer on a Ti13Nb13Zr alloy with and without a carbon nanotube coating deposited by electrophoretic deposition. Laser modification was performed for samples with and without carbon nanotube coating for two different laser powers of 800 W and 900 W and for different scan rates: 3 mm/s or 6 mm/s at 25 Hz, and the pulse duration was 2.25 ms or 3.25 ms. A scanning electron microscope SEM was used to evaluate the surface structure of the modified samples. To observe the heat-affected zones of the individual samples, metallographic samples were taken and observed under an optical microscope. Surface wettability tests were performed using a goniometer. A surface roughness test using a profilograph and a nanoindentation test by NanoTest™ Vantage was also performed. Observations of the microstructure allowed to state that for higher laser powers the surfaces of the samples are more homogeneous without defects, while for lower laser powers the path of the laser beam is clearer and more regular. Examination of the microstructure of the cross-sections indicated that the samples on which the carbon nanotube coating was deposited are characterized by a wider heat affected zone, and for the samples modified at 800 W and a feed rate of 3 mm/s the widest heat affected zone is observed. The wettability tests revealed that all the samples exhibit hydrophilic surfaces and the samples with deposited carbon nanotube coating increase it further. Surface roughness testing showed a significant increase in Ra for the laser-modified samples, and the presence of carbon nanotubes further increased this value. Nanoindentation studies showed that the laser modification and the presence of carbon coating improved the mechanical properties of the samples due to their strength.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"86366529","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}
Pub Date : 2021-10-29DOI: 10.11648/J.AM.20211004.11
V. Stolbovyi, A. Andreev, I. Serdiuk, I. Kolodii, A. Shepelev
Studies have been made into a new possibility of modifying the surface of steels having a low tempering temperature by nitriding them in a vacuum-arc gas discharge followed by heat treatment (heating, quenching and tempering). Generally, nitriding of hardened steels takes place at a temperature of about 500°C, and thus this process appears impossible for steels with tempering temperatures of the order of 200... 300°C. It is demonstrated here that a single ion-plasma nitriding of high-carbon steel with the composition of 0.9% C, 1% Cr, 1% Si, followed by heat treatment, provides the nitrided layer of 2.5 mm in depth, with the hardness between 9 and 11 GPa. Within the range of X-rays penetration, the nitride-hardened layer of the surface is defined as the nitrogen austenite-alpha ferrite mixture, which shows high wear resistance and impact toughness. This layer contributes, in particular, to three-/four-foldin crease in the operational life of cutting punches (made of this steel and used in the manufacture of metal sieves) as opposed to the punches that have undergone conventional heat treatment. After repeated nitriding of the same steel and its subsequent heat treatment according to standard technologies the nitrided layer thickness becomes nearly twice as large, and that allows for multiple regrinding of steel tools. A computer analysis of related publications entered into three International Databases (INIS, MSCI, SCOPUS) has been carried out.
{"title":"Vacuum-arc Nitriding of Carbon Steels Having Low Tempering Temperature","authors":"V. Stolbovyi, A. Andreev, I. Serdiuk, I. Kolodii, A. Shepelev","doi":"10.11648/J.AM.20211004.11","DOIUrl":"https://doi.org/10.11648/J.AM.20211004.11","url":null,"abstract":"Studies have been made into a new possibility of modifying the surface of steels having a low tempering temperature by nitriding them in a vacuum-arc gas discharge followed by heat treatment (heating, quenching and tempering). Generally, nitriding of hardened steels takes place at a temperature of about 500°C, and thus this process appears impossible for steels with tempering temperatures of the order of 200... 300°C. It is demonstrated here that a single ion-plasma nitriding of high-carbon steel with the composition of 0.9% C, 1% Cr, 1% Si, followed by heat treatment, provides the nitrided layer of 2.5 mm in depth, with the hardness between 9 and 11 GPa. Within the range of X-rays penetration, the nitride-hardened layer of the surface is defined as the nitrogen austenite-alpha ferrite mixture, which shows high wear resistance and impact toughness. This layer contributes, in particular, to three-/four-foldin crease in the operational life of cutting punches (made of this steel and used in the manufacture of metal sieves) as opposed to the punches that have undergone conventional heat treatment. After repeated nitriding of the same steel and its subsequent heat treatment according to standard technologies the nitrided layer thickness becomes nearly twice as large, and that allows for multiple regrinding of steel tools. A computer analysis of related publications entered into three International Databases (INIS, MSCI, SCOPUS) has been carried out.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-10-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"83591636","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}
Pub Date : 2021-10-28DOI: 10.11648/J.AM.20211003.12
S. Mohanan, P. Mohapatra, C. Kumar, Ramakrishna Adepu, V. M. Koranne, Y. S. Prasad, A. S. Reddy, R. Ramna
Prior to dispatch of sinter to the blast furnace for hot metal production, the sinter product from the sinter cooler is screened to remove smaller/finer particles. The undersize so generated is called internal return fines, which are generally recirculated into the sintering machine. A very high level of internal return fines generation limits the use of virgin ore for sintering which may hamper sinter productivity. Recently, the sinter plant at Tata Steel’s Kalinganagar works has faced issues of high internal return fines generation. As the sinter plant begins to increase its productivity levels, it becomes critical to control the generation of internal return fines to allow fresh material consumption. Limited literature is available on factors affecting the internal return fines generation in sinter plant. Given the current computational capabilities, a machine learning model was developed to ascertain the factors affecting the internal return fines generation. The development of the machine learning model and the optimization carried out based on model output is described in this work. The key parameters affecting the internal return fines generation were the sintering rate, sinter basicity, charge density and temperature in the ignition hood. In Kalinganagar, the increase in ignition hood temperature was limited by the furnace refractory condition. Further, the sinter basicity is determined by the percentage of sinter in blast furnace burden. Incorporating these constraints, the model was used to optimize the process parameters to generate the lowest possible return fines. The understanding generated from this machine learning framework has resulted in a reduction of 2-3% in internal return fines generation, which implied higher net sinter production.
{"title":"Prediction and Optimization of Internal Return Fines Generation in Iron Ore Sintering Using Machine Learning","authors":"S. Mohanan, P. Mohapatra, C. Kumar, Ramakrishna Adepu, V. M. Koranne, Y. S. Prasad, A. S. Reddy, R. Ramna","doi":"10.11648/J.AM.20211003.12","DOIUrl":"https://doi.org/10.11648/J.AM.20211003.12","url":null,"abstract":"Prior to dispatch of sinter to the blast furnace for hot metal production, the sinter product from the sinter cooler is screened to remove smaller/finer particles. The undersize so generated is called internal return fines, which are generally recirculated into the sintering machine. A very high level of internal return fines generation limits the use of virgin ore for sintering which may hamper sinter productivity. Recently, the sinter plant at Tata Steel’s Kalinganagar works has faced issues of high internal return fines generation. As the sinter plant begins to increase its productivity levels, it becomes critical to control the generation of internal return fines to allow fresh material consumption. Limited literature is available on factors affecting the internal return fines generation in sinter plant. Given the current computational capabilities, a machine learning model was developed to ascertain the factors affecting the internal return fines generation. The development of the machine learning model and the optimization carried out based on model output is described in this work. The key parameters affecting the internal return fines generation were the sintering rate, sinter basicity, charge density and temperature in the ignition hood. In Kalinganagar, the increase in ignition hood temperature was limited by the furnace refractory condition. Further, the sinter basicity is determined by the percentage of sinter in blast furnace burden. Incorporating these constraints, the model was used to optimize the process parameters to generate the lowest possible return fines. The understanding generated from this machine learning framework has resulted in a reduction of 2-3% in internal return fines generation, which implied higher net sinter production.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"87262777","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}
Pub Date : 2021-09-29DOI: 10.11648/J.AM.20211003.11
Nitin Amratav, K. K. Kumar, M. Pillai
Steelmaking is the second step in producing steel from iron ore. In this stage, impurities such as sulfur, phosphorus, and excess carbon are removed from the raw iron, and alloying elements such as manganese, nickel, chromium, and vanadium are added to produce the exact steel required. Modern steelmaking processes are broken into two categories: primary and secondary steelmaking. Primary steelmaking uses mostly new iron as the feedstock, usually from a blast furnace. Secondary steelmaking uses scrap steel as the primary raw material. Gases created during the production of steel can be used as a power source. Steelmaking is presently a grounded innovation driven by plant, exploratory and computational examination. The continuous casting process comprises many complicated phenomena in terms of fluid flow, heat transfer, and structural deformation. The important numerical modeling method of the continuous casting process has been discussed in reference in this work. With the recent advancement in metallurgical methods, the continuous casting process now becomes the main method for steel production. To achieve efficient and effective production, the manufacturers of steel keep on searching for new methods which increase productivity. The present work describes molten steel flow, heat transfer, solidification, electromagnetic applications, formation of the shell by solidification and coupling, etc.
{"title":"Computer Simulation of Continuous Casting Processes: A Review","authors":"Nitin Amratav, K. K. Kumar, M. Pillai","doi":"10.11648/J.AM.20211003.11","DOIUrl":"https://doi.org/10.11648/J.AM.20211003.11","url":null,"abstract":"Steelmaking is the second step in producing steel from iron ore. In this stage, impurities such as sulfur, phosphorus, and excess carbon are removed from the raw iron, and alloying elements such as manganese, nickel, chromium, and vanadium are added to produce the exact steel required. Modern steelmaking processes are broken into two categories: primary and secondary steelmaking. Primary steelmaking uses mostly new iron as the feedstock, usually from a blast furnace. Secondary steelmaking uses scrap steel as the primary raw material. Gases created during the production of steel can be used as a power source. Steelmaking is presently a grounded innovation driven by plant, exploratory and computational examination. The continuous casting process comprises many complicated phenomena in terms of fluid flow, heat transfer, and structural deformation. The important numerical modeling method of the continuous casting process has been discussed in reference in this work. With the recent advancement in metallurgical methods, the continuous casting process now becomes the main method for steel production. To achieve efficient and effective production, the manufacturers of steel keep on searching for new methods which increase productivity. The present work describes molten steel flow, heat transfer, solidification, electromagnetic applications, formation of the shell by solidification and coupling, etc.","PeriodicalId":7327,"journal":{"name":"Advances in Materials Science","volume":null,"pages":null},"PeriodicalIF":1.3,"publicationDate":"2021-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"74782255","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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