Calculating Method for Influence of Material Flow on Energy Consumption in Steel Manufacturing Process

From the viewpoint of systems energy conservation, the influences of material flow on its energy consumption in a steel manufacturing process is an important subject. The quantitative analysis of the relationship between material flow and the energy intensity is useful to save energy in steel industry. Based on the concept of standard material flow diagram, all possible situations of ferric material flow in steel manufacturing process are analyzed. The expressions of the influence of material flow deviated from standard material flow diagram on energy consumption are put forward.

Effects of pin geometry on the material flow behavior of friction stir spot welded 2A12 aluminum alloy

A three-dimensional finite volume model was established by the ANSYS FLUENT software to simulate the material flow behavior during the friction stir spot welding （FSSW） process. Effects of the full-threaded pin and the reverse-threaded pin on the material flow behavior were mainly discussed. Results showed that the biggest material flow velocity appeared at the outer edge of the tool shoulder. The velocity value became smaller with the increase of the distance away from the tool surface. In general, material flows downwards along the pin thread when the full-threaded pin is used. Meanwhile, both the materials of the upper and the lower plates flow towards the lap interface along the pin thread when the reverse-threaded pin is used. The numerical simulation results were investigated by experiment, in which 2A12 aluminum alloy was used as the research object. The effective sheet thickness （EST） and stir zone （SZ） width of the joint by the reverse-threaded pin were much bigger than those by the full-threaded pin. Accordingly, cross tension failure load of the joint by the reverse-threaded pin is 23% bigger than the joint by the full-threaded pin.

3D visualization of the material flow in friction stir welding process

The material flow in friction stir welded 2014 Al alloy has been investigated using a marker insert technique （MIT）. Results of the flow visualization show that the material flow is asymmetrical during the friction stir welding （FSW） process and there are also significant differences in the flow patterns observed on advancing side and retreating side. On advancing side, some material transport forward and some move backward, but on retreating side, material only transport backward. At the top surface of the weld, significant material transport forward due to the action of the rotating tool shoulder. Combining the data from all the markers, a three-dituensional flow visualization, similar to the 3D image reconstruction technique, was obtained. The three-dimensional plot gives the tendency chart of material flow in friction stir welding process and from the plot it can be seen that there is a vertical, circular motion around the longitudinal axis of the weld. On the advancing side of the weld, the material is pushed downward but on the retreating side, the material is pushed toward the crown of the weld. The net result of the two relative motions in both side of the advancing and the retreating is that a circular motion comes into being. Comparatively, the material flow around the longitudinal axis is a secondary motion.

Simulation of 3D material flow in friction stir welding of AA6061-T6

This paper reports the numerical simulation of the 3D material flow in friction stir welding process by using finite element methods based on solid mechanics. It is found that the material flow behind the pin is much faster than that in front of the pin. The material in front of the pin moves upwards and then rotates with the pin due to the effect of the rotating tool. Behind of the pin, the material moves downwards. This process of material movement is the real cause to make the friction stir welding process continuing successfully. With the increase of the translational velocity or the rotational velocity of the pin, the material flow becomes faster.

Influence of Material Flow in Steel Manufacturing Process on Atmosphere Environmental Load

The standard material flow diagram in steel manufacturing process was proposed to analyze the influences of various material flows on environmental load of 1tof final product.Two influence factors and reducing measures of environmental load were pointed out.The environmental load was appraised for a typical technological process in a Chinese steel plant.

Analysis of material flow and heat transfer in friction stir welding of aluminium alloys

A three-dimensional viscous-plastic.finite element model is established based on computational fluid mechanics. The material during the welding process is considered as non-Newtonian fluid abided by Norton-Hoff constitutive law, and viscous dissipation is assumed as the unique heat source. The model is used to numerically simulate the material flow and heat transfer in friction stir welding, and capture some useful process characteristics, .such as heat generation, temperature distribution and fluid.flow; besides, the velocity field is used to calculate streamlines of material flow, and the dimension of the deformation zone is measured.

Material flow behavior and microstructural evolution during refill friction stir spot welding of alclad 2A12-T4 aluminum alloy

In this study, we used the stop-action technique to experimentally investigate the material flow and microstructural evolution of alclad 2A12-T4 aluminum alloy during refill friction stir spot welding.There are two material flow components, i.e., the inward-or outward-directed spiral flow on the horizontal plane and the upward-or downward-directed flow on the vertical plane.In the plunge stage, the flow of plasticized metal into the cavity is similar to that of a stack, whereby the upper layer is pushed upward by the lower layer.In the refill stage, this is process reversed.As such, there is no obvious vertical plasticized metal flow between adjacent layers.Welding leads to the coarsening of S(Al2CuMg) in the thermo-mechanically affected zone and the diminishing of S in the stir zone.Continuous dynamic recrystallization results in the formation of fine equiaxed grains in the stir zone, but this process becomes difficult in the thermo-mechanically affected zone due to the lower deformation rate and the pinning action of S precipitates on the dislocations and sub-grain boundaries, which leads to a high fraction of low-angle grain boundaries in this zone.

Preliminary Research on Regional Material Flow Analysis:A Case Study of Chengyang District in Qingdao

The method ＂Material Flow Analysis （MFA）＂ is one of the effective tools to study law and quantification of material flow between economic system and ecological system. On the national level, economy-wide material flow analysis has been published for a number of countries. However, published studies on the regional or local level are still very limited and a standardized method does not exist yet. On the basis of framework of Material Flow Analysis proposed by Eurostat, the paper collected related data and analyzed material input and output for the Chengyang district in Qingdao. The results showed that DMI （Direct Material Input） and TMR （Total Material Requirement） in absolute number increased about 3.6 and 3.9 times, respectively from 1995 to 2004. Fossil fuel and mineral contributed to about 50.3%-76.3% of DMI. Imports of material increased about 5.0 times and became the most important Contributor to DMI, which showed that local economic growth was highly dependent on resources from other regions and countries. DPO （Domestic Processed Output） and TDO （Total Domestic Output） represent slow increasing trend, and DPO contributed to 22.2%-58.1% of TDO, suggesting local hidden flows were of obvious effect on TDO. The biggest component of DPO is CO2, approximately accounting for 90% of DPO. The material productivity increased 57.7% in last decade, reflecting improvement of efficiency of resources utilization in some extent. However, compared to developed countries and regions, material productivity of Chengyang district was relatively low. Therefore, in order to promote the sustainability, it is essential to develop circular economy and enhance materials productivity.

Establishment and Analysis on Material Flow Model in Argo-animal Husbandry Ecosystem

This paper analyzed the material flow situation in argo-animal husbandry ecosystem by compartment model. This model was an important mean for investigating the whole structural characteristics in ecosystem. Based on this analysis, characteristics of material cycle and integrity in the system were mastered. As an example of natural conditions in Yonghe Village, Shuangcheng Township, Shuangeheng Municipal, Heilongjang Province, the system of linear differential equations in system was established by extracting each compartment and investigating material flow and stability of this model was proved by Lyapunov linear theory. The result showed that this system could not be interfered by initial value in the state of present, input and output.

Exploring material flow in friction stir welding using stacked structure of 2024 and 6061 aluminum alloys

An experimental technique based on stacked structures was developed to observe the material flow behavior of the friction stir welding （FSW） process. Analysis of section views along different directions revealed important new details of the material flow in FSW process. In this work, a general flow model of FSW was constructed based on the analysis of different static section views of stacked structure weld. The formation of onion rings was found to be a geometric effect due to layered deposition attd the extrusion occurred at the interface between flow arm （FA） and stirring zone （SZ）.

Current status and future trends for material flow analysis applications at CSC

Material Flow Analysis(MFA) is a crucial instrument for sustainable development and creating industrial ecology system.MFA studies could balance and analyze the sources,flows,and consumes of specific materials or substances.The results of MFA studies could support the strategies or decisions making for energy, resource,and waste management,especially achieving sustainable resource management.At CSC,the dynamic simulating software,STELLA,is used to develop a MFA model for scenario analysis.CSC also uses the freeware STAN 2.0 as a tool for visualizing and simulating material flows and stocks.Case studies of greenhouse gases MFA for integrated steel works are conducted.The results showed that the carbon content of hot-metal is an important hidden flow for balance analysis,and the different GHG emission scenarios and mitigation action scenarios are assessed.In addition,the Iron-making GHG I/O MFA Model,based on worldsteel Global Steel Sector Approach(GSSA),is developed for calculating the CO_2 and energy intensity of coke making,sintering,and BF processes.This MFA model was used to analyze the CO_2 reduction potential for iron-making process.The cases conducted for MFA applications at CSC were such as greenhouse gas,zinc,etc.In the future,CSC is going to develop a 'CSC Environment Management and Decision Supporting System' which combine MFA,LCA(life cycle assessment),and environment risk assessment.This supporting system expects to promoting energy efficiency and best resource use,supporting environment policymaking,creating environmental information value,etc.

Modeling of material flow in friction stir welding process

This paper presents a 3D numerical model to study the material flow in the friction stir welding process. Results indicate that the material in front of the pin moves upwards due to the extrusion of the pin, and then the upward material rotates with the pin. Behind the rotating tool, the material starts to move downwards and to deposit in the wake. This process is the real cause to make friction stir welding process continuing successfully. The tangent movement of the material takes the main contribution to the flow of the material in friction stir welding process. There exists a swirl on the advancing side and with the increase of the translational velocity the inverse flow of the material on the advancing side becomes faster. The shoulder can increase the velocity of material flow in both radial direction and tangent direction near the top surface. The variations of process parameters do have an effect on the velocity field near the pin, especially in the region in which the material flow is faster.

Material Flow:An Emerging Business in China

AS a consequence of China’s past decades as a planned economy, with its over emphasis on production and neglect of circulation, the country’s material flow has long remained at an undeveloped level, with small-scale operation, poor organization, and a lack of equipment. For too long, production and circulation have been unrelated processes.

Effect of welding speed on the material flow patterns in friction stir welding of AZ31 magnesium alloy

The clear zigzag-line pattern on transverse cross sections can be used to explain the formation mechanism of the weld nugget when friction stir welded AZ31 magnesium alloy without any other insert material is used as mark. It provides a simple and useful method to research the joining mechanism of friction stir welding. The rotation speed is kept at 1000 r/min and the welding speed changes from 120 mm/min to 600 mm/min. The macrostructure on the transverse cross section was divided into several parts by faying surface. The results show that the shape and formation procedure of the weld nugget change with the welding speed. There are two main material flows in the weld nugget： one is from the advancing side and the other is from the retreating side. A simple model on the weld nugget formation of FSW is presented in this article.

Numerical simulation for the comparison of thermal and plastic material flow behavior between symmetrical and asymmetrical boundary conditions during friction stir welding

An accurate description of the contact condition between the tool and the workpiece material is one of the most important issues for expounding the underlying multi-physics coupled mechanism during friction stir welding(FSW)process.In the present study,a novel asymmetrical boundary condition around the tool-workpiece contact interface is proposed for the FSW of AA2024-T4 alloy.A three-dimensional computational fluid dynamics model is employed for the comparison of the coupled thermal and plastic material flow behavior between asymmetrical and symmetrical boundary conditions.Numerical results of heat generation,temperature distribution,tunnel defect formation and material flow streamline during the welding process are quantitatively analyzed.Besides,various experimental measuring methods are utilized to obtain information about temperature,thermal cycle,tool torque and horizontal cross-section around the exiting keyhole.It is revealed that the modeling results of heat flux density and temperature distribution around the pin,as well as material flow characteristics all change significantly for the two models with different boundary conditions.Particularly,the asymmetrical boundary condition is more capable of predicting temperature fluctuation,plastic material flow along the vertical direction,as well as tunnel defect formation during FSW.Therefore,the superiority of the model with asymmetrical boundary condition over the symmetrical one during the numerical simulation of FSW is elucidated.

Enhancing wood efficiency through comprehensive wood flow analysis:Methodology and strategic insights

Wood,an essential natural resource in human civilization,remains widely used despite advances in technology and material substitution.The surge in greenhouse gas emissions and environmental concerns accentuates the need for optimizing wood utilization.Material flow analysis is a powerful tool for tracking material flows and stocks,aiding resource management and environmental decision-making.However,the full extent of its methodological dimensions,particularly within the context of the wood supply chain,remains relatively unexplored.In this study,we delve into the existing literature on wood flow analysis,discussing its primary objectives,materials involved,temporal and spatial scales,data sources,units,and conversion factors.Additionally,data uncertainty,data reconciliation and crucial assumptions in material flow analysis are highlighted in this paper.Key findings reveal the significance of wood cascading and substitution effects by replacing non-wood materials,where they can reduce greenhouse gas emissions more than the natural carbon sink of forests and wood products.The immediate impact of short-term wood cascading might not be as robust as the substitution effect,with energy substitution showcasing better results than material substitution.However,it's crucial to note that these conclusions could experience significant reversal from a long-term and global perspective.Strategies for improving wood efficiency involve maximizing material use,advancing construction technologies,extending product lifespans,promoting cascade use,and optimizing energy recovery processes.The study underscores the need for standardized approaches in wood flow analysis and emphasizes the potential of wood efficiency strategies in addressing environmental challenges.

End-of-life batteries management and material flow analysis in South Korea

Consumers increasingly have worn-out batteries as electrical and electronic equipment with new technical developments are introduced into the market and quickly replace older models. As a result, large amounts of end-of-life （EOL） or waste batteries are generated. Such batteries may contain a variety of materials that includes valuable resources as well as toxic elements. Thus, the proper recycling and management of batteries is very important from the perspective of resource conservation and environmental effect. The collection and recycling of EOL batteries is relatively low in South Korea compared to other countries, although an extended producer responsibility （EPR） policy was adopted for battery recycling in 2003. In this study, the management and material flow of EOL batteries is presented to determine potential problems and quantitative flow, based on literature review, site visits to battery recycling facilities, and interviews with experts in the Korea Battery Recycling Association （KBRA）, manufacturers, and regulators in government. The results show that approximately 558 tons of manganese-alkaline batteries, the largest fraction among recycling target items, was disposed in landfills or incinerators in 2015, while approximately 2,000 tons of batteries were recovered at a recycling facility by simple sorting and crushing processes. By raising environmental awareness, more diverse and effective collection systems could be established for consumers to easily dispose of EOL batteries in many places. Producers, retailers and distributors in South Korea should also play an important role in the collection of EOL batteries from consumers. Lithium-ion batteries from many electronic devices must be included in the EPR system for resource recovery.

Material flow analysis(MFA)of an eco-economic system:a case study of Wujin District,Changzhou,China

The economic and ecological aspects of a social system are coherently linked and can be examined by its material and energy flows.In this study,we used the material flow analysis(MFA)to model the material input and output of the Wujin District of Changzhou City,Jiangsu Province in China.It was revealed that:(1)total material input and material input per capita increased with economic development,while the total material out-put and material output per capita decreased consistently;(2)except for water,the total material input continued to increase.Input of solid materials grew faster than that of gaseous materials,while the total material output declined.The gas output accounted for the largest pro-portion of the output resulting in primary environmental pollution as burned fossil fuel;(3)water use in agriculture continued with an increasing trend while that in industrial and residential sectors decreased per capita.The total wastewater discharge and wastewater discharge per capita decreased with a faster decreasing rate of residential was-tewater discharge followed by industrial wastewater discharge;(4)material input per unit GDP fluctuated and material output per unit GDP decreased.A decreasing trend in both water use and wastewater discharge per unit GDP was disclosed.These results suggest that the efficiency of resource use in the Wujin District has improved.This weakened the direct link between economic development and environmental deterioration.Additionally,we discussed the harmonic development between environment and economy.Potential limitations of MFA’s application were also discussed.It is suggested that effective measures should be taken for the enforcement of cir-cular economic strategies and the construction of a resource-saving economy.

An evolving trajectory-from PD,logistics,SCM to the theory of material flow

The growing interest in the material flow(MF)theory has invoked much interesting research in recent years.Although the MF theory is relatively new,a review of the related literature from a historical perspective shows that MF theory represents a new stage of the evolutionary development of interrelated subjects such as Physical Distribution(PD),Logistics,and Supply Chain Management(SCM).The purpose of this paper is to provide a summative review of the evolution of the subjects of PD,Logistics,and SCM,and their new development,MF theory.The paper aims at tracing how concepts and findings in PD,Logistics,SCM,and MF have been developed and have evolved.The study shows that PD evolved to Logistics in middle of the 1980s;starting from the late 1990s,Logistics has evolved to SCM;and today PD,Logistics,and SCM can be considered to be under the umbrella provided by a new theory called MF theory.This paper points out that MF theory is a necessity to deal with the overwhelming complexity of material flow systems in the global economy of the twenty-first century.

A STUDY ON YIELD AND FLOW OF ORTHOTROPIC MATERIALS

On the assumption that the yield criterion of orthotropic materials is isomorphic with Huber-Mises criterion of isotropic materials, we put forward a dimensionless stress yield criterion, and obtained the associated plastic flow law. Using experimental stress-strain curves in various simple stress states, generalized effective stress-strain formulae may be derived correspondingly in various forms.