SPHERICAL MICROSTRUCTURE FORMATION OF THE SEMI-SOLID HIGH CHROMIUM CAST IRON Cr20Mo2

The nondendritic semi-solid slurry preparation of high chromium cast iron Cr20Mo2 has been studied in this paper. The experiments show that the proeutectic austenitic particles are more spherical under a larger stirring power condition, even if the stirring time is shorter, while the proeutectic austenitic particles are not very much spherical under a smaller stirring power condition and some proeutectic austenitic dendrites also exist, even if the stirring time is very long. The experiments also show that when stirred for 5-6 minutes under the test condition, the semi-solid slurry with 40vol.%-50vol.% solid fraction and spherical proeutectic austenite in the size of 50-80μm can be obtained.

Acting mechanism of F,K,and Na in the solid phase sintering reaction of the Baiyunebo iron ore

The effect of F,K,and Na on the solid phase reaction of the Baiyunebo iron ore was investigated by differential thermal analysis （DTA） and X-ray diffraction（XRD）.It has been identified that alkaline elements K and Na in the Baiyunebo ore instigate the formation of low melting point compounds Na2SiO3 and Na2O·Fe2O3 and the generation of molten state in the solid phase sintering.Element F in the Baiyunebo ore facilitates the formation of cuspidine compound 3CaO·2SiO2·CaF2 in the solid phase reaction.The cuspidine compound is kept in solid as one of the final products through the entire sintering process due to its high melting point.In the sintering process,CaF2and SiO2 react with CaO first and form 3CaO·2SiO2·CaF2 and 3CaO·2SiO2,so the formation of ferrites,Na2O·Fe2O3,and 2CaO·Fe2O3 is inhibited.

Effects of Heat Treatment on Hardness and Dry Wear Properties of a Semi-Solid Processed Fe-27 wt pct Cr-2.9 wt pct C Cast Iron

EfFects of heat treatments on hardness and dry wear properties of a semi-solid processed Fe-26.96 wt pct Cr- 2.91 wt pct C cast iron were studied. Heat treatments included tempering at 500℃, destabilisation at 1075℃ and destabilisation at 1075℃ plus tempering at 500℃, all followed by air cooling. Electron microscopy revealed that, in the as-cast condition, the primary proeutectic austenite was round in shape while the eutectic M7C3 carbide was found as radiating clusters mixed with directional clusters. Tempering did not change the microstructure significantly when observed by scanning or transmission electron microscopy. Destabilisation followed by air cooling led to a precipitation of secondary M23C6 carbide and a transformation of the primary austenite to martensite. Precipitation behaviour is comparable to that observed in the conventionally cast iron. Tempering after destabilisation resulted in a higher amount of secondary carbide precipitation within the tempered martensite in the eutectic structure. Vickers macrohardness and microhardness in the proeutectic zones were measured. Dry wear properties were tested by using a pin-on-disc method. The maximum hardness and the lowest dry wear rate were obtained from the destabilisation-plus-tempering heat treatment due to the precipitation of secondary carbides within the martensite matrix and a possible reduction in the retained austenite.

Low Mantle Perovskite:Solid Solution, Spin State of Iron and Water Solubility

Silicate perovskites（（Mg, Fe）SiO 3 and CaS iO 3） are believed to be the major constituent minerals in the lower mantle. The phase relation, solid solution, spin state of iron and water solubility related to the lower mantle perovskite are of great effect on the geodynamics of the Earth＇s interior and on ore mineralization. Previous studies indicate that a large amount of iron coupled with aluminum can incorporate into magnesium perovskite, but this is discordant with the disproportionation of（Mg,Fe）SiO 3 perovskite into iron-free MgS i O3 perovskite and hexagonal phase（Mg0.6Fe0.4）SiO 3 in the Earth＇s lower mantle. MnS iO 3 is the first chemical component confirmed to form wide range solid solution with Ca SiO 3 perovskite and complete solid solution with MgS i O3 perovskite at the P-T conditions in the lower mantle, and addition of Mn Si O3 will strongly affects the mutual solubility between Mg Si O3 and CaS iO 3. The spin state of iron is deeply depends on the site occupation of the Fe3＋or Fe2＋, the synthesis and the annealing conditions of the sample. It seems that the spin state of Fe2＋ in the lower mantle perovskite can be settled as high spin, however, the existence of intermediate spin or low spin state of Fe2＋ in perovskite has not been clarified. Moreover, different results have also been reported for the spin state of Fe3＋ in perovskite. The water solubility of the lower mantle perovskite is related with its composition. In pure Mg SiO 3 perovskite, only less than 500 ppm water was reported. Al–Mg Si O3 perovskite or Al–Fe–MgS iO 3 perovskite in the lower mantle accommodates water of 1100 to 1800 ppm. Further experiments are necessary to clarify the detailed conditions for perovskite solid solution, to reliably analyze the valence and spin states of iron in the coexisting iron-bearing phases, and to compare the water solubility of different phases at different layers for deeply understanding the geodynamics of the Earth＇s interior and ore mineralization.

Influence of Semi-Solid Isothermal Heat Treatment on Microstructure of Gray Cast Iron

Materials serve as an enabling technology contributing to solutions in problems of concern to society. In this research, the effect of semi-solid isothermal heat treatment on graphite morphologies and matrix structure for gray cast iron were studied. Microstructure observations and measurements of flaky graphite morphology are reported as a function of isothermal heating time range of 5 to 25 minutes after isothermal heating temperature at 1163℃. The effect heating time, on the semisolid microstructures during partial re-melting was investigated. Flack graphite morphology was changed significantly by isothermal heating of gray cast iron at 1163℃ for heating time above 15 min resulting fine graphite morphology in matrix structure. Hardness increases with increasing heating time due to the amount of cementite and fine pearlite matrix for air cooled gray cast iron. The optimum heating treatment condition was achieved at the temperature of 1163℃ for the range of 15 to 20 min.

Thermodynamic data calculation for iron phases in sulfoaluminate cementitious materials prepared using solid wastes

The preparation of sulfoaluminate cementitious materials(SCM)is a promising way to massively utilize solid wastes.Iron phases are significant in SCM system but the thermodynamic data of some key minerals,such as6 CaO·Al2 O3·2 Fe2 O3(C6 AF2)and 6 CaO·2 Al2 O3·Fe2 O3(C6 A2 F),are missing,which greatly hinders the SCM optimization in a theoretical way.This work,for the first time,calculated the standard formation enthalpy,Gibbs free energy of formation,entropy and molar heat capacity for C6 AF2 and C6 A2 F and lowered the errors to the least with the reference of C4 AF data in the literature.By building the function diagram of Gibbs free energy changes with temperature for the basic iron phase formation reactions with the obtained thermodynamic data,it is proved that the formation likeliness of C6 AF2 is higher than that of C6 A2 F,as is accordant to the literatures and verifies the correctness of obtained data.This work provides a good theoretical foundation to optimize SCM mineral system and to study relevant mechanism deeply.

Influence of Semi-Solid Isothermal Heat Treatment on Microstructure and Mechanical Properties of Ductile Cast Iron

In this research, the effect of semi-solid isothermal heat treatment on microstructure, hardness and impact toughness of ductile iron (DI) is studied. Heat-treated air-cooled ductile iron shows spheroid graphite, cementite and fine pearlite matrix structure. At the early stages of heating time (up to 20 min), the DIs show significant decrease in amounts of graphite and significant increase in amounts of cementite. By increasing heating time, above 20 min, the DIs show slightly decrease in amounts of graphite and slightly increase in amounts of cementite. Hardness values increase by increasing heating time. Meanwhile, the impact toughness decrease with increasing heating time. The optimum heating treatment condition for reasonable structure and mechanical properties could be achieved at the temperature of 1165℃ for the heating time range of 10 to 15 min.

Low-cost solid FeS lubricant as a possible alternative to MoS2 for producing Fe-based friction materials

Three reaction systems of MoS_2-Fe, FeS -Fe, and Fe S-Fe-Mo were designed to investigate the use of FeS as an alternative to MoS_2 for producing Fe-based friction materials. Samples were prepared by powder metallurgy, and their phase compositions, microstructures, mechanical properties, and friction performance were characterized. The results showed that MoS_2 reacts with the matrix to produce iron-sulfides and Mo when sintered at 1050°C. Iron-sulfides produced in the MoS_2-Fe system were distributed uniformly and continuously in the matrix, leading to optimal mechanical properties and the lowest coefficient of friction among the systems studied. The lubricity observed was hypothesized to originate from the iron-sulfides produced. The Fe S-Fe-Mo system showed a phase composition, porosity, and density similar to those of the MoS_2-Fe system, but an uneven distribution of iron-sulfides and Mo in this system resulted in less-optimal mechanical properties. Finally, the Fe S-Fe system showed the poorest mechanical properties among the systems studied because of the lack of Mo reinforcement. In friction tests, the formation of a sulfide layer contributed to a decrease in coefficient of friction（COF） in all of the samples.

Separation of primary solid phases from Al-Si alloy melts

The iron-rich solids formed during solidification of Al-Si alloys which are known to be detrimental to the mechanical,physical and chemical properties of the alloys should be removed.On the other hand,Al-Si hypereutectic alloys are used to extract the pure primary silicon which is suitable for photovoltaic cells in the solvent refining process.One of the important issues in iron removal and in solvent refining is the effective separation of the crystallized solids from the Al-Si alloy melts.This paper describes the separation methods of the primary solids from Al-Si alloy melts such as sedimentation,draining,filtration,electromagnetic separation and centrifugal separation,focused on the iron removal and on the separation of silicon in the solvent refining process.

Solid FeS lubricant: a possible alternative to MoS2 for Cu–Fe-based friction materials

Molybdenum disulfide(MoS_2) is one of the most commonly used solid lubricants for Cu–Fe-based friction materials. Nevertheless, MoS_2 reacts with metal matrices to produce metal sulfides(e.g., FeS) and Mo during sintering, and the lubricity of the composite may be related to the generation of FeS. Herein, the use of FeS as an alternative to MoS_2 for producing Cu–Fe-based friction materials was investigated. According to the reaction principle of thermodynamics, two composites—one with MoS_2(Fe–Cu–MoS_2 sample) and the other with FeS(FeS–Cu_2S–Cu–Fe–Mo sample), were prepared and their friction behaviors and mechanical properties were compared. The results showed that MoS_2 reacted with the Cu–Fe matrix to produce FeS, metallic ternary sulfides, and Mo when sintered at 1050°C. The MoS_2–Cu–Fe and FeS–Cu_2S–Cu–Fe–Mo samples thereby exhibited similar characteristics with respect to phase composition, density, hardness, and tribological behaviors. Micrographs of the worn surfaces revealed that the stable friction regime for both composites stemmed from the iron sulfides friction layers rather than from the molybdenum sulfides layers.

Characterization of dolochar wastes generated by the sponge iron industry

Solid wastes generated by the metallurgical industry contribute significantly towards the enhancement of environmental pollution. The handling, utilization, and safe disposal of these solid wastes are major concerns for the world. Dolochar is such a solid waste generated by the sponge iron industry. Investigations were carried out on the physical, mineralogical, and chemical characteristics for the efficient utilization of dolochar. The detailed studies on physico-chemical properties and petrography were carded out by optical microscopy, X-ray diffraction （XRD）, and scanning electron microscopy （SEM）. Characterization studies revealed that the dolochar consists of quartz （free as well as locked）, free lime, Fe particles, and Ca or Mg and/or Ca＋Mg＋Fe oxide phases. The washability data of-300 ~m dolochar samples indicated that clean coal with 41wt% ash at 18% yield can be produced from dolochar with 78wt% ash. The studies further suggested that the liberation of the dolochar is hard to achieve for clear separation. The dolochar is observed to have high ash fusion temperature and the un- burned carbon can be best utilized for power generation.

Effects of different iron sources on the performance of LiFePO_4/C composite cathode materials

Olivine LiFePO4/C composite cathode materials were synthesized by a solid state method in N2 ＋ 5vol% H2 atmosphere. The effects of different iron sources, including Fe（OH）3 and FeC2O4·2H2O, on the performance of as-synthesized cathode materials were investigated and the causes were also analyzed. The crystal structure, the morphology, and the electrochemical performance of the prepared samples were characterized by X-ray diffractometry （XRD）, scanning electron microscopy （SEM）, laser particle-size distribution measurement, and other electrochemical techniques. The results demonstrate that the LiFePO4/C materials obtained from Fe（OH）3 at 800℃ and FeC2O4·2H2O at 700℃ have the similar electrochemical performances. The initial discharge capacities of LiFePO4/C synthesized from Fe（OH）3 and FeC2O4·2H2O are 134.5 mAh.g^-1 and 137.4 mAh.g^-1 at the C/5 rate, respectively. How- ever, the tap density of the LiFePO4/C materials obtained from Fe（OH）3 are higher, which is significant for the improvement of the capacity of the battery.

Mechanical properties of thixo-formed austempered ductile iron

Semi-solid processing of metallic materials has been investigated for some time;however,this innovative production process has not fully established for ferrous alloys like ductile cast iron in the industry yet.Ferrous alloys-specially ductile cast ironbecause of increasing complexity due to high temperature processing and some other limitations have been allocated a small share of this useful forming process to themselves.However,this work describes that thixo-forming of ductile iron despite all of the limitations is possible even for thin sections(less than 1 mm).Die temperature and injection velocity are the most effective parameters to thixo-forming particularly for high melting point materials such as ductile cast iron.Filling behavior,shape factor of graphites and fluidity of thixo-formed specimens were characterized.In addition,defects as well as shrinkage and cold laps were examined to achieve sound specimen.Subsequence to successful thixo-forming,two step austempering was performed to accomplish a uniform structure with minimum untransformed austenite volume(UAV).Following austempering,tensile test was carried out and the results show good combination of tensile strength and elongation for treated specimens(1 137 MPa strength and 12% elongation in best situation).

Application of Different Models for the Prediction of the Kinetics of Direct Reduction of Natural Iron Ores

Simulation of the direct reduction conditions was performed in a laboratory furnace. Lump samples from natural hematite iron ore were reduced by a gas mixture of H2 and CO (H2/CO =1.5) at temperatures of 700°C, 800°C and 900°C. The effect of reduction temperature on the reduction degree, reduction rate of samples and carbon deposition were investigated and discussed in this study. The thermo-gravimetric data obtained from the reduction experiments was run in a programme that calculates the solid conversion rate. Also, three models: 1) Grain Model (GM), 2) Volumetric Model (VM), and 3) the Random Pore Model (RPM), were used to estimate the reduction kinetics of natural iron ores. It was found that the RPM model result agreed best with the obtained experimental results. Furthermore, it gave better predictions of the natural iron oxide conversion and thereby the reduction kinetics.

Engineering Economy Analysis on the Production of Iron Ore in Nigeria

In line with the Federal government decision to attract direct foreign investment to the solid mineral sector and to further diversify the Nigerian economy;this study used the discounted cash flow micro-economic as-sessment to evaluate large-scale iron ore production in Nigeria. The iron ore project has an initial investment cost of US$ 73.934 m, annual expenditure and benefit of US$ 48.128 m and US$ 270 m respectively .The net present value (NPV), internal rate of return (IRR) and payback period of financial analysis at 100% ca-pacity utilizations are US$ 833.10 m, 444.36% and 6 years respectively. The economic assessment also shows a positive NPV at both 75% and 60% capacity utilizations. The study further show that the iron ore project has good economic potential and will also guide potential investor(s) in making decision on whether or not to commit resources to the project.

EFFECT OF NITROGEN ON MATRIX STRUCTURE OF GRAY CAST IRON

Effect of nitrogen on matrix structure of 3 different varieties of gray cast iron,i.e., sub-eutectic Fe-C-Si,near-eutectic Fe-C-Si and Fe-C-Si-Mn,has been investigated. The eutectie colony structure of gray cast iron may be refined,the pearlite content increased and the micro-hardness of pearlite and ferrite raised with an addition of nitrogen.The influ- ence of nitrogen on the transformation temperature of the equilibrium and non-equilibrium phases,as well as,the solution of nitrogen in ferrite and cementite seem to be the major rea- sons to strengthening the matrix structure of gray cast iron.

真空扩散对奥氏体灰铸铁渗硼层组织与性能影响的研究

为了改善奥氏体灰铸铁渗硼层厚度不足和脆性过大的问题,研究了渗硼处理和渗硼/真空扩散复合处理对奥氏体灰铸铁表面改性层摩擦磨损性能的影响和影响机理。利用光学显微镜、能谱仪、X射线衍射仪、电子探针等设备对单一处理和复合处理试样的渗层进行了金相组织、元素分布、物相组成、表面硬度、截面硬度以及磨痕分析。结果表明:真空扩散对渗硼层有着增厚的作用,能够有效的将脆性较大的FeB相转化为脆性相对较小Fe2B相,改善渗硼层的耐磨性,但会使得渗层的表面硬度略微降低,渗层中石墨的粗化现象更为加重。

Characteristics of Magnesium-iron-aluminium Composite Oxides and Their Influence on Properties of Magnesia-based Bricks

The composition,structure and micro-morphology of magnesium- iron- aluminum composite oxides were investigated using various methods such as XRF,SEM,EDS,XRD and KMn O4-titration. Compared to hercynite,the composite oxides have completely different phases including solid solution（ Mg O）0. 77（ Fe O）0. 23,composite spinel Mg Fe0. 2Al1. 8O4 and a small amount of Mg Fe2O4. The composite oxides exhibit excellent corrosion resistance to cement clinker and potassium salts.The products produced by magnesite and the composite oxides show better performance than magnesia- hercynite bricks,especially the corrosion resistance and thermal shock resistance.

钛工业固废制备氧化铁红及其在陶瓷黑色料中的应用

钛工业固废中的富铁尾泥因常年堆积对环境造成了严重污染,为实现富铁尾泥无害化、资源化处理,本研究通过酸浸-除杂-氧化-煅烧工艺路径,利用其中铁资源生产的氧化铁红作为铁源,制备铁铬尖晶石并将其应用在黑色陶瓷。考察了初始Fe^(2+)浓度、反应物摩尔比及氧化温度对氧化铁黄晶种的影响,以此为基础,探究了不同煅烧温度对氧化铁红、氧化铁红形成铁铬尖晶石及黑色陶瓷发色的影响。结果表明:由富铁尾泥酸浸提纯后得到氯化亚铁溶液,在Fe^(2+)浓度为0.4 mol/L、反应物摩尔比为2.2∶1、氧化温度为35℃的条件下,所得的氧化铁黄晶种在750℃煅烧温度下制备出纯度为98.875%、平均粒径为2.973μm、圆棒状、结晶度高的氧化铁红。以此为原料,在1280℃煅烧制备得到的铁铬尖晶石在黑色陶瓷色板发黑效果最好,色度值L^(*)为37.35,与标样相比仅相差0.57。

铁尾矿基多固废混凝土抗压性能及微观结构分析

针对铁尾矿堆存困难、综合利用率低和活性低的问题,以铁尾矿钢渣脱硫灰为复合掺合料制备多固废混凝土。通过抗压性能测试,研究复合掺合料掺量、铁尾矿细度对混凝土抗压强度的影响,并利用压汞法(MIP)和背散射电子成像技术(BSE)探究混凝土的微观结构。结果表明:复合掺合料的掺入对混凝土早期抗压强度影响较大,掺量小于20%的混凝土28 d抗压强度与无掺合料组抗压强度基本持平,30%掺量的混凝土抗压强度随铁尾矿比表面积的增大而先增大后减小;掺入复合掺合料和减小铁尾矿细度能够改善混凝土孔结构和提高界面过渡区的密实度。