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The paper considers a three-stage technology for angular rolling of the pipe workpiece. This technology facilitates the expansion of the range of flange parts available by eliminating a number of drawbacks of the known methods of metal forming. In the presented paper, we analyze the results of numerical calculations and experiments, as well as the effective deformation values in blank material, using computer simulation in the DEFORM-3D software package. The results of the computer simulation were reached taking into account experimental studies of the rheological properties of copper alloy L68 in the form of a strain hardening curve using the Instron-8850 complex. The results of the ratio of basic geometric dimensions expanded the range of flange parts under investigation and allowed us to consider angular rolling technology with a variable angle of inclination of the rolling roll from a three-stage perspective, especially in small-scale production.

The paper presents the results of microstructure tests of EN AC-46000 hypoeutectic Al&ndash, Si alloy with and without high-melting-point elements: chromium, molybdenum, vanadium, and tungsten. The above-mentioned elements were used individually or simultaneously in various combinations. The tested castings were made using two technologies: shell molding and high pressure die casting (HPDC). Using X-ray diffraction and microanalysis of the chemical composition an attempt to determine the phase structure of the tested alloy was made. It has been shown that the microstructure of the base alloy consists of dendrites of &alpha, (Al) solid solution and complex eutectic mixtures: ternary &alpha, (Al) + Al15(Fe,Mn)3Si2 + &beta, (Si) and quaternary &alpha, (Al) + Al2Cu + AlSiCuFeMgMnNi + &beta, (Si). High-melting point elements, regardless of the combination used, attach mainly to intermetallic phases rich in Fe and form the Al15(Fe,Mn,M)3Si2 phase, where M is any high melting point element or a combination of such elements. It has been shown that the area fraction of the above-mentioned phase increases with increasing content of high melting point elements. A greater area fraction of the Al15(Fe,Mn,M)3Si2 phase in the casting from the shell mold in relation to the high pressure die casting has been also found.

Nitrogen and Sulfur in non-oriented electrical steel would form precipitates, which would severely affect its magnetic properties. Precipitates in compact strip production (CSP) process non-oriented electrical steel were investigated using a transmission electron microscope (TEM) and scanning electron microscopy (SEM). The precipitation mechanism and influence on grain growth were analyzed experimentally and theoretically. The results showed that the main particles in steel were AlN, TiN, MnS, Cu2S, and fine oxide inclusions. The spherical or quasi-spherical of MnS and Cu2S were more liable to precipitate along grain boundaries. During the soaking process, the amount of MnS precipitated on the grain boundary was much larger than that of Cu2S. AlN and TiN in cubic shape precipitated inside grains or grain boundaries. Precipitates preferentially nucleated at grain boundaries, and TiN, MnS mainly precipitated during soaking. In the subsequent processes after soaking, AlN and Cu2S would precipitate unceasingly with the decrease in the average size. The distribution density, the volume fraction, and the average size of the precipitates in the annealed sheets were 9.08 &times, 1013/cm3, 0.06%, and 54.3 nm, respectively. Precipitates with the grain size of 30&ndash, 500 nm hindered the grain growth, the grains with 100&ndash, 300 nm played a major role in inhibiting the grain growth, and the grains with the grain size of 70&ndash, 100 nm took the second place.

The purpose of this paper was to analyze the process factors affecting the occurrence of lustrous carbon defects in ductile cast iron castings when using the lost-foam casting (LFC) method. This phenomenon results in creating raw surface defects, which sometimes may even lead to cast iron scrapping. A series of trial melting batches were carried out for variable process assumptions. The analysis was performed to reflect, to the greatest extent possible, real foundry production conditions. Industrial tests were performed in Odlewnia Rafamet Sp. z o.o., Kuźnia Raciborska, Poland. The polystyrene patterns created by gluing components together, used in the tests, met the requirements of the high-tech lost-foam casting (LFC) process. The performed analysis allowed the obtaining of lustrous carbon defects in test castings as well as the determination of the process parameters with the highest impact on lustrous carbon inclusions in ductile iron castings. The test results were used to eliminate the possibility of creating a defect and thus directly improve the efficiency of the lost-foam casting (LFC) process used in the foundry.

The as-quenched medium-carbon low-alloy Fe-0.36wt.%C-1wt.%Cr steel was subjected to warm deformation via uniaxial compression at temperatures of 400&ndash, 700 &deg, С and strain rates of 10&minus, 4&ndash, 10&minus, 2 s&minus, 1. At low temperatures (400&ndash, 550 &deg, C), the microstructure evolution was mainly associated with dynamic recovery with the value of activation energy of 140 &plusmn, 35 kJ/mol. At higher temperatures (600&ndash, C), dynamic recrystallization was developed, and activation energy in this case was 243 &plusmn, 15 kJ/mol. The presence of nanoscale carbide particles in the structure at temperatures of 400&ndash, 600 &deg, C resulted in the appearance of threshold stresses. A two-component &lt, 001&gt, //compression direction (CD) and &lt, 111&gt, //CD deformation texture was formed during deformation. Deformation at the low temperatures resulted in the formation of elongated ferritic grains separated mainly by high-angle boundaries (HAB) with a strong &lt, //CD texture. The grains with the &lt, //CD orientation were wider in comparison with those with the &lt, //CD orientation. The development of substructure in the form of low-angle boundaries (LAB) networks was also observed in the &lt, //CD grains. The development of dynamic recrystallization restricted the texture formation. The processing map for warm deformation of the 0.36C-1Cr steel was constructed.

MnS inclusions in bearing steel have long been considered to significantly affect the fatigue life of bearing steel. In this paper, the sizes of inclusions in bearing steel with different sulfur contents were analyzed and the precipitation behavior of MnS was calculated using thermodynamics. Furthermore, the positive role of MnS in bearing steel was discussed. Results showed that when the size of inclusions in bearing steel was increased, the proportion of MnS components in composite inclusions gradually decreased. When the sulfur content was increased, the shape of inclusions changed from a particle shape to a strip shape. With increasing MnS content, the inclusion ratio of Al2O3 was significantly reduced in the Al2O3&ndash, CaO&ndash, MgO&ndash, MnS quaternary inclusion system, particularly for MnS proportions greater than 20%. The content of sulfur in bearing steel significantly affects the precipitation temperature of MnS. When sulfur content increases from 0.001% to 0.007%, the precipitation temperature of MnS increases from 1493 K to 1633 K as the precipitation of MnS moves from the austenite solid phase to the liquid and solid phases, and the precipitation size of MnS inclusions significantly increases. The size of oxide inclusions should be controlled to improve MnS wrap oxide inclusions in steel. Based on these results, a composition control with high sulfur levels and low oxygen levels should be adopted to improve the fatigue performance of steel.

A fixture hardening process for aerospace gear box components of alloy S156 (16NiCrMo16-5, 1.6722) is investigated by thermomechanical metallurgical 2D axisymmetric Finite Element simulations. Material parameters are experimentally determined. Contact and transformation plasticity effects among others are implemented in Abaqus&reg, with user subroutines. The study aims to optimize the mandrel diameter of a fixture hardening tool for processing of planet gears. Plasticity, transformation plasticity, arising contact forces, and pressure depending on different mandrel sizes are investigated in depth. Distortion is evaluated and an optimal setting is derived from the calculations. Results show that cylindricity, defined here as the difference between maximum and minimum radius of the part, and maximum contact pressure, both can be reduced by increasing the mandrel radius. Physical effects and distortion evolve strongly nonlinear. Analysis methods highlighting cylindricity depending on the different mandrel diameters are developed to illustrate this nonlinear behavior and to enhance knowledge about the process.

The ferromanganese (FeMn) alloy is produced through the smelting-reduction of manganese ores in submerged arc furnaces. This process generates large amounts of furnace dust that is environmentally problematic for storage. Due to its fineness and high volatile content, this furnace dust cannot be recirculated through the process, either. Conventional MnO2 production requires the pre-reduction of low-grade ores at around 900 °C to convert the manganese oxides present in the ore into their respective acid-soluble forms, however, the furnace dust is a partly reduced by-product. In this study, a hydrometallurgical route is proposed to valorize the waste dust for the production of battery-grade MnO2. By using dextrin, a cheap organic reductant, the direct and complete dissolution of the manganese in the furnace dust is possible without any need for high-temperature pre-reduction. The leachate is then purified through pH adjustment followed by direct electrowinning for electrolytic manganese dioxide (EMD) production. An overall manganese recovery rate of &gt, 90% is achieved.

The combination of high strength and formability of transformation induced plasticity (TRIP) steels is interesting for the automotive industry. However, the poor weldability limits its industrial application. This paper shows the results of six low-alloy TRIP steels with different chemical composition which were studied in order to correlate retained austenite (RA) and non-metallic inclusions (NMI) with their resistance spot welded zones to their joints&rsquo, final mechanical properties. RA volume fractions were quantified by X-ray microdiffraction (&micro, SXRD) while the magnetic saturation technique was used to quantify NMI contents. Microstructural characterization and NMI of the base metals and spot welds were assessed using scanning electron microscopy (SEM). Weld nuggets macrostructures were identified using optical microscopy (OM). The lap-shear tensile test was used to determine the final mechanical properties of the welded joints. It was found that NMI content in the fusion zone (FZ) was higher than those in the base metal and heat affected zone (HAZ). Whereas, traces of RA were found in the HAZ of highly alloyed TRIP steels. Lap-shear tensile test results showed that mechanical properties of spot welds were affected by NMI contents, but in a major way by the decomposition of RA in the FZ and HAZ.

In the present work, an evaluation of the volume fraction of austenite in austempered ductile iron (ADI) is presented by means of three different methods. Experimental tests were conducted on ADI samples after different austempering conditions and contained different volume fractions of the phase components in the metallic matrix (ferrite plates + austenite). A comparison of the volume fraction of austenite was carried out by metallographic magnetic methods using a variable field, as well as X-ray quantitative phase analysis. The main purpose of this work is to show the effectiveness of the proposed magnetic method for estimating the volume fraction of austenite in ADI cast iron. It is evident that the new method in which variable magnetic fields are used to quantify the phase composition exhibits very high accuracy within the second stage of the austempering transformation, in which the metallic matrix consists of ferrite plates and high-carbon austenite. Finally, this research shows that within the first and third stages the estimation of the volume fraction of the austenite is hampered by errors resulting from the presence of martensite (first stage) and carbide phases (third stage).

The axial fan blades used in underground mines are usually manufactured in AlSi12CuMgNi alloy (EN AC 48000). They must have a high mechanical strength to withstand the stresses resulting from the rotation speed of the rotor and a high resistance to erosive wear caused by suspended particles from underground mining and transport operations. The aim of this paper is to determine the most suitable thermal treatment to simultaneously improve their mechanical strength and erosive wear resistance. To this end, two solution treatments at 525 &deg, C with cooling in water were analysed, as well as several ageing times at 170 &deg, C. The crystalline phases present in the as-cast state were quantified by X-ray diffraction following quenching and different ageing processes. Furthermore, erosion wear resistance was measured by means of compressed air blasting with corundum particles according to ASTM G76 (2004). The highest wear resistance was obtained in the as-cast state using gravity die casting, with the presence of Al4Cu2Mg8Si7 and Al3CuNi. This wear resistance was higher than that obtained after the ageing treatment. However, a trade-off between mechanical strength and wear resistance was observed after 12 h ageing, where the hardness obtained exceeded 160 HV and the wear resistance became similar to that obtained in the as-cast state.

The linear contraction and hot tearing behavior of 9Cr3Co3W heat-resistant steel during solidification were studied by combining in-situ casting experiments and the corresponding numerical simulations. The linear contraction, stress and temperature of the samples were detected during solidification. The results show that the linear contraction of 9Cr3Co3W heat-resistant steel was 1.7% in the sand mold. Meanwhile, the critical temperature and stress of the hot tearing that occurred at the hot spot were 1304 &deg, C and 0.72 MPa, respectively. The occurrence of hot tearing was observed at the tip of secondary dendrites along the primary dendritic arms, where the solute elements were significantly enriched at the final solidification.

How to utilize low grade complex iron resources is an issue that has attracted much attention due to the continuous and huge consumption of iron ores in China. High-aluminum iron ore is a refractory resource and is difficult to upgrade by separating iron and alumina. An innovative technology involving synergistic reducing and synergistic smelting a high-aluminum iron ore containing 41.92% Fetotal, 13.74% Al2O3, and 13.96% SiO2 with a high-manganese iron ore assaying 9.24% Mntotal is proposed. The synergistic reduction process is presented and its enhancing mechanism is discussed. The results show that the generation of hercynite (FeAl2O4) and fayalite (Fe2SiO4) leads to a low metallization degree of 66.49% of the high-aluminum iron ore. Over 90% of the metallization degree is obtained by synergistic reducing with 60% of the high-manganese iron ore. The mechanism of synergistic reduction can be described as follows: MnO from the high-manganese ore chemically combines with Fe2SiO4 and FeAl2O4 to generate Mn2SiO4, MnAl2O4 and FeO, resulting in higher activity of FeO, which can be reduced to Fe in a CO atmosphere. The main products of the synergistic reduction process consist of Fe, Mn2SiO4, and MnAl2O4.

Geometallurgy is an important addition to any evaluation project or mining operation. As an integrated approach, it establishes 3D models which enable the optimisation of net present value and effective orebody management, while minimising technical and operational risk to ultimately provide more resilient operations. Critically, through spatial identification of variability, it allows the development of strategies to mitigate the risks related to variability (e.g., collect additional data, revise the mine plan, adapt or change the process strategy, or engineer flexibility into the system). Geometallurgy promotes sustainable development when all stages of extraction are performed in an optimal manner from a technical, environmental, and social perspective. To achieve these goals, development of innovative technologies and approaches along the entire mine value chain are being established. Geometallurgy has been shown to intensify collaboration among operational stakeholders, creating an environment for sharing orebody knowledge and improving data acquisition and interpretation, leading to the integration of such data and knowledge into mine planning and scheduling. These aspects create better business optimisation and utilisation of staff, and lead to operations that are more resilient to both technical and non-technical variability. Geometallurgy encompasses activities that utilise improved understanding of the properties of ore and waste, which impact positively or negatively on the value of the product, concentrate, or metal. Properties not only include those that impact on processing efficiency, but also those of materials which will impact on other actions such as blasting and waste management. Companies that embrace the geometallurgical approach will benefit from increased net present value and shareholder value.

Pb&ndash, BHA complexes have been shown to be selective for the separation of tungsten and cassiterite minerals from calcium minerals. These minerals could be enriched synchronously to some extent using Pb&ndash, BHA complexes flotation. However, it is difficult to further improve the quality and recovery of the scheelite, wolframite, and cassiterite concentrate due to their different behavior in flotation, such as flotation rate and sensitivities to depressants. Moreover, the super fine particles create some challenges for the cleaning flotation process. In this study, advanced gravity separators for super fine particles were introduced for the cleaning process based on the slight difference in the specific gravity of scheelite, wolframite, and cassiterite. The new process featured pre-enrichment using Pb&ndash, BHA flotation, and upgrading using gravity separation, taking into account both the similarities and differences in floatability and density of the different minerals. The grades of WO3 and Sn in the concentrate of the new process reached to 61% and 2.89%, respectively, and the recovery of Sn was significantly improved. In addition, gravity separation is highly efficient, cost effective, and chemical-free, which is environmentally friendly. This study has proven that physical separation can be used for the purification of flotation products and provide some solutions for separation problems of complex refractory ores, which has, up until now, been rarely reported in the literature and/or applied in mineral processing.

Empirical systems for the classification of rock mass are used primarily for preliminary support design in tunneling. When applying the existing acceptable international systems for tunnel preliminary supports in high-stress environments, the tunneling quality index (Q) and the rock mass index (RMi) systems that are preferred over geomechanical classification due to the stress characterization parameters that are incorporated into the two systems. However, these two systems are not appropriate when applied in a location where the rock is jointed and experiencing high stresses. This paper empirically extends the application of the two systems to tunnel support design in excavations in such locations. Here, the rock mass characterizations and installed support data of six tunnel projects are used. The back-calculation approach is used to determine the Q value using the Q-system support chart, and these values are then used to develop the equations and charts to characterize the stress reduction factor (SRF), which is also numerically evaluated. These equations and charts reveal that the SRF is a function of relative block size, strength&ndash, stress ratio, and intact rock compressive strength. Furthermore, the RMi-suggested supports were heavier than the actual installed ones. If the approximate inverse relation between stress level (SL) and SRF is used, the difference between the actual and the recommended supports increases when using the RMi-recommended rock support chart for blocky ground. An alternate system is made for support recommendation using a Q-system support chart. In this system, the ground condition factor is modified from the available parameters, and a correlation is developed with a modified Q system.

To explore the feasibility of hot metal desulfurization using red mud, the sulfur distribution ratio (LS) between CaO-SiO2-Al2O3-Na2O-TiO2 slag and carbon-saturated iron is evaluated in this paper. First, the theoretical liquid areas of the CaO-SiO2-Al2O3 (-Na2O-TiO2) slag are discussed and the fluxing effects of Al2O3, Na2O, and TiO2 are confirmed. Then, LS is measured via slag-metal equilibrium experiments. The experimental results show that LS significantly increases with the increase of temperature, basicity, and Na2O content, whereas it decreases with the increase of Al2O3 and TiO2 content. Na2O in the slag will volatilize with high temperatures and reducing conditions. Furthermore, based on experimental data for the sulfur distribution ratio between CaO-SiO2-Al2O3-Na2O-TiO2 slag and the carbon-saturated iron, the following fitting formula is obtained: log L S = 45.584 &Lambda, + 10568.406 &minus, 17184.041 &Lambda, T &minus, 8.529

In this paper, the precipitation of carbide and wear loss of high-carbon 8 mass% Cr tool steel at two tempering conditions (i.e., 773⁻803 K and 823⁻853 K) were studied by INCA Steel, EPMA-1720H, XRD, and ML-10 tester. The results show that the particles of test steels include the carbides (Cr7C3 and Cr23C6) and carbides nucleated on Al2O3. When carbides are of the same size, the number of carbides in test steel at a tempering temperature of 773⁻803 K is greater than that at a tempering temperature of 823⁻853 K, especially when the size of carbides is less than 5 μm. Compared with the test steel tempered at 823⁻853 K, the distance between adjacent actual particles reduced by 80.6 μm and the maximum amount of reduction was 9.4% for single wear loss at the tempering temperature of 773⁻803 K. It can be concluded from thermodynamics results that Al2O3 inclusions began to precipitate in liquid, and the precipitation of carbides was at the solid⁻liquid region. Al2O3 can be used as the nucleation interface of carbide, thus promoting the formation of carbides. During the cooling of molten steel, a lower temperature can increase the difference of actual solubility product bigger than equilibrium solubility product, thus promoting the carbide formation.

The study addresses the effect of magnesium and other alloying elements on rolling “β-fiber” texture formation during hot deformation of aluminum alloys. For the study, flat cast ingots from three aluminum alloys with variable magnesium content were deformed in a Gleeble testing unit with different parameters of thermomechanical treatment. Immediately after completion of deformation, the samples were quenched using an automatic cooling system and the microstructure and crystalline texture was analyzed by optical microscopy and X-ray analysis. The analysis demonstrated that an increase in alloying components, magnesium in particular, leads to an increase in brass-type texture and a decrease in S and copper-type texture. The reason was that the simulation of the deformation texture development revealed a great contribution of impurity atoms rather than the decrease in stacking fault energy.

An investigation into the corrosion resistance of steels with various contents of carbon and microalloying elements was carried out. It was shown that the presence of a large amount of nanosized (2–3 nm and less) precipitates of the interphase type, particularly niobium carbonitride and vanadium carbonitride, leads to a decrease in the corrosion resistance of hot-rolled sheet products. It was found that, after heat treatment of rolled products at 710 °C, the corrosion resistance of the metal is improved. One of the reasons for this is a decrease in the amount of interphase precipitates, which negatively affect the corrosion resistance of steel, while particles formed in austenite and ferrite do not have such an effect. To ensure high corrosion resistance of steels for oil-field pipelines, microalloying with niobium instead of vanadium is advisable, as well as heat treatment at temperatures above 710 °C.

304 stainless steel is one of the most common stainless steels due to its excellent corrosion resistance and mechanical properties. Typically, a good balance between ductility and strength derives from deformation-induced martensite transformation (DIMT), but this mechanism has not been fully explained. In this study, we conducted in situ neutron diffraction measurements during the tensile deformation of commercial 304 stainless steel (at room temperature) by means of a Time-Of-Flight type neutron diffractometer, iMATERIA (BL20), at J-PARC MLF (Japan Proton Accelerator Research Complex, Materials and Life Science Experimental Facility), Japan. The fractions of &alpha, &prime, (BCC) and &epsilon, (HCP) martensite were quantitatively determined by Rietveld-texture analysis, as well as the anisotropic microstrains. The strain hardening behavior corresponded well to the microstrain development in the austenite phase. Hence, the authors concluded that the existence of martensite was not a direct cause of hardening, because the dominant austenite phase strengthened to equivalent values as in the martensite phase. Moreover, the transformation-induced plasticity (TRIP) mechanism in austenitic steels is different from that of low-alloy bainitic TRIP steels.

The production of clean steel is associated with high-quality steel grades for demanding applications. The formation of oxide inclusions mainly depends on the deoxidation practice, it is usually carried out through Al additions, but alumina inclusions can have detrimental effects. An alternative zirconium inclusion modification was used in a creep-resistant steel to improve the cleanliness of laboratory-made steel. The thermodynamics behind the inclusion modification are presented, the reaction products are identified and the steel cleanliness improvement is quantified. The resulting influence of zirconium addition on non-metallic inclusions and mechanical properties is discussed. While the Zr additions drastically reduce the non-metallic inclusion size and area, additions above a certain amount result in the formation of zirconium nitrides that ultimately soften the martensitic steel due to the depletion of nitrogen in solid solution.

In order to improve the cold rolled steel strip flatness, the load distribution of the tandem cold rolling process is subject to investigation and optimization. The strip deformation resistance model is corrected by an artificial neural network that is trained with the actual measured data of 4500 strip coils. Based on the model, a flatness prediction model of strip steel is established in a five-stand tandem cold rolling mill, and the precision of the flatness prediction model is verified by rolling experiment data. To analyze the effect of load distribution on flatness, the flatness of stand 4 is calculated to be 7.4 IU, 10.6 IU, and 16.8 IU under three typical load distribution modes. A genetic algorithm based on the excellent flatness is proposed to optimize the load distribution further. In the genetic algorithm, the classification of flatness of stand 4 calculated by the developed flatness prediction model is taken as the fitness function, with the optimal reduction of 28.6%, 34.6%, 27.3%, and 18.6% proposed for stands 1, 2, 3, and 4, respectively. The optimal solution is applied to a 1740 mm tandem cold rolling mill, which reduce the flatness classification from 10.8 IU to 3.2 IU for a 1-mm thick steel strip.

Bath temperature stability is a very important parameter with which to evaluate pot thermal balance. In this paper, a transient thermo-electric finite element model of reduction cell is established to simulate the fluctuation curve of bath temperature under different alumina feeding rates and different energy inputs. The model results show that short-term fluctuation of the temperature curve is influenced by different alumina feeding rate under underfeeding and overfeeding, but the long-term fluctuation depends on whether energy input matches average feeding rate. If the difference between energy input and heat consumed by alumina reaches the latter&rsquo, s 10%, the temperature changes about 1.8 &deg, C after four cycles. Based on model results, the paper analyzes the relationship among alumina feeding rate, bath temperature fluctuation and heat balance. The matching of heat input and heat consumed by alumina is of crucial importance to maintaining bath temperature stability.

In this study, oxidizing roasting, segregation roasting, and magnetic separation are used to extract cobalt and iron from refractory Co-bearing sulfur concentrate. The Co-bearing sulfur concentrate containing 0.68% Co, 33.26% Fe, and 36.58% S was obtained from V-Ti magnetite in the Panxi area of China by flotation. Cobalt pyrite and linneite were the Co-bearing minerals, and the gangue minerals were mica, chlorite, feldspar, and calcite in Co-bearing sulfur concentrate. The results show that cobalt is transformed from Co-pyrite and linneite to a Co2FeO4-dominated new cobalt mineral phase, and iron is transformed from pyrite to Fe2O3 and an Fe3O4-dominated new iron mineral phase after oxidizing roasting. Cobalt changed from CoFe2O4 to a new cobalt mineral phase dominated by [Co] Fe solid solution, and iron changed from Fe2O3 to a new iron mineral phase dominated by metal Fe and Fe3O4 after segregation roasting. Cobalt concentrate with a cobalt grade of 15.15%, iron content of 71.22%, and cobalt recovery of 90.81% as well as iron concentrate with iron grade of 60.06%, cobalt content of 0.11%, and iron recovery of 76.23% are obtained. The main minerals in the cobalt concentrate are Fe, [Co]Fe, Fe3O4, and SiO2, and the main minerals in the iron concentrate are Fe3O4, FeO, Ca2Si2O4, and Ca2Al2O4.

The impact of microsegregation models on thermophysical properties and solidification behaviors of a high strength steel was investigated. The examined microsegregation models include the classical equilibrium Lever rule, the extreme non-equilibrium Scheil-Gulliver, as well as other treatments in the intermediate regime proposed by Brody and Flemings, Clyne and Kurz, Kobayashi and Ohnaka. Based on the comparative analyses performed on three representative regions with varied secondary dendrite arm spacing sizes, the classical equilibrium Lever rule and non-equilibrium Scheil scheme were employed to determine the thermophysical features of the studied steel, using the experimentally verified models from literature. The evaluated thermophysical properties include effective thermal conductivity, specific heat capacity and density. The calculated thermophysical data were used for three-dimensional simulation of the casting and solidification process of a 40 metric ton steel ingot, using FEM code Thercast&reg, The simulations captured the full filling, the thermo-mechanical phenomena and macro-scale solute transport in the cast ingot. The results demonstrated that Lever rule turned out to be the most reasonable depiction of the physical behavior of steel in study in large-size cast ingot and appropriate for the relevant macrosegregation simulation study. The determination of the model was validated using the experimentally measured top cavity dimension, the thermal profiles on the mold outside surface by means of thermocouples, and the carbon distribution patterns via mass spectrometer analysis.

It is recognized recently that primary &ldquo, Chinese-script&rdquo, Nb(C,N) carbonitride is critical to the development of cast austenitic heat-resistant steels for ultra-high temperature applications. In this paper, the precipitation behavior of Nb(C,N) carbonitride in a novel creep and fatigue resistant steel was investigated by the use of the liquid metal cooling directional solidification (LMC-DS) method under different withdraw rates. Thermodynamic calculations were also performed to aid in the understanding of the solidification behavior. Microstructural characterization and thermodynamic calculation agreed that the alloy solidified in the path of primary austenite, eutectic Nb(C,N) carbonitride, and secondary ferrite, regardless of the withdraw rate. However, the primary and secondary dendrite arm spacing decreased significantly with an increase in the withdraw rate, and a quantitative relationship was established. Furthermore, the eutectic reaction range increased at a higher withdraw rate, due to the rapid increase of the solid phase fraction and the accumulation of solutes in the interdendritic liquid phase. This gave rise to a decline in the interlamellar spacing of primary Nb(C,N) carbonitride sheets and rods for the higher withdraw rate. Therefore, a fine &ldquo, Nb(C,N) carbonitride in this type of alloys can be achieved through increasing the withdraw rate or the cooling rate during casting.

Copper staves have been widely applied in large blast furnaces especially those whose inner volumes exceed 2000 m3 due to high cooling capacity. In the past decade, copper staves suffered severe damages in some blast furnaces, which not only shortened their campaign lives, but also caused huge economic losses. In order to make out this phenomenon, the damage mechanism of copper staves was investigated via analyzing the chemical composition, thermal conductivity, metallographic aspects and microstructure in this paper. As a result, the working state was more likely to damage copper staves instead of their materials. At the beginning, the poor quality of the coke and the large bosh angle promoted the development of edge airflow, which intensified the erosion of refractory materials, resulting in the fall-off of slag crusts and damage of cooling water pipes. After repair, the cooling capacity of copper staves still declined, causing the temperature to rise easily, consequently, hydrogen attack happened when the temperature reached 370 &deg, C, which degraded the performance of copper staves. Therefore, copper staves were worn too quickly to form slag crusts, which finally failed under the hydrogen attack and the scouring of the edge airflow at high temperatures.

Steels used for high-speed train wheels require a combination of high strength, toughness, and wear resistance. In 0.54% C-0.9% Si wheel steel, the addition of 0.075 or 0.12 wt % V can refine grains and increase the ferrite content and toughness, although the influence on the microstructure and toughness is complex and poorly understood. We investigated the effect of 0.03, 0.12, and 0.23 wt % V on the microstructure and mechanical properties of medium-carbon steels (0.54% C-0.9% Si) for train wheels. As the V content increased, the precipitation strengthening increased, whereas the grain refinement initially increased, and then it remained unchanged. The increase in strength and hardness was mainly due to V(C,N) precipitation strengthening. Increasing the V content to 0.12 wt % refined the austenite grain size and pearlite block size, and increased the density of high-angle ferrite boundaries and ferrite volume fraction. The grain refinement improved the impact toughness. However, the impact toughness then reduced as the V content was increased to 0.23 wt %, because grain refinement did not further increase, whereas precipitation strengthening and ferrite hardening occurred.

In this paper, the process of direct reduction roasting using magnetic separation to produce direct reduction iron (DRI) from high-phosphorus oolitic hematite, using coal slime and blast furnace dust as reductant, is investigated. The possible use of slime coal and blast furnace dust as reductant and the dephosphorization behavior during the process of direct reduction was studied. Experimental results showed that both blast furnace dust and coal slime can be used as reductant under certain conditions in the process. The dephosphorization mechanism of blast furnace dust and coal slime were investigated by X-ray diffraction (XRD) and scanning electron microscope (SEM)-energy dispersive X-ray spectroscopy (EDS). A DRI with 91.88 wt. % iron grade, 88.38% iron recovery and 0.072 wt. % P can be obtained with 30 wt. % blast furnace dust as reductant. The program not only used blast furnace dust but also recovered iron from blast furnace dust and high-phosphorus oolitic hematite. The analysis results revealed that phosphorus is distributed in gangue mineral and fluorapatite when blast furnace dust is used as reductant. Phosphorus-bearing minerals were not reduced to phosphorus element when the blast furnace dust was the reductant, but part of the fluorapatite reduced to phosphorus which smelt into metallic iron with coal slime as reductant. This led to a high phosphorus content of DRI. This research could provide support to the idea concept for recycling of carbon-containing solid waste and to assist the effective recovery of refractory iron ore by direct reduction&ndash, magnetic separation.

Minerals 8(12), 544 (2018). doi:10.3390/min8120544 special issue: "Special Issue "Marine Minerals of the Deep Sea: Mineralogy, Crystallography and Their Use for Tailored Processing and Metal Extraction" / Guest Editor Dr. Carsten Rühlemann, Dr. Thomas Kuhn Federal Institute of Geosciences and Natural Resources (BGR), Hannover, Germany", Published by MDPI, Basel

High content of gold in near-surface oxide zones above the gold ore deposit could be recovered using cyanidation. However, restricting the use of cyanide in mines has made it difficult to recover gold within the oxide zone. In this study, we investigated an application of the reductive microwave roasting and magnetic separation (RMR-MS) process for the effective gold recovery from ores in a near-surface oxide zone. Ore samples obtained from the near-surface oxide zone in Moisan Gold Mine (Haenam, South Korea) were used in RMR-MS tests for the recovery of iron and gold. The effect of the RMR process on the recovery of iron and gold was evaluated by given various conditions of the microwave irradiation as well as the dosages of reductant and additive. The microwave roasting resulted in a chemical reduction of non-magnetic iron oxide minerals (hematite) to magnetite minerals, such as magnetite and maghemite. This mineral phase change could induce the effective separation of iron minerals from the gangue minerals by magnetic separation process. The increased iron recovery was directly proportional to the gold recovery due to the coexistence of gold with iron minerals. The RMR-MS process could be a promising method for gold recovery from the ores in near-surface oxide zones.

Recently, increasing attention has been paid to alternative ironmaking processes due to the desire for sustainable development. Aiming to develop a new direct reduction technology, the paired straight hearth (PSH) furnace process, the carbothermic reduction of ore-coal composite pellets in a tall pellets bed was investigated at the lab-scale in the present work. The experimental results show that, under the present experimental conditions, when the height of the pellets bed is 80 mm (16&ndash, 18 mm each layer, and 5 layers), the optimal amount of carbon to add is C/O = 0.95. Addition of either more or less carbon does not benefit the production of high quality direct reduced iron (DRI). The longer reduction time (60 min) may result in more molten slag in the top layer of DRI, which does not benefit the actual operation. At 50 min, the metallization degree could be up to 85.24%. When the experiment was performed using 5 layers of pellets (about 80 mm in height) and at 50 min duration, the productivity of metallic iron could reach 55.41 kg-MFe/m2&middot, h (or 75.26 kg-DRI/m2&middot, h). Therefore, compared with a traditional shallow bed (one or two layers), the metallization degree and productivity of DRI can be effectively increased in a tall pellets bed. It should be pointed out that the pellets bed and the temperature should be increased simultaneously. The present investigation may give some guidance for the commercial development of the PSH process in the future.

This paper reports the recoveries of iron, chromium, and nickel from pickling sludge using coal-based smelting reduction. The influences of slag basicity (CaO/SiO2, which is controlled by high phosphorus oolitic hematite iron ores), reduction temperature, reduction time, and the C/O mole ratio on the recoveries of Fe, Cr, and Ni are investigated systematically. The experimental results show that high recoveries of Fe (98.91%), Cr (98.46%), and Ni (99.44%) are produced from pickling sludge with optimized parameters for the smelting reduction process. The optimized parameters are a slag basicity of 1.5, a reduction temperature of 1550 &deg, C, a reduction time of 90 min, and a C/O mole ratio of 2.0. These parameters can be used as technical support for the recycling of pickling sludge with pyrometallurgy.

The influencing factors of ammonia content and centrifugal speed on ammonium rhenate recovery from waste superalloy were systematically analyzed. It was found that proper ammonia content and centrifugal speed could promote crystal growth and a higher purity of ammonium rhenate was obtained. Moreover, the XRD patterns showed that excessive ammonia content and inappropriate centrifugal speed restrained the growth of (101) crystal plane and (112) crystal plane, which caused the crystal structural regularity and relative crystallinity to attenuate. The microscopic morphology and purity of the crystal also changed.

Modern steel plants produce today a large portfolio of various steel grades, many for end-uses demanding high quality. In order to utilize the maximum productivity of the continuous-casting machine, it is sometimes necessary to cast steel grades with different chemical compositions in one sequence. It is important, therefore, to know the possibilities of a specific continuous-casting machine to make the Intermix connections as short as possible. Any interference with established procedures may, however, have a negative impact on the cleanliness of the cast steel. Using physical and numerical simulation tools, it was found that reducing the steel level in the tundish during the exchange of ladles makes it possible to shorten the transition zone. However, when the steel level is reduced, the flow of steel is impaired, which can have a negative effect on the cleanliness of the cast steel and, in extreme cases, may even lead to entrapment of slag in the mold. The cleanliness of cast steel was evaluated using one of the most advanced tools for automatic steel cleanliness evaluation, AZtecFeature (Oxford Instruments, Abingdon, UK), which enables determination of the type, size, distribution, and shape, as well as the chemical composition, of individual types of non-metal inclusions.

This paper presents results of tests performed to determine the minimum concentration of a surfactant used at which the probability of occurrence of coalescence of air bubbles during flotation is low. Tests of the coalescence phenomenon were carried out using selected flotation frothing agents such as poly(ethylene glycol) butyl ethers, which are the ingredients of industrial flotation frothers known under the brand name of CORFLOT. Studies were carried out for three successive butyl ethers in the homologous series: ethylene glycol butyl ether (C4E1), diethylene glycol butyl ether (C4E2), triethylene glycol butyl ether (C4E3). Critical coalescence concentration (CCC) surfactant values were determined using the linear regression method. The investigation proved the existence of a clear relationship between the number of ethylene glycol groups in the ether molecule CnH2n+2(OC2O5)nOH and the value of the CCC. The results obtained show a correlation between the CCC values and the molecular weights (MW) of the tested frothers. This article shows the relationship between CCC value and hydrophilic&ndash, lipophilic balance (HLB)/MW for the family of polyglycol ethers. Results show the correlation between the critical coalescence concentration and the value of HLB index, being the measure of hydrophilic&ndash, lipophilic balance of surfactants (such as flotation frothers), expressed by the weight ratio of hydrophilic portion of the surfactant molecule and its molecular weight. Histograms of air bubbles created a distribution curve similar to the Gauss distribution pattern. The average diameter of air bubbles tends to decrease along with increasing concentration of the tested surfactants. Two characteristic zones that may be distinguished on the graphs show the relationship between Sauter mean diameter and frother concentration. The tests carried out demonstrate that the critical coalescence concentration may be used to characterize the flotation process, as, knowing the CCC values of the frothers used, we are able to control the consumption of foaming agents during mineral processing.

Ceria is the main component in glass polishing powders due to its special physico-chemical properties. Glass polishing powder loses its polishing ability gradually during usage due to the accumulation of other compounds on the polishing powder or due to changes in the particle size distribution. The recovery of cerium from the glass polishing waste results in the efficient utilization of natural resources. This paper reviews processes for the recovery of rare earths from polishing waste. Glass polishing powder waste can be reused via physical, physico-chemical or chemical processes by removing silica and/or alumina. The removal of silica and/or alumina only improves the life span up to some extent. Therefore, removal of other elements by chemical processes is required to recover a cerium or cerium-rich product. However, cerium leaching from the polishing waste is challenging due to the difficulties associated with the dissolution of ceria. Therefore, high acid concentrations, high temperatures or costly reducing agents are required for cerium dissolution. After leaching, cerium can be extracted from the leach solution by solvent extraction or selective precipitation. The product can be used either in glass polishing again or other high value added applications.

The valuable minerals in copper-nickel sulfide ore can easily be oxidized, leading to the reduction of their flotation recovery and a difficulty in separating them from gangue. In order to solve the problem, the reaction mechanism of the octanohydroxamic acid (OHA) on oxidized pyrrhotite was revealed through micro-flotation, adsorption tests, zeta potential measurements, and X-ray photoelectron spectroscopy (XPS) analysis. The results show that this is a feasible way to find a suitable collector that can directly react to oxidation products on the surface of pyrrhotite. OHA can efficiently reclaim oxidized pyrrhotite and achieve the selective separation of a pyrrhotite-serpentine mixture in a weak alkaline environment. The adsorption tests, zeta potential measurements, and XPS analyses show that OHA can interact with an oxidized pyrrhotite surface, and the interaction between OHA and serpentine is very weak. The XPS analyses indicate that the OHA collector can chelate with Fe(OH)3 on the surface of oxidized pyrrhotite and form an &ldquo, O, O&rdquo, five-ring chelate. At the same time, the OHA collector may compete with the hydroxyl groups of hydrophilic substances on the mineral surface to produce hydrophobic products and reduce the hydrophilic substances on the mineral surface.

The fine phase transformation process of chalcocite (Cu2S) leaching in acidic ferric sulfate solution was studied by leaching experiments and synchrotron radiation X-ray diffraction (SRXRD) tests. The results showed that the dissolution process of chalcocite was divided into two stages. In the first stage, Cu2S was firstly transformed to Cu5FeS4 and Cu2&minus, xS, then the galvanic effect between Cu5FeS4 and Cu2&minus, xS accelerated the dissolution process of Cu1.8S &rarr, Cu1.6S &rarr, CuS, and finally Cu5FeS4 was also transformed to CuS. While in the second stage, CuS was transformed to elemental sulfur, which formed the passivation layer and inhibited the leaching of chalcocite. Specifically, Cu5FeS4 was detected during the chalcocite leaching process by SRXRD for the first time. This research is helpful for revealing the detailed leaching process of chalcocite.

We elucidate here the determining role of Nb interlayer on mechanical properties of Ti/steel clad plate fabricated by vacuum rolling cladding (VRC) as a function of different heating temperatures. A critical analysis on the clad interface via electron probe micro-analyzer, X-ray diffractometer and shear testing were conducted to investigate the influence of TiC, Fe-Nb and TiFe compounds and Nb-Ti solid solution on microstructural evolution and shear properties of Ti/steel clad plate. The inter-diffusion between Ti, C and Fe was effectively restrained by adding the Nb interlayer at heating temperature of 800 &deg, C, and average shear strength of 279 MPa was achieved. With increase of heating temperature, Nb-Ti solid solution was formed at the Ti/Nb interface, which reduced mechanical properties of clad plate at 900 &deg, C. At 1000 &deg, C, TiC and Nb-Fe compounds and Nb-Ti solid solution were formed at the interface, and minimum average shear strength of 152 MPa was achieved. The detailed analysis on the clad interface suggested that ideal shear strength can be obtained through the addition of Nb interlayer and selecting appropriate heating temperature.

Refinement of as-cast structures is one of the most effective approaches to improve mechanical properties, formability, and surface quality of steel castings and ingots. In the past few decades, addition of rare earths (REs), lanthanum and cerium in particular, has been considered as a practical and effective method to refine the as-cast steels. However, previous reports contained inconsistent, sometime even contradictory, results. This review summaries the major published results on investigation of the roles of lanthanum or/and cerium in various steels, provides reviews on the similarity and difference of previous studies, and clarifies the inconsistent results. The proposed mechanisms of grain refinement by the addition of lanthanum or/and cerium are also reviewed. It is concluded that the grain refinement of steels by RE additions is attributed to either heterogeneous nucleation on the in-situ formed RE inclusions, a solute effect, or the combined effect of both. The models/theories for evaluation of heterogeneous nucleation potency and for solute effect on grain refinement of cast metals are also briefly summarized.

The characteristics and formation mechanisms of intragranular acicular ferrite (IAF) in steel with MgO nanoparticle additions were systematically investigated for different isothermal heat-treatment temperatures, and its influence on mechanical properties was also clarified. The results indicate that the inclusions were finely dispersed and refined after adding MgO nanoparticles. In addition, with decreasing heat-treatment temperature, the microstructure changed from grain boundary ferrite (GBF) and polygonal ferrite (PF) to intragranular acicular ferrite. Moreover, the steel with MgO additions had excellent mechanical properties in the temperature range of 973 to 823 K and an average Charpy absorbed energies value of around 174 J at 873 K due to the significant refinement of the microstructure and nucleation of intragranular acicular ferrite.

Understanding the changes of a mineral during ore processing is of capital importance for the development of strategies aimed at increasing the efficiency of metal extraction. This task is often difficult due to the variability of the ore in terms of composition, mineralogy and texture. In particular, surface processes such as metal re-adsorption (preg-robbing) on specific minerals are difficult to evaluate, even though they may be of importance as the re-adsorbed material can be blocking the valuable mineral and negatively affect the extraction process. Here, we show a simple yet powerful approach, through which surface processes in individual minerals are identified by combining polarization microscopy (MP) and X-ray photoelectron spectroscopy (XPS). Taking as an example a silver-containing polymetallic sulfide ore from the Peruvian central Andes (pyrite-based with small amounts of galena), we track the changes in the sample during the course of cyanidation. While polarization microscopy is instrumental for identifying mineralogical species, XPS provides evidence of the re-adsorption of lead on a pyrite surface, possibly as lead oxide/hydroxide. The surface of pyrite does not show significant changes after the leaching process according to the microscopic results, although forms of oxidized iron are detected together with the re-adsorption of lead by XPS. Galena, embedded in pyrite, dissolves during cyanide leaching, as evidenced by PM and by the decrease of XPS signals at the positions associated with sulfide and sulfate. At the same time, the rise of a lead peak at a different position confirms that the re-adsorbed lead species cannot be sulfides or sulfates. Interestingly, lead is not detected on covellite surfaces during leaching, which shows that lead re-adsorption is a process that depends on the nature of the mineral. The methodology shown here is a tool of significant importance for understanding complex surface processes affecting various minerals during metal extraction.

Nb&ndash, Mo low-alloyed steels are promising advanced high strength steels (AHSS) because of the highly dislocated bainitic ferrite microstructure conferring an excellent combination of strength and toughness. In this study, the potential of precipitation strengthening during coiling for hot-strip Nb&ndash, Mo-bearing low-carbon steels has been investigated using hot-torsion and aging tests to simulate the hot-rolling process including coiling. The obtained microstructures were characterized using electron backscatter diffraction (EBSD), highlighting the effects of Nb and Mo additions on formation and tempering of the bainitic ferrite microstructures. Further, the evolution of nanometer-sized precipitates was quantified with high-resolution transmission electron microscopy (HR-TEM). The resulting age hardening kinetics have been modelled by combining a phenomenological precipitation strengthening model with a tempering model. Analysis of the model suggests a narrower coiling temperature window to maximize the precipitation strengthening potential in bainite/ferrite high strength low-alloyed (HSLA) steels than that for conventional HSLA steels with polygonal ferrite/pearlite microstructures.

The refining process is one of the essential stages of aluminum production. Its main aim is to remove hydrogen, that causes porosity and weakens the mechanical and physical properties of casting aluminum. The process is mainly conducted by purging inert gas through the liquid metal, using rotary impellers. The geometry of the impellers and the processing parameters, such as flow rate of gas and rotary impeller speed, influence the gas dispersion level, and therefore the efficiency of the process. Improving the process, and optimization of parameters, can be done by physical modelling. In this paper, the research was carried out with the use of a water model of batch reactor, testing three different rotary impellers. Varied methods were used: visualization, which can help to evaluate the level of dispersion of gas bubbles in liquid metal, determination of residence time distribution (RTD) curves, which was obtained by measuring the conductivity of NaCl tracer in the fluid, and indirect studies, completed by measuring the content of dissolved oxygen in water to simulate hydrogen desorption. The research was carried out for different processing parameters, such as flow rate of refining gas (5&ndash, 25 L&middot, min&minus, 1) and rotary impeller speed (3.33&ndash, 8.33 s&minus, 1). The obtained results were presented graphically and discussed in detail.

High reactivity coke is beneficial for achieving low carbon emission blast furnace ironmaking. Therefore, the preparation of highly reactive ferro-coke has aroused widespread attention. However, the effects of the particle size of iron ore on the pyrolysis behaviour of a coal-iron ore briquette are still unclear. In this study, the effect of three particle sizes (0.50–1.00 mm, 0.25–0.50 mm and

Adhesion plays an important role in bacterial dissolution of metal sulfides, since the attached cells initiate the dissolution. In addition, biofilms, forming after bacterial attachment, enhance the dissolution. In this study, interactions between initial adhesion force, attachment behavior and copper recovery were comparatively analyzed for Acidithiobacillus ferrooxidans, Acidithiobacillus thiooxidans, and Leptospirillum ferrooxidans during bioleaching of chalcopyrite. The adhesion forces between bacteria and minerals were measured by atomic force microscopy (AFM). L. ferrooxidans had the largest adhesion force and attached best to chalcopyrite, while A. ferrooxidans exhibited the highest bioleaching of chalcopyrite. The results suggest that the biofilm formation, rather than the initial adhesion, is positively correlated with bioleaching efficiency.

Arsenopyrite is a common sulphide mineral occurring in deposits of gold ore that makes the extraction of gold difficult and, thus, pre-treatment is necessary prior to gold leaching. Bioleaching pre-treatment of arsenopyrite has drawn significant attention owing to its environmental friendliness, low cost and simple operation. A critical impedance of bioleaching to its large-scale industrial application is the slow leaching kinetics. Various passivating products on the surface of arsenopyrite have been found to limit the bioleaching process. This paper reports results from an in-depth investigation into the formation process of passivating products from arsenopyrite bioleaching by Acidithiobacillus ferrooxidans in 9K culture medium including bioleaching experiments and physicochemical analyses of the materials as well as thermodynamic analyses of the leaching system. The results of phase transformation and morphological change of the solid products suggest that the passivation occurring in the bioleaching of arsenopyrite is largely attributed to an initially formed passivating film consisting mainly of realgar (As2S2), orpiment (As2S3) and elemental sulphur (S0) on the arsenopyrite surface. Based on the results, the paper also proposes possible passivation mechanisms to allow for a better understanding on the passivation behaviour of the bioleaching of arsenopyrite.

Trialkylamine (N235)-tributyl phosphate (TBP) impregnated resins (N-TIRs) were prepared, so as to evaluate the effects of the addition of TBP on the preparation and adsorption performance of N235-impregnated resins (NIRs). The results show that TBP can obviously increase the impregnation ratio and shorten the impregnation equilibrium time of the N-TIRs when compared to that of the NIRs (57.73% versus 36.95% and 5 min versus 240 min). It is confirmed that TBP can interact with N235 during the impregnation process, which shorten the adsorption equilibrium time and increases the adsorption capacity of the N-TIRs for V(V) when compared to that of the NIRs (6 h versus 10 h and 50.95 mg&middot, g&minus, 1 versus 46.73 mg&middot, 1). The kinetics fitting results demonstrate that the adsorption of V(V) onto N-TIRs and NIRs all conform to pseudo-second order kinetic model and chemical reaction is the rate-limiting step of the whole adsorption process. In the meanwhile, the reaction constant (Ks) implies that the chemical reaction rate of V(V) with the impregnated extractants in N-TIRs is faster than that in NIRs. The N-TIRs present higher stability and selectivity than NIRs. This study manifests that the addition of a secondary reagent may be a potential and novel technique on the preparation of SIRs and the enhancement of adsorption and separation for ions.