Metallurgical and Materials Engineering (E-Journal)
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Algorithm for quantifying the particle size distribution of non-metallic inclusions formation in steel production
Get PDFWhen the quantitative characterization of non-metallic inclusions in steel is done and the effect of limiting factors is assessed, and based on that the possibility of reconstruction of the total content of non-metallic inclusions in steel is estimated, further considerations can be directed towards predicting the model of size distribution curve. The aim of this work is to establish relations on the basis of which it will be possible to quantify the content of non-metallic inclusions in extra-pure steels, when metallographic control is difficult or even impossible by routine procedures
Experimental Study of Fatigue Durability in Bending Effect on Welded Joints in Steel Profiles
Get PDFShips are always prone to fatigue through high periodic loads, usually caused by waves and changing load conditions. So, fatigue is an important factor in design. One of the reasons for fatigue in welding parts is variable bending loads. In this paper, a specimen of low-carbon steel T-Bar profiles is used, along with plates of the same type of steel that have been welded by the manual electrode welding process. To determine the distribution of static and dynamic forces created by welding, the specimens were subjected to bending (three-point loading) and tensile tests, and finally fatigue tests. The T-Bar Steel profile has more tolerance for fatigue loads than welded. The load T-Bar profile has not failed until the two million cycles, while the welding specimen has failed in about 3×105 cycles. Finally, strong penetrating welds should be used if a stronger welding joint is required
Simultaneous optimization of machine and tool parameters for EDM using WC/Co P/M electrode made with micron and nano sized particles
Get PDFMulti-response characteristic optimization is the most desired aspect of the components produced from electric discharge machining (EDM). Obtaining the optimal combination of parameters for surface roughness (SR) and micro-hardness (MH) is always a challenging task as the machining parameters favourable to one performance measure adversely affects the other. The present paper deals with the simultaneous optimization of SR and MH of D2 alloy steel during EDM with tungsten carbide (WC)/cobalt (Co) P/M electrode by considering electrode and machine tool parameters. Experimental run order was planned with Taguchi’s orthogonal arrays (OA) and in the present investigation, it is based on L18 OA. The analysis of variance (ANOVA) performed for the grey relational grade (GRG) showed that the tool parameter "particle size" (PS) is the most influential factor (61.43%) for simultaneous improvement of performance measures. The P/M electrode made of fine particle size (i.e., at nano level) has improved the process stability and reduced the arcing and short-circuiting results in reduced surface roughness. Simultaneously, the formation of the hard intermetallic phase’s viz., Fe3C, Cr23C6, W2C, Fe6W6C, and Cr2Fe14C on the EDMed surface has increased the surface hardness. The optimal set of parameters was validated through confirmation experiments
Tensile and flexural behaviour of graphite filler particles and pineapple leaf fiber (palf) reinforced polymer composites
Get PDFNew composites materials are developed to meet the demand for medical devices, vehicles, protective equipment, sporting goods, etc. In present investigations, the effects of graphite filler particles in the epoxy were studied separately by preparing epoxy with 5 and 10 vol.% of graphite filler particles composites by hand layup technique. Further, the combined effect of graphite filler particles and pineapple leaf fibers (PALF) on the mechanical behaviour of epoxy composites was studied by preparing epoxy with 5 vol.% of graphite -30 vol.% of PALF and epoxy with 10 vol.% of graphite -30 vol.% of PALF composites. Prepared composites were subjected to evaluating various mechanical properties like tensile strength, elongation, and flexural strength as per ASTM standards. By adding graphite filler particles and PALF fibers tensile, and flexural strength were improved with a slight reduction in the percentage elongation. Further, these conventional results were validated by FEM analysis using MSC Patran and Nastran Student Version
Application of thermal analysis in ferrous and nonferrous foundries
Get PDFThis paper is devoted to the memory of Professor Ljubomir Nedeljkovic (1933-2020), Head of the Department of Iron and Steel Metallurgy University of Belgrade, Serbia. Assessment of the melt quality is one of the most important casting process parameters, which allowed sound production of intricated cast parts. At the present time, various devices have been applied at foundry floors to control melt quality. Thermal analysis is one of them, widely used for melt quality control in ferrous and non-ferrous casting plants. During solidification, metal and alloys released latent heat, which magnitude is dependent on the type of phases that form during the solidification process. Plotting temperature versus time data during solidification provides useful information related to the actual solidification process. The applied technique is called thermal analysis, whereas the cooling curve is the name of such a plot. The main aim of this paper is to give a short overview of the present thermal analysis application in various foundries and to indicate the future potential use of this technique
Static-dynamic model for endpoint control used in Smederevo's BOF shop
Get PDFThis paper describes the computer model for BOF control that was in use at Smederevo, Serbia, during the period 1994-2006. The model was developed at the Institute of Metallurgy of the Smederevo Steelwork in mid-1994 and was motivated by the fact that the plant in Smederevo, by that time, had many years of experience in endpoint control using Intermediate Stop Practice (ISP). The vision for the model was to continuously improve and adapt to the working conditions of production through self-learning and adjustments. The model belongs to the well-known family of Static-Dynamic models (SDMs). It is aimed to reduce the "oxygen off-to-start tap" time and thus increase productivity and reduce production costs. The paper briefly describes the metallurgical software, operator operations and provides some information on the model's effectiveness
Comprehensive study of the effect of hot-dipping process parameters on Sn-Sb coating properties for α-brass substrate
Get PDFThis study's main purpose is to achieve an optimal hot-dip coating condition of Sn-Sb for an α-brass alloy. Therefore, the hot-dipping parameters, including pre-flux lubricants, immersion temperature, time, and withdrawal speed were investigated. ZnCl2 and SnCl2 were used as pre-flux bath additives. The temperature of the immersion bath was selected to be in the range of 250-300 °C. Also, the exposing time and withdrawal speed of the specimens during the hot-dipping process were in the range of 10-60 sec and 254-1524 mm/min, respectively. Visual inspection of the coating revealed that by using SnCl2 as a pre-flux additive, high-quality smooth coating is achieved. According to the AFM result, the initial roughness value of the substrate was 450 nm. The coating's roughness value with SnCl2 and SnCl2+ZnCl2 pre-fluxes were in the range of 300-500 and 700-900 nm, respectively. Therefore, ZnCl2 pre-flux is associated with a rougher surface. Corrosion test analysis revealed that both coating condition with different pre-fluxes leads to increasing corrosion resistance however better improvement in corrosion behavior is accomplished by smooth coating surface. The quantitative analysis of the polarization curve revealed that the corrosion rate of the smooth coating is decreased 7-12.5 times in comparison with the substrate. According to the SEM analysis, the predominant phases which were appeared at the interface of the coating and substrate were Cu3Sn and Cu6Sn5. SEM analysis revealed that the Cu3Sn intermetallic compound was this first phase, which was promoted near to the substrate vicinity during the hot-dipping process
Synthesis of holmium orthoferrite nanoparticles by the co-precipitation method at high temperature
Get PDFHolmium orthoferrite HoFeO3 nanoparticles were synthesized by a simple co-precipitation method via the hydrolysis of Ho (III) and Fe (III) cations in boiling water with 5% aqueous ammonia solution. After annealing the precipitate at 750 and 850 °C for 1 hour, the single-phase HoFeO3 product formed with particle size < 50 nm. The synthesized nanopowders are paramagnetic materials with remanent magnetization Mr < 0.01 emu ·g-1, the coercive force Hc = 20÷21 Oe, and magnetization Ms ~ 2.73 emu ·g-1 at 300 K in a maximum field of 16,000 Oe
Some advanced welding technologies applied for repair welding in power plants
Get PDFSteels are subjected to many time-dependent degradation mechanisms when they are applied in electric power plants. They are exposed to high temperatures, multi-axial stresses, creep, fatigue, corrosion, and abrasion during such services. Used under these threatening conditions, those materials could develop various damages or failures or even form cracks. Therefore, it is desirable to prevent in-service failures, improve reliability, and extend the plant's operational life. The efficiency of the electric power plant, among other processes, depends on effective maintenance. The paper presents the evaluation of advanced procedures and knowledge in the field of steel repair welding in the maintenance of the power plants. Most repair welding of low alloy steels requires high-temperature post-weld heat treatment (PWHT), but in certain repairs, however, this is not always possible. Application of the nickel-based filler metal could also be an alternative to performing post-weld heat treatment (PWHT). The repair work expenses could be reduced if the repair is performed on-site. The novel developed repair welding procedures presented in this paper were applied for emergency weld repairing of the steel pipelines in thermal power plant, repairing without disassembling the working wheel of the coal mill in thermal power plant and "on-site" repairing turbine shaft of the hydropower plant. For all the presented repair welding procedures, weldability analysis based on the analytical equations and technological ''CTS'' and ''Y'' tests to determine the sensitivity to cold and hot crack forming were applied. Tensile tests, absorbed energies tests, banding tests, and hardness measurements were performed on trial joints, which were used to develop and verify the applied methodologies. Presented advanced weld repair technologies enable repairs for a shorter time and at lower costs compared to conventional procedures
Effect of SEN immersion depth on mold flow profile and slag entrapment during continuous casting of steel
Get PDFMold flux entrapment during continuous casting of steel contributes to both surface and sub-surface defects in the final product. Continuous casting operating parameters such as casting speed, SEN immersion depth, SEN port geometry, argon flow, and mold EMS significantly affect the mold flow conditions and flow profile. During continuous casting operation, SEN immersion depth is continuously varied to avoid localized erosion of SEN, and it impacts the flow dynamics in the mold. In the present work, water modeling studies were carried out for a wide range of mold widths (1200-1800 mm) and casting speeds (0.8-1.4 m/min) on a 0.5 scaled down water model to optimize casting speed for different combinations of SEN immersion depth and mold width. Results from water modeling were further validated using nail board studies in the actual plant. A safe operating matrix was identified from these experiments to avoid mold slag entrapment during continuous casting