Search Results (13,940)

Widely employed in diverse engineering applications, stiffened steel plates are often subjected to biaxial compressive loads. Under these conditions, buckling may occur, initially within the elastic range but potentially progressing into the elasto-plastic domain, which can lead to permanent deformations or structural collapse. To increase the ultimate buckling stress of plates, the implementation of longitudinal and transverse stiffeners is effective; however, this complexity makes analytical stress calculations challenging. As a result, numerical methods like the Finite Element Method (FEM) are attractive alternatives. In this study, the Constructal Design method and the Exhaustive Search technique were employed and associated with the FEM to optimize the geometric configuration of stiffened plates. A steel plate without stiffeners was considered, and 30% of its volume was redistributed into stiffeners, creating multiple configuration scenarios. The objective was to investigate how different arrangements and geometries of stiffeners affect the ultimate buckling stress under biaxial compressive loading. Among the configurations evaluated, the optimal design featured four longitudinal and two transverse stiffeners, with a height-to-thickness ratio of 4.80. This configuration significantly improved the performance, achieving an ultimate buckling stress 472% higher than the unstiffened reference plate. In contrast, the worst stiffened configuration led to a 57% reduction in performance, showing that not all stiffening strategies are beneficial. These results demonstrate that geometric optimization of stiffeners can significantly enhance the structural performance of steel plates under biaxial compression, even without increasing material usage. The approach also revealed that intermediate slenderness values lead to better stress distribution and delayed local buckling. Therefore, the methodology adopted in this work provides a practical and effective tool for the design of more efficient stiffened plates. Full article

In the process of producing ferroalloys, a large amount of secondary raw materials is formed, including slag, aspiration dusts and sludge. The recycling of secondary raw materials can create resources and bring environmental and economic benefits. Wet secondary raw materials (WSRMs) are characterized by a high chromium oxide content (averaging 24%), but due to their high moisture levels, they cannot be directly used in arc furnaces. As a strategic approach, mixing WSRMs with drier, more chromium-rich dusts (up to 45% Cr₂O₃) has been proposed. This not only reduces the overall moisture content of the mixture but also enhances the metallurgical value of the charge material. This paper presents the results of laboratory studies on the agglomeration of secondary wet raw materials using briquetting, extrusion and pelletizing methods. The main factors influencing the quality of the resulting product were analyzed, including the method of agglomeration, the composition of the mixture, as well as the type and dosage of the binder component. The strength characteristics of the finished agglomerated samples were evaluated in terms of resistance to splitting, impact loads and falling. Notably, the selected binders are organic and polymer substances capable of complete combustion under metallurgical smelting conditions. Full article

This study investigates the hot deformation behaviour and flow stress prediction of metastable β-Ti-15Mo alloy, a promising material for biomedical applications requiring strength–modulus optimisation and thermomechanical tunability. Isothermal compression tests were performed within the temperature range of 923–1173 K and at strain rates of 0.17, 1.72, and 17.2 ${\mathrm{s}}^{-1}$ to assess the material’s response under industrially relevant hot working conditions. The alloy showed significant sensitivity to temperature and strain rate, with dynamic recovery (DRV) and dynamic recrystallisation (DRX) dominating the softening behaviour depending on the conditions. A strain-compensated Arrhenius-type constitutive model was developed and validated, resulting in an apparent activation energy of approximately 234 kJ/mol. Zener–Hollomon parameter analysis confirmed a transition in deformation mechanisms. Although microstructural and diffraction data suggest possible contributions from nanoscale phase transformations, including ω-phase dissolution at high temperatures, these aspects remain to be fully elucidated. The model offers reliable predictions of flow behaviour and supports optimisation of thermomechanical processing routes for biomedical β-Ti alloys. Full article

The increasing depletion of high-grade nickel sulfide deposits and the growing demand for nickel have intensified global interest in oxidized nickel ores (ONOs), particularly those located in Kazakhstan. This study presents a comprehensive review of the mineralogical and chemical characteristics of ONOs from the Shevchenkovskoye cobalt–nickel ore deposit and other Kazakhstan deposits, highlighting the challenges they pose for conventional beneficiation and metallurgical processing. Current industrial practices are analyzed, including pyrometallurgical, hydrometallurgical, and pyro-hydrometallurgical methods, with an emphasis on their efficiency, environmental impact, and economic feasibility. Special attention is given to the potential of hydro-catalytic leaching as a flexible, energy-efficient alternative for treating low-grade ONOs under atmospheric conditions. The results underscore the necessity of developing cost-effective and sustainable technologies tailored to the unique composition of Kazakhstani ONOs, particularly those rich in iron and magnesium. This work provides a strategic framework for future research and the industrial application of advanced leaching techniques to unlock the full potential of Kazakhstan’s nickel resources. Full article

In the present paper, impedance spectroscopy was employed to study the corrosion and anodic oxidation of stainless steel (AISI 316L at 280 °C/9 MPa) in contact with the boron-free primary coolant of a small modular reactor at two levels of KOH concentration. Analysis of impedance spectra with a distribution of relaxation times revealed contributions from the oxide layer and its interface with the coolant. Glow-Discharge Optical Emission Spectroscopy (GDOES) was used to estimate the thickness and elemental composition of the formed oxides. A quantitative interpretation of the impedance data using the Mixed-Conduction Model allowed us to estimate the kinetic and transport parameters of oxide growth and dissolution, as well as iron dissolution through oxide. The film thicknesses following exposure agreed with ex-situ analyses. The obtained corrosion and release rates were used for comparison with laboratory and industrial data in nominal pressurized water reactor primary coolants. Full article

To address the critical challenge of synergistically enhancing both high-temperature mechanical properties and thermal conductivity in neutron-absorbing materials for dry storage of spent nuclear fuel, this study proposes an innovative strategy. This approach involves the controlled distribution, size, and crystalline states of nano-Al₂O₃ within an aluminum matrix. By combining plastic deformation and heat treatment, we aim to achieve a structurally integrated functional design. A systematic investigation was conducted on the microstructural evolution of Al₂O₃/10 wt.% B₄C/Al composites in their forged, extruded, and heat-treated states. We also examined how these states affect high-temperature mechanical properties and thermal conductivity. The results indicate that applying hot extrusion deformation along with optimized heat treatment parameters (500 °C for 24 h) allows for a lamellar dispersion of nano-Al₂O₃ and a crystallographic transition from amorphous to γ-phase. As a result, the composite demonstrates a tensile strength of 144 MPa and an enhanced thermal conductivity of 181 W/(m·K) at 350 °C. These findings provide theoretical insights and technical support for ensuring the high density and long-term safety of spent fuel storage materials. Full article

The dispersion behavior of ceramic particles in aluminum alloys during rapid solidification critically affects the resulting microstructure and mechanical performance. In this study, we investigated the nucleation and growth of Al₃(Sc,Zr) on TiB₂ surfaces in a 2TiB₂/Al–8Ni–0.6Sc–0.1Zr alloy, fabricated via wedge-shaped copper mold casting and laser surface remelting. Thermodynamic calculations were employed to optimize alloy composition, ensuring sufficient nucleation driving force under rapid solidification conditions. The results show that the formation of Al₃(Sc,Zr)/TiB₂ composite interfaces is highly dependent on cooling rate and plays a pivotal role in promoting uniform TiB₂ dispersion. At an optimal cooling rate (~1200 °C/s), Al₃(Sc,Zr) nucleates heterogeneously on TiB₂, forming core–shell structures and enhancing particle engulfment into the α-Al matrix. Orientation relationship analysis reveals a preferred (111)α-Al//(0001)TiB₂ alignment in Sc/Zr-containing samples. A classical nucleation model quantitatively explains the observed trends and reveals the critical cooling-rate window for composite interface formation. This work provides a mechanistic foundation for designing high-performance aluminum-based composites with uniformly dispersed reinforcements for additive manufacturing applications. Full article

As the use of data models and data science techniques in industrial processes grows exponentially, the question arises: to what extent can these techniques impact the future of manufacturing processes? This article examines the potential future impacts of these models based on an assessment of existing trends and practices. The drive towards digital-oriented manufacturing and cyber-based process optimization and control has brought many opportunities and challenges. On one hand, issues of data acquisition, handling, and quality for proper database building have become important subjects. On the other hand, the reliable utilization of this available data for optimization and control has inspired much research. This research work discusses the fundamental question of how far these models can help design and/or improve existing processes, highlighting their limitations and challenges. Furthermore, it reviews state-of-the-art practices and their successes and failures in material process applications, including casting, extrusion, and additive manufacturing (AM), and presents some quantitative indications. Full article

Improving the corrosion resistance of magnesium (Mg) alloys is a long-term challenge, especially when cost-effectiveness is taken into account. In this work, Mg-1Bi and Mg-1Sn extruded alloys are prepared, and the effects of cost-effective Bi and Sn on the corrosion behavior of Mg alloys are comparatively studied. The corrosion resistance of the Mg-1Sn alloy (P_H: 2.83 ± 0.19 mm y⁻¹) is better than that of the Mg-1Bi alloy (P_H: 13.75 ± 1.12 mm y⁻¹), being about five times greater. In addition to the relatively low dislocation density in Mg-1Sn alloy, the difference in corrosion resistance is mainly attributed to two aspects of influence brought about by the addition of Sn and Bi. The Mg₂Sn phase introduced by the addition of Sn has a potential difference (PD) of ~30 mV, which is significantly lower than that (~90 mV) of the Mg₃Bi₂ phase introduced by adding Bi, thereby weakening the micro-couple corrosion tendency of the Mg-1Sn alloy. The addition of Bi has little effect on the corrosion film, while the addition of Sn makes the corrosion film on the Mg-1Sn alloy contain SnO₂, improving the compactness of the corrosion film and thereby enhancing the corrosion protection effect. Full article

Compared with vanadium extraction by sodium roasting followed by water leaching, the calcification roasting–sulfuric acid leaching method is considered a promising approach for the comprehensive utilization of vanadium titanomagnetite, as it avoids the introduction of alkali metals. However, during vanadium extraction by sulfuric acid heap leaching, the diffusion of leaching reagents and leaching products was hindered by the deposition of leaching solid products. To address this issue, this study systematically investigated the leaching kinetics and the mechanisms underlying the deposition of leaching solid products. The results indicated that vanadium leaching was governed by a combination of liquid film diffusion and internal diffusion through solid-phase products during days 0–2, and by internal diffusion alone from day 2 to day 9. The primary solid products formed during leaching were calcium sulfate and silica gel. Calcium sulfate precipitated and grew within the pore via two-dimensional nucleation, while silicates formed silica gel through dehydration. By optimizing the sulfuric acid leaching conditions—specifically, maintaining an H⁺ concentration of 2 mol/L, a leaching temperature of 40 °C, and a liquid-to-solid ratio of 5:1—the formation of calcium sulfate and silica gel was effectively suppressed. Under these conditions, the vanadium leaching efficiency reached 75.82%. Full article

430 stainless steel exhibits soft magnetic properties, excellent formability, and corrosion resistance, making it widely used in industrial applications. This study investigates the effects of different cold working rates on the properties of 430 stainless steel subjected to various magnetic annealing atmospheres (F-1.5Si, F-1.5Si-10%, F-1.5Si-40%, F-1.5Si-10% (MA), F-1.5Si-40% (MA), F-1.5Si-10% (H₂), and F-1.5Si-40% (H₂)). The results indicate that increasing the cold working rate improves the material’s mechanical properties; however, it negatively impacts its magnetic and corrosion resistance properties. Additionally, the magnetic annealing process improves the mechanical properties, while atmospheric magnetic annealing optimizes the overall magnetic performance. In contrast, magnetic annealing in a hydrogen atmosphere does not enhance the magnetic properties as effectively as atmospheric magnetic annealing. Still, it promotes the formation of a protective layer, preserving the mechanical properties and providing better corrosion resistance. Furthermore, regardless of whether magnetic annealing is conducted in an atmospheric or hydrogen environment, materials with 10% cold work rate (F-1.5Si-10% (MA) and F-1.5Si-10% (H₂)) exhibit the lowest coercive force (286 and 293 A/m in the 10 Hz test condition), making them ideal for electromagnetic applications. Full article

Parametric changes in the first coordination shell (FCS) of a vitreous metallic Pd_42.5Cu₃₀Ni_7.5P₂₀ alloy are analysed, aiming to confirm the identification of the glass transition temperature (T_g) via processing of XRD patterns utilising radial and pair distribution functions (RDFs and PDFs) and their evolution with temperature. The Wendt–Abraham empirical criterion of glass transition and its modifications are confirmed in line with previous works, which utilised the kink of the temperature dependences of the minima and maxima of both the PDF and the maxima of the structure factor S(q). Massive fluctuations are, however, identified near the T_g of the derivatives of the minima and maxima of the PDF and maxima of S(q), which adds value to understanding the glass transition in the system as a true second-order-like phase transformation in the non-equilibrium system of atoms. Full article

Steel is an important product in many engineering sectors; however, steelmaking remains one of the largest ${\mathrm{CO}}_2$ emitters. Therefore, new governmental policies drive the steelmaking industry toward a cleaner and more sustainable operation such as the gas-based direct reduction–electric arc furnace process. To become carbon neutral, utilizing more scrap is one of the feasible solutions to achieve this goal. Addressing knowledge gaps regarding scrap heterogeneity (size, shape, and composition) is essential to evaluate the effects of increased scrap ratios in basic oxygen furnace (BOF) operations. This review systematically examines heat and mass transfer correlations relevant to scrap melting in BOF steelmaking, with a focus on low Prandtl number fluids (thick thermal boundary layer) and dense particulate systems. Notably, a majority of these correlations are designed for fluids with high Prandtl numbers. Even for the ones tailored for low Prandtl, they lack the introduction of the porosity effect which alters the melting behavior in such high temperature systems. The review is divided into two parts. First, it surveys heat transfer correlations for single elements (rods, spheres, and prisms) under natural and forced convection, emphasizing their role in predicting melting rates and estimating maximum shell size. Second, it introduces three numerical modeling approaches, highlighting that the computational fluid dynamics–discrete element method (CFD–DEM) offers flexibility in modeling diverse scrap geometries and contact interactions while being computationally less demanding than particle-resolved direct numerical simulation (PR-DNS). Nevertheless, the review identifies a critical gap: no current CFD–DEM framework simultaneously captures shell formation (particle growth) and non-isotropic scrap melting (particle shrinkage), underscoring the need for improved multiphase models to enhance BOF operation. Full article

The 1.9 billion metric tons of steel globally manufactured in 2023 justify the steel industry’s pivotal role in modern society’s growth. Considering the rapid development of countries that have not fully taken part in the global market, such as Africa, steel production is expected to increase in the next decade. However, the environmental burden associated with steel manufacturing must be mitigated to achieve sustainable production, which would align with the European Green Deal pathway. Such a burden is associated both with the GHG emissions and with the solid residues arising from steel manufacturing, considering both the integrated and electrical routes. The valorisation of the main steel residues from the electrical steelmaking is the central theme of this work, referring to the steel electric manufacturing in the Dalmine case study. The investigation was carried out from two different points of view, comprising the action of a plasma electric reactor and a RecoDust unit to optimize the recovery of iron and zinc, respectively, being the two main technologies envisioned in the EU-funded research project ReMFra. This work focuses on those preliminary steps required to detect the optimal recipes to consider for such industrial units, such as thermodynamic modelling, testing the mechanical properties of the briquettes produced, and the smelting trials carried out at pilot scale. However, tests for the usability of the dusty feedstock for RecoDust are carried out, and, with the results, some recommendations for pretreatment can be made. The outcomes show the high potential of these streams for metal and mineral recovery. Full article

Porous intermetallic compounds have the properties of porous materials as well as a combination of covalent and metallic bonds, and they exhibit high porosity, structural stability, and corrosion resistance. In this work, a porous TiNi₃ intermetallic compound was fabricated through reactive synthesis of elemental powders. Next, detailed studies of its phase composition and pore structure characteristics at different sintering temperatures, as well as its corrosion behavior against an alkaline environment, were carried out. The results show that the as-prepared porous TiNi₃ intermetallic compound has abundant pore structures, with an open porosity of 56.5%, which can be attributed to a combination of the bridging effects of initial powder particles and the Kirkendall effect occurring during the sintering process. In 1 M KOH solution, a higher positive corrosion potential (−0.979 V_SCE) and a lower corrosion current density (1.18 × 10⁻⁴ A∙cm⁻²) were exhibited by the porous TiNi₃ intermetallic compound, compared to the porous Ni, reducing the thermodynamic corrosion tendency and the corrosion rate. The corresponding corrosion process is controlled by the charge transfer process, and the increased charge transfer resistance value (713.9 Ω⋅cm²) of TiNi₃ makes it more difficult to charge-transfer than porous Ni (204.5 Ω⋅cm²), thus decreasing the rate of electrode reaction. The formation of a more stable passive film with the incorporation of Ti contributes to this improved corrosion resistance performance. Full article