Search Results (221)

Significant amounts of smelting slag are generated during the production of steel, refined copper, and refined magnesium. These slags contain abundant valuable metallic elements, such as Fe, Cu, Zn, Co, and Mg, that have not been fully utilized in the past. This study proposes a method for modifying copper slag by mixing it with steel slag and magnesium slag, followed by roasting with additions of Fe₂O₃ and MgO. The samples were roasted at 1400 °C for 30 min, cooled to 1000 °C at 1.5 °C/min, and then water-quenched to room temperature. Phase transformations during modification were analyzed using FactSage 8.0, DSC–TG, and XRD. The effects of factors such as the content of Fe₂O₃ and MgO on the modification efficiency were investigated. The results indicate that, under the condition of maintaining a steel slag: copper slag: magnesium slag ratio of 37:37:26 and adjusting the basicity (CaO/SiO₂ ratio) with CaO to 2.0, the addition of Fe₂O₃ and MgO promotes the formation of spinel. However, excessively high contents of Fe₂O₃ and MgO lead to refinement of the spinel grains and reduce the iron grade of the concentrate. Within the investigated composition range, the samples with total Fe₂O₃ and MgO contents of 27.66 wt% and 7.56 wt%, respectively, showed the best magnetic separation performance among the tested compositions. Through magnetic separation, the concentrate has good economic and industrial application value in industries such as steelmaking and powder metallurgy, while the tailings can be utilized as raw materials for manufacturing ceramics, glass–ceramics, cement, and concrete. Full article

This study investigates the effect of SiC nanoparticle addition on the microstructure, interfacial reactions, and mechanical properties of Zn5Al3Ti active solder used for ultrasonic soldering of AlN ceramic to copper substrates. Composite solders containing 3 and 6 wt.% SiC nanoparticles were prepared and applied under flux-free ultrasonic soldering conditions. The solder alloys were evaluated by tensile testing, while the soldered joints were evaluated by shear strength testing. The solder microstructure and interfacial regions were characterized using SEM/EDS analysis. The results showed that the addition of SiC nanoparticles modified the microstructure of the Zn5Al3Ti solder and influenced the mechanical performance of the ceramic/metal joints. Among the investigated systems, the AlN/Zn5Al3Ti + 6 wt.% SiC/Cu joint exhibited the highest shear strength, reaching approximately 101 MPa. SEM/EDS observations revealed the formation of compact multilayered interfacial regions, including possible Cu–Zn intermetallic phases at the Cu/solder interface and Al–Ti–Zn-based reaction products near the solder/AlN interface. The improved joint performance may be attributed to the combined effect of SiC-induced microstructural modification, the presence of Si-containing particles, and the formation of compact metallurgical bonds. The results indicate that Zn5Al3Ti solder modified with 6 wt.% SiC nanoparticles is a promising material for producing strong AlN/Cu joints under the applied ultrasonic soldering conditions. Full article

The determination of soluble elemental contaminants in tattoo inks is challenged by the lack of standardized extraction procedures, limiting the comparability of analytical results and the assessment of exposure-relevant fractions under the European REACH framework. In this study, artificial sweat extraction was applied as a mild and physiologically relevant approach to evaluate elements potentially released from tattoo inks under sweat-simulated skin-contact conditions. Seventy-eight commercial tattoo inks of different colors were extracted with artificial sweat at 37 °C for 1 h and analyzed by inductively coupled plasma mass spectrometry. Optimization of collision/reaction cell conditions, dilution strategy, and internal standard correction effectively reduced matrix-related interferences caused by the high salt and chloride content of artificial sweat, ensuring reliable quantification. Matrix-matched calibration was required due to significant signal suppression for several analytes. Method accuracy and precision, assessed using NIST 1643f and spiked samples, were generally satisfactory. Elemental release showed marked color-dependent trends, particularly for Cu, Zn, Ba, Al, Ga, Si, Sr, and Zr, reflecting differences in pigment composition and formulation. Soluble Ba, Cu, and Zn remained below EU regulatory limits. While total digestion remains essential for complete characterization, the proposed methodology provides a simple and transferable tool for exposure-oriented assessment of potentially bioaccessible elements in tattoo inks. Full article

Structural parameters for over seventy complexes of the composition Cu(η²-X^1×2)(Y³) or Cu(κ²-X¹X²)(Y³) were analyzed in this work, being the third of a series of structural studies on three coordinated copper(I) complexes. Bidentate (X¹X²) with monodentate (Y³) donor ligands build up distorted trigonal planar coordination spheres around copper(I) atoms. The bidentate ligands (X¹X²) create three-, four-, and five-membered metallocyclic rings. The three-membered are: -C¹-C²-Cu-C³; -B¹=B²-Cu-Cl³; -P≡C²-Cu-C³, -B¹-B²-Cu-X³, and B¹-C²-Cu-C³. The X¹-Cu-X² angles indicate a total mean value of 44.2°. The four-membered complexes are -H¹-B(H₂)-H²-Cu-C³; -H¹-B(Ph₂)-H²-Cu-C³; -O¹AlO²-Cu-N³; -O¹CeO²-Cu-N³; -S¹CP²-Cu-C³; -N¹PN²-Cu-C³; -N¹PS²-Cu-P³; -N¹SiO¹-Cu-Cl³; --N¹CS²-Cu-C³; -Si¹-NSi²-Cu-C³, and O¹CO²-Cu-C³, and show a total mean value of the L-Cu-L angles of 71.0°. The five-membered are: -N¹-C=C-N²-Cu-Y³ (more common) and N=C-C=N-Cu-C³. In this group, there are also copper(I) complexes in which the central Ns of five-membered metallocycle are “interlocked” in macrocycles. The X¹-Cu-X² angles exhibit an average value of 82.9°. There is a wide variety of monodentate (Y³) ligands in the studied complexes. The mean value of Cu-Y³ elongates with covalent radius (Å) of coordinate atoms in the sequence: 1.846(13) Å (N³, 0.75) < 1.884(21) Å (O³, 0.73) < 1.928(18) Å (C³, 0.77) < 2.126(18) Å (Cl³, 0.99) < 2.140(5) Å (S³, 1.02) < 2.194(4) Å (P³, 1.06) < 2.246(12) Å (Br³, 1.14) < 2.2445(18) Å (I³, 1.33). The data show that angular distortion from regular trigonal geometry grows in the following order: five-, four-, and three-membered. Full article

Clay minerals in coal play a key role in controlling mineralogical composition, geochemical signatures, and the industrial behavior of coal and its combustion residues. This study investigates the occurrence, provenance, and potential applications of clay minerals in Carboniferous ash-rich coals from the Bogatyr, Lenin, and Saradyr coal mines in northeastern Kazakhstan. A total of 60 coal samples were analyzed using XRD, SEM–EDS/BSE, XRF, and ICP-OES following acid leaching. Based on ash yield, 52 samples were classified as coal (<50% ash), while 8 samples were classified as carbonaceous shale or mudstone (>50% ash). Mineralogical assemblages show clear variability among the studied mines. Saradyr samples are strongly quartz-dominated with lower clay proportions, Bogatyr samples exhibit highly heterogeneous quartz–clay–mica assemblages, whereas Lenin samples are relatively more clay-rich and dominated by kaolinite and illite-group minerals. Across all samples, kaolinite is the dominant clay mineral (16.6–46 wt.%), occurring mainly as authigenic pore- and cell-filling aggregates. Minor phases include illite–muscovite (7.1–29.9 wt.%), illite–smectite (up to 7.6 wt.% in Bogatyr), and smectite–montmorillonite (0.4–0.7 wt.%). Clay minerals occur as discrete particles, coatings, and pore fillings, contributing to ash formation; however, their correlation with ash yield is weak (R = 0.03–0.05), reflecting heterogeneous mineral inputs and diagenetic overprinting. All geochemical data are reported on a high-temperature coal ash (HTA) basis (815 °C). Geochemical indices (CIA, CIW, CIX) and Al₂O₃/TiO₂ ratios (1.8–17.4) indicate variable provenance and moderate to high weathering intensity, reflecting mixed mafic to intermediate source rocks. A total of 23 trace elements were identified. Au occurs at trace levels (up to 0.02 ppm), while selected rare earth elements (REE: Ce, Dy, Eu, La, Nd, Sm, Y, Yb) average 0.2–0.3 ppm, indicating negligible economic recovery potential. REEs show a strong positive correlation with clay minerals (r = 0.93), indicating adsorption and minor structural incorporation. In contrast, Au correlates with As, V, Zn, Cu, Ni, and Nb, suggesting sulfide association. HTA is enriched in SiO₂–Al₂O₃ phases dominated by kaolinite and quartz, indicating strong potential for cement, geopolymer, ceramic, and zeolite applications. Full article

The rapid expansion of crystalline silicon photovoltaic (PV) modules has increased the demand for sustainable and high-value recycling strategies for end-of-life (EOL) modules. A significant challenge is the removal of impurities such as carbon, oxygen, and non-metallic inclusions introduced into silicon solar cells during the dissociation of PV laminates. To address this, we propose a non-consumable electrode electroslag remelting (NCE-ESR) process to effectively eliminate inclusions. In this process, the reverse flow of alloy droplets and the extensive contact area are crucial during the reverse flow slag washing. Initially, we studied the occurrence characteristics of inclusions in silicon solar cells obtained after pyrolysis from enterprises. Pyrolysis facilitated the formation of inclusions like Si-O, C-O, Al-O, and Si-N, particularly in the fine size range below 5 μm. To enhance impurity removal, the recycled Si was alloyed with Cu, which increased the melt density and impurity activity. Based on optimized thermodynamics and physical properties, we designed a novel electroslag composition of 40%CaO-40%SiO₂-20%CaF₂ suitable for silicon alloy refining. Notably, during the reverse flow slag washing of the Cu-Si alloy, the maximum removal rate of inclusions reached 77.42%. The average diameter of inclusions was reduced to below 6 μm, and the removal rates of impurity elements such as Al, O, and C exceeded 98.09%, 94.86%, and 86.08%, respectively. Finally, we independently developed the NCE-ESR equipment and conducted a kilogram-scale amplification test. The results indicated that the impurity removal rates of Al and O exceeded 97%, and the final inclusion size was less than 10 μm. This study demonstrates a scalable and environmentally friendly approach for the high-value recycling of silicon resources from decommissioned PV modules. Full article

Silicomanganese slag (SiMnS), a Mn-bearing by-product from silicomanganese alloy production, is often stockpiled in large quantities and may pose environmental concerns due to potential metal leaching. This study develops an OPC-rich hybrid SiMnS–steel slag–fly ash–OPC-activated composite binder, referred to as SMSAB, in which OPC accounts for 55% of the solid precursor mass. Different alkali contents and sodium silicate moduli were investigated, and the optimised paste was characterised in terms of mechanical strength, reaction products, pore structure, carbon-footprint and heavy-metal leaching. The best performance was obtained at an alkali content of 4% and a sodium silicate modulus of 1.0, giving 28-day compressive and flexural strengths of 65.13 MPa and 3.37 MPa, respectively. XRD, SEM-EDS, FTIR and MIP results showed that the main reaction products were C-(A)-S-H, N-A-S-H and C-N-A-S-H gels, which refined the pore structure and produced a dense matrix. The reduction in Mn leaching may be associated with physical encapsulation, possible charge-balancing interactions within gel structures, changes in Mn-related bonding environments and the presence of Mn-bearing phases. Leaching concentrations of Zn, Mn, Cr, Cu and Ni satisfied the Grade III groundwater limits used in China. The calculated carbon intensity of SMSAB was 3.97 kg·(m³·MPa)⁻¹, indicating a favourable strength-to-emission balance compared with the reference systems considered. It should be noted that the present work examines paste specimens only; aggregate skeleton, traffic loading, freeze–thaw cycling and wet–dry/moisture cycling were not included. Therefore, the results demonstrate binder-level potential rather than direct qualification of SMSAB as a pavement base or subbase material. Full article

A comparative investigation of the corrosion behavior evolution of 15%SiCp/Al-Cu-Mg aluminum matrix composites (AMC) subjected to different heat treatments in a salt spray environment containing 5wt% NaCl was performed. Metallographic microscopy was used to observe the surface morphology of the corroded materials. Field-emission transmission electron microscopy (TEM) and scanning electron microscopy (SEM) were used for microstructural evaluation and elemental analysis of the samples. Polarization curves and electrochemical impedance spectroscopy (EIS) were also employed to investigate the corrosion performance of the particle-reinforced aluminum matrix composites under different heat treatments. The test results indicate that, in addition to the influence of various grain boundary precipitates and electrochemical inhomogeneities between the precipitate-free zone (PFZ) and the aluminum matrix, differences in electrochemical properties between the SiC reinforcement particles and the aluminum alloy matrix are also a primary factor contributing to the corrosion of the aluminum-based composites in a 5wt% NaCl salt spray environment. Microstructural observations and electrochemical testing of AMC specimens at different corrosion stages indicate that under-aged samples exhibit relatively higher intergranular corrosion susceptibility. Under prolonged exposure to a salt spray environment, the over-aged specimen exhibited more pronounced galvanic corrosion phenomena, specifically, a significant decrease in Charge transfer resistance (R_ct) values and an increase in CPE values. R_ct results indicate that naturally aged AMC exhibits higher corrosion resistance than artificially aged AMC. With increased salt spray corrosion time, varying degrees of crevice corrosion occurred at the Al–SiC interface in all heat-treated samples. Full article

Efficient joining of hard metals to steels is crucial for supporting sustainable manufacturing under emissions strategies to minimize CO₂. CoNiCrFeCu high-entropy alloy containing scandium (Sc) was designed as a filler for laser braze-welding of WC-Co and steel. The designed compositions with different Sc levels were melted and cast in a high-vacuum non-consumable arc furnace. The results showed that the as-cast microstructure was a complex mixture of a networked Ni₂Si, elongated Cr-Fe-Co solid-solution phase, and Fe-Ni-Co-Cu solid-solution phase. Scandium was shown to have formed compounds with nickel/cobalt and copper. The TG-DSC analysis confirmed that the melting points of the designed compositions were between 973.7 °C and 981.5 °C. The maximum spreading area of the CoNiCrFeCu-0.9Sc composition on AISI 1045 steel was 64.83 mm², and on the WC-Co cermet it was 78.63 mm². The interface between the fusion zone and AISI 1045 steel exhibited an epitaxial growth of dendrites from the steel base metal. The interface between WC-Co and the fusion zone exhibited a partial penetration of brazing filler into the Co matrix, forming a metallurgical bonding between the dissimilar materials. Sc, as an alloying element in the filler metal, enhanced the bond formation because it decreased the solidus temperature and increased wetting. Full article

Lightweight high-entropy alloys are primarily designed to overcome the strength-to-density ratio limitations of conventional counterparts and often consist of elements with drastically different melting temperature and vapor pressure. Their chemistry, therefore, imposes challenges on alloy synthesis, particularly through liquid metal engineering routes, since elements with high vapor pressure (e.g., Mg, Zn, Li) vaporize before the higher-melting-point ingredients (e.g., Cu, V, Ni) are fully molten, resulting in volatile element loss. To overcome this challenge, a novel pressure-assisted induction melting (PAIM) process was developed and the proprietary furnace for its implementation was designed and built. The system allows precision melting of up to 10 cm³ of an alloy at temperatures up to 1700 °C while addressing the partial pressure requirements during the melting progress. The chamber is prepared using rough vacuum and re-filled with inert gas such as argon with the operating pressure range from about 10⁻⁴ MPa up to maximum of 1.6 MPa (233 psi). The alloy chemical composition can be modified in situ by feeding solid additives at specific melting stages through the isolated airlock without disrupting the pressure conditions within the chamber. The viability of the concept was verified by synthesis of two lightweight non-equimolar high-entropy alloys: Mg-rich Mg₅₀(MnAlZnCu)₅₀ and Al-rich Al₃₅Mg₃₀Si₁₃Zn₁₀Y₇Ca₅. The experiments showed that sequential multi-step melting procedures, designed based on inputs from FactSage computational analysis, when combined with PAIM synthesis, allowed manufacturing fully dense and chemically homogenous complex alloy compositions with optimal volumes for materials discovery research. Full article

The growing importance of renewable energy sources and the implementation of circular economy principles highlight the need for the rational management of biomass combustion by-products. The aim of this study was to assess the chemical composition of ash produced through the combustion of various biomass fractions from four varieties of common hazel (Corylus avellana L.) in the context of its potential for secondary use. The analysis covered the shells, husks, leaves, and shoots of the following varieties: Kataloński, Olbrzymi z Halle, Olga, and Webba Cenny. Combustion was carried out under laboratory conditions at a temperature of 550 °C, and the content of macro- and micro-element oxides (P₂O₅, K₂O, CaO, SO₃, Cl, SiO₂, MnO, Fe₂O₃, NiO, CuO) and potentially toxic elements (ZnO, TiO₂, Cr₂O₃) was determined using the EDXRF method. The results showed significant variation in the chemical composition of the ash depending on the biomass fraction and variety. The highest P₂O₅ content was found in the leaves of the Kataloński variety (5.02), whilst the highest K₂O concentration was found in the husk of the Olga variety (47.33%). The maximum CaO content was found in the leaves of the Webba Cenny variety (32.60). The leaf and husk fractions were characterised by the highest content of nutrients of fertilising importance, whilst the shells exhibited the lowest values for most macronutrients. The content of potentially toxic elements was low. The results obtained indicate that the selective utilisation of specific fractions of hazel biomass can increase the efficiency of mineral recovery whilst maintaining environmental safety, in line with the principles of the circular economy. Full article

To address the lack of suitable glass systems for silicon nitride (Si₃N₄) surface metallization, which requires high wettability and thermal stability, and robust bonding between the copper layer and the ceramic substrate, a novel Bi₂O₃-TeO₂-B₂O₃-CuO glass system was developed. This study systematically investigated the influence of Bi₂O₃ concentration, glass properties, optimized paste composition, and brazing mechanism using phase analysis, microstructural characterization, particle size statistics, thermal analysis, and tensile testing. An optimal glass composition containing 20 mol% Bi₂O₃ was identified, exhibiting high thermal stability (ΔT = 224 °C) and a coefficient of thermal expansion of 9.63 × 10⁻⁶ °C⁻¹. At a brazing temperature of 750 °C, the glass demonstrated excellent wettability with a contact angle of 27°. A conductive paste comprising 94 wt% Cu and 6 wt% glass yielded a thick film with a minimum resistivity of 6.25 μΩ·cm and a maximum tensile strength of 25.2 MPa. Mechanism analysis revealed that the superior wettability drives the liquid glass phase to form a thin intermediate layer that significantly reinforces adhesion. These findings contribute to the research and development of subsequent novel glass systems with superior performance. Full article

As hypersonic aircraft applications become increasingly extreme, traditional regenerative cooling channels primarily using high-temperature alloys as wall materials can no longer simultaneously meet the dual requirements of thermal protection and lightweight design. This study, based on hypersonic environments with Mach numbers exceeding 8, selects five materials with significant advantages from metals, ceramics, and C/SiC composite materials to conduct a coupled design of wall materials for the flow and heat transfer characteristics of n-decane under 3 MPa pressure. The results show that the heat transfer ability of different material combination schemes is closely related to the thermal–physical properties of the materials, and the materials with obvious advantages in specific thermal–physical properties are dominant. Under a heat flux of 1.5 MW/m², the GH3128 + Cu composite scheme demonstrates a 17.5% increase in Nusselt number and a 17.6% improvement in comprehensive heat transfer coefficient compared to the traditional high-temperature alloy scheme. When the heat flux triples to 4.5 MW/m², the temperature variation of the GH3128 + Cu composite scheme is only 50% of that of the steel + C/SiC composite scheme. This indicates that multi-material coupling exerts both synergistic effects and inhibitory effects on flow and heat transfer characteristics, highlighting the importance of flexible material selection tailored to different tactical and technical requirements. Full article

This study investigates the reaction thermodynamics of the sodium oxide-fluxed aluminothermic reduction of pyrolusite-based manganese ore under self-propagating high-temperature synthesis (SHS) conditions, using Si, Cr, and Cu as collector metals. The experimental results are compared with thermochemical equilibrium calculations using FactSage 7.3 thermochemistry software. Experimental mixtures were prepared with controlled additions of aluminium, sodium silicate, calcium oxide, and collector metals and heated to the ignition temperature in a muffle furnace preheated to 1350 °C. The resulting alloys and slags were analysed for bulk composition. Collector metals significantly influence alloy carbon saturation and manganese recovery. The individual reaction’s Gibbs free energy values and the gas–slag–metal equilibrium were calculated. Discrepancies between the experimental and equilibrium-predicted results highlight the kinetic factors of SHS processes, particularly with respect to aluminium uptake and manganese volatilisation. The main difference is the alloy’s aluminium uptake. The difference between the calculated and experimental aluminium levels is, in part, due to the higher partial oxygen pressure predicted in the gas–slag–metal equilibrium calculations, compared with that of the likely Al–Al₂O₃ governing reaction equilibrium. Short-circuiting of aluminium to the alloy is also a possible contributing factor. The findings provide insights into optimising feed formulations and process parameters for improved manganese recovery. Full article

Heavy metals (HMs) and metal-oxide nanoparticles (NPs) frequently co-occur in freshwater systems, yet their combined effects on microbial predators remain poorly understood. Here, the freshwater ciliate Coleps hirtus was used to evaluate the cytotoxicity of single and binary mixtures of HMs (Cd, Cu, Zn) and NPs (ZnO, CuO, TiO₂, SiO₂), and to characterize associated antioxidant responses. Acute toxicity was assessed after 24 h by estimating LC₂₀ and LC₅₀ values, while mixture toxicity for Cd + Zn and Cd + ZnO was analyzed using the Toxic Unit approach and the MixTOX framework. Non-enzymatic (TPC, DPPH, HRSA) and enzymatic (CAT, GST, GPx, SOD) antioxidants were quantified as sublethal biomarkers at concentrations below lethal thresholds. HMs were markedly more toxic than NPs, with a toxicity ranking of Cu > Cd >> Zn, whereas NPs followed ZnO > CuO >> TiO₂ >> SiO₂. Cd + Zn mixtures showed predominantly antagonistic or non-interactive effects, while Cd + ZnO mixtures exhibited strong synergistic toxicity with a non-linear dependence on mixture composition, as supported by MixTox modeling. Exposure to HMs and NPs induced significant and often coordinated changes in antioxidant biomarkers, with binary mixtures eliciting stronger responses than single contaminants. Together, these findings indicate that mixture composition strongly influences both toxicity outcomes and oxidative stress responses in C. hirtus. The combination of clear, mixture-dependent toxicity patterns and robust oxidative stress responses makes C. hirtus a promising bioindicator for freshwater environments impacted by HMs and NPs. Full article