Search Results (11)

The investment casting of titanium and its alloys relies on a high resistance of the crucibles and shell molds in terms of temperature and reactivity. The availability of ceramic crucibles that offer sufficient resistance to the titanium melt enables vacuum induction melting (VIM). CaZrO₃ prepared from a mixture of CaO and ZrO₂ as a raw material for refractory ceramics shows a high corrosion resistance against metallic melts even under very high temperatures up to 1800 °C. Crucibles and shell molds of CaZrO₃ were successfully produced and used in subsequent casting trials. This study is focused on the refractory crucibles suitable for casting Ti-6Al-4V (Ti-64) using a tilt casting machine. In order to evaluate the crucible reaction and, therefore, the quality of the castings, chemical analyses, investigations of the microstructures and hardness measurements were carried out. Careful control of the melting duration is mandatory to avoid crucible reactions that otherwise result in contamination of the cast with oxygen and zirconium. This was achieved by modified coil geometries. Under optimized casting conditions, the oxygen and zirconium impurity limits of ASTM B367-09 for titanium castings were met. Based on the correlations found, optimized casting parameters with regard to material quantity, coil geometry and heating power could be determined in order to provide guidance for a high-quality casting process with VIM. Full article

Vacuum induction melting is a more energy-efficient process for the preparation of a titanium alloy with good homogeneity and low cost. But the crucial problem for this technology is in developing a crucible refractory with high stability. In the present work, a novel (Ca,Sr,Ba)ZrO₃ crucible was prepared by slip casting and its performance in melting NiTi alloy was studied. The results showed that a single solid solution was formed with a homogeneous distribution of metal elements after sintering at 1500 °C. It was found that the total content of oxygen and nitrogen remaining in the TiNi alloy after melting in the (Ca,Sr,Ba)ZrO₃ crucible was 0.0173 wt.%, which fulfills the ASTM standard on biomedical TiNi alloys. The good resistance of the (Ca,Sr,Ba)ZrO₃ crucible to molten NiTi has a relationship with the sluggish diffusion effect of high-entropy ceramics. This study provides insights into the process of designing highly suitable crucible material for melting a NiTi alloy. Full article

In this study, the effect of adding different contents of yttrium (Y) during vacuum induction melting in Al₂O₃ and Y₂O₃ crucibles on the purification of DD5 alloys was investigated. The results show that the Y₂O₃ crucible exhibited great crucible stability and an excellent desulfurization effect when melting a Y-containing DD5 alloy. The S content of the alloy was reduced from 5.03 ppm to 1.36 ppm with the addition of 0.50 wt.% Y. Element Y combined with free S in the melt to form the YS phase, which was removed from the condensate shell and slag during the vacuum induction melting (VIM) process. Meanwhile, when the alloy was melted in the Y₂O₃ crucible with 0.50 wt.% Y addition, there was a reduction in S content from 2.77 ppm to 1.36 ppm compared to the Al₂O₃ crucible. Additionally, the loss of Y decreased from 0.12 wt.% to 0.05 wt.%. Full article

The synthesis of β-Ga₂O₃ ceramic was achieved using high-energy electron beams for the first time. The irradiation of gallium oxide powder in a copper crucible using a 1.4 MeV electron beam resulted in a monolithic ceramic structure, eliminating powder particles and imperfections. The synthesized β-Ga₂O₃ ceramic exhibited a close-to-ideal composition of O/Ga in a 3:2 ratio. X-ray diffraction analysis confirmed a monoclinic structure (space group C2/m) that matched the reference diagram before and after annealing. Photoluminescence spectra revealed multiple luminescence peaks at blue (~2.7 eV) and UV (3.3, 3.4, 3.8 eV) wavelengths for the synthesized ceramic and commercial crystals. Raman spectroscopy confirmed the bonding modes in the synthesized ceramic. The electron beam-assisted method offers a rapid and cost-effective approach for β-Ga₂O₃ ceramic production without requiring additional equipment or complex manipulations. This method holds promise for fabricating refractory ceramics with high melting points, both doped and undoped. Full article

In this paper influence of the excess Ca and Cu cations on the critical temperature (Tc) and critical transport current density (J_c) of high-temperature superconducting ceramics of the compositions (HTSC) Bi_1.6Pb_0.4Sr₂Ca_2.1Cu_3.1O_y, Bi_1.6Pb_0.4Sr₂Ca_2.25Cu_3.25O_y and Bi_1.6Pb_0.4Sr₂Ca₃Cu₄O_y synthesized by the glass-ceramic method has been studied. The synthesis of superconducting ceramics was carried out on the basis of the glass phase, obtained by ultra-fast quenching of the melt. Melting of the mixture of starting components was carried out without the use of a crucible under the influence of IR radiant heating. Analysis of the elemental composition of the samples of the initial precursors showed a significant deviation from stoichiometry in oxygen (increase), as well as a decrease in calcium content. The synthesis of HTSC ceramics was carried out at a temperature of 849–850 °C for 96 h with intermediate grinding every 24 h. Studies of the phase composition of ceramic samples by X-ray diffraction have shown that HTSC ceramics consist only of a superconducting high-temperature phase Bi-2223. Studies of current-carrying characteristics by the four-point probe method according to the criterion of 1 µV/cm² have shown that high-temperature superconducting ceramics of the compositions Bi_1.6Pb_0.4Sr₂Ca_2.1Cu_3.1O_y, Bi_1.6Pb_0.4Sr₂Ca_2.25Cu_3.25O_y and Bi_1.6Pb_0.4Sr₂Ca₃Cu₄O_y have an increased density of critical transport current of 9.12 A/cm², 7.62 A/cm² and 7.26 A/cm², respectively. At the same time, it was found that with a decrease in the content of Ca and Cu cations in HTSC ceramics, an increase in the critical current density is observed. Full article

The use of a hot-forged TiAl alloy enables the fabrication of large parts that are difficult to manufacture by casting or isothermal forging. Ti-42Al-5Mn (at%) is the world’s first TiAl alloy in this category and has been used to manufacture practical large-scale structural defense components since around 2010. This paper discusses the developmental status and practical applications of this alloy. In addition, recent developments in process stabilization and improvements in material properties, which have been issues for the practical use of this TiAl alloy in the past, are also discussed. Full article

Cobalt-chromium (CoCr) alloys have been used in dentistry for dental bridges, crowns and implants for decades. When using CoCr alloys, a number of fractures have occurred in the Dental Laboratory, both when handling the castings and after they have been placed in the patient’s mouth. It is assumed that the key cause of the resulting fractures of CoCr dental bridges is the casting process, which includes the preparation and mixing of the basic components of the CoCr dental alloy, unstable solidification and the final treatment of the tooth casting surface. The aim of this study was, therefore, to examine three castings differently prepared from the CoCr alloy. For the initial CoCr alloy, we selected the one supplied directly from the manufacturer; three test samples were CoCr alloy remelted four times in the same crucible, while the fourth sample was the remaining solidified alloy from the crucible, taken at the last remelting. Characterisation of the microstructure of all four samples was performed by optical and scanning electron microscopy equipped with an energy dispersive X-ray spectroscope and X-ray diffractometry. Microhardness measurements were also performed. The investigation revealed that the microstructure of the castings is composed of a CoCr alloy matrix with a eutectic interdendritic composition and interdendritic precipitates, which were rich in W and Mo. The two oxides were identified as chromium oxide with silicon content and chromium oxide, which originated from the CoCr alloy as casting residue. The high content of silicon in the chromium oxide can be attributed to the silicon oxide from the ceramic melting crucible, mixed in with the remains from the CoCr alloy melting. The second oxide showed a more regular elemental content for chromium oxide, mixed with a small quantity of impurities and the casting CoCr alloy. Based on this research, some recommendations were made for working with CoCr alloys in the Dental Laboratory, with the aim of reducing the risk of dental bridge fractures in the future. Full article

This paper investigates the effect of the size and volume fraction of SiC, along with that of the processing temperature, upon the nitridation behavior of aluminum powder during the nitridation-induced self-formed aluminum composite (NISFAC) process. In this new composite manufacturing process, aluminum powder and ceramic reinforcement mixtures are heated in nitrogen gas, thus allowing the exothermic nitridation reaction to partially melt the aluminum powder in order to assist the composite densification and improve the wetting between the aluminum and the ceramic. The formation of a sufficient amount of molten aluminum is key to producing sound, pore-free aluminum matrix composites (AMCs); hence, the degree of nitridation is a key factor. It was demonstrated that the degree of nitridation increases with decreasing SiC particle size and increasing SiC volume fraction, thus suggesting that the SiC surface may act as an effective pathway for nitrogen gas diffusion. Furthermore, it was found that effective nitridation occurs only at an optimal processing temperature. When the degree of nitridation is insufficient, molten Al is unable to fill the voids in the powder bed, leading to the formation of low-quality composites with high porosities. However, excessive nitridation is found to rapidly consume the nitrogen gas, leading to a rapid drop in the pressure in the crucible and exposing the remaining aluminum powder in the upper part of the powder bed. The nitridation behavior is not affected by these variables acting independently; therefore, a systematic study is needed in order to examine the concerted effect of these variables so as to determine the optimal conditions to produce AMCs with desirable properties for target applications. Full article

In this paper we report the fabrication of glass-clad BaO-TiO₂-SiO₂ (BTS) glass–ceramic fibers by powder-in-tube reactive molten-core drawing and successive isothermal heat treatment. Upon drawing, the inserted raw powder materials in the fused silica tubing melt and react with the fused silica tubing (housing tubing) via dissolution and diffusion interactions. During the drawing process, the fused silica tubing not only serves as a reactive crucible, but also as a fiber cladding layer. The formation of the BTS glass–ceramic structure in the core was verified by micro-Raman spectroscopy after the successive isothermal heat treatment. Second-harmonic generation and blue-white photoluminescence were observed in the fiber using 1064 nm and 266 nm picosecond laser irradiation, respectively. Therefore, the BTS glass–ceramic fiber is a promising candidate for all fiber based second-order nonlinear and photoluminescence applications. Moreover, the powder-in-tube reactive molten core method offers a more efficient and intrinsic contamination-free approach to fabricate glass–ceramic fibers. Full article

The amount of waste electrical and electronic equipment (WEEE) in the world has grown rapidly during recent decades, and with the depletion of primary ores, there is urgent need for industries to study new sources for metals. Waste printed circuit boards (WPCB) are a part of WEEE, which have a higher concentration of copper and precious metals when compared to primary ore sources. PCB materials can be processed using pyrometallurgical routes, and some industrial processes, such as copper flash smelting, have utilized this type of waste in limited amounts for years. For the purpose of recycling these materials through smelting processes, this work studied the behavior of WPCB scrap when dropped on top of molten slag. A series of experiments was carried out during this research at a temperature of 1350 °C, in an inert atmosphere with different melting times. The time required for complete melting of the PCB pieces was 2–5 min, after which molten alloy droplets containing Cu, Pb, Sn, Ni, Au, and Ag formed and started descending toward the bottom of the crucible. The ceramic fraction of the PCB material mixed with slag and the polymer fraction was pyrolyzed during the high-temperature experiments. The results give an understanding of PCB melting behavior and their use as a part of the smelting furnace feed mixture. However, more research is needed to fully understand how the different elements affect the process as the amount of PCB in the feed increases. The physical behavior and distribution of PCB materials in fayalite slag during the smelting process are outlined, and the results of this work form a basis for future studies about the chemical reaction behavior and kinetics when PCB materials are introduced into the copper smelting process. Full article

To obtain appropriate crucible materials for vacuum induction melting of MCrAlY alloys, four different oxide ceramics, including MgO, Y₂O₃, Al₂O₃, and ZrO₂, with various microstructures were designed and characterized. The high-temperature wettability and interactions between Ni-20Co-20Cr-10Al-1.5Y alloys and oxide ceramics were studied by sessile drop experiments under vacuum. The results showed that all the systems exhibited non-wetting behavior. The contact angles were stable during the melting process of alloys and the equilibrium contact angles were 140° (MgO), 148° (Y₂O₃), 154° (Al₂O₃), and 157° (ZrO₂), respectively. The interfacial reaction between the ceramic substrates and alloys occurred at high temperature. Though the ceramics had different microstructures, similar continuous Y₂O₃ reaction layer with thicknesses of about 25 μm at the alloy-ceramic interface in MgO, Al₂O₃, and ZrO₂ systems formed. The average area percentage of oxides in the alloy matrices were 0.59% (MgO), 0.11% (Al₂O₃), 0.09% (ZrO₂), and 0.02% (Y₂O₃), respectively. The alloys, after reacting with MgO ceramic, had the highest inclusion content, while those with the lowest content were in the Y₂O₃ system. Y₂O₃ ceramic was the most beneficial for vacuum induction melting of high-purity Y-containing Ni-based alloys. Full article