Search Results (17)

During the operation of structures, the components and materials from which they are made are exposed to various environmental, technological, and operational impacts. In this context, the use of a modified water-dispersion composition containing finely dispersed fillers with enhanced protective and performance characteristics proves to be effective. This article examines the development of a paint-and-coating composition using hollow glass microspheres and modified diatomite as finely dispersed fillers. The influence of technological factors on the properties of coating materials based on a synthesized acrylic dispersion and fillers—such as modified diatomite and hollow glass microspheres ranging from 20 to 100 μm in size with a bulk density of 0.107–0.252 g/cm³—is analyzed. The optimal formulation of the coating materials was determined to ensure the required coating quality. Experimental results demonstrate the improved strength and hardness of the coating due to the use of acrylic dispersion obtained through an emulsifier-free method and modifiers in the form of finely dispersed fillers. It has been established that the resulting samples also exhibit high adhesion to mineral and metallic substrates, along with excellent corrosion resistance. Moreover, the incorporation of acrylic dispersion contributes to increased elasticity of the coating, resulting in improved resistance to washing and abrasion. The developed protective material can be applied to a variety of surfaces, including walls, ceilings, and roofs of buildings and structures, pipelines, and many other applications. Thus, modified water-dispersion compositions based on synthesized acrylic dispersion showed the following results: resistance to sticking—5, which is the best; chemical resistance and gloss level with standard single-phase acrylic dispersion—no destruction or change in gloss. The adhesion of coatings cured under natural conditions and under the influence of UV radiation was 1 point. The developed formulations for obtaining water-dispersion paint and varnish compositions based on synthesized polymer dispersions, activated diatomite, and hollow glass microspheres, meet all the regulatory requirements for paint and varnish materials in terms of performance, and in terms of economic indicators, the cost of 1 kg of paint is 30% lower than the standard. Full article

The processes of rock excavation and processing involve intense mechanical stresses on cutting, displacing, and transporting tools, inevitably leading to the phenomenon of dry friction wear. The factors influencing the intensity and mechanisms of wear are complex and interdependent, being conditioned by the physical–mechanical properties of the rocks, the geometric characteristics and materials of the tools, as well as the cutting process parameters (cutting force, feed rate). Previous studies have mainly addressed the global aspect of wear without delving into the microstructural evolution of the contact surfaces during the friction process. In this paper, through controlled tribometric tests, we have investigated in detail the abrasive wear mechanisms of metallic materials in contact with different types of rocks, with an emphasis on the role played by surface roughness and the mineralogical properties of the rocks. Experimentally, we varied the applied forces and the number of friction cycles to simulate different working conditions and evaluate how these parameters influence wear intensity and surface morphology evolution. Microstructural analysis of the samples, combined with roughness measurements, allowed the identification of the predominant degradation mechanisms (abrasion, adhesion, fatigue) and their correlation with the material properties and the friction process parameters. The results have shown a strong correlation between the wear capacity of rocks and their petrographic properties, such as hardness, porosity, and hard mineral content. It was also found that the roughness of the contact surfaces plays an essential role in wear mechanisms, influencing both the initiation and propagation of its effects. Depending on the experimental data, we have developed a classification of rocks based on their abrasive potential and proposed criteria for the optimal adoption of materials and working parameters for the tools of technological equipment depending on the type of rock encountered. The results of this study can contribute to improving the durability of tools, as well as mining equipment, and reducing operating costs. Full article

The speciation of heavy metals (Mn, Fe, Co, Ni, Cu, Zn, Cd, and Pb) in the bottom sediments of the Mozhaisk Reservoir and the Moskva River is described. They were characterized using the Tessier sequential selective extraction procedure trace element concentrations determined by inductively coupled plasma–mass spectrometry (ICP-MS). The bottom sediments of the Mozhaisk Reservoir are characterized by higher concentrations of the examined metals compared to the channel alluvium of the Moskva River. In this case, the most widespread metal compounds in the bottom sediments of the Mozhaisk Reservoir are firmly bound (stable form) to the mineral matrix. High concentrations of the firmly bound forms of metals (Co, Ni, Cu, Zn, Cd, Pb, and Fe) in the bottom sediments are due to an increased proportion of the silt fraction (0.1–0.01 mm) entering the reservoir due to abrasion of its shores. The only exceptions are Mn and Cd, which are present in labile compounds with carbonates and hydroxides of iron and manganese. In the bottom sediments of the Moskva River, strongly bound forms prevail for most metals—for Ni, Zn, and Cd, they are complex compounds with Fe and Mn hydroxides; for Co, Cu, Pb, and Fe, they are compounds with stable silicate minerals. The proportion of labile bioavailable forms of metals in the bottom sediments of the Moskva River is higher than in the reservoir due to anthropogenic input. Among the labile forms of the metal compounds, carbonates predominate. The proportion of elements in the most mobile exchange form and in compounds with organic matter is not large and does not exceed 14% for most elements. The only exceptions are Co and Cd, for which the concentration of the exchange form reaches 25%. Full article

This paper presents the results of research conducted in the field of the technology of surface hardening of castings from unalloyed and low-alloy nodular cast iron using the laser remelting method. The range of studies included macro- and microhardness measurements using Rockwell and Vickers methods as well as metallographic microscopic examinations using a scanning electron microscope. Moreover, abrasive wear resistance tests were performed using the pin-on-disk method in the friction pair of nodular cast iron—SiC abrasive paper and the reciprocating method in the friction pair of nodular cast iron—unalloyed steel. Analysis of the test results shows that the casting surface layer remelting by laser for unalloyed nodular cast iron results in a greater improvement in its resistance to abrasive wear in the metal–mineral system, as compared to low-alloy cast iron. Additionally, carrying out the laser hardening treatment of the surface layer made of the tested grades of nodular cast iron is justified only if the tribological system of the cooperating working parts and allowable dimensional changes during their operation are known. Full article

Thermokarst lakes in the Western Siberian Lowland (WSL) are major environmental factors controlling organic carbon and trace metal storage in inland waters and greenhouse gas emissions to the atmosphere. In contrast to previously published research devoted to lake hydrochemistry, hydrobiology, sedimentary carbon, and processes controlling the lake total dissolved (<0.45 μm) solute composition, the colloidal forms of organic carbon (ОC), and related elements remain poorly known, especially across the permafrost gradient in this environmentally important region. Here we sampled 38 thermokarst lakes in the WSL, from the continuous to the permafrost-free zone, and we assessed both the total (<0.45 μm) and low-molecular-weight (<1 kDa) concentrations of 50 major and trace elements using conventional filtration and in situ dialysis. We aimed at quantifying the relationships between the colloidal content of an element and the lake surface area, permafrost coverage (absent, sporadic, isolated, discontinuous, and continuous), pH, and the concentrations of the main colloidal constituents, such as OC, Fe, and Al. There was a positive correlation between the lake area and the contents of the colloidal fractions of DOC, Ni, rare earth elements (REE), and Hf, which could be due to the enhanced mobilization of OC, trace metals, and lithogenic elements from silicate minerals in the soil porewater within the lake watershed and peat abrasion at the lake border. In all permafrost zones, the colloidal fractions of alkalis and alkaline-earth metals decreased with an increase in lake size, probably due to a decrease in the DOC concentration in large lakes. There was an increase in the colloidal fractions of DOC, Fe, Al, trivalent and tetravalent trace cations, Mn, Co, Ni, As, V, and U from the southern, permafrost-free zone to the northern, permafrost-bearing zones. This observation could be explained by an enhanced feeding of thermokarst lakes by suprapermafrost flow and the thawing of dispersed peat ice in the northern regions. Considering the large permafrost gradient of thermokarst lakes sampled in the present study, and applying a space-for-time substitution approach, we do not anticipate sizable changes in the colloidal status of DOC or major or trace elements upon climate warming and the permafrost boundary shifting northwards. For incorporating the obtained results into global biogeochemical models of OC, metal micronutrients, and toxicant migration in the permafrost regions, one has to consider the connectivity among lakes, soil waters, and rivers. For this, measurements of lake colloids across the main hydrological seasons, notably the winter period, are necessary. Full article

Mechanical mining is a widely used method of separating materials from the face to obtain a useful mineral (e.g., coal, metal ores, salts, and diamonds), to make underground workings (e.g., mine galleries, tunnels, and underground garages), level roads, shape slopes, or to dig ditches. Mechanical mining is applied in the mining branch, tunnelling, road, and construction industries. Depending on the mechanical properties of the rocks, most frequently described by uniaxial compression strength, various machines and tools are used. The methods of mining high-strength abrasive rocks that have been used and developed in recent years are particularly applicable to the mining of copper, gold, tungsten, platinum ores, diamond deposits, and tunnelling. In addition to rock strength, the effectiveness of the mining process is affected by abrasiveness, which influences the rate of abrasive tool wear. Therefore, in various research and development centres, but also in production companies, tools are tested on unique stands. Tests are carried out to determine the cutting resistance and assess the wear rate. This article reviews methods and benches for testing mining tools, conical picks, and discs. Various solutions for testing single tools and cutting heads have been presented. The analysis conducted has revealed that despite the large number and great diversity of different test benches, there are no appropriate methods and stands for testing the wear rate of materials intended for mining tools. Full article

The analysis of the behavior in exploitation of the extraction, transportation and utilization of hard rock type mineral substances proved that one of the most extended and aggressive forms of wear is abrasive wear. The effects of abrasive wear on the machine components and their economic implications are significant, especially due to the operational pauses coming up in the technological flows that serve specific activities. This study presents two ways of limiting the consumption of tamping tools for the railway machines that are submitted to abrasive wear, namely, by reconditioning with the help of electrodes for overlaying welding with alloys of preestablished characteristics; by executing cast cleats from composite material in which metal carbides were infiltrated by diffusion. The great number of cast cleats tested in exploitation allowed a reliability and maintainability analysis to be made using the Weibull++ program, including the determination of the necessary number of cleats for 5000 h of functioning. The results of the experiments performed to this end demonstrated that both the reconditioning and execution of spare parts, with the help of reusable materials, could be solutions for sustainability in several economic fields, especially in those where the production costs are high. Full article

Over the recent few decades, due to climate warming and the continuing exploration of Arctic seas’ mineral resources, the scientific interest in contamination problems has deepened significantly. In this study, for the first time, we characterize the distribution features of 47 elements (major and trace elements, including heavy metals, metalloid As, and Cs-137 technogenic radionuclide) in surface bottom sediments from some areas of the Barents, Kara, Laptev, and East-Siberian Seas. The lithogenic material was the main factor that controlled variability in many elements (Be, Al, Ti, Cr, Ga, Rb, Sr, Y, Zr, Nb, Ba, REE, Pb, Th, U, W, and Cs). Among the hydrogenic processes, the formation of Fe and Mn oxyhydroxides has the greatest impact on the Mn, Fe, Co, Ni, Cu, Ge, and Mo, and insignificantly V and Sb, variability in sediments. These, along with minor to moderate values of enrichment factor (EF) for most elements, allowed us to conclude that the observed element distribution is related to predominantly natural processes of thermal abrasion, river-run, and atmospheric input. The exception is As, which exhibited the elevated EF (up to 20) in the western and central Kara Sea, as well as in the Vilkitsky Strait. Since no significant relationship between As and Fe andMn oxyhydroxides distribution was found, we may assume primarily an anthropogenic source of As, related to the peat and/or coal combustion. According to the criteria of Ecological Risks assessment, all the examined areas have a low degree of risk. Data on the specific activity of Cs-137 correspond to the background average values characteristic for these regions. The highest levels of Cs-137 concentration (Bq/kg) were detected in the sediments of the Ob and Yenisei Rivers’ estuaries. Full article

This article presents research on the structural and mechanical properties of an innovative metal matrix composite (MMC) coating designed for use in conditions of intense metal-mineral abrasive wear. The layer, which is intended to protect the working surface of drilling tools used in the oil and natural gas extraction sector, was padded using the multi-run technique on a sheet made of AISI 4715 low-alloy structural steel by Laser Direct Metal Deposition (LDMD) using a high-power fiber laser (FL). An innovative cobalt alloy matrix powder with a ceramic reinforcement of crushed titanium carbide (TiC) and tungsten-coated synthetic polycrystalline diamond (PCD) was used as the surfacing material. The influence of the preheating temperature of the base material on the susceptibility to cracking and abrasive wear of the composite coating was assessed. The structural properties of the coating were characterized by using methods such as optical microscopy, scanning electron microscopy (SEM), energy dispersion spectroscopy (EDS), transmission electron microscopy (TEM) and X-ray diffraction analysis (XRD). The mechanical properties of the hardfaced coating were assessed on the basis of the results of a metal-mineral abrasive wear resistance test, hardness measurement, and the observation of the abrasion area with a scanning laser microscope. The results of laboratory tests showed a slight dissolution of the tungsten coating protecting the synthetic PCD particles and the transfer of its components into the metallic matrix of the composite. Moreover, it was proved that an increase in the preheating temperature of the base material prior to welding has a positive effect on reducing the susceptibility of the coating to cracking, reducing the porosity of the metal deposit and increasing the resistance to abrasive wear. Full article

The geological context of this study is established in the iron oxide-copper-gold (IOCG) deposit of Sossego (Canaã dos Carajás, Brazil), where hydrothermal alterations in shear zones concentrated the metals of interest and added new characteristics to the metavolcanic-sedimentary and granite rocks. The mineral transformation of rocks by hypersaline fluids enriched in metals and silica also modifies some metallurgical properties, such as abrasiveness. Special bench tests on rock drill cores are used in mapping the abrasiveness of rocks, with the Bond abrasion test being more commonly used in the mining industry, but it has a restrictive sampling protocol and mass requirement for geometallurgical studies. As a counterpoint, the test of the Laboratoire Central des Ponts et Chaussées/Central Laboratory of Bridges and Roads (LCPC) requires a smaller amount of fine material and a finer granulometric range. The study on the use of LCPC was implemented in 40 samples, using Bond Ai as a reference. The results showed a strong correlation between both methodologies (R² = 95%), validating the use of LCPC to quantify abrasiveness in the Sossego mine. It was also possible to classify the most abrasive lithologies. Full article

The article is the continuation of a cycle of works published in a Special Issue of MDPI entitled “Innovative Technologies and Materials for the Production of Mechanical, Thermal and Corrosion Wear-Resistant Surface Layers and Coatings” related to tests concerning the microstructure and mechanical properties of innovative surface layers made using the Powder Plasma Transferred Arc Welding (PPTAW) method and intended for work surfaces of drilling tools and machinery applied in the extraction industry. A layer subjected to tests was a metal matrix composite, made using powder based on a nickel alloy containing spherical fused tungsten carbide (SFTC) particles, which are fused tungsten carbide (FTC) particles and spherical particles of tungsten-coated synthetic metal–diamond composite (PD-W). The layer was deposited on the substrate of low-alloy structural steel grade AISI 4715. The results showed that the chemical composition of the metallic powder as well as the content of the hard phase constituting the matrix enabled the making of a powder filler material characterised by very good weldability and appropriate melting. It was also found that the structure of the Ni-WC-PD-W layer was complex and that proper claddings (characterised by the uniform distribution of tungsten carbide (WC)) were formed in relation to specific cladding process parameters. In addition, the structure of the composite layer revealed the partial thermal and structural decomposition of tungsten carbide, while the particles of the synthetic metal–diamond composite remained coherent. The deposited surface layer was characterised by favourable resistance to moderate dynamic impact loads with a potential energy of 200 J, yet at the same time, by over 12 times lower metal–mineral abrasive wear resistance than the previously tested surface layer made of cobalt-based composite powder, the matrix of which contained the hard phase composed of TiC particles and synthetic metal–diamond composite. The lower abrasive wear resistance could result from a different mechanism responsible for the hardening of the spherical particles of the hard phase susceptible to separation from the metal matrix, as well as from a different mechanism of tribological wear. Full article

The article discusses test results concerning an innovative surface layer obtained using the cladding with powder plasma transferred arc welding (PPTAW) method. The above-named layer, being a metal matrix composite (MCM), is characterised by high abrasive wear resistance, resistance to pressure and impact loads, and the possibility of operation at elevated temperatures. The layer was made using powder in the form of a cobalt alloy-based composite reinforced with monocarbide TiC particles and superhard spherical particles of synthetic metal–diamond composite provided with tungsten coating. The surface layer was deposited on a sheet made of low-alloy structural steel grade AISI 4715. The layer is intended for surfaces of inserts of drilling tools used in the extraction industry. The results showed the lack of the thermal and structural decomposition of the hard layer reinforcing the matrix during the cladding process, its very high resistance to metal-mineral abrasive wear and its resistance to moderate impact loads. The abrasive wear resistance of the deposited layer with particles of TiC and synthetic metal–diamond composite was about than 140 times higher than the abrasive wear resistance of abrasion resistant heat-treated steel having a nominal hardness of 400 HBW. The use of diamond as a metal matrix reinforcement in order to increase the abrasive resistance of the PPTAW overlay layer is a new and innovative area of inquiry. There is no information related to tests concerning metal matrix surface layers reinforced with synthetic metal–diamond composite and obtained using PPTAW method. Full article

In this article, the results of research on the metal-mineral-type abrasive wear of a wear-resistant plate made by a tubular electrode with a metallic core and an innovative chemical composition using the manual metal arc hardfacing process were presented. The properties of the new layer were compared to the results of eleven wear plates manufactured by global suppliers, including flux-cored arc welding gas-shielded (FCAW-GS, Deposition Process Reference Number: 138), flux-cored arc welding self-shielded (FCAW-SS, Deposition Process Reference Number: 114), automated hardfacing, and manual metal arc welding (MMAW, Deposition Process Reference Number: 111) hardfacing T Fe15 and T Fe16 alloys, according to EN 14700:2014. Characterization of the hardfaced layers was achieved by using hardness tests, optical microscopy, confocal microscopy, scanning electron microscopy, and EDS (Energy Dispersive Spectroscopy) and X-ray diffraction analyses. Based on wear resistance tests in laboratory conditions, in accordance with ASTM G65-00: Procedure A, and surface layer hardness tests, in accordance with PN-EN ISO 6508-1, the wear plates most suitable for use in metal-mineral conditions were chosen. The results demonstrated the high metal-mineral abrasive wear resistance of the deposit weld metal produced by the new covered tubular electrode. The tubular electrode demonstrated a high linear correlation between the surface wear resistance and the hardness of the metal matrix of the tested abrasive wear plates. In addition to hardness, size, shape, the dispersion of strengthening phases, and the base metal content, depending on hardfacing technology and technological parameters, impact wear resistance is represented by volumetric loss caused by effect-free or constrained dry abrasive medium contact. The presented results can be used in machine part material selection and wear planning for applications in inspection, conservation, and regeneration interval determination. The obtained results will be applied in a real-time wear rate prediction system based on the measurement of the working parameters. Full article

The concentration of selected trace elements and the magnetic properties of samples of the lichen Evernia prunastri exposed for 3 months in Milan (Italy) were investigated to test if magnetic properties can be used as a proxy for the bioaccumulation of chemical elements in airborne particulate matter. Magnetic analysis showed intense properties driven by magnetite-like minerals, leading to significant correlations between magnetic susceptibility and the concentration of Fe, Cr, Cu, and Sb. Selected magnetic particles were characterized by Scanning Electron Microscope and Energy Dispersion System microanalyses, and their composition, morphology and grain size supported their anthropogenic, non-exhaust origin. The overall combination of chemical, morphoscopic and magnetic analyses strongly suggested that brake abrasion from vehicles is the main source of the airborne particles accumulated by lichens. It is concluded that magnetic susceptibility is an excellent parameter for a simple, rapid and cost-effective characterization of atmospheric trace metal pollution using lichens. Full article

Some marine and offshore structure elements exploited in the water cannot be brought to the surface of the water as this will generate high costs, and for this reason, they require in-situ repairs. One of the repair techniques used in underwater pad welding conditions is a wet welding method. This paper presents an investigation of the abrasive wear resistance of coatings made in wet welding conditions with the use of two grades of covered electrodes—an electrode for underwater welding and a commercial general use electrode. Both electrodes were also used for manufacturing coatings in the air, which has been also tested. The Vickers HV10 hardness measurements are performed to demonstrate the correlation in abrasive wear resistance and the hardness of each specimen. The microscopic testing was performed. For both filler materials, the coatings prepared in a water environment are characterized by higher resistance to metal–mineral abrasion than coatings prepared in an air environment—0.61 vs. 0.44 for commercial usage electrode and 0.67 vs. 0.60 for underwater welding. We also proved that in the water, the abrasive wear was greater for specimens welded by the general use electrode, which results in a higher hardness of the layer surface. In the air welding conditions, the layer welded by the electrode for use in the water was characterized by a lower hardness and higher resistance to metal–mineral abrasion. The microstructure of the prepared layers is different for both the environment and both electrodes, which results in abrasive wear resistance. Full article