Search Results (47)

Highly developed countries generate large volumes of industrial waste, the type and quantity of which are strongly linked to the characteristics of the industries that produce it. Industrial waste can adversely affect the environment, so its disposal and management are a major challenge. Understanding the characteristics of a given waste type (e.g., its chemical and phase composition, technical parameters and likelihood of releasing constituents into aquatic and soil environments) allows its potential economic applications to be determined. A simple application of mineral waste is in the production of artificial aggregates, which are increasingly used as a substitute for natural aggregates. In Poland, artificial aggregates are widely produced from metallurgical waste from steel and non-ferrous metallurgy, which may contain numerous components that are potentially environmentally damaging. Depending on their occurrence form (i.e., mineral composition), these contaminants have varying potential to be released into aquatic and soil environments. This study presents the results of mineral and chemical composition analyses and leachability tests conducted on aggregates produced from metallurgical waste, including slags from blast furnaces, steelmaking, Zn and Pb production, and Ni production. The studied aggregates are characterised by chemical and phase composition differences, resulting from the type of slag from which they originate. The chemical composition of blast furnace slag is dominated by CaO, SiO₂, Fe₂O₃, and MgO; steelmaking slag by CaO, Fe₂O₃, and SiO₂; Zn and Pb production slag by SiO₂, Fe₂O₃, SO₃, and CaO; and Ni production slag by SiO₂, Fe₂O₃, CaO, and Al₂O₃. The phase composition of all the tested aggregates is dominated by silicates resistant to leaching (weathering), which results in low levels of Al, Ca, Cr, Mn, Zn, Pb, Cu, As, Sr and Ni leaching, not exceeding 1.6%. Full article

In this study, a correlative approach using Raman spectroscopy and scanning electron microscopy (SEM) is introduced to meet the challenges of identifying impurities, especially carbon-related compounds in metal injection-molded (MIM) Mg-0.6Ca specimens designed for biomedical applications. This study addresses, for the first time, the issue of carbon residuals in the binder-based powder metallurgy (PM) processing of Mg-0.6Ca materials. A deeper understanding of the material microstructure is important to assess the microstructure homogeneity at submicron levels as this later affects material degradation and biocompatibility behavior. Both spectroscopic and microscopic techniques used in this study respond to the concerns of secondary phase distributions and their possible stoichiometry. Our micro-Raman measurements performed over a large area reveal Raman modes at ~1370 cm⁻¹ and ~1560 cm⁻¹, which are ascribed to the elemental carbon, and at ~1865 cm⁻¹, related to C≡C stretching modes. Our study found that these carbonaceous residuals/contaminations in the material microstructure originated from the polymeric binder components used in the MIM fabrication route, which then react with the base material components, including impurities, at elevated thermal debinding and sintering temperatures. Additionally, using evidence from the literature on thermal carbon cracking, the presence of both free carbon and calcium carbide phases is inferred in the sintered Mg-0.6Ca material in addition to the Mg₂Ca, oxide, and silicate phases. This first-of-its-kind correlative characterization approach for PM-processed Mg biomaterials is fast, non-destructive, and provides deeper knowledge on the formed residual carbonaceous phases. This is crucial in Mg alloy development strategies to ensure reproducible in vitro degradation and cell adhesion characteristics for the next generation of biocompatible magnesium materials. Full article

Superaustenitic stainless steels (SASSs) are one of the families of high-performance stainless steels, the so-called “super” grades. While sharing the face-centered cubic lattice structure typical of standard austenitic stainless steels, their chemical composition is significantly more complex. This enables them to offer an exceptional balance of superior corrosion resistance and high mechanical strength. However, the intricate chemical makeup of SASSs brings challenges, such as the phenomenon of segregation and precipitation of deleterious intermetallics. Consequently, this leads to several challenges in their processing and use. This work aims to present SASSs in detail, starting from their chemistry and metallurgy and ending with processing and applications. Hence, the first part will be dedicated to the analysis of chemistry, resulting grades, microstructure and secondary phases along with the conditions determining their formation. Afterwards, physical, mechanical and corrosion resistance characteristics will be set forth in such a way as to understand their origin and implications for processing and possible uses, with a focus on processability limitations. In fact, manufacturing and processing options significantly affect the types of products that can be developed, and, when considered alongside material attributes and costs, they help define the target markets for these alloys. Full article

Compared with powder metallurgy, centrifugal casting, jet molding, and other technologies, Laser Melting Deposition (LMD) stands out as an advanced additive manufacturing technology that provides substantial advantages in the melt forming of functional gradient materials and composites. However, when high-temperature and high-speed laser energy is applied, the resulting materials are susceptible to porosity, which restricts their extensive use in fatigue-sensitive applications such as turbine engine blades, engine connecting rods, gears, and suspension system components. Since fatigue cracks generally originate near pore defects or at stress concentration points, it is crucial to investigate evaluation methods for pore defects and stress concentration in LMD applications. This study examines the effect of pore defects on stress concentration in LMD-manufactured AlSi10Mg using the crystal plasticity finite element method and proposes a stress concentration coefficient characterization approach that considers pore size, morphology, and location. The simulation results indicate a competitive mechanism between pores and grains, where the larger entity dominates. Regarding the influence of aspect ratio on stress concentration, as the aspect ratio decreases along the stress direction, the stress concentration increases significantly. When pores are just emerging from the surface (s/r = 1), the stress concentration caused by the pore reaches its maximum, posing the highest risk of material failure. To assess the extent to which the aspect ratio, position, and size of pores affect stress concentration, a statistical correlation analysis of these variables was conducted. Full article

The quality of manufacturing processes largely depends on applying modern design methods and technologies. Much progress has been made in the field of metallurgy and the physics of welding, including the weld pool hydrodynamics, the surface and volumetric forces of different origins, the modeling of the SP crystallization process, and the structural transformation morphology in SWC. Additionally, attempts have been made to use the normalized parameters of fracture mechanics to evaluate the material SU. The above-mentioned solutions have also been given a more specific character by establishing SINTAP procedures and computational welding mechanics (CWM). This study discusses a universal method for welded joint evaluation according to the most significant criteria and relevant descriptive features. Full article

Recirculation in vanadium mining enhances resource efficiency but risks ammonia nitrogen (NH₃-N) accumulation, severely compromising leaching yields. To address this bottleneck, we developed a bioaugmentation strategy using Pseudomonas sp. S.P-1 acclimated to vanadium stress. Under optimized conditions (sodium citrate as a carbon source, C/N = 5, 5% inoculum, and pH = 8), the strain achieved exceptional NH₃-N (2000 mg·L⁻¹) removal (>99.25% within 16 days; residual NH₄⁺ < 15 mg·L⁻¹), 12.7% higher than the original bacteria. Mechanistic studies revealed that vanadium exposure triggered dual adaptive responses: enhanced biosorption via the stimulated synthesis of extracellular polymeric substances (EPS) enriched with negatively charged functional groups (C=O, -COOH-, and C-N), improving NH₄⁺ adsorption capacity, and metabolic activation via an elevated transmembrane electrochemical potential and an accelerated substrate uptake due to cell membrane permeability, while up-regulation of ammonia monooxygenase (AMO) activity (123.11%) facilitated efficient NH₄⁺→NH₂OH conversions. Crucially, this bio-process enabled simultaneous NH₃-N degradation (89.2% efficiency) and vanadium recovery, demonstrating its dual role in pollution control and critical metal recycling. By integrating microbial resilience with circular economy principles, our strategy offers a scalable prototype for sustainable vanadium extraction, aligning with low-carbon metallurgy demands in clean energy transitions. This study investigated the ability of vanadium stress to enhance microbial ammonia nitrogen metabolism, and by acclimatizing S.P-1 to vanadium-containing solutions, we aimed to address the dual problems of NH₃-N accumulation and vanadium toxicity in wastewater recirculation. Full article

Rare earth elements (REEs) possess unique physical and chemical properties that render them indispensable in various industries, including electronics, energy production and storage, hybrid and electric vehicles, metallurgy, and petro-chemical processing. The criticality of REE underscores the need to enhance the efficiency of primary resource extraction and promote circularity through increased recycling from secondary sources. This paper provides a brief overview of REE recovery from secondary sources, particularly waste from electronic and electric equipment (WEEE). The discussion encompasses direct reuse of magnets, short-loop recycling (direct recycling), hydro- and pyrometallurgical processes, highlighting microwave (MW) technology. Original results are presented, focusing on the recovery of neodymium (Nd) from permanent magnet scraps from hard disk drives (HDD-PC) using microwave-assisted liquid metal extraction (LME) with magnesium (Mg) as the extractant. The subsequent separation of Nd from the Mg-Nd alloy via vacuum Mg distillation that is reused in the process is described. The experimental study demonstrates that the LME process, conducted in a microwave furnace, is a viable method for recovering Nd from permanent magnet scraps, which are essential for reducing the environmental impact of REE extraction and promoting a circular economy. By separating Nd from the alloy through vacuum distillation (450–550 mmHg), at temperatures of 850–900 °C for 8 h, a Nd sponge with a content of 95–98 wt.% Nd was obtained. The extracted content of Nd in the Mg alloy increases with increasing temperature and holding time. It was found that ≈ 97% of the Nd in the scrap was extracted from 2 to 5 mm crushed scrap at 800 °C for 8 h, using a LiF-LiCl-MgF₂ protecting flux in a furnace Ar atmosphere. Full article

The paper presents the original results of cyclic testing of materials that are identical in chemical composition but produced by two different technologies: conventional metallurgy and additive manufacturing. For the aluminium alloy AlSi10Mg and the austenitic steel 316L, tensile curves, tension–compression and torsion alternating fatigue curves are experimentally obtained and presented. The experimental results are compared for two fabrication technologies—conventional metallurgy and additive DLMS technology. The results indicate a significant effect of anisotropy on the fatigue performance of the AM materials and a different slope of the fatigue life curves in the cyclic torsion versus cyclic tension–compression. The static and, in particular, the fatigue properties of both materials are discussed in relation to the microstructure of the materials after conventional production and after additive manufacturing. This comparison allowed us to explain both the causes of the anisotropy of the AM materials and the different slope of the curves for normal and shear stresses under cyclic loading. Using the example of the strength assessment of bicycle frames, the possibility of progressively wider use of additive manufacturing for load-bearing structures is presented. Full article

This paper investigates the enhancement of the microstructure and properties of Ag-10La_0.7Sr_0.3CoO₃ composites, prepared by powder metallurgy, through the application of high-current pulsed electron beam (HCPEB) irradiation. The X-ray diffraction results showed that the irradiated samples exhibited selective orientations on the surface of their (200) and (311) crystal planes. Microstructural observations revealed a dense remelted layer on the samples’ surface after HCPEB irradiation. The surface hardness of the samples increased after 15 treatments, showing an improvement of 36.76%. This is primarily attributed to fine-grain strengthening, surface remelting, and recrystallization. Further, the electrical conductivity of the samples treated 15 times increased by 74.8% compared to that of the original samples. Electrochemical test results showed that the samples treated 15 times showed the lowest corrosion current density in a 3.5 wt.% NaCl solution. This improved corrosion resistance is attributable to the refinement of the surface’s microstructure and the introduction of residual compressive stress. This study demonstrates the significant impact of HCPEB irradiation on the regulation of the properties of Ag-10La_0.7Sr_0.3CoO₃ composites. Full article

The conventional iron and steel industry (ISI), driven by coal utilization as its predominant feedstock, constitutes a substantial source of greenhouse gas emissions. Hydrogen metallurgy presents the opportunity to mitigate carbon emissions in ISI from the origin. Among hydrogen metallurgical approaches, the hydrogen-based direct reduction iron (H-DRI) process stands out for its substantial carbon reduction capabilities and established technological maturity. The present paper provides a comprehensive review of the development and application surrounding the H-DRI process. Firstly, the main chemical reactions of H-DRI and the relevant important parameters are introduced. Subsequently, an overview is provided of several prominent H-DRI processes, including HYL, Midrex, Midrex-H₂^®, HYL-III, HYL-ZR, BL, and Finmet, elucidating their characteristics through comparative analysis. Moreover, some research results of H-DRI process optimization are summarized. Leveraging insights garnered from globally representative projects exemplifying the industrial deployment of H-DRI technology in recent years, the trajectory of and prospective trends for industrial development in the field of H-DRI processes are explored. Further, prevailing challenges and impediments encountered in the adoption of H-DRI processes are identified, culminating in strategic recommendations tailored towards fostering future advancements. In the long term, the H-DRI process is expected to become a key path to achieve ISI cleaner production. Full article

Powder metallurgy–hot isostatic pressing (PM-HIP) is a form of advanced manufacturing that offers the ability to produce near-net shape components that are otherwise not achievable via conventional forging or wrought manufacturing. Accessing the design space of PM-HIP is dependent upon the ability to achieve uniform or known properties in finalized components, which has resulted in a number of programs aimed at identifying properties achievable via PM-HIP manufacturing. One result of these programs has been the consistent observation of a variation in toughness observed for the low-alloy steel ASTM A508 Grades 3 and 4N. While observed, the degree of variability and the mechanism resulting in the variability have not yet been fully defined. Thus, a systematic approach to evaluate the variation observed in impact toughness in PM-HIP ASTM A508 Grade 4N was proposed to elucidate the responsible metallurgical mechanism. Four unique billets manufactured from two heats of powder with different particle size distributions (PSDs) were fabricated and tested for impact toughness and tensile properties. The degradation in impact toughness was confirmed to be location-specific where the near-can region of all billets had reduced impact toughness relative to the interior of each billet. The mechanism driving the location-specific property development was identified to be mobile oxygen that follows the thermal gradient that develops during the HIP cycle and leads to a redistribution of mobile oxygen where oxygen is concentrated ~1” inboard of the original canister/billet interface. Redistributed oxygen then forms stable oxides along coincident prior particle and prior austenite grain boundaries, effectively reducing the impact toughness. With the mechanism now addressed, necessary actions can be taken to mitigate the effect of the oxygen redistribution, allowing for use in PM-HIP A508 Grade 4N in commercial industry. Full article

Yunnan Province is rich in mineral resources. Early mining, processing, metallurgy, and other mining activities produce three industrial wastes (waste water, waste gas, and waste residue) causing environmental pollution. Considering the legacy site of a mineral processing plant in Yunnan as the research object, 21 sampling points in the study area and 12 control sampling points in the periphery were set up to determine the contents of the heavy metal(loid)s As, Hg, Cd, Cu, Ni, Pb, and Cr in the soil. The spatial distribution of heavy metal(loid)s was interpolated and analyzed using Arcmap10.8, and combined with the single-factor index, Nemero Comprehensive Pollution Index, and the health risk assessment method for the heavy metal(loid) pollution status and health risk of the soil were evaluated. The soil in the study area was acidic, with the largest average value of elemental As and the largest percentages of control and screening values. The results of the single-factor and Nemero composite pollution index showed the following trend: As > Pb > Cd > Cu > Ni > Hg. Cd, Cu, and Pb mainly originate from mining and metallurgy and Hg from the combustion of fossil fuels, while soil-forming substrates are the main sources of Ni. Pollution by As was the most prominent element, whereas pollution by Cd, Cu, and Pb in some areas also cannot be ignored to prevent negative impacts on residents. It is recommended to remediate and treat the soil on site for public events; therefore, this study fills the gap in studying potential ecological risks, human health risk assessments, and sources of exposure (oral ingestion, respiratory ingestion, dermal contact). Full article

Effectively managing the quality of iron ore is critical to iron and steel metallurgy. Although quality inspection is crucial, the perspective of sintered surface identification remains largely unexplored. To bridge this gap, we propose a deep learning scheme for mining the necessary information in sintered images processing to replace manual labor and realize intelligent inspection, consisting of segmentation and classification. Specifically, we first employ a DeepLabv3+ semantic segmentation algorithm to extract the effective material surface features. Unlike the original model, which includes a high number of computational parameters, we use SqueezeNet as the backbone to improve model efficiency. Based on the initial annotation of the processed images, the sintered surface dataset is constructed. Then, considering the scarcity of labeled data, a semi-supervised deep learning scheme for sintered surface classification is developed, which is based on pseudo-labels. Experiments show that the improved semantic segmentation model can effectively segment the sintered surface, achieving 98.01% segmentation accuracy with only a 5.71 MB size. In addition, the effectiveness of the adopted semi-supervised learning classification method based on pseudo-labels is validated in six state-of-the-art models. Among them, the ResNet-101 model has the best classification performance, with 94.73% accuracy for the semi-supervised strategy while only using 30% labeled data, which is an improvement of 1.66% compared with the fully supervised strategy. Full article

Objective: The aim of the present work is to study the microstructure, wear behavior, physical properties, and micro-hardness of the aluminum matrix AA6061 reinforced with TiC and B₄C nanoparticles with different concentrations of 2.5, 5, 7.5, 10, and 12.5 wt.%. Methodology: Al/B₄C and Al/TiC nanocomposites were fabricated with a powder metallurgy route. A dry sliding wear test was performed with a pin-on-disc machine. The wear test was performed at the applied loads of 3, 6, 9, 12, and 15 N at a constant time for about 10 min. The microstructural analysis of the fabricated nanocomposites was examined via field emission scanning electron microscopy (FESEM) and X-ray diffraction (XRD) analysis. The obtained data: The results of this work show that increasing the applied load leads to a decrease in the wear rate of the aluminum matrix and its nanocomposites. The wear rate of the aluminum matrix without any additives is about 7.25 × 10⁻⁷ (g/cm), while for Al/TiC and Al/B₄C, it is 5.1 × 10⁻⁷ (g/cm) and 4.21 × 10⁻⁷ (g/cm), respectively. An increment in B₄C percent increases the actual density, while an increment in TiC percent minimizes the actual density at 2.90 g/cm³ and 2.51 g/cm³, respectively. An increment in B₄C percent decreases by 4.61%, while the porosity slightly increases with increases in TiC percent of 6.2%. Finally, the micro-hardness for Al/B₄C is about 92 (HRC), and for Al/TiC, it is about 87.4 (HRC). Originality: In the present work, nanocomposites were fabricated using a powder metallurgy route. Fabricated nanocomposites are important in engineering industries owing to their excellent wear resistance, low thermal distortion, and light weight compared with other nanocomposites. On the other hand, Al/B₄C and Al/TiC nanocomposites fabricated with a powder metallurgy route have not previously been investigated in a comparative study. Therefore, an investigation into these nanocomposites was performed. Full article

Acid mine drainage originates from mining waste, tailings and overburden being exposed to air and water; it is also observed in abandoned mines, characterized by high acidity and increased concentrations of sulfate and heavy metals. It is considered a notorious pollutant, mostly affecting superficial and ground water quality. Until 1977, Lavrion mines have been the heart of dynamic Greek mining and extractive metallurgy. The present paper discusses the possibility of using low-cost eco-friendly materials, i.e., natural and synthetic zeolites for the in situ rehabilitation of Lavrion mine soil. Na-P1 synthetic zeolite prepared from Meliti fly ash and two natural zeolites from Samos tuffs mostly containing clinoptilolite and mordenite, respectively, were employed. The results indicated that all three aluminosilicates alleviated two basic soil parameters closely correlated with fertility, i.e., high acidity and low CEC. Regarding toxic metals leaching, Na-P1 synthetic zeolite proved more efficient, reducing heavy metal contents in the leachates by 38%, 72%, 61%, 67%, 77% and 33% for Pb, Cd, Zn, Cu, Mn and Fe, respectively. This was attributed to both the increased pH and CEC values of the Na-P1 zeolite. Between the Samos zeolites, the richest in mordenite exhibited the better performance. Full article