Search Results (7)

Additive manufacturing methods can constitute a valuable alternative to conventional production techniques for components used in the heavy industry, particularly in foundry applications. This innovative manufacturing approach enables an expanded product portfolio as well as higher precision and geometrical complexity of ceramic components. One additive technology applicable to ceramic processing is robocasting, classified within the direct ink writing (DIW) family. In this method, a semi-fluid ceramic paste is extruded to build the part layer by layer; the shaped green body is subsequently fired (sintered) to attain its final functional properties. This study presents the results of materials characterization of printed ceramic filters, encompassing phase composition analysis, density measurements, three-point bending strength testing, hardness, and microstructural examination. The investigations demonstrated that the oxide ceramic Al₂O₃ processed by the modern robocasting method exhibits mechanical performance at a comparably high level relative to classical manufacturing routes (slip casting, ceramic injection molding, dry pressing). Moreover, the porosity results indicate that 3D printing technology enables lower post-sintering porosity. Full article

The article provides a brief overview of technologies and methods for processing dispersed metallic waste generated during ferroalloy production, including high-carbon ferrochrome (HCFeCr). It is noted that the most cost-effective and rational method for reusing metallic dust is briquetting. Considering the development of briquetting technologies, as well as the latest equipment and binder materials involved in this process, aspiration dust from ferrochrome crushing can be fully utilized in metallurgical recycling. To verify this assumption, laboratory studies were conducted using polymer-based binders and liquid glass as a baseline option. The methodology of briquetting using both laboratory and industrial presses is described, along with an assessment of the mechanical properties of the briquettes. The studies indicate that the introduction of an inert filler (gas-cleaning dust) into the metallic dust composition improves the briquetting ability of the mixture by enhancing adhesion between metal particles and the binder. The obtained industrial briquette samples exhibit high mechanical strength, ensuring their further use in metallurgical processing. The study concludes that semi-dry briquetting using hydraulic vibropresses is a promising approach for the utilization of dispersed ferroalloy waste. Full article

This paper investigates the preparation and properties of high-strength artificial blocks made from dredged silt with a clay content of 52.0%. A comparative analysis of the mechanical properties of dredged silt blocks produced using semi-dry pressing and vibration molding methods was conducted. The study examined the effects of using fly ash (FA) and ground granulated blast-furnace slag (GGBS) as substitutes for cement on the compressive strength, splitting tensile strength, and dry shrinkage of the blocks. Additionally, the microstructure of the dredged silt blocks was analyzed using scanning electron microscopy (SEM), mercury intrusion porosimetry (MIP), and thermogravimetric analysis. The results show that specimens prepared using the pressing method exhibit better mechanical performance with compressive and splitting tensile strength reaching 64.8 MPa and 5.6 MPa at 28 d, respectively, which increased by 111.07% and 143.48% compared to specimens prepared through vibration molding. The addition of FA and GGBS reduces the early strength of the block to a certain extent but without a significant adverse effect on later strength. GGBS demonstrates faster hydration and a better filling effect. The addition of GGBS or FA refines the pore structure and reduces the diameter of pores in the paste, which is beneficial for improving the dry shrinkage performance of the block. At 120 d, the dry shrinkage of blocks containing 50% FA and GGBS shows a reduction of 29.7% and 27.1%, respectively, compared to blocks made with cement. The properties of the silt blocks can be notably enhanced through mechanical force, particle gradation, and hydration action. The preparation of artificial blocks such as road bricks and ballast blocks using dredged soil as the main raw material has been applied in projects such as the Yangtze River waterway regulation in China and Skikda Port in Algeria. Full article

The search for ways to utilize and recycle industrial by-products is the basic principle that governs rational environmental management, synthesis of “green” materials, and appears as one of the main criteria for sustainable development in most countries of the world. Gypsum-containing waste (GCW) derived from industries, represents a large-tonnage product. The production of gypsum materials could be one of the ways to recycle GCW products. GCW from various industries can be used as an alternative to natural raw materials when producing gypsum binders. However, the features of GCW do not allow the production of a high-quality binder when traditional technologies are applied, so it requires the development of additional methods or the introduction of various modifiers to the binder system. One of the ways to increase the efficiency of GCW as a raw material for the production of gypsum binders is to apply a semi-dry pressing method, at reduced values of the W/S ratio of the binder. The objective of this research was to study the possibility of increasing the efficiency of GCW using citrogypsum for production of gypsum materials, by optimization of the mix design and by applying a semi-dry pressing method, using a lower pressure load at the molding stage. The mix design and technological parameters were optimized using mathematical planning of the experimental method. Parameters such as the amount of citrogypsum as an additive in the raw mixture, molding pressure, and water–solid (W/S) ratio were taken as input parameters of variation. To plot the relationship of the input–output parameters, the SigmaPlot software was applied, to analyze and demonstrate scientific and statistical data in the form of nomograms. It has been established that the use of the semi-dry pressing method with the optimal mix design and technological parameters, makes it possible to obtain gypsum samples with demolding strengths up to 2 MPa, and final compressive strengths up to 26 MPa. The incorporation of citrogypsum and the optimal W/S ratio of 0.25, results in positive effects, such as a reduction in the sticking properties of the mix during the demolding stage, and the homogeneity of compaction and visual appearance of the samples were also improved. Full article

The use of organic amendments is seen to be a promising method for enhancing crop productivity and soil health. Therefore, this study was performed for two consecutive years (2019 and 2020) to determine the effects of organic biochar (BC), sugar industry press mud (MUD), and poultry manure (PM) combined with inorganic amendments on the yield and nutritional quality of forage sorghum at the College of Agriculture, Bahauddin Zakariya University, Bahadur sub-campus, Layyah, Pakistan. The treatments were comprised of the following: control (no inorganic or organic amendments added); recommended dose of NPK (59:72:30 kg ha⁻¹); half dose of NPK (29.5:36:15 kg ha⁻¹); recommended dose of poultry manure (PM) at 5 t ha⁻¹; recommended dose of press mud (MUD) at 40 t ha⁻¹; recommended dose of biochar (BC) at 11 t ha⁻¹; BC + half NPK; MUD + half NPK; PM + half NPK; PM + BC + half NPK; PM + MUD + half NPK; BC + MUD + half NPK; PM + BC + MUD + half NPK. The treatments were carried out in a triplicate randomized complete block design. Results revealed that combined application of PM + BC + MUD + 1/2 NPK significantly enhanced the plant height (201 cm), number of leaves (17), stem diameter (18 mm), stem dry weight (201.7 g), leaf dry weight (30.4 g), leaf area (184.3 cm²), green forage yield (31.8 Mg ha⁻¹), and dry biomass yield (12.7 Mg ha⁻¹) compared with the control treatment. Forage quality traits, including crude protein (CP), brix percentage, acid detergent fiber (ADF), and acid detergent lignin (ADL), showed maximum value with the combined application of PM + BC + MUD + 1/2 NPK. ADF and ADL are linked with lower digestibility; therefore, it was concluded that the combined application of PM + BC + MUD + 1/2 NPK can improve the productivity, dry biomass yield, and CP of sorghum, but reduces the digestibility under semi-arid conditions, such as those in Central Pakistan. Full article

The additive manufacturing of BaTiO₃ (BT) ceramics through stereolithography (SLA) 3D printing at 465 nm wavelength was demonstrated. After different milling times, different paste compositions with varied initial micron-sized powders were studied to find a composition suitable for 3D printing. The pastes were evaluated in terms of photopolymerization depth depending on the laser scanning speed. Furthermore, the microstructure and properties of the BT ceramic samples produced through SLA 3D printing were characterized and compared with those of ceramics fabricated through a conventional die semi-drying pressing method. Three-dimensional printed samples achieved relative densities over 0.95 and microhardness over 500 HV after sintering, nearly matching the relative density and microhardness attained by the pressed samples. Upon poling, the 3D-printed samples attained acceptable piezoelectric module d₃₃ = 148 pC/N and dielectric constants over 2000. At near full density, BT piezoceramics were successfully fabricated through SLA 3D printing at 465 nm wavelength, achieving photopolymerization depth of more than 100 microns. This work paves the relatively low-cost way for 3D printing of piezoelectric ceramics using conventional micron-sized powders and high printed layer thickness. Full article

In view of growing interest and investment in continuous manufacturing, the development and utilization of mathematical model(s) of the manufacturing line is of prime importance. These models are essential for understanding the complex interplay between process-wide critical process parameters (CPPs) and critical quality attributes (CQAs) beyond the individual process operations. In this work, a flowsheet model that is an approximate representation of the ConsiGma ${}^{\mathrm{TM}}$ -25 line for continuous tablet manufacturing, including wet granulation, is developed. The manufacturing line involves various unit operations, i.e., feeders, blenders, a twin-screw wet granulator, a fluidized bed dryer, a mill, and a tablet press. The unit operations are simulated using various modeling approaches such as data-driven models, semi-empirical models, population balance models, and mechanistic models. Intermediate feeders, blenders, and transfer lines between the units are also simulated. The continuous process is simulated using the flowsheet model thus developed and case studies are provided to demonstrate its application for dynamic simulation. Finally, the flowsheet model is used to systematically identify critical process parameters (CPPs) that affect process responses of interest using global sensitivity analysis methods. Liquid feed rate to the granulator, and air temperature and drying time in the dryer are identified as CPPs affecting the tablet properties. Full article