A quasi-chemical viscosity model for fully liquid slags in the Al2O3-CaO-'FeO'-SiO2 system

A structurally based viscosity model for fully liquid silicate slags has been proposed and applied to the Al2O3-CaO-'FeO'-SiO2 system at metallic iron saturation. The model links the slag viscosity to the internal structure of melts through the concentrations of various anion/cation structural units (SUs). The concentrations of structural units are equivalent to the second nearest neighbor bond concentrations calculated by the quasi-chemical thermodynamic model. This viscosity model describes experimental data over the entire temperature and composition range within the Al2O3-CaO-'FeO'-SiO2 system at metallic iron saturation and can be extended to other industrial slag systems.

Phase equilibria in high MgO ferro-manganese and silico-manganese smelting slags

Liquidus isotherms and phase equilibria have been determined experimentally for a pseudo-ternary section of the form MnO-(CaO+MgO)-(SiO2+Al2O3) with a fixed Al-2,O-3,/SiO2, weight ratio of 0.17 and MgO/CaO weight ratio of 0.17 for temperatures in the range 1473-1673 K. The primary phase fields present for the section investigated include manganosite (Mn,Mg,Ca)O; dicalcium silicate alpha-2(Ca,Mg,Mn)O (.) SiO2; merwinite 3CaO(.) ((Mg,Mn)O.2SiO(2); wollastonite [(Ca,Mg,Mn)(OSiO2)-Si-.]; ;tephroite [2(Mn,Mg)O.SiO2]; rhodonite [(Mn,Mg)O. diopside [(CaO,MgO,MnO,Al2O3)(SiO2)-Si-.]; tridymite (SiO2), SiO2] and melilite [2CaO (.) (MgO,MnO,Al2O3).2(SiO2,Al2O3)]. The liquidus temperatures relevant to ferro-manganese and silico-manganese smelting slags have been determined. The liquiclus temperature is shown to be principally dependent on the modified basicity weight ratio (CaO+Mgo)/(SiO2+Al2O3) at low MnO concentrations, and dependent on the mole ratio (CaO+ MgO+MnO)/(SiO2+Al2O3) at higher MnO concentrations.

Effects of Al2O3 on phase equilibria in the olivine primary phase field of the MgO-"FeO"-SiO2-Al2O3 system in equilibrium with metallic iron

Liquidus temperatures and phase equilibria have been determined in the olivine primary phase field of the MgO-FeO-SiO2-Al2O3 system. Liquidus isotherms have been determined in the temperature range from 1748 to 1873K. The results are presented in the form of pseudo-ternary sections of the MgO-FeO-SiO2 with 2 and 3wt% Al2O3 in the liquid. The study enables the liquidus to be described for a range of SiO2/MgO ratios. It was found that liquidus temperatures in the olivine primary phase field decrease with the addition of Al2O3.

Effect of Al2O3 and Cr2O3 on loquidus temperatures in the cristobalite and tridymite primary phase fields of the MgO-"FeO"-SiO2 ststem in equilibrium with metallic iron

The effects of alumina and chromite impurities on the liquidus temperatures in the cristobalite/tridymite (SiO2) primary phase fields in the MgO-FeO-SiO, system in equilibrium with metallic iron have been investigated experimentally. Using high temperature equilibration and quenching followed by electron probe X-ray microanalysis (EPMA), liquiclus isotherms have been determined in the temperatures range 1 673 to 1 898 K. The results are presented in the form of pseudo-ternary sections of the MgO-FeO-SiO, system at 2, 3 and 5 wt% Al2O3, 2 wt% Cr2O3, and 2 wt% Cr2O3+2 wt% Al2O3. The study enables the liquidus to be described for a range of SiO2/MgO and MgO/FeO ratios. It was found that liquiclus temperatures in the cristobalite and tridymite primary phase fields, decrease significantly with the addition of Al2O3 and Cr2O3.

Kinetics of reduction of FeO from slag by graphite and coal chars

The rates of reduction of FeO from iron-saturated FeO-CaO-Al2O3-SiO2 slags by graphite, coke, bituminous coal and anthracitic coal chars at temperatures in the range 1 673-1873 K have been measured using a sessile drop technique. The extents of reaction were determined using EPMA analysis of quenched samples, and on line gas analysis using a quadrupole mass spectrometer. The reaction rates have been shown to be dependent critically on carbon type. For the reaction geometry used in this investigation the reduction rates of graphite and coke are observed to be faster than with coal chars. This unexpected finding is shown to be associated with differences in the dominant chemical and mass transfer mechanisms occurring at the reaction interface. High reaction rates are observed to occur with the formation of liquid Fe-C alloy product and the associated gasification of carbon from the alloy. The rates of reduction by coal chars are determined principally by the chemical reaction at the carbon/gas interface and slag phase mass transfer.

Observations of the reduction of FeO from slag by graphite, coke and coal char

The reduction of FeO from iron-saturated FeO-CaO-Al2O3-SiO2 slags by graphite, coke and coal char at 1 673 K has been investigated using a sessile drop technique. Metallographic analysis of samples quenched from the reaction temperature, and in situ observations of the reaction interface, reveal significant differences in the slag/carbon contact, and in the morphologies of the product iron and its composition; these differences were found to depend on the carbon type used in the reduction. In particular it has been shown that, in the case of graphite and coke, liquid Fe-C droplets were rapidly formed at the slag/C interface. Reactions of the slag with coal chars, in contrast, result predominantly in the formation of solid iron. These observations indicate that the reaction pathways, and hence reaction kinetics, are dependent on carbon type.

Hydrogen storage of magnesium-based nanocomposites system

Hydrogen storage in traditional metallic hydrides can deliver about 1.5 to 2.0 wt pct hydrogen but magnesium hydrides can achieve more than 7 wt pct. However, these systems suffer from high temperature release drawback and chemical instability problems. Recently, big improvements of reducing temperature and increasing kinetics of hydrogenation have been made in nanostructured Mg-based composites. This paper aims to provide an overview of the science and engineering of Mg materials and their nanosized composites with nanostructured carbon for hydrogen storage. The needs in research including preparation of the materials, processing and characterisation and basic mechanisms will be explored. The preliminary experimental results indicated a promising future for chemically stable hydrogen storage using carbon nanotubes modified metal hydrides under lower temperatures.

Mechanics of raceway hysteresis in a packed bed

When a gas is introduced at high velocity through a nozzle into a packed bed, it creates a raceway in the packed bed. It has been found that the raceway size is larger when it is formed by decreasing the gas velocity from its highest value than when it is formed by increasing the gas velocity. This phenomenon is known as raceway hysteresis. A hypothesis has been oroposed to explain the hysteresis phenomenon based on a force-balance approach which includes frictional, bed-weight, and pressure forces. According to this hypothesis, the frictional force acts in different directions when the raceway is expanding and contracting. In this article, the entire packed bed has been divided into radial and Cartesian co-ordinate systems, and the forces acting on the raceway have been solved analytically for a simplified one-dimensional case. Based on the force-balance approach, a general equation has been obtained to predict the diameter of the raceway for increasing And decreasing velocities. A reasonable agreement has been found between the theoretical predictions and experimental observations. The model has also been compared with published experimental and plant data. The hysteresis mechanism in the packed beds can be described reasonably by taking into consideration the direction of frictional forces for the increasing- and decreasin-velocity cases. The effects of the particleshape factor and void fraction on the raceway hysteresis are examined.

Segregation of particles and its influence on the morphology of the eutectic silicon phase in Al-7 wt.% Si alloys

A new modification phenomenon is reported for Al-Si alloys, where the Al-Si eutectic is refined by segregated TiB2 particles. The TiB2 particles are pushed to the Al-Si phase boundary during solidification of the eutectic and it is believed that at high concentrations the TiB2 particles restrict solute redistribution causing refinement of the Si. (c) 2005 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Thermal strain in the mushy zone related to hot tearing

A volume-averaged two-phase model addressing the main transport phenomena associated with hot tearing in an isotropic mushy zone during solidification of metallic alloys has recently been presented elsewhere along with a new hot tearing criterion addressing both inadequate melt feeding and excessive deformation at relatively high solid fractions. The viscoplastic deformation in the mushy zone is addressed by a model in which the coherent mush is considered as a porous medium saturated with liquid. The thermal straining of the mush is accounted for by a recently developed model taking into account that there is no thermal strain in the mushy zone at low solid fractions because the dendrites then are free to move in the liquid, and that the thermal strain in the mushy zone tends toward the thermal strain in the fully solidified material when the solid fraction tends toward one. In the present work, the authors determined how variations in the parameters of the constitutive equation for thermal strain influence the hot tearing susceptibility calculated by the criterion. It turns out that varying the parameters in this equation has a significant effect on both liquid pressure drop and viscoplastic strain, which are key parameters in the hot tearing criterion. However, changing the parameters in this constitutive equation will result in changes in the viscoplastic strain and the liquid pressure drop that have opposite effects on the hot tearing susceptibility. The net effect on the hot tearing susceptibility is thus small.

Influence of anodising current on the corrosion resistance of anodised AZ91D magnesium alloy

The thickness, chemical composition and microstructure of anodised coatings formed on magnesium alloy AZ91D at various anodising current densities were measured. It was found that all these parameters could be affected by anodising current density, and hence the coatings formed at different anodising current densities had different corrosion resistances. This suggests that the corrosion performance of an anodised coating could be improved if a properly designed current waveform is used for anodising. In addition, based on the experimental results, some physical, chemical and electrochemical reactions involved in the anodising process were proposed to explain the anodising behaviour in this paper. (c) 2005 Elsevier Ltd. All rights reserved.

The effect of the atmosphere and the role of pore filling on the sintering of aluminium

Alloys of Al-3.8Cu-1Mg-0.7Si, Al-4Cu-0.6Si-0.1Mg, Al-4Cu-1.2Mg and Al-1.9Mg-1.9Si were made using air atomised powder and conventional press-and-sinter powder metallurgy techniques. These were sintered under nitrogen with a controlled water content which varied from 3 to 630 ppm (a dew point of -69 to -25 degrees C), nitrogen-5%hydrogen, argon and argon-5% hydrogen, all at atmospheric pressure, or a vacuum of

Heterogeneous nucleation of Mg-Al alloys

Grain size is one of the most important microstructural characteristics determining the mechanical properties and therefore the service performance of polycrystalline materials. Heterogeneous nucleation involves the addition or in situ formation of potent nuclei in the system to promote nucleation events, leading to a fine grain structure. This paper reports experimental results using graphite and SiC as potential grain refining agents to form in situ nuclei for Mg in Mg-Al alloys, and demonstrates the key role of Al4C3 in grain refilling this important alloy system. This insight will contribute to the design and development of the most cost effective, eco-friendly grain refining agents for Mg-Al alloys. (c) 2006 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Influence of geometry on galvanic corrosion of AZ91D coupled to steel

The influence of geometric factors on the galvanic current density distribution for AZ91D coupled to steel was investigated using experimental measurements and a BEM model. The geometric factors were area ratio of anode/cathode, insulation distance between anode and cathode, depth of solution film covering the galvanic couple and the manner of interaction caused by two independent interacting galvanic couples. The galvanic current density distribution calculated from the BEM model was in good agreement with the experimental measurements. The galvanic current density distribution caused by the interaction of two independent galvanic couples can be reasonably predicted as the linear addition of the galvanic current density caused by each individual galvanic couple. (c) 2005 Elsevier Ltd. All rights reserved.