Alumina Inclusions Research Articles

Development of a Reliable Kinetic Model for Ladle Refining

Kinetic modeling of ladle refining can be used by steel plants to improve steelmaking and to produce cleaner steels. It can also help researchers to understand the process better. There have been several recent attempts to develop a kinetic model that can predict changes in steel, slag, and inclusion compositions with time. Often the models require parameters that can be difficult to measure under plant conditions, and model limitations have not been discussed in detail. In this study, a two-parameter kinetic model has been developed to predict changes in steel, slag, and inclusion compositions during ladle refining; the two parameters are the mass-transfer coefficient in steel and the inclusion flotation rate constant. The model was based on FactSage macro-processing. Examples of results show that the model can be used to diagnose effects of steel and slag sampling practices and to estimate alloy dissolution time. The model results demonstrate that the presence of solids in slag can significantly reduce the rate of steel–slag reaction while maintaining a high inclusion flotation rate. Some limitations of the model are discussed: the overprediction of calcium transfer to alumina inclusions and the absence of information on inclusions originating from entrained slag.

Initiation Thresholds and Dynamic Characteristics of an Explosion for Thin Samples of PETN-Al Composites under Laser Irradiation

In this paper, we measured thresholds Hcr of explosive decomposition of thin (h = 1 mm) samples of PETN-Al composites with densities in the range of ρ = 0.9–1.7 g/cm3 and variations in the concentration of aluminum inclusions in the range of 0.025–1.0 wt % upon exposure to pulses of a neodymium laser (λ = 1064 nm, 14 ns). For each ρ, inclusion concentrations nopt, at which the threshold for explosive decomposition of Hcr is minimal, are obtained. The velocities of air shock waves (ASWs) were determined depending on sample density ρ, and the times of the start of explosive decomposition were determined depending on the inclusion concentration. The amplitude (in relative units) and time shift of the maximal pressure of an ASW at the piezodetector are determined depending on sample density. It is concluded that the explosion is governed by the SW mechanism at high densities. As sample ρ decreases, the completeness of the explosion increases, with the most likely mechanism for small ρ being explosive burning. The efficiency of explosive decomposition is higher for samples with lower densities.

A phase‐field model for the study of isothermal dissolution behavior of alumina particles into molten silicates

AbstractParticle dissolution process refers to the dissolving of one liquid or solid phase into another solvent phase. This process is of vital importance in the engineering material science, and chemical engineering, etc. Here, we develop a phase‐field model with diffusion‐controlled processes at interfaces for isothermal dissolution of alumina inclusion particles in molten silicates, referred as “slag,” with comprehensive compositions applied in process metallurgy. The interfacial energy between solid inclusion particle and molten silicate can vary with different temperatures and chemical compositions. This model is validated using experimental data of high‐temperature confocal laser scanning microscopy (HT‐CLSM) technique. Moreover, the developed model is applicable to predict the dissolution behavior of solid particle in a realistic size scale. The possibility of the model application is illustrated with studies of different physical parameters that affect particle dissolution behavior. The phase‐field simulations show that inclusion morphology influences both the dissolution profile and time, and the influence decreases with the increased temperature. Increasing same amount of Al2O3 component in slag, the increased degrees of the alumina dissolution time in silicates with different V‐ratio values, a ratio between the mass percent of CaO and that of SiO2, are almost the same. If the V‐ratio of slag is relatively small, an increased MgO component in the silicate will significantly decrease the particle dissolution time. On the contrary, the change in MgO component in the silicate will have a minor effect if the value of V‐ratio is quite large. In order to rapidly dissolve the inclusion, basicity index (BI) of molten silicate should be larger than 1.4. A balance between BI and MgO component in slag is suggested to be considered to design or optimize molten silicate (slag) for its application in the refining process of steel manufacturing.

Evaluation of very high cycle fatigue zones in 42CrMo4 steel with plate-like alumina inclusions

Quenched and nitrided 42CrMo4 specimens, treated by different reactive filters were tested in very high cycle fatigue regime using ultrasonic method. Despite total alumina reduction fatigue limit showed no improvement due to large alumina plates whose parameters were studied. Areal roughness of fatigue crack zones was measured by confocal laser scanning microscopy. Periodic arrest marks were studied and used for crack growth rate calculation. Smooth area was experimentally defined as a zone between fine granular area and fisheye by imaging, roughness minima, fixed ΔK = 6.4 and crack growth rate of ∼10−10 m/cycle. Classification of internal crack zones is proposed.

Hierarchical Bulk Nanoporous Aluminum for on-Board Hydrogen and Heat Generation By Hydrolysis in Pure Water

Despite the remarkable key features of hydrogen energy technology such as the high gravimetric energy density of hydrogen, the zero-emissions electricity generated using fuel cells, and the high natural abundance of hydrogen resources (particularly in the form of water), there are still many scientific and engineering challenges that must be addressed before a true sustainable hydrogen economy can be realized. Two of these challenges include sustainable hydrogen generation without CO2 emissions and effective storage of this hydrogen for specific applications. In this presentation, I will present a sustainable method to produce hydrogen on-board, which could be used to overcome the two challenges mentioned above. Our approach involves: (i) Fabrication by selective alloy corrosion of hierarchical bulk nanoporous aluminum characterized by the coexistence of both macroscopic and mesoscopic ligament/pore structures, with the mesoscopic ligaments in the range of 10-20 nm. (ii) Recovery of the sacrificial material simultaneously during selective alloy corrosion, which contributes to sustainability of the process. (iii) Use of this hierarchical bulk nanoporous aluminum to produce hydrogen and heat on-board by hydrolysis with “pure” water, with a yield of ~52-85 % during hydrogen production without incorporation of any catalyst or reaction promoter in the aluminum-water system. Besides hydrogen and heat generations, I will demonstrate the combustion of this bulk nanoporous aluminum in air and under ambient conditions, which implies that this material could be attractive as a combustion fuel catalyst, e.g. to enhance the ignition and combustion of solid propellants. Thanks to a new carbon-free sustainable pathway to extract aluminum by Elysis (https://elysis.com/en), a joint venture composed of high-profile aluminum suppliers including Rio Tinto and Alcoa, and aluminum consumers including Apple, aluminum can be obtained by electrolysis of Al2O3 without CO2 emissions. The inclusion of this carbon-free aluminum in our process will make it possible to produce hydrogen from nanoporous aluminum and pure water without greenhouse gas emissions at any stage of the process.

Quantum Oscillations in Flux-Grown SmB6 with Embedded Aluminum

SmB_{6} is a candidate topological Kondo insulator that displays surface conduction at low temperatures. Here, we perform torque magnetization measurements as a means to detect de Haas-van Alphen (dHvA) oscillations in SmB_{6} crystals grown by aluminum flux. We find that dHvA oscillations occur in single crystals containing embedded aluminum, originating from the flux used to synthesize SmB_{6}. Measurements on a sample with multiple, unconnected aluminum inclusions show that aluminum crystallizes in a preferred orientation within the SmB_{6} cubic lattice. The presence of aluminum is confirmed through bulk susceptibility measurements, but does not show a signature in transport measurements. We discuss the ramifications of our results.

Meteoritic evidence of a late superflare as source of 7Be in the early Solar System

Fossil meteoritic records of short-lived, now-extinct radionuclides provide crucial high-resolution temporal information about the events, processes and activity of the Sun during the early phases of Solar System formation1. The proposed genesis of one such radionuclide,10Be, by spallation reactions of carbon and oxygen2–5 led to the hypothesis of enhanced irradiation in the early Solar System6–8. An alternative scenario of production of 10Be (half-life t1/2 = 1.386 ± 0.016 million years9) by a neutrino process in a supernova arising from the core collapse of a low-mass star (11.8 solar masses, M⊙) has recently been suggested10 and can explain the observed abundance of 10Be in the early Solar System. Here, we report well-resolved excesses in 7Li/6Li of up to ~21.5% in a calcium- and aluminium-rich inclusion (CAI) from the Efremovka meteorite that correlate with 9Be/6Li, suggestive of in situ decay of 7Be. The in situ decay of 7Be to 7Li, with a characteristic half-life of 53.12 ± 0.07 days11, entails multiple episodes of enhanced irradiation in the early Solar System, which have been observed recently in other Sun-like stars12,13. The short half-life of 7Be limits its production by interaction of solar energetic particles (SEPs) with the nebular gas and solids, and provides constraints on the genealogy and chronology of CAIs. Irradiation of the solid and gaseous precursors of CAIs of solar composition by a superflare (X-ray luminosity approximately 1032 erg s−1) during the terminal phase of class I or II of the pre-main-sequence stages of the Sun explains the isotopic properties, distinctive petrographic features and diffusivity constraints in the CAI. Li and Be isotopic measurements of calcium–aluminium inclusions (CAIs) in the Efremovka meteorite suggest that the solid and gaseous precursors of CAIs were irradiated by a superflare during the last stages of the pre-main-sequence evolution of the Sun.

Investigation into the Structure and Oxidation Mechanism of FeAlCr/Al2O3 Detonation Spraying Coatings

The oxidation resistance of detonation spraying coatings of the FeAlCr/Al2O3 powder fabricated by mechanically assisted self-propagating high-temperature synthesis using aluminothermic reactions of oxide reduction is investigated. The powder has a sufficiently homogeneous composite structure consisting of chromium-alloyed ordered B2-FeAl and fine inclusions of α-Cr2O3 and α-Al2O3. The detonation coatings sprayed on stainless steel substrates have a typical layered structure without cracks and spalling. The coating thickness is 250–300 μm, and microhardness is in a range of 5.9–6.1 GPa. Coatings of the synthesized powder mainly inherit its structure and phase composition, although certain aluminum and chromium oxidation occurs when spraying. The features of the cyclic and isothermal oxidation of coatings in air in a temperature range of 900–1000°C are studied. It is established that the oxidation resistance of detonation coatings of the synthesized powder after oxidation in air for 48 h at 950°C is close that of coatings formed from the FeAl‒FexAly powder with an aluminum content of 45 wt %. At the same time, the linear thermal expansion coefficient (LTEC) of FeAlCr/Al2O3 coatings is closer to the LTEC of the base material, while their creep resistance is higher when compared the latter due to the presence of fine refractory oxide inclusions. It is assumed that α-Cr, Cr2O3, and numerous fine alumina inclusions present in the synthesized powder (and which form when spraying) accelerate the protective film, formation suppressing hematite nucleation and growth at early oxidation stages at temperatures up to 950°C.

Study on the Influence of FeTi‐Addition on the Inclusion Population in Ti‐Stabilized ULC Steels and Its Consequences for SEN‐Clogging

During the continuous casting of Ti‐stabilized ULC/IF steel grades clogging of the submerged entry nozzle (SEN) is frequently observed. A new statistical evaluation indicates that increasing Ti/Al‐ratios in these steels lead to an increase in the occurrence of clogging and its intensity. Investigations of samples of two TiULC heats, taken at the RH‐degasser, show a remarkable increase of inclusions due to FeTi‐addition. The presence of Ti‐bearing alumina particles contrary to the thermodynamical expectations, indicate that their formation takes place as a consequence of FeTi‐addition. Laboratory‐scale experiments confirm the formation of alumina inclusions containing traces of Ti. Their size is found to be significantly smaller compared to pure alumina inclusions. Rising numbers of small inclusions within the steel are suspected to accelerate the buildup of clogging deposits. Two mechanisms are proposed to explain the formation of these particles. On the one hand ferrotitanium acts as a source of oxygen, resulting in the formation of new inclusions during dissolution. On the other hand, the modification of preexisting deoxidation products in regions with high Ti‐contents may play a role.

Enhanced Fatigue Behavior in Quenched and Tempered High-Strength Steel by Means of Double Surface Treatments

The aim of this study is to maximize the fatigue life of a high-strength steel. For this purpose, two different kinds of double surface treatments were studied: shot peening plus vibratory finishing and shot peening plus grit blasting. First, a high-intensity peening treatment was applied, with the aim of inducing a deep region submitted to high compressive residual stresses, and a second surface treatment was followed, to reduce the roughness induced in the first treatment and mitigate the damage produced on the specimen surface. The use of such double treatments was demonstrated to be a good choice to achieve high surface hardening and deep compressive residual stress profiles and to minimize surface defects. The fatigue life of the steel was greatly enhanced following the application of both double surface treatments. A vibratory treatment applied for 24 h after the application of a previous shot peening treatment was able to increase the average fatigue life of the single shot-peened samples almost sevenfold, but a much greater fatigue enhancement was produced using grit blasting for only 60 s. Anyway, both second treatments are able to remove the damaged surface layer produced in the first high-intensity shot peening treatment. The obtained results also revealed that an appropriate combination of surface treatments (shot peening + secondary treatment) avoided the initiation of cracks at the surface of the specimens under cyclic bending loads. Instead, crack initiation took place beneath the compressive residual stress field, induced in alumina inclusions that acted as stress concentrators.

Sustainable alkaline activation of fly ash, aluminium anodising sludge and glass powder blends with a recycled alkaline cleaning solution

Introduction of new residues and wastes in the development of alkaline activated materials is a major concern regarding the spreading and dissemination of this technique. Such increase in the spectrum of available raw materials will decrease the need for long-distance transportation of the more traditional precursors that have been tirelessly used in the past two decades (e.g. fly ash, blast furnace slag). Additionally, the use of commercial activators severely hinders its environmental and financial performance, promoting the need to develop waste-based activators. In this paper, wastes from the aluminium anodising and extrusion processes and from the production of optical lenses were combined with low-calcium fly ash, to produce binders exclusively made from wastes and residues. The performance was assessed through uniaxial compression strength tests, which were accompanied by the monitorisation of several physical properties, including temperature, pH and weight; and by a thorough microscopic analysis, including scanning electron microscopy, coupled with energy dispersive spectroscopy, and x-ray diffraction, for mineralogy characterisation. Results show that the addition of glass powder and aluminium anodising sludge to class-F fly ash optimised the final precursor, which was then successfully activated with a disposed solution, originally used to clean the aluminium extrusion steel dies. The inclusion of soluble silicon and aluminium in the precursor raised the compression strength after short-term curing, compared with pastes prepared only with fly ash.

Inherent negative refraction on acoustic branch of two dimensional phononic crystals

Guided by theoretical predictions, we have demonstrated experimentally the existence of negative refraction on the two lowest acoustic-branch passbands (shear and longitudinal modes) of a simple two-dimensional phononic crystal consisting of an isotropic stiff (aluminum) matrix and square-patterned isotropic compliant (PMMA) circular inclusions. We experimentally distinguished the shear and longitudinal modes to ensure that there are no couplings between the two modes and that the shear-mode negative refraction is an inherent property of periodic composites with stiff matrix and compliant inclusions. We have also discovered that a composite with compliant (PMMA) matrix and stiff (aluminum) inclusions does not display negative shear-mode refraction on its first branch. At frequencies and wave vectors where the refraction on the acoustic-branch passbands is negative, the effective mass-density and the effective stiffness tensors of the crystal are positive-definite, and this is an inherent property of such phononic crystals.The equi-frequency contours and energy flux vectors as functions of the phase-vector components, reveal a rich body of refractive properties that can be exploited to realize, for example, beam splitting, focusing, and frequency filtration on the lowest passbands of the crystal where the dissipation is minimum. By proper selection of material and geometric parameters these phenomena can be realized at remarkably low frequencies (large wave lengths) using rather small simple two-phase unit cells.

Agglomeration of Solid Inclusions in Molten Steel

Agglomeration of alumina inclusions in the molten steel is investigated through the free energy analysis of the cavitation between inclusions. The mechanism of agglomeration, the activation state, the stable state, the equilibrium state, and the critical separation for the cavitation are discussed. The equilibrium energy is proportional to the square of the inclusion radius, EEq = 0.710R P 2 , while the critical separation is directly proportional to the inclusion radius, dC = 0.146RP. Agglomerates of micron inclusions are hardly broken up by the turbulence in steelmaking practice.

An experimental study of the inclusion behavior during maraging steel processing

Two maraging steel rods with different sulfur content, deliberately seeded with alumina (Al2O3) inclusions, were remelted in an electron beam furnace. The aim was on one hand to highlight the emergence of non-metallic inclusions at the liquid metal surface and on the other hand to study the effect of the presence of a surface active element (sulfur) on their behavior. Thein situreal time observation of Al2O3clusters was possible using both high-speed video and infrared thermography. The inclusions emerge and tend to collide and quickly agglomerate into rafts. A semi-quantitative analysis confirmed that almost 100% of inclusions are captured at the free surface. The electron beam creates large thermal gradients in the impingement zones; this induces thermocapillary convection (Marangoni effect). The flow direction depends on the sulfur content. This tendency was well-observed by following the trajectories of inclusion rafts.

Пороги инициирования и динамические характеристики взрыва для тонких образцов композитов ТЭН-Al при лазерном воздействии

AbstractIn this paper, we measured thresholds H _cr of explosive decomposition of thin ( h = 1 mm) samples of PETN-Al composites with densities in the range of ρ = 0.9–1.7 g/cm^3 and variations in the concentration of aluminum inclusions in the range of 0.025–1.0 wt % upon exposure to pulses of a neodymium laser (λ = 1064 nm, 14 ns). For each ρ, inclusion concentrations n _opt, at which the threshold for explosive decomposition of H _cr is minimal, are obtained. The velocities of air shock waves (ASWs) were determined depending on sample density ρ, and the times of the start of explosive decomposition were determined depending on the inclusion concentration. The amplitude (in relative units) and time shift of the maximal pressure of an ASW at the piezodetector are determined depending on sample density. It is concluded that the explosion is governed by the SW mechanism at high densities. As sample ρ decreases, the completeness of the explosion increases, with the most likely mechanism for small ρ being explosive burning. The efficiency of explosive decomposition is higher for samples with lower densities.

Siderophile element constraints on the thermal history of the H chondrite parent body

The abundances of highly siderophile elements (HSE: Re, Os, Ir, Ru, Pt, Pd), as well as 187Re-187Os and 182Hf-182W isotopic systematics were determined for separated metal, slightly magnetic, and nonmagnetic fractions from seven H4 to H6 ordinary chondrites. The HSE are too abundant in nonmagnetic fractions to reflect metal-silicate equilibration. The disequilibrium was likely a primary feature, as 187Re-187Os data indicate only minor open-system behavior of the HSE in the slightly and non-magnetic fractions. 182Hf-182W data for slightly magnetic and nonmagnetic fractions define precise isochrons for most meteorites that range from 5.2 ± 1.6 Ma to 15.2 ± 1.0 Ma after calcium aluminum inclusion (CAI) formation. By contrast, 182W model ages for the metal fractions are typically 2–5 Ma older than the slope-derived isochron ages for their respective, slightly magnetic and nonmagnetic fractions, with model ages ranging from 1.4 ± 0.8 Ma to 12.6 ± 0.9 Ma after CAI formation. This indicates that the W present in the silicates and oxides was not fully equilibrated with the metal when diffusive transport among components ceased, consistent with the HSE data. Further, the W isotopic compositions of size-sorted metal fractions from some of the H chondrites also differ, indicating disequilibrium among some metal grains. The chemical/isotopic disequilibrium of siderophile elements among H chondrite components is likely the result of inefficient diffusion of siderophile elements from silicates and oxides to some metal and/or localized equilibration as H chondrites cooled towards their respective Hf-W closure temperatures. The tendency of 182Hf-182W isochron ages to young from H5 to H6 chondrites may indicate derivation of these meteorites from a slowly cooled, undisturbed, concentrically-zoned parent body, consistent with models that have been commonly invoked for H chondrites. Overlap of isochron ages for H4 and H5 chondrites, by contrast, appear to be more consistent with shallow impact disruption models.The W isotopic composition of metal from one CR chondrite was examined to compare with H chondrite metals. In contrast to the H chondrites, the CR chondrite metal is characterized by an enrichment in 183W that is consistent with nucleosynthetic s-process depletion. Once corrected for the correlative nucleosynthetic effect on 182W, the 182W model age for this meteorite of 7.0 ± 3.6 Ma is within the range of model ages of most metal fractions from H chondrites. The metal is therefore too young to be a direct nebular condensate, as proposed by some prior studies.

Impact of spinel forming systems (Fe-/Mg-/Mn-Al-O) as functional coating materials for carbon-bonded alumina filters on steel melt filtration

Since solid, non-metallic inclusions influence considerably the quality of casted steel products, carbon-bonded alumina foam filters are used in secondary metallurgical treatments to remove these particles from steel melts. In order to attain a significant improvement of the filtration process, five different carbonaceous spinel compounds from the Fe-/Mg-/Mn-Al-O systems are applied on carbon-bonded alumina filters in this study and investigated with regard of their filtration efficiency. However, these spinel compounds decompose partially during sintering at 1400 °C under reducing atmosphere, wherefore the resulting coatings contain not only spinel compounds, but also oxidic and metallic components. The subsequent interaction with molten steel leads to the development of multicrystal structures on the filter surface, which stem from interfacial reactions between coating materials, molten steel, and inclusions. As a result of this procedure, a reduction of almost 60% alumina inclusions is measured with the aid of an automatic SEM, whereby spinel compounds from the Fe-Mn-Al-O system achieve highest filtration efficiencies.

Rate of MgO Pickup in Alumina Inclusions in Aluminum-Killed Steel

This work aims to clarify the rate and mechanism of MgO pickup by alumina inclusions and the effect of oxide impurities in MgO crucibles on this transformation. Two MgO crucibles from different batches from the same supplier were used in laboratory experiments with Al-killed steel. A kinetic model was developed, based on mass-transfer control in the liquid steel. Rate constants were fitted using inclusion analysis. The rate of magnesium transfer from the two types of crucibles was found to differ by a factor of 20; faster magnesium transfer was associated with formation of a slag layer on the inner surface of the crucible wall (rather than a solid spinel product layer). The kinetic model was also used to simulate industrial scale ladle refining (1) to illustrate the effects of total oxygen concentration and (2) to evaluate the contribution of steel-refractory reaction (in addition to steel-slag reaction) on the rate of MgO pickup in alumina inclusion. The rate of MgO pickup was higher with a lower inclusion concentration. For ladle desulfurization, the extent of MgO pickup in inclusions is directly linked to the extent of desulfurization; both reactions are controlled by the oxygen potential at the steel-slag interface.

Enhanced cerebellar myelination with concomitant iron elevation and ultrastructural irregularities following prenatal exposure to ambient particulate matter in the mouse

Accumulating evidence indicates the developing central nervous system (CNS) is a target of air pollution toxicity. Epidemiological reports increasingly demonstrate that exposure to the particulate matter (PM) fraction of air pollution during neurodevelopment is associated with an increased risk of neurodevelopmental disorders (NDDs) such as autism spectrum disorder (ASD). These observations are supported by animal studies demonstrating prenatal exposure to concentrated ambient PM induces neuropathologies characteristic of ASD, including ventriculomegaly and aberrant corpus callosum (CC) myelination. Given the role of the CC and cerebellum in ASD etiology, this study tested whether prenatal exposure to concentrated ambient particles (CAPs) produced pathological features in offspring CC and cerebella consistent with ASD. Analysis of cerebellar myelin density revealed male-specific hypermyelination in CAPs-exposed offspring at postnatal days (PNDs) 11–15 without alteration of cerebellar area. Atomic absorption spectroscopy (AAS) revealed elevated iron (Fe) in the cerebellum of CAPs-exposed female offspring at PNDs 11–15, which connects with previously observed elevated Fe in the female CC. The presence of Fe inclusions, along with aluminum (Al) and silicon (Si) inclusions, were confirmed at nanoscale resolution in the CC along with ultrastructural myelin sheath damage. Furthermore, RNAseq and gene ontology (GO) enrichment analyses revealed cerebellar gene expression was significantly affected by sex and prenatal CAPs exposure with significant enrichment in inflammation and transmembrane transport processes that could underlie observed myelin and metal pathologies. Overall, this study highlights the ability of PM exposure to disrupt myelinogenesis and elucidates novel molecular targets of PM-induced developmental neurotoxicity.

A Kinetic Model for Modification of MgAl2O4 Spinel Inclusions During Calcium Treatment in the Ladle Furnace

A common approach in the processing of Al-killed steels is the modification of alumina inclusions by calcium treatment. A model for this process has already been developed by the current authors and validated by means of plant data. Often, magnesium aluminate spinels are also present and transformed to magnesium calcium aluminate inclusions during calcium treatment. In the current study, a fundamental kinetic model is proposed for modification of spinel inclusions considering mass transfer of solute through the boundary layer to the inclusion and diffusion within the product layer. Sensitivity analysis has been carried out to determine rate-controlling step for spinel modification. The rate of transformation of spinel inclusions is compared with alumina inclusions reported in the current authors’ prior model.