Cast Iron Chips Research Articles

Epoxy Composites with Post-Production Gray Cast-Iron Powders.

Processing of cast-iron castings by machining is associated with a large amount of post-production waste in the form of cast-iron chips, which constitute up to about 5% of the weight of the entire casting. In the case of serial production, this generates large amounts of post-production waste, constituting a constantly growing scale of environmental problems. The aim of this research was to develop a simple and cheap method of utilizing post-production waste of gray cast-iron chips from the machining process for the production of small structural elements of water supply fittings. The analysis of the state of knowledge indicates that the simplest method of managing waste chips is to use them as a starting material in the process of manufacturing polymer composites. The most frequently chosen material for the matrix of polymer composites reinforced with metal powders is epoxy resin. The epoxy composite was produced by the vacuum-assisted casting method. This paper presents the results of tests of morphological, mechanical, and corrosion properties of epoxy composites filled with grey cast-iron powder with a grain size below 0.075 mm and a mass content in the composite of 65%. The composite cured at 130 °C for 90 min had the best mechanical properties. The sample cured at 130 °C for 90 min was observed to have the optimum effect, with a tensile strength of 28.35 MPa, a flexural strength of 55.4 MPa, and a compressive strength of 53.8 MPa. All tested composites were characterized by very good thermal resistance and, in comparison to gray cast iron, over 2.5 times lower weight and an over three times lower corrosion rate in the tap water environment.

Research of the Influence of the Scheme and Modes of Pressing Steel and Cast Iron Chips on the Energy-Power Parameters of the Briquetting Process

Research of the Influence of the Scheme and Modes of Pressing Steel and Cast Iron Chips on the Energy-Power Parameters of the Briquetting Process

Studying the influence of heat treatment modes on the properties of medium-carbon steel

Problem. Parts of modern machines and structures operate under high dynamic loads, stress concentrations, and low or high temperatures. All of this contributes to brittle fracture and reduces the reliability of machines. Therefore, structural steels must, in addition to high mechanical properties, have high structural strength, which is manifested in the conditions of its actual use in the form of parts, structures, etc. [1] A properly selected heat treatment mode allows to obtain an optimal combination of properties in a part, thereby ensuring its reliability and operational durability.
 Goal. The aim of the study is to determine the effect of heat treatment parameters on the hardness, impact strength, and structure of 40 and 40X medium-carbon steels. Method. In the course of the work, a set of mechanical studies was carried out on samples of 40 and 40X steels in the initial state and after various heat treatment modes. Results. Based on the analysis of mechanical studies, the influence of heat treatment parameters on the mechanical properties and structure of medium-carbon steels 40 and 40X was studied. On the basis of mechanical and microstructural studies, the relationship between the effect of economical alloying of medium-carbon steel and the main indicators of mechanical properties in the range of heating temperatures was established. The experiments conducted in this work allowed us to obtain a comparative characterization of the effect of various technological parameters of heat treatment on the structure and properties of medium-carbon steels 40 and 40X, which are being improved. The factors that may affect the quality of parts made from these steel grades were also identified. Summarizing the results of metallographic studies and mechanical properties, the following conclusions can be drawn: 1. Steel 40, which has low supercooled austenite stability, must be cooled sharply (cold water, 8-12% aqueous solutions of NaOH or NaCl, etc.) to obtain continuous hardenability of parts. 2. The addition of 1 % chromium increases the stability of supercooled austenite, i.e. increases the hardenability of steel, so parts made of economical 40X alloy steel can be cooled in oil. However, if the part is large, a higher cooling rate should be used – in water. 3. Normalizing can be recommended for 40 and 40X steels as a work hardening heat treatment that increases ductility and impact strength. However, if the hardness level of the normalized alloy steel is high, then full or isothermal annealing should be used. 4. To prevent decarburization of steel at high temperatures and long holding times, protective atmospheres must be used. In the case of processing parts in furnaces with an oxidizing atmosphere, the parts must be filled with graphite, because cast iron chips do not provide reliable protection against oxidation. 5. In the range of tempering temperatures of improving steels recommended by the reference literature (400-600 °C), a monotonic decrease in hardness of both steels occurs, but in carbon steels, the hardening is more intense than in alloy steels. 6. To prevent the development of tempering brittleness of the second kind, to which 40X steel is prone, cooling during tempering should be accelerated (in oil, water), especially if the tempering temperature exceeds 550 °C.

Aggregate technology for processing uranium-phosphorite ore

The paper describes an aggregate technology for extraction of uranium and related rare earth elements, scandium and phosphorus from uranium-phosphorite ores with the recycling of spent reagents for the production of nitrogen-phosphorus fertilizers. It is shown that increasing the fraction of nitric acid in the mixture with sulfuric acid (melange) for leaching uranium to 100% increases the extraction of all valuable elements up to 95–98%. Optimal parameters (hydro module, duration and acidity) of the raw material processing have been determined. Reducing the content of sulfuric acid in melange to 15% reduces the yield of gypsum with the content of radionuclides of natural origin, which must be buried. The isolation of uranium, thorium, rare earth elements, scandium and radioactive isotopes (Ra, Po, Ac, Pb) is carried out by chemical precipitation using iron in the form of cast iron chips. As a result of processing, a nitrate-phosphate solution purified from radioactive elements and impurities is formed, based on which a complex nitrogen-phosphorus fertilizer "Nitrofos" is fabricated.

Physico-mechanical Properties of Basalt-based Brake Pad as Alternative to Ceramics Brake pad

A basalt-based automobile brake pad was developed through optimization of the volume fractions and manufacturing parameters, a mathematical model was developed based on rule of mixture for the optimization of the volume fraction and the solution obtained using excel solver is as follow; basalt 38%, cast iron chips 26%, bronze 12%, glass fibre 12% and phenolic resin 12%. The manufacturing parameters were design using full factorial design of three levels and three factors, twenty-seven runs were obtained from the design, consequently twenty-seven samples were produced by compression moulding. The constituent materials were properly mixed to obtained homogeneous mixture and compressed into a mould with a cavity similar to the shape of the friction pad this was done at different moulding pressures of 30MPa, 27MPa and 24MPa, the curing temperatures were 1800C, 2000C and 2200C and the curing of 5minutes, 10minutes and 15 minutes as obtained from the factorial design. The samples produced were subjected to tests, the results showed that the basalt brake pad has the following properties; compressive strength of 137mPa, coefficient of friction 0.476, hardness 70HRB, density of 2768kg/m3 thermal conductivity of 0.66W/mK, water absorption of 0.377%, oil absorption of 0.25%, void content of 18.93%, wear rate of 9.0X10 -4g/m and the TGA result shows that the basalt-based brake pad is thermally stable up to a temperature of 5000C. The properties of the basalt-based brake pad are within the acceptable range and can satisfactorily substitute basalt.

Facile synthesis of protic ionic liquids hybrid for improving antiwear and anticorrosion properties of water-glycol

Protic ionic liquids (PILs) hybrid was applied as a lubricant additive with various functions in water-ethylene glycol solution (WG). The anticorrosion performance of the hybrid was evaluated by means of cast iron chips test and electrochemical measurement. It improves the anticorrosion effect of WG on cast iron. Meanwhile, the tribology experiment shows that the hybrid reinforces antifriction and antiwear properties of WG. Combining SEM/EDAX and XPS analyses of the worn surface with contact angle test, we concluded that the prepared hybrid has prominent anticorrosion and lubrication effects due to coexistence of an adsorption layer constructed by PILs and a tribofilm comprising FeS2.

Processing of metal wastes for high damping metal composite

Abstract The material of aluminum and the gray cast iron are widely used, so that also produce a large scale of waste from the manufacturing processes. In relation with supporting the global program of sustainable recycling-oriented society, the waste of aluminium and gray cast iron chips will be utilized in this research to become a valuable, functional and useful material. The waste of gray cast iron chips and aluminum chips were used in this research. Three compositions were provided in this research namely, composition of Al chips with addition 0, 20, and 40 vol.% of gray cast iron chips. The process was initiated by compacting the chips to become a billet with 70 mm length and 60 mm in diameter. The hot extrusion was carried out at 400°C with pressure at 500 Ton. The lubricant that was used at the die was MoS2, mean while the graphite colloid was utilized as lubricant at main cylinder of extrusion. Final diameter of the product was 15 mm. The process then was continued with swaging the specimens. The process of swaging was done following 3 steps in room temperature, initiated by swaging from 15 mm to become 14 mm, continued by swaging until reach 12.5 mm and finally by swaging the specimen until reach 11 mm in diameter. The hammering vibration test then was carried out to obtain the damping capacity of the specimen with length of the specimen at 150 mm and 11 mm in diameter. For specimen with composition 0% gray cast iron, the value of damping capacity (α) is found 45[s-1]. For specimen with composition 20% gray cast iron, the value of damping capacity is found 61 [s-1]. The damping capacity for the specimen with composition 40% gray cast iron is found very hight that reach up to 90 [s-1]

Vibration Behavior of Composite Materials Produced by Waste Metal Recycling

In this study, waste metal chips were transformed into metal matrix composites by isostatic hot pressing and the vibrational behavior of these composite materials was investigated. Bronze chips (CuSn10) was used as a matrix component and spheroidal cast iron (GGG40) chips were used as reinforcement component. The metal matrix composites are produced with different GGG40 contents as 40%-30%-20% and 10%. Metal chips were pressed at pressure of 170 MPa and a temperature of 450 °C during production. The results of natural frequency and modal stiffness were evaluated on the basis of mixture ratios by applying the impact hammer test to the metal matrix composite materials produced.

Circular economy practice: From industrial metal waste to production of high wear resistant coatings

Recently, recycling has become an essential issue in the industrial sector due to the soared consumption of materials and energy. One of the few possible ways to recycle metal waste is re-melting and converting the waste to new products. However, it requires a lot of energy, causes environmental contamination and is not applicable worldwide. Landfilling is no longer an option. This research paper focuses on finding an alternative way to recycle industrial waste by using the Submerged Arc Welding method (SAW) and metal waste, what is collected by manufacturing companies, in order to produce wear resistant hard-facings. When selecting metal waste, the greatest attention was given to waste of alloys with carbide forming elements. Turnings, shavings, and chips, as well as debris of high speed tool steel (HS6-5-2), ledeburitic high chromium cold work steel (X210Cr12), cast iron chips, waste of boron carbide B4C, worn grinding wheels (SiC), sintered hardmetal (H123, HG30) all were chosen as the remedy for reinforcement. Five possible compositions of above mentioned waste were discussed and tested on wear. SAW technique with properly chosen parameters: current 180–200 A, voltage 22–24 V, travel speed – 14.4 m/h was adapted for the production of hard-facings. Two methods to introduce waste metal powder to the weld zone were utilized: spreading of powder over the surface of substrate, and mixing with standard flux. Hard-facings obtained from waste materials were tested on abrasive emery wear. Volume-wear loss in most cases was compared to commercial steel grades. Wear results confirmed expectations as wear resistance of waste based hardfacings ∼2 times exceeded the wear resistance of commercial alloys.

Transmissibility, Isolation Region and Damping Characteristics of Gray Cast Iron and Aluminium Composite

All The metal composite was prepared in this research by utilizing waste of aluminum and gray cast iron chips in supporting the global program of sustainable recycling-oriented society. The process was carried out via hot extrusion at 400°C. Three compositions were provided in this research, namely the composition of aluminum chips with addition 0 vol.%, 20 vol.%, and 40 vol.% of gray cast iron chips. Increasing the gray cast iron was found affect on reducing the natural frequency of the product. Addition about 20 vol.% of gray cast iron decreases the value of damping capacity. Conversely, addition about 40 vol.% gray cast iron increases the value of damping capacity significantly. It was also found that the addition of gray cast iron could extend the isolation region and decreased the transmissibility at the isolation region.

Microstructure and wear properties of Fe–TiC composite coatings produced by submerged arc cladding process using ferroalloy powder mixtures

Fe-TiC composite coatings were produced on the surface of plain carbon steel by submerged arc cladding process. Mixtures of cast iron chips and ferrotitanium powder with different weight ratio between 1 and 6 were used as the alloying element sources. Cladding was performed by carbon‑manganese steel wire. Results showed that increase in the cast iron to ferrotitanium (CTF) weight ratio from 1 to 6 decreased the Ti wt% from 3.93 to 0.96 and increased the carbon concentration from 0.26 to 0.51 wt%. Titanium carbide reinforcing particles were detected in the microstructures of all coatings. Meanwhile, their size and volume fraction, as well as the microstructure of the matrix strongly was depending on the CTF weight ratio. The highest mean hardness value of 960 HV was obtained for the cladding produced by the CTF weight ratio of 6 with the TiC reinforced martensitic microstructure. Pin on disk wear test results showed that the hardest coating had the best wear resistance with the plowing and cutting wear mechanisms.

Mechanical properties and microstructure of composites produced by recycling metal chips

In this study, the processing and mechanical properties of porous metal matrix composites (MMCs) composed of spheroidal cast iron chips (GGG40) and bronze chips (CuSn10) and formed by hot isostatic pressing were investigated. Bronze chips (CuSn10) were used as a matrix component, and spheroidal cast iron (GGG40) chips were used as a reinforcement component. The MMCs were produced with different CuSn10 contents (90wt%, 80wt%, 70wt%, and 60wt%). The hot isostatic pressing process was performed under three different pressures and temperatures. The produced MMCs were characterized using density tests, Brinell hardness tests, and compression tests. In addition, the consolidation mechanism was investigated by X-ray diffraction (XRD) analysis and scanning electron microscopy. The test results were compared with those for bulk CuSn10 and bulk GGG40. Mechanical tests results revealed that the metallic chips can be recycled by using hot pressing and that the mechanical properties of the produced MMCs were similar to those of bulk CuSn10. XRD and microscopy studies showed that no intermetallic compounds formed between the metallic chips. The results showed that the CuSn10 and GGG40 chips were consolidated by mechanical interlocking.

Predicting breakage behavior and particle size of bronze and cast iron machining chips pulverized by jet milling

It has been proposed that the breakage behavior of particulate materials can be described by two material parameters fmat and Wmin. fmat describes the resistance of the material to fracture in impact pulverization and Wmin characterizes the specific energy which a particle can absorb without fracture. It is shown in this study that this concept can be used to quantify breakage behavior of bronze and cast iron chips in jet milling process and also to predict particle size of the jet milled product. Different tin bronze and cast iron chips with varying initial size were pulverized in a target plate jet mill with different velocity. fmat was found to be in the range of 0.06–0.09 and 0.18–0.25 for bronze and cast iron alloys, respectively. For the cast iron alloys fmat increased with increasing content of carbon and silicon. Similarly, for the bronze alloys, fmat increased with increasing tin content. An equation was developed to predict mean particle size of the jet milled chips as a function of the kinetic energy, initial chip size and material parameters. The experimental results of various alloys confirmed that the mean particle size after single and multiple impacts were accurately predicted.

Low-Velocity Impact Behavior of Porous Metal Matrix Composites Produced by Recycling of Bronze and Iron Chips

In this study, the low-velocity impact behavior of porous metal matrix composites (MMCs) has been investigated. The MMCs consisting of spheroidal cast iron chips (GGG-40) and bronze chips (CuSn10) were produced by hot isostatic pressing. The MMCs were produced with different CuSn10 contents as 90–80–70–60%. The hot isostatic pressing was performed under three different pressures and temperatures. The produced MMCs were exposed to low-velocity impact loading under 2 m/s by using a drop weight test stand. The test results were compared with the bulk CuSn10 and bulk GGG-40, separately. The test results revealed that hot-isostatic-pressed MMCs can successfully represent bulk material properties when subjected to low-velocity impact loading even these MMCs have porosity 2–8%.

The Influence of Graphite Content and Milling Time on Hardness, Compressive Strength and Wear Volume of Copper - Graphite Composites Prepared Via Powder Metallurgy

Copper – graphite composites are widely used in sliding bearings and brushes due to their excellent thermal and electrical conductivities and high wear resistance. The aim of this research is to study the Influence of graphite content and milling time on hardness, compressive strength, wear volume and friction coefficient of copper - graphite composites prepared via powder metallurgy. A powder mixture containing 0,5,10,15,20 and 25 vol% graphite was milled for 1,3,5,7 and 9 hours. The milled mixture was cold pressed at 700 MPa for 30 second, followed by sintering at 900 oC for one hour. It was found through this work that increasing milling time results an appreciate increase in hardness and radial compressive strength, slight reduction in wear volume and slight increase in the coefficient of friction for all compositions except that for pure copper in which a considerable increase in wear volume and decrease in the coefficient of friction was observed. On the other hand, increasing the graphite volume fraction increases the composite hardness, till an optimum value, and decreases the radial compressive strength. A great decrease in both wear volume and coefficient of friction was observed on increasing graphite content up to 25 vol%. Finally, a graphite, cast iron chips and fireclay sintering configuration was found to be an effective procedure which minimize oxidation to levels comparative with those observed previously by sintering in argon or hydrogen atmospheres.

The Influence of the Graphite Content and Milling Time on the Hardness, Compressive Strength and Wear Volume of Copper - Graphite Composites Prepared Via Powder Metallurgy

Copper – graphite composites are widely used in sliding bearings and brushes due to their excellent thermal and electrical conductivities and high wear resistance. The aim of this research is to study the Influence of the graphite content and milling time on hardness, compressive strength, wear volume and friction coefficient of copper - graphite composites that prepared via powder metallurgy. A powder mixture containing 0,5,10,15,20 and 25 vol% graphite was milled for 1,3,5,7 and 9 hours. The milled mixture was cold pressed at 700 MPa for 30 second, followed by sintering at 900 ℃ for one hour. It was found through this work that increasing milling time results an appreciate increase in hardness and radial compressive strength. Slight reduction in wear volume and slight increase in the coefficient of friction for all compositions except that for pure copper in which a considerable increase in wear volume and decrease in the coefficient of friction was observed. On the other hand, increasing the graphite volume fraction increases the composite hardness, to reach an optimum value, and decreases the radial compressive strength. A great decrease in both wear volume and coefficient of friction was observed due to increasing the graphite content up to 25 vol%. Finally, a graphite, cast iron chips and fireclay sintering configuration was found to be an effective procedure which minimizes oxidation to levels comparative with those observed previously by sintering in argon or hydrogen atmospheres.

The Influence of Graphite Content and Milling Time on Hardness, Compressive Strength and Wear Volume of Copper - Graphite Composites Prepared Via Powder Metallurgy

Copper – graphite composites are widely used in sliding bearings and brushes due to their excellent thermal and electrical conductivities and high wear resistance. The aim of this research is to study the Influence of graphite content and milling time on hardness, compressive strength, wear volume and friction coefficient of copper - graphite composites prepared via powder metallurgy. A powder mixture containing 0,5,10,15,20 and 25 vol% graphite was milled for 1,3,5,7 and 9 hours. The milled mixture was cold pressed at 700 MPa for 30 second, followed by sintering at 900 o C for one hour. It was found through this work that increasing milling time results an appreciate increase in hardness and radial compressive strength, slight reduction in wear volume and slight increase in the coefficient of friction for all compositions except that for pure copper in which a considerable increase in wear volume and decrease in the coefficient of friction was observed. On the other hand, increasing the graphite volume fraction increases the composite hardness, till an optimum value, and decreases the radial compressive strength. A great decrease in both wear volume and coefficient of friction was observed on increasing graphite content up to 25 vol%. Finally, a graphite, cast iron chips and fireclay sintering configuration was found to be an effective procedure which minimize oxidation to levels comparative with those observed previously by sintering in argon or hydrogen atmospheres. DOI: http://dx.doi.org/10.25130/tjes.24.2017.31

Arsenic Removal from Mine Waters with Sorption Techniques

Potential low-cost sorption materials (mostly industrial by-products) were screened for removal of arsenic from mine effluent water. First, the maximum adsorption capacities were determined in batch tests with various liquid to solid ratios. The highest arsenic sorption capacity, 46 mg As/g of sorption material, was measured for cast iron chips. The most promising materials were also studied in batch tests that assessed the reaction kinetics and in kinetic column tests for their behavior in a filter or reactive barrier application. The column tests revealed the cast iron chips caused clogging in the percolation column when operating with real mine water. A commercial ferric oxi-hydroxide sorption material developed for As removal for drinking water showed good As removal in the column tests. Around 10,000 bed volumes of mine process water containing 2 mg/L of arsenic was treated with this material, and treated water concentrations ranged between 0 and 0.05 mg/L before breakthrough. The measured adsorption capacity for the commercial ferric oxi-hydroxide sorption material was 8.3 mg As/g.

Effect of Partial Replacement of Cement with Blast Furnace Slag and Sand with Cast Iron Chips on the Strength of Concrete

Effect of Partial Replacement of Cement with Blast Furnace Slag and Sand with Cast Iron Chips on the Strength of Concrete

INVESTIGATIONS ON OPERATION OF ROTARY TILTING FURNACES

Rotary tilting furnace (RTF) is a new type of fuel furnaces, that provide the most efficient heating and recycling of polydisperse materials. The paper describes results of the investigations on thermal processes in the RTF, movement of materials and non-isothermal gas flow during kiln rotary process. The investigations have been carried out while using physical and computer simulations and under actual operating conditions applying the pilot plant. Results of the research have served as a basis for development of recommendations on the RTF calculations and designing and they have been also used for constructional design of a rotary tilting furnace for heating and melting of cast iron chips, reduction smelting of steel mill scale, melting of aluminum scrap, melting of lead from battery scrap. These furnaces have a high thermal efficiency (~50 %), technological flexibility, high productivity and profitability. Proven technical solutions for recycling of ferrous and non-ferrous metals develop the use of RTF in the foundry and metallurgical industry as the main technological unit for creation of cost-effective small-tonnage recycling of metal waste generated at the plants. The research results open prospects for organization of its own production for high-quality charging material in Belarus in lieu of imported primary metal. The proposed technology makes it possible to solve environmental challenge pertaining to liquidation of multi-tonnage heaps of metal-containing wastes.