Cupola Slag Research Articles

Enhancement of mechanical properties and machinability of aluminium composites by cupola slag reinforcements

AbstractRapid evolution in engineering and manufacturing demands light weight material with enhanced mechanical properties. Aluminium metal matrix composites with ceramic reinforcement particulates serve this demand due to their reduced density, improved strength and hardness along with higher resistance to wear and corrosion. However, the material cost and reduced machinability hinders the full potential of utilization. To overcome these challenges, in this work cupola slag, an industrial waste generated as by product of cast iron production, has been incorporated as reinforcement of aluminium composites using low cost stir casting method. The enhancement of material properties and machinability by cupola slag inclusion on base alloy has been investigated in detail. Moreover, introspection about the underlying mechanisms responsible for the improvement in material properties has been studied using detailed microstructure and fractographic analysis. The results show improvement of in material properties and machinability up to 7 wt.–% cupola slag inclusion, beyond which the reduced wettablity prohibits sound castings. The ultimate tensile strength and specific strength observed to be improved by 18.20 % and 33.23 % respectively for 7 wt.–% slag reinforced composites when compared with base alloy. This work can be a successful addition to the knowledge pool of ongoing research on low‐cost novel material with enhanced properties.

INVESTIGATION OF THE MECHANICAL AND TRIBOLOGICAL BEHAVIOURS OF CUPOLA SLAG AND MWCNT-REINFORCED EPOXY HYBRID NANOCOMPOSITES: A SUSTAINABLE APPROACH FOR ENVIRONMENTAL PRESERVATION

This experimental investigation explores the mechanical and tribological characteristics of cupola slag (CS) and multiwall carbon nanotubes (MWCNTs) reinforced hybrid nanofiller epoxy composites. Cupola slag is an industrial by-product that is generated during the melting of cast iron. The disposal of slag residues in landfills results in environmental pollution. In the context of environmental preserving as well developing new engineering composites material from waste to resource. MWCNTs possess an excellent strength-to-weight ratio, high stiffness, and thermal properties. The mechanical and tribological characteristics of the hybrid nanocomposites comprising epoxy were examined by varying the weight fraction of fillers composed of CS and MWCNTs. The experimental results indicated that the ECSM3 hybrid nanocomposites have superior tensile strength and the flexural modulus improved by 92 % and 78 % respectively when compared with epoxy. Similarly, the tribology performance of the ECSM3 exhibited improved specific wear resistance of 97 %, 106 % and 88 % on the dry-sliding loads of 10 N, 20 N and 30N, respectively. A morphological analysis was carried out on fractured and worn surfaces of the specimen to understand the homogeneous dispersion and matrix-interlocking mechanism between the hybrid nanofillers and the epoxy matrix. The integration of CS alongside MWCNTs for the fabrication of epoxy hybrid nanocomposites represents a stride towards sustainable and eco-friendly technology in the production of multifunctional composite materials for diverse engineering applications.

Physico-chemical characterization of cupola slag: Enhancing its utility in construction

Cupola slag is a waste material of the steel and iron industries. Its composition is determined by the cupola furnace and other elements used in steel and iron manufacturing. This paper investigates the characterization behavior of various cupola slag materials. As a result, x-ray fluorescence (XRF), x-ray diffraction (XRD), thermogravimetry differential thermal analysis, and scanning electron microscopy (SEM) methods were used to characterize three cupola slag samples from distinct origins. In addition, various physical properties were used to compare different cupola slags. The specific gravity values of CS-1 (cupola slag-1 sample), CS-2 (cupola slag-2 sample), and CS-3 (cupola slag-3 sample) are 1.36, 2.5, and 2.917, respectively. The density and water absorption for CS-1, CS-2, and CS-3 are 1414.86, 1477.71, and 1796 kg/m3, and 0.37%, 0.32%, and 0.26%, respectively. Cupola slag also includes a larger percentage of lime, according to XRF data, which contributes to its improved binding characteristics. A higher calcium oxide content in CS-3 could facilitate the pozzolanic process. The presence of angular particles that aid in material binding is seen in the SEM image. Compounds with a nanostructure are then flawlessly blended into the mixture and grouped with calcium alumina silicates formed by cement hydration. The XRD pattern of cupola slag exhibits high peaks, indicating that the material is crystalline in character and can be utilized as sand. It also shows the presence of other chemical compounds, such as silica, which ranges from 30% to 45%. CS-1 and CS-2 have comparable XRD patterns. However, CS-3 has a somewhat different pattern because of the greater CaO content. Weight loss begins at higher temperatures, which shows that the material is stable at higher temperatures, according to a thermo-gravimetric study. The differential thermal analysis curve of CS-3 indicates that the material remains stable up to a temperature of 600 °C. The physical characteristics of all cupola slag samples show that cupola slag may be utilized to make sustainable building materials because of its lower specific gravity, density, and water absorption.

Study of durability and mechanical properties for utilization of cupola slag as a coarse aggregate in M20 grade green concrete

Cupola slag is an industrial waste generated from cupola furnaces during cast iron production. The disposal of cupola slag is a matter of burden for the manufacturers of casting industry. This experimental study aims to reuse cupola furnace slag (CFS) in the construction industry, developing a novel way of solid waste management. In the M20 grade concrete, CFS is used as coarse aggregate (CA), partially replaced by 0–50 wt % in the step of 10 wt %. The mechanical and durability properties of the CFS-based concrete were examined after the required days of curing. The experimental result exposed that the dry density decreases with the increased weight percent of CFS in concrete. The cast samples with up to 40 wt% partial replacement of CFS effectively meet the requirements for the M20 grade of concrete in terms of compressive strength. A similar trend for the split tensile strength was observed, like the compressive strength. Durability test results reveal that water penetration depth increases with increased CFS weight percent in concrete. Moreover, in the case of rapid chloride penetration test, chloride ions penetration is decreased with the increase of CFS weight percent in concrete. FESEM, EDS and XRD were used to examine the microstructure, elemental mapping and phase analysis of the CFS-based concrete. According to the investigation, CFS is a sustainable material that works well as a partial replacement for natural CA in concrete.

Machinability of cupola slag incorporated LM11 matrix composites in turning: Surface roughness and MRR analysis

This study explores the potential of using cupola slag, a byproduct of cast iron production, as reinforcement in Al-4.5-Cu (LM11) matrix composites. The composites were fabricated using a low-cost stir casting method, with varying percentages of cupola slag (0 %, 3 %, 5 %, and 7 %) added to the matrix. The cast composites were then evaluated based on their microstructure, microhardness density and machinability indices, including material removal rate, surface roughness, chip thickness and chip analysis during dry turning. A full factorial design of experimentation was employed to determine the effects of different process inputs on machinability, with feed, spindle speed, and weight percentage of cupola slag as the variables. The results showed that 7 wt% cupola slag incorporation improved machinability, but beyond this percentage, the casting became unstable due to reduced wettability. This study offers valuable insights into the machinability of cupola slag embedded cast composites and the influence of different process inputs on their machinability by using a low-cost stir casting method and an unwanted byproduct as reinforcement, this approach offers a novel and sustainable alternative for the reinforcement of metal matrix composites.

Effective Utilization of Industrial and Constructional Solid Waste Materials in Foundry Mould Making to Prevent Environment Pollution and Conserve Natural Silica Sand

<p>Green sand moulding uses silica sand for metal casting. Silica sand mining and delivery to foundries destroy the ecosystem, making metal casting unsustainable. Due to increased sand-casting output and massive civil buildings in India, the silica sand supply is declining. The depletion and shortage of silica sand necessitate the search for viable replacements. Industrial solid waste from large-scale industrialization pollutes land, air, and water. In order to use industrial waste in large amounts, an attempt is made to use it as a replacement for natural resources. The main objective of this research is to reduce the consumption of silica sand in the foundry mould-making process. Silica sand is replaced with industrial solid waste, cupola slag, and construction solid waste sources like spent fire bricks and quarry dust, up to a considerable amount, to save the natural resources. Utilization of solid waste material in the mould-making process will reduce production costs and environmental pollution, like dumping solid waste materials on land. Sand tests like permeability, green compression strength, dry compression strength, and compactability were conducted to assess the moulding properties of these alternative moulding materials. The process parameters considered for this investigation were the percentage of bentonite binder and the percentage addition of alternative mould materials with silica sand. The various sand tests showed that 40%, 30%, and 20% of quarry dust, spent fire bricks, and cupola slag, respectively, will adequately replace silica sand for mould making. A bentonite binder of 8% is suitable for quarry dust mould, and a 10% bentonite binder is required for spent fire brick particles and cupola slag to yield better results. Aluminium castings were produced at the optimal mixture of these solid waste particles and silica sand. The results of mechanical tests such as hardness, tensile, and impact tests are comparable to those of silica sand castings.</p>

Effect of cupola slag as a coarse aggregate on compressive strength of concrete

The global exponential rise in natural resource consumption poses a serious problem, which is causing a shortage of these resources. As a result, research towards the efficient management and finding alternatives of conventional resources is gaining more importance. Investigating the utilization of industrial by-products in the construction industry can be considered as a potential solution in reducing the consumption of conventional construction materials. Steel slag is an industrial by-product which is generated in huge amount and disposed in the environment as a waste material. Various types of steel slag are produced depending on the furnace type used in the industry. Cupola slag is one such type of steel slag produced from cupola furnace,in the process of manufacturing cast iron. The potential of cupola slag as a partial replacement of coarse aggregate was studied in this paper. Physical and chemical characteristics of cupola slag were studied. The preliminary properties of cupola slag were found to be similar to the natural aggregates and could be incorporated into the concrete. The aim of the study is to observe the effect of the percentage increment of cupola slag on concrete. The slag percentage was changed in each mix design while maintaining other design parameters constant. The coarse aggregate is partially replaced by 30%, 35%, 40% and 50% with cupola slag without replacing the natural sand. All the mix proportions of designed concrete were studied for compressive strength at the age of 7 days and 28 days. The maximum compressive strength of 66.36 MPa was observed for 30% substitution on 28th day. It was found that, further increase in substitution causes a decrease in strength. The results indicate that cupola slag can be used in concrete efficiently up to 30% and can provide a promising solution for reducing industrial waste landfill, ensuring a sustainable environment.

Cupola slag as partial replacement of coarse aggregate in concrete

Cupola slag, an industrial waste, is a foundry by product causes air, soil and water pollution and also responsible for global warming. The physical properties of cupola slag suggest that it can be used as replacement of coarse aggregate in concrete mix. The M20 grade concrete has been prepared for experimental study with water: cement ratio = 0.55. The coarse aggregate has been replaced with cupola slag by 0 to 50% in step of 10 weight percentage. It is observed that the workability has reduced with the increases in weight percent of copula slag. Maximum reduction of workability has been noted at the 50% replacement of coarse aggregate by cupola slag as compared to the controlled concrete sample. The compressive strengths of the concrete samples have been tested after 7 days and 28 days of curing. The criteria for M20 grade concrete are successfully attained by the samples up to 40 wt% of cupola slag replacement and with further addition of cupola slag i.e. the sample with 50 wt% of replacement fails to qualify as M20 grade concrete. Therefore. It can be concluded that the cupola slag can be used as coarse aggregate in concrete which can reduce environmental pollution and global warming.

Waste slags as sustainable construction materials: a compressive review on physico mechanical properties

Rapid industrialization and urbanization in emerging nations have resulted in the accumulation of various industrial wastes. As a result, reusing and recycling these wastes into an economical, durable, and environmentally friendly building material may be the most effective means of mitigating their environmental impact. Such wastes are being dumped in greater quantities, which pollute the ecosystem and the land. As a result, its efficient use and management are required, which presents a global issue for its viable recycling and safe disposal. The current review examines the use of various slags, including cupola slag, electric arc furnace slag (EAFS), steel furnace slag (SFS), and ground granulated blast furnace slag (GGBFS) in the development of sustainable construction materials considering the potential of such waste in greener concrete composites towards eco-friendly infrastructure. In order to produce environmentally acceptable construction materials, these waste slags have been used as a partial and full replacement of cement, fine and coarse aggregate with or without supplementary materials ranging from 10 to 60% for cupola slag, 20 to 50% for EAFS, 10 to 50% for GGBFS, and 10 to 30% for SFS are suggested. This review will be an inclusion that helps readers to identify gaps in experimental viability, material characterization, and physico-mechanical behaviour of waste slags, pointing to the potential for application in the production of sustainable building materials.

Experimental investigation on feasibility of industrial waste to resource conversion for cupola slag

Cupola slag, an industrial waste produced as by-product in producing cast iron. Demand for cast iron is high consequently, there is significant slag formation. These waste slags ends in landfill and pollutes the environment. Pollution due to cupola slag can be reduced by conversion of waste to resource. In this work waste slag has been analysed physically and chemically to understand its conversion potential. An experimental attempt has been made to convert cupola slag to reinforcement in aluminium metal matrix composite (AMC) for fabrication of economic metal matrix composites by stir casting route. Experimental studies are designed to observe the feasibility of waste to resource conversion along with effect of size of reinforcement on the mechanical, physical and microstructural properties of AMCs. The results indicate feasible conversion from waste to resource. Microstructural studies baked by energy dispersive spectroscopy (EDS) and elemental mapping indicates uniform and successful inclusion of reinforcement in the matrix of composites. The grains have been refined by the addition of slag particle in the Al alloy matrix. Microhardness has been increased in composites when compared to base alloy. Coarse (100 μm) reinforcement particle composites are observed to have better mechanical properties than that of fine (40 μm) reinforcement particles.

Fabrication and machinability studies on cupola slag reinforced aluminium metal matrix composites using Taguchi method

In this experimental work dry turning of fabricated low cost cupola slag reinforced aluminium metal matrix composites have been performed. The objective of this work is to analyze the successful fabrication and machinability of cast composites in terms cutting force. Fabrications have been done by following stir casing route and quality of cast composites have been analyzed by SEM and EDS. Experimental planning and optimization has been done using Taguchi method. Weight percentage of cupola slag reinforcement,feed rate and spindle speedhas been selected as process parameters. Confirmatory experiments have been conducted to validate the model and tool morphology of tool used in confirmatory experiment has been investigated for tool wear studies.

Recycling Cupola Slag in Concrete as Partial Replacement of Fine Aggregate for Sustainable Construction

Abstract: In the current study an effort has been made to investigate the impact of cupola slag inclusion, on the mechanical and durability properties of concrete. Different percentages (10%, 20%, 30%, 50%, and 80%) of cupola slag were used to substitute fine aggregate and corresponding results have been observed. Also, different mechanical and durability tests were carried out to check the suitability of replacing natural fine aggregate by cupola slag. Compressive strength was found to be increased by cupola slag inclusion up to a percentage replacement of fine aggregates of 30%, after which further cupola slag addition resulted in a loss of strength. For flexural and tensile strength similar trends were observed. On the other hand, as the amount of cupola inclusion increased from 0% to 80%, a decreasing trend in both water penetration depth and water absorption was observed. Likewise, for all the aforementioned criteria a notable improvement in chloride penetration was observed due to the inclusion of cupola slag. The study basically focuses on present concern regarding industrial waste which poses a risk to the environment. Industrial waste has been utilized in a sustainable manner, as it has shown improvement in properties as compared to ordinary concrete mix. Such type of modified concrete can be employed in harsh exposure conditions as can be found from durability tests. The findings of this study show that cupola slag is a sustainable matter that works well as a partial replacement for natural sand.

Performance assessment of mechanical and durability properties of cupola slag geopolymer concrete with fly and rice husk ashes

Research into substituting recycled materials for cement and aggregates can yield beneficial natural resource conservation, waste management, cost savings, and reduced embodied energy in concrete. Hence, this research investigates the potential adoption of coal fly ash (CFA) and rice husk ash (RHA) as geopolymer binders to partially substitute cement in varying proportions up to 25%. However, cupola furnace slag (CFS) was also used as a partial substitute of crushed granite from 0% to 35% in steps of 5% in the production of geopolymer concrete (GPC). The selected geopolymer binders were synthesized using an alkaline solution. Workability, compressive strength, and rapid chloride penetration tests on fresh and hardened normal concrete (NC) as control and GPC containing CFS were evaluated at different water-binder ratios. The findings revealed that integrating 15%CFA, 20%RHA, and 30%CFS with w/b of 0.50 and 0.65 improved the workability by 180% and 105.7%, respectively, but compressive strength is significantly reduced. The findings further showed that combining 75%OPC, 20%CFA, 5%RHA, 100%RS, 20%CFS, and 80%CG results in optimal compressive strength of 19.68 N/mm2 and, 21.49 N/mm2 at 28 days and 56 days with w/b of 0.50, respectively, as contrasted to the lowest possible strength requirement. The Rapid Migration Test (RMT) was used to determine the chloride ions permeability in various concrete mixes. The results show that GPC produced with the combination of 15%CFA, 20%RHA 65%OPC, 30%CFS, and 70%CG with w/b of 0.65 is more durable and has higher chloride ion penetration resistance than most other mix proportions.

Scope for cupola slag reuse in construction: a sustainable green solution

Scope for cupola slag reuse in construction: a sustainable green solution

Behaviour of cupola slag and TiO2 nanoparticles in concrete as partial replacement for coarse aggregates and cement

Behaviour of cupola slag and TiO2 nanoparticles in concrete as partial replacement for coarse aggregates and cement

Durability of high-performance self-compacted concrete using electric arc furnace slag aggregate and cupola slag powder

The current trend in the development of self-compacting concrete with sustainable construction materials has served as a guide to design a novel self-compacting concrete, with siderurgical by-products (steel slag aggregates and cupola slag powder as supplementary cementing material) that also meets the demands of high-performance concrete. This research sets out to clarify the unknown behavior of slag concrete, its durability, which is the ability to withstand any process that tends to deteriorate it. In order to assess the durability of this eco-friendly concrete, three control mixes were manufactured with the same high-quality coarse aggregate (diabase) and three different fines, limestone filler, fly ash and cupola slag powder. All the mixtures were subjected to the same tests, the results demonstrate that steel slag concrete shows an excellent response against carbonation, a slightly lower response against thermal shock cycles, similar drying shrinkage and a superior response against the action of freezing-thawing cycles and abrasion wear in comparison to the control mixes.

Use of industrial waste burnt residue to develop sustainable brick

An increase in environmental concern has occurred from the accumulation of mismanaged industrial burned residue, particularly in developing countries. Recycling these wastes as a sustainable building material seems to be a potential solution not only to the pollution problem, but also to the cost of green building design. In order to develop sustainable construction materials, industrial and incinerated leftover materials are being used. The goal of this research is to find out more about the probability of replacing natural soil in brick production with burned industrial waste, such as Cupola Slag and fly ash. This study is based on various mix proportions for making bricks keeping constant cement by 10 %. Brick mixture was prepared with cupola slag and fly ash for various proportions. From the five distinct mixes with variable CS from 80% to 60%, the M1 mix with 80 % CS, 10% FA, 10% Cement had the highest compressive strength 4.5 N/mm2. Compressive strength for burnt clay bricks is 3.5 N/mm2 which is less than cupola slag bricks, while the brick mix M5 (60 CS: 30 FA: 10 cement) had the lowest water absorption and density 6.53 % and 1350.57 kg/m3. This study reveals that used of cupola slag and fly ah in combination gives satisfactory results to be used in making sustainable bricks. This study also reflects the use of burnt residue to developed sustainable building blocks.

Performance of concrete made from cupola furnace slag and recycled concrete aggregate

Portland cement concrete (PCC) is an unquestionably flexible and valuable material for any nation's infrastructure and construction development. Nevertheless, the negative health impacts of cement production, the aggregate fraction of concrete, and the building supply shortage are some drawbacks of concrete use. Cupola slag (CS) and recycled coarse concrete (RCA) wastes from industrial processes, construction, and demolition sites are disposed of into the environment, resulting in pollution that threatens marine, agriculture, and public health. Therefore, CS and RCA as a binder and coarse aggregate in concrete production would help protect the environment. This study presents the outcome of an experimental investigation on (i) partial substitution of cement at percentage levels of 0% to 25% in steps of 5% with granulated cupola slag, (GCF); (ii) partially substitution of coarse granite from 0% to 50% in steps of 10%; with coarse cupola slag (CCS); and (iii) complete replacement of CG with recycled coarse aggregates and subsequently partially replaced with CCS from 0% to 50% in steps of 10%. The fresh and hardened properties of concrete, such as workability and compressive strength, were tested. The test results generally showed that the workability increases with an increase in percentage replacement. However, at 7, 14, 28, and 56 days concrete produced from the partial replacement of cement with GCF had the optimum compressive strength of 9.65 N/mm2, 15.85 N/mm2, 20.37 N/mm2, and 22.15 N/mm2 at 10% replacement. The strength, however, increased by 13.67%, 23.54%, 29.42%, and 25.42% compared to the control sample. Similarly, concrete produced from the partial replacement of CG with CCS gave the optimum compressive strength at 10% replacement with a value of 14.89 N/mm2 at 28 days. The compressive strength obtained from the complete replacement of CG with RCA was lower compared with the control samples at 7, 14, 28, and 56 days. It can be concluded that the concrete made with CS and RCA show a satisfactory development and consistency in strength as compared to control sample.

Properties of Concrete Made from Cupola Furnace Slag and Recycled Construction Aggregates

The replacement of traditional constituents of concrete with waste has garnered a lot of interest due to the increasing demand for natural resources used in concrete production. Hence, this study presents the outcome of an experimental investigation on the effect of partial replacement of Ordinary Portland Cement (OPC) at percentage levels of 0% to 25% in steps of 5%, partial and complete replacement of sand and granite in the percentage of 0 to 50 in steps of 10% with cupola slag and recycled construction aggregates. The fresh and hardened properties of concrete such as workability, compressive strength, and microstructural characteristics were assessed. The test results showed a decrease in workability as the percentage replacement of cupola furnace slag (CFS) and recycled construction aggregates (RCA) increases. Concrete produced at 28 days from the partial replacement of cement and sand with cupola slag has an optimum compressive strength of 20.37 N/mm2 at 10% and 22.81 N/mm2 at 20%, resulting in improved strength of 29.4% and 56.82%, respectively when compared with the control. In contrast, granite’s partial replacement with coarse cupola slag and complete replacement of sand and granite gave a lesser compressive strength when compared with the control samples at 7, 14, 28, and 56 days. The porosity of the concrete with optimum compressive strength from each mix was studied using microscopic and image analysis. The result showed that the addition of cupola slag in granulated and fine forms decreases the porosity, hence leading to higher compressive strength.

Properties of Concrete Made from Cupola Furnace Slag and Recycled Construction Aggregates

The replacement of traditional constituents of concrete with waste has garnered a lot of interest due to the increasing demand for natural resources used in concrete production. Hence, this study presents the outcome of an experimental investigation on the effect of partial replacement of Ordinary Portland Cement (OPC) at percentage levels of 0% to 25% in steps of 5%, partial and complete replacement of sand and granite in the percentage of 0 to 50 in steps of 10% with cupola slag and recycled construction aggregates. The fresh and hardened properties of concrete such as workability, compressive strength, and microstructural characteristics were assessed. The test results showed a decrease in workability as the percentage replacement of cupola furnace slag (CFS) and recycled construction aggregates (RCA) increases. Concrete produced at 28 days from the partial replacement of cement and sand with cupola slag has an optimum compressive strength of 20.37 N/mm2 at 10% and 22.81 N/mm2 at 20%, resulting in improved strength of 29.4% and 56.82%, respectively when compared with the control. In contrast, granite’s partial replacement with coarse cupola slag and complete replacement of sand and granite gave a lesser compressive strength when compared with the control samples at 7, 14, 28, and 56 days. The porosity of the concrete with optimum compressive strength from each mix was studied using microscopic and image analysis. The result showed that the addition of cupola slag in granulated and fine forms decreases the porosity, hence leading to higher compressive strength.