Ferrosilicon Research Articles

Effect of utilising ferrosilicon and recycled steel fibres on ultra-high-strength concrete containing recycled granite

This study investigates the utilisation of a combination of a few materials with various ratios, such as ferrosilicon (FS), recycled steel fibres (RSFs) resulting from waste tires and recycled granite (RG), to enhance the mechanical behaviour of ultra-high-strength concrete (UHSC). FS is a novel material that may be utilised as a partial replacement for the cement generated from the industrial waste product of FS alloy. The replacement ratios of FS used in this study are 10%, 20% and 30%. In addition to RSFs resulting from waste tires with ratios by volume of 0.5%, 1%, 1.5% and 2%, RG with replacement ratios of 25%, 50%, 75% and 100% from natural dolomite are used. The outcomes are represented in slump values, compressive strength, splitting tensile strength, flexural strength and modulus of elasticity. Microstructure analysis is also conducted to demonstrate the details of FS. Results reveal that the relatively better ratios to obtain high mechanical properties are 50% replacement of RG from natural dolomite and 20% replacement of FS from cement. The compressive strength of this mixture increases by about 11.11% over that of its reference mixture. The inclusion of RSFs obviates the brittle failure pattern of the tested cylinders, and a ductile failure occurs.

Sustainable Fast Setting Early Strength Self Compacting Concrete(FSESSCC) Using Metakaolin

Sustainability in construction, using concrete as construction material, is initiated to obtain through cement, i.e. binder, optimisation and by application of secondary cementitious materials(SCMs) as component substitute of cement. The cement production industry has previously attained notable improvements in sustainability by use of byproducts of various industries as SCMs through blending suitable materials, like ferro silicon industrial by product mirco silica, steel industry by product finely ground granulated blast furnace slag, thermal power industry byproduct fly ash etc., to diminish the CO2 emission from the manufacturing plants of cement. Pozzolanicity and pore- filling qualities are the two pre requisite characteristics of the SCMs so they can play effective role in reducing the cement quantity in concrete and there by achieve sustainability. But as these quality features are inadequate in most of the industrial waste byproducts as they are not purposefully/specifically/ precisely manufactured but they are only the byproducts of industries produced as a process of manufacturing some products like steel, ferro silica alloys etc., or using some other materials like coal for producing energy. Also these SCMs are globally not obtainable everywhere. Construction industry is thus struggling with considerable cement consumption in its various activities and there by releasing enormous amounts of CO2 emissions, consumption of natural resources thereby depleting the same and increase in cost of cement production due to imposed green tax and shortage of suitable raw materials. Therefore, there is an emergent preference towards finding out various substitutive inorganic binders from native sources for partly substituting cement in concrete construction. One of the solutions to achieve sustainability in concrete construction is to use moderate reactive SCMs like flyash(FA), GGBFS(ground granulated blast furnace slag) in higher quantity and reactive SCMs like SF etc., so that demerits of slow setting and late strength gain in concrete prepared with moderate SCMs like GGBFS,fly ash etc., can be compensated by reactive SCMs,in lower quantities. Recently clays are observed to be an ample possibility as a promising reactive SCMs as they are richer in alumina and silica, and have good pozzolanic properties in definite raw, calcination situations or surface alterations forms for producing sustainable concretes with lower expenses and more eco-friendliness. In this study experimental investigation presented on the utilisation of metakaolin (MK), a high reactive SCM, in combination with GGBFS, a moderately reactive SCM, in the development of fast setting early strength sustainable self consolidating concrete(SCC) intended to use in fast track repairs/construction. Influence of MK on properties in fresh state and solidified state of SCC were studied and its effect on durability characteristics of SCC established.

Properties and Microstructure of High Strength Concrete Incorporating Different Supplementary Cementitious Materials

The construction industry has recently focused on the use of sustainable and innovative building materials, which called for the production of many supplementary cementitious materials with concrete to make the concrete produced durable and sustainable. Since high-strength concrete has many advantages other than its high strength, it has recently been used in non-traditional applications after for a long time confined to well-known traditional applications. This study presents the effect of micro Ferrosilicon (FS) and mineral materials on high-strength concrete properties, where silica fume (SF), FS, and metakaolin (Mk) were used as additives to cement.Besides the consistency test, all-ages compressive strength, splitting tensile strength, modulus of elasticity strengthand water permeability were investigated on the produced HSC.Microstructure analyses are carried out by SEM and EDX tests. The results showed a continuous decrease in a slump with the increase in mineral material, however, 15% FS and 15% MK were determined as the optimum percentage of the desired mechanical property. HSC performs up to 88 MPa compressive strength, 7.49 MPa tensile strength, and 39.89 GPa modulus of elasticity, as well as good durability properties. Finally, the high-strength concrete under consideration is suitable for use in both conventional and non-conventional applications and supports sustainable development and infrastructure development.

Effect of ferrosilicon and silica fume on mechanical, durability, and microstructure characteristics of ultra high-performance concrete

This paper presents a new material that can be used as a partial substitute for cement in the production of ultra high-performance concrete (UHPC). This material is an industrial waste product of ferrosilicon (FS) alloy, which is available as furnace slag. It is used as a partial substitute for cement after grinding until it reaches the stage of microparticles with a surface area of 12,850 (cm2/gm). UHPC mixtures are designed with cement replacement ratios of 5%, 10%, 15%, 20% and 25% by FS, and same proportions of silica fume (SF). Fresh concrete properties are assessed by applying tests of air content and workability. Mechanical properties are assessed by applying tests of compressive strength, split tensile strength, flexural strength and modulus of elasticity. Moreover, transport properties are assessed by chloride penetration resistance and initial sorptivity water permeability test. Microstructure analyses are carried out by SEM-EDX and XRD tests. Results show that the increase in cement replacement rates by SF and FS by 25% of cement mass reduces slump flow to 345 and 356 mm, respectively, whereas it is 385 for the control mixture. Inclusion up to 20% FS enhances compressive strength by 210.4 MPa compared with 178.6 for the control mix at 90 days. In addition, including up to 25% FS improves the transport properties of UHPC by increasing permeability resistance compared with the control mixture.

Removing metallic impurities from ferrosilicon alloy by Ar-O 2 gas blowing

Removing metallic impurities from ferrosilicon alloy by Ar-O 2 gas blowing

UTILIZATION OF INDUSTRIAL WASTE MATERIAL IN HIGHWAY CONSTRUCTION

Highways play an important role in developing the country. Highways affect directly on the economy, society, culture and security, so the scientists are looking for developing the performance of highways and low maintenance cost. The main objective of this study is to modify the bituminous mixed by utilization of waste industrial materials. , There are many wastes industrial materials can be used in bitumen. A study has been carried out in this search to illustrate the use of fly ash, (byproduct of combustion Pulverized coal in power plants , it produced during combustion of coal in bituminous paving mixes), Silica Fume,( by- product of producing silicon metal or ferro silicon alloys in smelters using arc furnaces) . For comparison, control mixes with modified bituminous mixes has been considered. Marshall Test has been conducted for the purpose of mix design as well as appreciation of paving mixes. It is observed that the mixes with fly ash and silica fume as modifiers modify the properties compared to control mixes. In this paper Silica Fume and Fly Ash are used as a modifier. Marshall stability test was conducted according to( ASTM D 6927-06 ). The percentages of modified mixtures used are 2, 4, 6, 8 and 10 % by bitumen weight. The results showed that the Marshall stability modified with SF and F.A were increased by 18.4% and 22.3 % respectively. So, we can concluded that adding SF and FA to asphalt binder success in improving the properties of bituminous mixes for flexible pavement. Hence, it has been recommended to utilize Silica Fume and Fly Ash wherever available, not only reducing the cost of construction, but also solve the bituminous mixes properties. Keywords: Marshall Stability test, S.F, F.A, bituminous mixes, waste industrial material

A study of X-ray, gamma and neutron shielding parameters in Si- alloys

We have studied the X-ray and gamma radiation shielding parameters such as mass attenuation coefficient, linear attenuation coefficient, half value layer, tenth value layer, effective atomic numbers, exposure buildup factors and specific gamma ray constant in aluminum silicon alloys (Al-47, Al– 32S, Al-43, Fe–Si, Al-356, Al-355 and Al-A355). We have also studied the neutron shielding properties such as coherent neutron scattering length, incoherent neutron scattering lengths, coherent neutron scattering cross section, incoherent neutron scattering cross sections, total neutron scattering cross section and neutron absorption cross sections in aluminium silicon alloys. It has been compared the shielding properties among the studied aluminium silicon alloys. From the detail study it is found that mean free path, HVL and TVL is minimum and exposure buildup factor is maximum for ferro-silicon alloy. Hence it is clear that ferro-silicon alloy is good absorber for X-ray and gamma radiation. The attenuation parameters for neutron are large for ferro silicon alloy. Hence, we suggest ferro silicon alloy is the best shielding materials for X-ray, gamma and neutrons.

Research of Phase Composition of Graphitizing Ferro Silicon Barium Inoculants

A quality analysis of the graphitizing ferro silicon barium inoculants, made by two fundamentally different technological processes had done. The investigation conducted using electron-microscopic and X-ray spectrum analysis. A criteria of inoculants efficiency estimated by its graphitizing capacity or chilltest bleaching value at mass/temperature registering was offered to production quality characterization.It was shown the possibility of qualitative identification phase composition and inoculants parties superficial macro analysisand their correlation with quality, which main criteria is efficiency(graphitizing power), defining by chill test bleaching value. It were given a specific recommendations to inoculants use depending on quality requirement.

MICRO-CRYSTAL STRUCTURE OF 57Fe15Cr25Ni0.32Mn0.96Si AUSTENITE STEEL AFTER 850°C-5H TEMPERATURE-QUENCHING TREATMENTS FOR HIGH TEMPERATURE MATERIAL APPLICATIONS

MICRO-CRYSTAL STRUCTURE OF 57Fe15Cr25Ni0.32Mn0.96Si AUSTENITE STEEL AFTER 850°C-5H TEMPERATURE-QUENCHING TREATMENTS FOR HIGH TEMPERATURE MATERIAL APPLICATIONS. A serial austenite stainless steel, namely A2-type, has been synthesized by using casting technique at temperature more than 1250 °C in the induction furnace that used an electromagnetic inductive-thermal system. The steel is dedicated for structural component material in multi-purpose applications such as in high-temperature operating environments. So, the material must be resistant to mechanical loads, high temperature, corrosion and irradiation. In order to increase the strength of materials, temperature-quenching treatments are required in some cooling media. Mineral element was extracted from crude ores of Indonesian mines and commercial scrap materials, i.e: ferro scrap, ferro chrome, nickel, manganese, and ferro silicon; all of them in granular shape were prepared to alloy the steel. Titanium was not added to this austenite low carbon steel. The OES-chemical composition in %wt of the materials is 57%Fe, 15%Cr, 25%Ni, 0.34%C and less than 0.1% of impurities that comprised of: titanium, phosphor, copper, niobium and sulphur elements in the steel. X-ray diffraction pattern shows that ascast material had an fcc crystal structure with lattice parameter of 3.632 Å. Meanwhile, two of samples, i.e: annealing and oil quench, have strictly similar lattice parameter to that of air (normalizing) quench (3.580 Å). On the other hand, the lattice parameter of water quenched samples has a slightly lower lattice parameter than the ascast lattice , i.e. 3.587 Å. The peak shift of (111) and (200) -plane in the diffraction profile, is very significant, approximately 0.63 degrees between ascast sample and the last two samples. Ascast microstructure reveals that the austenite phase grains look large and describe an undeformed structure, with an average grain size of about 6 mm, while the annealed sample was larger. Air- and oil- quenched sample microstructures showed a fine grain which was very different to water quenched sample microstructure that showed a coarse grain. The viscousity (h) of the quenching medium had an important role in the formation of grain boundary, because the rate of decreasing temperature was heavily influenced by the diffusion of heat from the high to low temperature spaces.

The Effects of Silicon on The Hardness and Wear of Ferritic Grey Cast Iron on Shoe Brake of Train

Grey cast iron has been used for a shoe brake of train due to the enough strength and the low cost. The shoe brake made of cast iron sometimes makes a problem in the operation of the train, because it make the wheel of the train is worn-out. The aim of this research is to find the data of cast iron in accordance with the wear rate and hardness properties by addition of various silicon contents. Cast iron returned (scrap) was melted by induction furnace and then poured into the sand mold of the shoe brake. The 75% ferro silicon was added to make the addition of the silicon content to the melted cast iron. Samples (specimen) of grey cast iron was made with five variation of silicon contents. The composition, hardness, and wear rate test was performed to the each sample. Maximum hardness and wear rate was happened at the cast iron of silicon content of 3.3% Si.

Evaluation of the anticorrosive performance of epoxy coatings containing new core/shell pigments

Purpose Core-shell is structured particles having several chemical compositions. The advantage of these particles arise from their specific design, to be used in decreasing costs by using inexpensive material (natural ore or waste material) as carrier for thin shell of active material. This study aims to prepare ferrites/silica core-shell pigments and compare their inhibition efficiency to original ferrites. These pigments have shells of different ferrites that comprise 10-15 per cent of the prepared pigments on silica fume. Silica fume which is the core is a byproduct in the ferro–silicon industry; this core comprises 85-90 per cent of the prepared pigments. Design/methodology/approach The prepared core-shell pigments were characterized using transmission electron microscopy analysis, energy-dispersive X-ray analysis and sequential wavelength dispersive X-ray fluorescence. These pigments were integrated in epoxy-based paint formulations, and the physical, mechanical and corrosion properties of dry films were examined. The corrosion properties were studied by using immersion test in 3.5 per cent NaCl for 28 days. Findings This study showed that these new eco-friendly and inexpensive pigments are similar to ferrites in their inhibition performance, i.e. they exhibited high corrosion prevention. Research limitations/implications Domestic waste materials were reused in paints and only simple modification was used, and then, their effectiveness showed similar performance to that of the original pigments. Originality/value Ferrite and ferrite/silica pigments are environmentally friendly pigments that can replace other hazardous pigments (e.g. chromates) with almost the same quality in their performance; also, they can be used in industries other than paints (e.g. paper, rubber and plastics composites).

Experimental investigation on high performance RC column with manufactured sand and silica fume

In recent years, the use High Performance Concrete (HPC) has increased in construction industry. The ingredients of HPC depend on the availability and characteristics of suitable alternative materials. Those alternative materials are silica fume and manufactured sand, a by products from ferro silicon and quarry industries respectively. HPC made with silica fume as partial replacement of cement and manufactured sand as replacement of natural sand is considered as sustainable high performance concrete. In this present study the concrete was designed to get target strength of 60 MPa as per guide lines given by ACI 211- 4R (2008). The laboratory study was carried out experimentally to analyse the axial behavior of reinforced cement HPC column of size 100×100×1000mm and square in cross section. 10% of silica fume was preferred over ordinary portland cement. The natural sand was replaced by 0, 20, 40, 60, 80 and 100% with Manufactured Sand (M-Sand). In this investigation, totally 6 column specimens were cast for mixes M1 to M6 and were tested in 1000kN loading frame at 28 days. From this, Load-Mid height deflection curves were drawn and compared. Maximum ultimate load carrying capacity and the least deflection is obtained for the mix prepared by partial replacement of cement with 10% silica fume & natural sand by 100% M-Sand. The fine, amorphous and pozzalonic nature of silica fume and fine mineral particles in M- Sand increased the stiffness of HPC column. The test results revealed that HPC can be produced by using M-Sand with silica fume.

Distribution Status of Trace Oxygen in Fe<sub>3</sub>Si-Si<sub>3</sub>N<sub>4</sub>

The distribution status of trace oxygen in the ferro-silicon nitride (Fe3Si-Si3N4) was investigated at the present, which was prepared by flash combustion synthesis method from FeSi75. The results showed that while the grain size of FeSi75 used in preparing Fe3Si-Si3N4 was less than0.074 mm, “active oxidation” occurred firstly, silicon was oxidized to form gaseous SiO(g), oxygen partial pressure was reduced in the system, silicon reacted with nitrogen directly to form Si3N4 while the system oxygen partial pressure approached less than 10-19MPa (T=1823K). O2(g) promoted the formation of Si3N4, Gaseous SiO(g) finally reacted with nitrogen and Si to form Si2N2O. The ferro silicon nitride was characterized by X-ray diffractometer and scanning electron microscope, the distribution of Si2N2O was uneven in the silicon nitride, and Si2N2O mainly distributed around Fe3Si or near the hole.

Microstructure and Mechanical Properties of Austenitic Compacted Cast Iron with Additive Manganese

High composition of austenitic matrix in microstructure is contributed to its special characteristic in reducing cracking and distortion. This special alloy will be in austenitic matrix when high temperature and also at room temperature which make it successful avoid matrix volume changes. In this study, austenitic compacted iron with minimum nickel contain of 12wt% is produced by using in-mould magnesium treatment. Magnesium Ferro Silicon (MgFeSi) used in determining the graphite form. Some of nickel replace by manganese in range of 9wt% to 12wt% Mn while Nickel remain at 12wt% Ni at all parameter. This research focuses on to investigate the effect of alloying elements on microstructure and mechanical properties. The outcome compared to standard of unmodified austenitic cast iron as in ASTM standard. The matrix obtained was all in austenitic matrix with the presence of compacted graphite distribution throughout the matrix. It is appeared that result shows increment of manganese at the centre region between graphite in the microstructure. It is occurred when percentage of manganese addition was increased. There are increases in hardness compared to unmodified austenitic iron. Tensile strength decreases when the manganese content increases in alloy.

<i>In-situ</i> Investigation on the Reduction of Magnesiochromite with Ferrosilicon between 1373–1573 K

<i>In-situ</i> Investigation on the Reduction of Magnesiochromite with Ferrosilicon between 1373–1573 K

Structural Characterization and Its Physical Properties of Non-standard A1 Austenite Steel

New austenite stainless steel code-named A1 has been synthesized using the foundry method. The steel was prepared using mineral elements extracted from crude ores in Indonesian mines and commercial scrap materials, in this case ferro scrap, ferro chrome, nickel, manganese, and ferro silicon; all of them were in the granular shape. The starting materials are inserted into an induction foundry furnace that operates on an electromagnetic inductive-thermal system. Moreover, a small quantity of titanium was added to this austenite steel that already has a very low carbon content. The neutron diffraction pattern shows that the material had an fcc crystal structure with lattice parameter of 3.5935 A. Neutron diffraction residual stress and texture measurements were performed on the austenite samples. The residual stress along the [220] crystallographic direction in the A1 alloy is compressive except in the normal direction where it is tensile. Tension as high as -629 MPa was observed in both the axial, transversal and normal directions. No region of high pole densities has been found in the material indicating a weak texture. The average value of the observed hardness is around of 205 on the Vickers scale for original casting sample; and the average hardness value of

Trends and developments in green cement and concrete technology

The cement industry faces a number of challenges that include depleting fossil fuel reserves, scarcity of raw materials, perpetually increasing demand for cements and concretes, growing environmental concerns linked to climate change and an ailing world economy. Every tonne of Ordinary Portland Cement (OPC) that is produced releases on average a similar amount of CO 2 into the atmosphere, or in total roughly 6% of all man-made carbon emissions. Improved production methods and formulations that reduce or eliminate CO 2 emissions from the cement manufacturing process are thus high on the agenda. Emission reduction is also needed to counter the impacts on product cost of new regulations, green taxes and escalating fuel prices. In this regard, locally available minerals, recycled materials and (industry, agriculture and domestic) waste may be suitable for blending with OPC as substitute, or in some cases replacement, binders. Fly ash, Blast furnace slag and silica fumes are three well known examples of cement replacement materials that are in use today that, like OPC, have been documented and validated both in laboratory tests and in practice. The first is a by-product of coal combustion, the second of iron smelting and the third of electric arc furnace production of elemental silicon or ferro silicon alloys. This paper presents a concise review of the current state-of-the-art and standards underpinning the production and use of OPC-based cements and concretes. It outlines some of the emerging green alternatives and the benefits they offer. Many of these alternatives rely on technological advances that include energy-efficient, low carbon production methods, novel cement formulations, geopolymers, carbon negative cements and novel concrete products. Finally, the economics of cement production and the trends in the UK, US and the Gulf Cooperation Council (GCC) Region are presented, to help guide and inform future developments in cement production based on maximizing the value of carbon reduction.

압축강도 300MPa 이상의 초고강도 분체콘크리트 개발을 위한 실험적 연구

본 연구에 사용한 시멘트는 보통 포틀랜드 시멘트이며, 공극 최소화를 위한 충전재는 미세석영을 사용하였고 고강도화에 따른 취성파괴 문제를 개선하기위해 강섬유를 사용하여 압축강도 300 ㎫ 이상의 초고강도 분체콘크리트를 개발 하고자 하였다. 콘크리트의 강도를 크게 향상시키기 위한 연구의 일환으로 계면영역의 부착강도를 향상시킬 수 있는 크기 0.6 ㎜ 이하의 규사, 백운석, 보크사이트, 페로실리콘을 선정한 후 각각의 배합비, 양생조건을 달리하여 압축강도를 비교분석 하였다. 초고강도 분체콘크리트는 보통콘크리트와 달리 사용재료의 영향이 대단히 중요하다. 분체콘크리트의 압축강도 측정 결과 페로실리콘 ＞ 보크사이트 ＞ 백운석 ＞ 규사 순으로 골재의 강도가 압축강도에 큰 영향을 미치는 경향을 알 수 있었으며 페로실리콘의 경우 시멘트 중량 기준하여 혼입량 110%일 때 가장 큰 강도를 나타내었다. SEM 촬영 결과 C-S-H수화물이 비교적 많이 생성되었고, 고온고압양생으로 토버모라이트와 조놀라이트가 생성된 것을 확인 하였다. 또한 골재의 세립화, 분체의 치밀충전화 및 반응성 재료의 사용으로 인해 페이스트가 고강도화 되고, 강섬유를 사용하여 인성을 보강함으로써, 28일 압축강도 341 ㎫의 초고강도 분체콘크리트를 성공적으로 개발 하였다.

Tribological properties of oxidised boride coatings grown on AISI 4140 steel

In this study, we investigated the wear behaviour of borided and borided + short-duration oxidized AISI 4140 steel. Boronizing was carried out in a slurry salt bath consisting of borax, boric acid and ferro silicon. Also, short-duration oxidizing treatment was applied to borided steel to produce glass-like boron oxide layer. The short-duration oxidizing was performed at 750 °C for 3 min. Optical and scanning electron microscope (SEM) cross-sectional examinations of borided layer revealed a needle-shaped morphology. The presence of non-oxide boride type ceramics FeB and Fe 2B formed on the surface of steel substrate was confirmed by classical metallographic technique and X-ray diffraction (XRD) analysis. The hardness of borides formed on the surface of steel substrate and unborided steel substrate were 1446–1690 HV 0.1 and 280 HV 0.1, respectively. The wear behaviour of borided steel were characterised by using a pin-on-disc technique. The borided and short-duration oxidized steels, in the form of pins were allowed to slide against a hard AISI 440C stainless steel disc (63 HRc). The sliding velocity of 1 m s − 1 for borided and short-duration oxidized steel and the nominal load on the pin was 20 N. The highest wear rates were observed on disc slide against the base steel, whilst the lowest wear rates occurred during sliding against the borided and short-duration oxidized steel surfaces. It was observed that the friction coefficient of unborided (hardened + tempered) and borided steels ranged from 0.50 to 0.60, but after short-duration oxidizing, the friction coefficient of borided steel was dropped to 0.12.

The manufacture of continuous smelting electrodes from carbon paste briquettes

Continuously consumed electrodes are used in the manufacture of ferro alloys, aluminium, silicon metal and calcium carbide. The raw material for the electrodes is a carbon paste which is normally added to the electrode in large solid sections. The option of manufacturing such electrodes from small paste ‘briquettes’ is examined with respect to an industrial experiment used to predict the quality of a briquette-formed electrode. It is shown that successful predictive models may be formulated using a two-phase slow-flow approach. Consideration is also given to the briquette manufacture of Persson and Bruff electrodes, two different commercially important devices for the production of silicon.