Filler Material Research Articles

A Primary Study on the Applicability of Gel-Type Filler Materials to Root Pass Welds of the Thick Plate

Welding generally uses filler material to create deposited weld metal. Filler materials play a significant role in welding by providing the material needed to fill and form the joint. Existing filler materials are limited in the workspace and welding position and need help responding flexibly to welds of complex shapes. This study conducted primary research to develop a gel-type filler material with adhesion and flexibility that can cope with limited workspace and location. We attempted to provide a new approach to welding by mixing metal powder and binder to create a gel-type filler material. Root pass welding of thick plates was performed using a laser heat source. The bead appearance and cross-section of the weld zone were observed according to the type and composition of the metal powder, the binder content, and the method of synthesizing the metal powder. The physical characteristics of the weld were analyzed through observation of the hardness and microstructure of the weld.

It's not just a phase: shaping the future of 3D photoprinted polymers with polymerization‐induced phase separation

AbstractAdditive manufacturing is a technology that promises to disrupt the conventional manufacturing industry due to its ability to create complex structures with improved macroscopic control not available with existing techniques like molding or milling. In addition to superior macroscopic structural control, photoprinting methods such as digital light projection can enable molecular‐scale control over the fabrication process by taking advantage of the self‐sorting or assembly properties of the monomers themselves. Polymerization‐induced phase separation (PIPS) allows for the remarkable introduction of microscopic control into additive manufacturing, using polymer‐rich and polymer‐poor regions that rely on incompatibilities to phase separate during polymerization creating new complex materials not achieved by traditional methods. With the incorporation of porogens or filler materials, microporosity and/or surface functionalization can be introduced in a facile one‐step printing process. This expands the potential applications of 3D printed materials, to include micro‐ and macroscale structural control. Using PIPS as a design strategy, polymeric materials with previously unprecedented capabilities can be produced with ease enabling 3D printing to grow into its full potential as a manufacturing tool. © 2024 Society of Chemical Industry.

Utilisation of reservoir sediments for engineering applications

In this paper, a detailed characterisation of Tungabhadra (TB) reservoir sediment, such as physical, chemical, geotechnical, morphological and mineralogical attribute, is performed to identify the suitability of dredged sediment as engineering material. Characteristics of sediment is, however, compared with Indian Standard codes for specific engineering applications. Through this study, it is depicted that sediment obtained from the TB Dam reservoirs as such cannot be used for engineering purpose (such as a fill material for highway construction, as sand for concreting and plastering and as foundry sand and other applications); these sediments need prior treatment before using them for the above-mentioned applications. However, it can also be noted that to enhance the strength properties of sediment, air-cooled blast furnace slag (ABS) can be used as a stabiliser. On the other hand, ABS is treated as waste material in steel industry. Thus, it is concluded from this study that TB Dam sediment can be used for many engineering applications provided proper screening and stabilisation technique is adopted. Thus, the cost of dredging is converted into profit by selling the TB Dam sediments for engineering applications.

Repair of Injection Moulds by Welding for Pre-Hardened 1.2714 Hh Steel

The welding of injection molds by laser deposition is a very common procedure in recent years in the maintenance departments of plastic injection factories. This is due to the advantages it has compared to traditional welding methods, namely the speed of the laser welding process, a lower deposition of the metal composition in the repaired area (small volume of deposited material), as well as the accuracy of the deposition on the surface the piece. But, in addition to these advantages, there are also a number of disadvantages compared to classic welding. As the main disadvantage in the case of laser welding of injection molds, the maximum weldable thickness is limited. This paper presents an analysis of weld quality and mechanical fracture of laser deposition according to deposition types and welding techniques of 1.2714 HH pre-hardened steel. The material 1.2714 HH is a basic material used in recent years in the production of molds due to its hardness, namely 40-45 HRC units. In laser welding, different welding strings are possible, each influencing the laser deposition preparation process, the possibility of performing the deposition in the respective area, as well as obtaining a desired mechanical stability. Starting from these considerations, a number of factors will be analyzed using 1.2714HH steel samples: welding strings, welding strings depth, filler material and welding parameters. V – notches were made and filled for welded samples with laser welding deposits. V – notches were made and filled for welded samples with laser welding deposits.

Effect of Filler Wire Composition on Weld Metal Microstructure and Mechanical Properties in X80 Steel Laser Welds

Laser welding was performed using different filler wires, ER70S steel, commercially pure iron, and pure nickel filler, in the context of welding X80 pipeline steel to assess the microstructure and mechanical properties of the weld metal. Introducing an ER70S wire promoted acicular ferrite formation in the fusion zone, compared to a bainitic microstructure in an autogenous laser weld. The use of pure iron wire was considered as a potential strategy for reducing hardenability, as it led to the dilution of alloying elements in the fusion zone, increasing ferrite content and reducing weld metal hardness to a level compliant with API pipeline standards. The addition of pure nickel wire was used to reveal the degree of weld metal mixing imposed by the laser (thus providing an unambiguous tracer element) when it is combined with filler material dilution in the fusion zone, revealing that the upper region contained 38% wire material and the lower region only 12%. This accounts for the differences observed between the upper versus lower portions of the weld metal when other wires are used, and the use of hardness mapping and micro-indentation demonstrates the correlation between the variations in mechanical properties and microstructural differences introduced by incomplete mixing of the filler wire elements.

Neo-Hookean modeling of nonlinear coupled behavior in circular plates supported by micro-pillars

In the contemporary era, the enhancement of wearable capacitive sensors is achieved through the utilization of polymeric micropillars as filler materials between electrode plates. To gain a deeper understanding of the dynamic response of the system, nonlinear coupled governing equations of a circular microplate motion resting on an array of polymeric micropillars have been derived. These equations are used to model the system’s behavior. In addition, the squeezing motion of the micro-pillars is characterized using the incompressible Neo-Hookean model. Both static and dynamic responses, including transient and steady-state solutions, are investigated in detail by discretizing over spatial coordinates using a weak formulation approach. A frequency response analysis is conducted using a continuation-based method. This entails expanding the steady-state solution using a Fourier transform and employing the energy balance principle. The unknown coefficients of the expansion series are calculated using a gradient descent-based learning approach that is physically motivated. Furthermore, a dynamic step size strategy for frequency increments is employed to effectively follow the solution path. This strategy is implemented via the ARC length method. In this study, we examine the impact of varying PDMS (polydimethylsiloxane) hydrogel mechanical and geometrical configurations. It can be reasonably concluded that the mechanical properties of the pillars and the geometrical configuration of the circular plate and micropillars have a significant impact on the maximum tolerable pressure, fast transient response, and frequency response analysis.

The influence of cooling time on the alloy distribution in weld metals

This research explores the impact of cooling time on the distribution of alloying elements within weld metals of high-strength steel, a critical factor in optimizing welding processes for advanced structural applications. Using gas metal arc welding (GMAW) and two different filler materials, this study systematically varies cooling times to analyze the resulting chemical compositions. Energy Dispersive X-ray (EDX) analysis was employed to examine the alloy content in the weld metal, base material, and heat-affected zone (HAZ). The results demonstrate that cooling time significantly influences the concentration of alloying elements, such as chromium, nickel, and manganese, within the weld metal, revealing complex diffusion behaviours that are dependent on the thermal cycles introduced during welding. Notably, an in-depth analysis of the HAZ shows a distinct diffusion pattern for silicon, indicating intricate microstructural changes. These findings highlight the importance of controlling cooling time to optimize the microstructural and chemical properties of welded joints in high-strength steels, with implications for improving weld performance and reliability.

Model Test on Acoustic Emission Monitoring of Loess Slope Failure

The three stages of loess collapse are characterized by notable concealment and sudden onset due to the sudden nature of loess collapse and the prolonged duration of the peristaltic deformation stage. Traditional displacement monitoring methods struggle to detect early signals of instability and failure, leading to poor timeliness in disaster warnings. This project begins by examining non-force field information related to the loess collapse process. It focuses on acoustic emission monitoring and employs model tests to identify effective waveguide rods for monitoring loess collapse. Additionally, the project investigates the evolution anomalies of acoustic emission parameters before and after loess collapse failure, aiming to establish early warning criteria for loess collapse based on acoustic emission. This work provides a theoretical basis for monitoring and early warning of loess collapses. This study evaluates five parameters of the active waveguide system: sensor installation method, filling material, waveguide rod wall thickness, outer wrapping material, and outer wrapping wall thickness. The densities of the filler materials were tested using the optimal parameters derived from the tests to identify the best configurations for active acoustic emission (AE) waveguide systems suitable for monitoring loess collapse. Subsequently, a one-sided connected loess collapse model was employed for indoor tests, integrating real-time AE monitoring with the active waveguide method. This model facilitates the exploration of AE response characteristics during loess collapse and the analysis of destructive forms of loess collapse and time-sequence evolution of AE ringing counts throughout the deformation and destruction process. Results indicate that using filler materials with high elasticity modulus, high compactness, and low Poisson’s ratio, along with thin outer wrapping and waveguide rod walls, leads to strong AE signals. As deformation damage of loess collapse intensifies, the number of AE ringing counts notably increases. A rapid rise in cumulative ringing counts can indicate a “sudden increase”, or the b-value may stabilize, providing precursor information for loess collapse.

Study on the Properties of All-Solid Waste Fluidized Filling Materials Applied to Mine Void Area Filling Engineering

The extraction of mining resources, as well as processing processes such as ore beneficiation and smelting, generate large amounts of tailings that are difficult to directly utilize. Meanwhile, substantial filling materials are required for the voids formed after mining operations, and the environmental issues and safety hazards brought on by massive solid waste disposal cannot be ignored. By utilizing solid waste with alkaline and pozzolanic activity as the binder component and gold tailings as filler aggregate to prepare filler material to fill up the void areas, the purpose of waste treatment can be achieved. In this study, salt sludge, steel slag, ground granulated blast furnace slag, and gold tailings were used to prepare all-solid waste fluidized filling material for filling mine void areas, which not only solves the engineering safety problem of easy collapse of the mine airspace in the mining process but also ensures a backfill effect with high strength, which continuously guarantees the uninterrupted progress of the mining project. At the same time, the preparation of fluidized materials can consume a large amount of tailings and other solid waste, solving the problem of their stockpiling. The components of the solid wastes used are all general industrial solid wastes, so the preparation of the fluidized materials will not have an impact on the surrounding environment. The effects of binder ratios on the workability of the filling materials were investigated by means of the slump and slump flow tests. Combined with the unconfined compressive strength test, the change in backfill material strength with curing age and the water–binder ratio was studied. The experimental results showed that the slump and slump flow value of the filling material were positively correlated with the water–binder ratio. The water–binder ratio range satisfying a slump value of 180~260 mm and a slump flow value not less than 400 mm was 0.95~1.106. However, the strength decreased with the increase in the water–binder ratio, conforming to a hyperbolic relationship. The all-solid waste fluidized filling material had strengths not less than 0.22, 1.09, and 1.95 MPa at 3, 7, and 28 d, respectively, meeting the workability requirements. Finally, a method for determining the optimal range of water–binder ratio considering both workability performance and strength is proposed based on the relationship between slump value, slump flow value, unconfined compressive strength, and the water–binder ratio.

The impact of TiC particle addition to Ag–Cu-Ti filler material on the microstructure and mechanical properties of AlN ceramic/Cu brazed joints

The impact of TiC particle addition to Ag–Cu-Ti filler material on the microstructure and mechanical properties of AlN ceramic/Cu brazed joints

Optimizing Membrane Performance using Various Filler Materials in Membrane Fabrication for Enhancing Gas Separation Efficiency: A Review

The membrane technology has been receiving significant interest in both research and industrial applications, particularly in the separation of CO2/CH4. These methods, as published, aim to overcome the limitations of pure polymeric membranes and offer an alternative approach in separation techniques where membrane technology can overcome the constraints of conventional methods such as Solid Phase Extraction (SPE) and Liquid-Liquid Extraction (LLE). Fabricating membranes using fillers as adsorbents can enhance membrane separation performance due to their porous nature. Hence, the selection of suitable fillers is crucial to maximize membrane efficiency in separating analytes. This paper will review 3 types of fillers-metal-organic frameworks, carbonaceous nanomaterials and mesoporous molecular sieves-from various research papers published in recent years. HIGHLIGHTS Additives introduced to polymeric membrane to increase the membrane performances in terms of selectivity and permeability. Short review of materials used for fabrication of mixed matrix membrane. Modification of selected additives used to study its effects on membrane performances. Recent advancement of hybrid additives materials, combining MOF and carbonaceous materials. GRAPHICAL ABSTRACT

Effect of carbon nanotube incorporation on the mechanical and physical properties of hydroxyapatite/glass ionomer nanocomposite

This manuscript discusses the potential use of multi-walled (MW) carbon nanotubes (CNTs) as a filler material in hydroxyapatite/glass ionomer cement HA/GIC nanocomposite to enhance its properties: mechanical and physical. Four different proportions (1, 2, 3, and 5 wt%) of CNTs were added to the HA/GIC nanocomposite to determine the optimum ratio that can lead to the best properties of the new nanocomposite biomaterial. Mechanical mixing technique followed in dentistry was used in preparing all samples. FTIR, PSA, XRD, TEM, and SEM were used to characterize the fabricated Pellets. In addition, the new nanocomposite samples were evaluated using compressive and diametral tensile tests. Overall, increasing the weight ratio of CNTs added to the nanocomposite (from 1 to 5 wt%) caused about a 40% reduction in the compression strength of the samples. However, a slight increase (about 4%) was detected at 2 wt% CNTs samples. Also, a distinct increase in the elasticity of the composite (about 50%) was reported. The best results of diametral tensile strength were found at a 3 wt% CNTs. Furthermore, for all samples, adding CNTs to the composite changed the sample’s color from A2 and B2 to totally black color.

The Use of Waste Materials Red Mud and Fly Ash as Road Embankment Fill

This study provides a comprehensive evaluation of red mud as a sustainable material for road base construction, particularly in combination with bottom ash. Red mud, a by-product of the Bayer process used in alumina extraction, is known for its high alkalinity and heavy metal content. For this reason, this waste material causes environmental challenges. Red mud sourced from the Eti Aluminum Factory in Seydişehir, Konya (Turkey), was stabilized with bottom ash. Then, these waste materials were tested through a number of experiments, such as in relation to their Atterberg limits, compaction characteristics, unconfined compressive strength (UCS), California bearing ratio (CBR), and microstructure through a scanning electron microscopy (SEM) analysis. The results highlight that the UCS of stabilized red mud samples significantly improved with the addition of bottom ash and longer curing periods. Specifically, the UCS values increased from 0.5 MPa to 2.5 MPa after 28 days of curing. Moreover, RM specimens stabilized with 25% bottom ash achieved a CBR value of 146.64% after 28 days, far exceeding Turkey’s road fill material requirement, which mandates a minimum unsoaked CBR value of 15%. These findings indicate that red mud stabilized with bottom ash not only meets but exceeds the structural requirements for road base materials. This approach provides a sustainable solution for the environmental management of red mud while contributing to infrastructure development. Through the recycling of these industrial by-products, this study presents a viable method to reduce waste and support economic and environmental sustainability in road construction projects.

Electrochemical Exfoliation of Graphene and Formation of its Copolyamide 6/66 Nanocomposites by Wet Phase Inversion and Injection Molding

AbstractElectrochemically exfoliated graphene (EEG) is compounded with copolyamide 6/66 (PA6/66) to investigate the influence of the carbonaceous filler material on the thermal, rheological, and mechanical properties of the composite. Toward that end, the environmentally friendly electrochemical exfoliation in aqueous solution is further developed to furnish graphene in large quantities. Separating the exfoliation process from the incorporation into the polymer matrix by wet phase inversion (WPI) allowed in‐depth characterization of the EEG by scanning electron microscopy (SEM), atomic force microscopy (AFM), and Raman spectroscopy. The crystallinity of copolyamide 6/66‐EEG is significantly changed, as revealed by differential scanning calorimetry (DSC). Likewise, the new composite materials exhibit different flow properties, as well as increased mechanical reinforcement with additive concentration. This is proven by dynamic shear rheology and three‐point stress tests compared to the neat polymer.

Assessment of the Possibility of Application of New Types of Filler Materials in the Renovation of Functional Surfaces of Crane Wheels

This paper presents the results of research from the renovation of functional parts of crane wheel surfaces. The aim of the research was to verify the possibilities of changing the chemical composition of the additive materials for submerged arc cladding, in order to increase the resistance of the wheel surfaces to wear. The base material of the crane wheel was heat-treated carbon steel for castings, mat. no. 1.0553. The renovation process was carried out on three equal wheels. Conventionally used additive material, the same one used for the interlayer and two covering layers, was used on one wheel. On two other wheels, newly increased tubular wires with a higher proportion of carbide-forming additives (Cr, Mo) were used for the carbide coating of two covering layers, in addition to their conventional additive material. Low-alloy additive material was applied to the newly elevated wires. The quality of the clads was assessed using non-destructive tests. Subsequently, microstructural analysis was carried out on the test samples taken from the renovated wheels, by means of light microscopy. On the cross cuttings, the course of hardness was evaluated using Vickers analysis. The resistance of functional surfaces to adhesion wear was evaluated based on weight losses measured using the AMSler experimental equipment. The results of the experiments showed an increase in the tribological resistance of the surfaces, specifically by 45% due to the newly developed wire C1 and by 18% due to wire B1, and it is therefore possible to recommend renovation.

The Effects of Material‐Filled Voids on Detonation Wave Shape in Rubberized RDX Explosives

AbstractThe sensitivity of explosives is affected by inhomogeneities within the material. This is evident in the increased shock sensitivity of explosives with slightly lower densities resulting from an increased number of hotspots. The influence of hotspots on explosive initiation has been well studied; however, few studies have been conducted on the effect of intermediate‐sized voids (0.1–10 mm) on a propagating detonation wave. Cylindrical voids filled with air have been studied for diameters ranging from 0.3 mm to 0.8 mm for both 1,3,5,7‐tetranitro‐1,3,5,7‐tetrazocane (HMX) and 1,3,5‐trinitro‐1,3,5‐triazinane (RDX)‐based rubberized explosives. Continuing the investigation into single cylindrical voids, this study examined the effects of 0.5 mm diameter voids filled with different inert cylindrical metals on the detonation wave shape for an RDX‐based rubberized explosive. The metals selected for experiments were 1066 aluminum, brass, copper, and tungsten. The propagation of the detonation wave was captured using a digital streak camera. Experimental results showed that the extent of detonation wave shaping was closely tied to the density differential between the bulk explosive and metal insert. Forty‐four different filler materials, including non‐metals, were simulated using a hydrodynamic code to further analyze material inclusion effects. The main factors hypothesized to be of interest were bulk sound speed, shock impedance, and filler material density. We found that the local detonation delay could be correlated fairly well to a ratio of bulk sound speed and density. Understanding the influence of material inclusions on detonation performance and wave shape allows for tailoring of detonations.

Fabrication and characterization of novel glass-ionomer cement prepared from oyster shells

Glass ionomer cement (GIC) is one of the most widely used restorative materials for temporary fillings and reconstructions in dentistry, but it has relatively poor mechanical properties that make its use limited, especially in places subject to high pressure. Thus, to extend the applicability of GIC, samples based on SiO2, P2O5, Al2O3, CaF2, and NaF were prepared with the addition of calcium oxide CaO extracted from natural sources (oyster shells) in different ratios of 0, 5, 10, 15, 20, and 25% wt. The suggested glass samples were evaluated, and their physical and mechanical properties were compared. XRD, SEM, and FTIR were performed on the samples. 24 specimens were prepared for each test in order to assess the mechanical properties as per the specific requirements. The tests included measuring bending strength, elastic modulus, adjusted direct tensile strength, absorption, water solubility, and diffusion coefficients after the specimens were stored in distilled water for 60 days. All calculations were carried out in accordance with standard procedures. The findings indicated a slight improvement in the bending resistance of the recommended GIC. Glass modified with 20% by weight of calcium oxide was the best among the ratios in terms of the results obtained and compared to the traditional commercial type. The malleable strength of the sample was 54.121 MPa, while the flexural modulus increased, the tensile strength reached 10.154 MPa, and the solubility was 25.87 µg/mm3 after storage for 60 days. These indicate that the developed material is suitable for use as a dental restoration material when compared to international commercial cement specifications.

Effects of waste wollastonite filler on hot mix asphalt performance

Asphalt pavement plays a critical role in global infrastructure, necessitating substantial annual investments for maintenance and repair. Enhancing asphalt mixture performance is essential for prolonging pavement life and reducing associated costs. This study explores the use of waste wollastonite, a neutral mineral composed of silica and lime, as a filler material in asphalt mixtures. Comprehensive micro-scale performance tests, including Marshall Stability, resistance modulus, indirect tensile strength, and moisture sensitivity, were conducted on samples incorporating waste wollastonite. The findings indicate that replacing lime filler with waste wollastonite significantly improves asphalt performance; specifically, complete substitution resulted in increases in Marshall Stability, Marshall Quotient, and resistance modulus by 30%, 28%, and 26%, respectively. Furthermore, a 70% replacement of lime with waste wollastonite led to a 9% increase in tensile strength ratio while demonstrating a notable reduction in indirect tensile strength compared to control samples. These results suggest that waste wollastonite is a viable and effective filler option for enhancing the durability of asphalt mixtures.

Utilization Status of Oil-Based Drilling Cutting Pyrolysis Residues in The Field of Building Materials

The exploitation of shale gas generates a large amount of oil-based drill cuttings, which are harmful to the environment due to their content of petroleum hydrocarbons, heavy metals, and organic pollutants. Thermal desorption technology is one of the main techniques for treating oil-based drill cuttings. This paper focuses on oil-based drilling cutting pyrolysis residues and summarizes its current research status in the construction materials field. Currently, the application of oil-based drilling cutting pyrolysis residues has achieved certain results in road fill, cement production, ceramsite production, and wall materials, and further exploration and development are needed in the future to develop high value-added products and expand the pathways for the high-value utilization of oil residues.

Comparative study of microstructural evolution and mechanical properties in friction stir processed, reinforced friction stir processed, and heat-treated reinforced friction stir processed Al composites

The development of friction stir welding (FSW) created the basic foundation for friction stir processing (FSP). This process entails refining the local microstructure and achieving the localised plastic deformation due to the stirring effect of the tool, which may involve adding additional filler material as required. The rotating tool involved in the process has a shoulder and pin responsible for heat generation for plastic deformation and localised mixing. The rotating tool is inserted and traversed on the desired surface, tailoring the material properties. The tool’s exposure to the surface causes localised plastic deformation and thermal gradient, and microstructural changes occur locally. The present investigation uses Friction Stir Processing (FSP) to fabricate an aluminium metal matrix composite. Recently, the use of aluminium alloy has been replaced by composites because of their increased mechanical and physical properties (specific properties). The experiment leads to manufacturing an aluminium metal matrix composite using aluminium oxide, boron carbide and commercially pure copper dust. Later, the effect of heat treatment on the respective metal matrix composite is studied. A comparative study among three different types of FSP techniques viz. FSP, Reinforced FSP, and Heat-treated Reinforced FSP have been performed. The tool revolution speed (RPM) and tool traverse speed of 400 RPM and 10 mm/min had been implemented, respectively. The T4 Heat-Treatment cycle was used during the current investigation. This investigative study was performed to analyse the changes in grain sizes and hardness values at the stir zone (SZ), thermo-mechanically affected zone (TMAZ), heat affected zone (HAZ) and on the base materials (BM) of the samples. The reinforced FSP metal matrix composite (MMC) showed an 81.26% increase in the micro-hardness value (HV) compared to the base metal. Further on analysing the microstructures, the reinforced FSP composite showed a 65.20% reduction in grain size. Moreover, the Heat-Treated sample showed an increase in the micro-hardness value by 99.8%.