Flow Behavior Of Slurries Research Articles

Rheological Behavior of Al-7Si-0.3Mg Alloy at Mushy State

In recent years, semisolid manufacturing has emerged as an attractive option for near net shape forming of components with aluminum alloys. In this class of processes, the key to success lies mainly in the understanding of rheological behavior of the semi-solid slurry in the temperature range between liquidus and solidus. The present study focuses on the non-Newtonian flow behavior of the pseudo plastic slurry of Al-7Si-0.3Mg alloy for a wide shear range using a high-temperature Searle-type rheometer. The rheological behavior of the slurry is studied with respect to relevant process variables and microstructural features such as shear rate, shear duration, temperature history, primary particle size, shape, and their distribution. The experiments performed are isothermal tests, continuous cooling tests, shear jump tests, and shear time tests. The continuous cooling experiments are aimed toward studying the viscosity and shear stress evolution within the slurry matrix with increasing solid fraction at a constant shear rate. Three different cooling rates are considered and their effect on flow behavior of the slurry was studied under iso-shear condition. Descending shear jump experiments are performed to understand the viscous instability of the slurry.

Effects of iron oxides on the rheological properties of cementitious slurry

Iron oxide has been considered a promising host for immobilizing and encapsulating radioactive 99Tc (t1/2=2.1×105 year), which significantly enhances the stability of 99Tc within a cementitious waste form. However, the flow behavior of cementitious slurry containing iron oxide has never been investigated to ensure its workability, which directly influences the preparation and performance of the cementitious waste form monolith. Variation in the rheological properties of the cementitious slurry were studied using rheometry and ultrasonic wave reflection to understand the effects of various iron oxides (magnetite, hematite, ferrihydrite, and goethite) during the cement setting and stiffening processes. The rheological behavior significantly varied with the addition of different chemical compounds of iron oxides. Complementary microscopic characteristics such as colloidal vibration currents, morphology, and particle size distributions further suggest that the most adverse alteration of cement setting and stiffening behavior caused by the presence of goethite may be attributed to its acicular shape.

Performance characterisation of AG/SAG mill pulp lifters using CFD techniques

The pulp lifter is an integral component of autogenous (AG) and semi-autogenous (SAG) grinding mills as it controls the throughput, performance and efficiency of mills. The slurry transport from the AG/SAG mill through grate holes into the discharge trunnion is the main function of the pulp lifter. This process develops complex flow behaviour in the region of the grate and pulp lifter. Efficient and effective removal of pulp/slurry from the mill is the key objective of the pulp lifter design.This work aims to understand slurry flow behaviour in pulp lifter sections and its contribution to mill performance using computational fluid dynamics (CFD) modelling and Laser Doppler Anemometry (LDA) measurements applied to a laboratory scale mill. The CFD model is validated against the LDA measurements, and then used to build a cohesive computational framework for modelling industrial pulp lifters, to investigate unique problems associated with their design and performance.

Microstructure observation and quantification of the liquid fraction of M2 steel grade in the semi-solid state, combining confocal laser scanning microscopy and X-ray microtomography

Microstructure is of crucial importance to the flow behavior of semi-solid slurries during the thixoforging process. Therefore, a thorough understanding of the microstructure evolution is required. In order to achieve this, high temperature confocal laser scanning microscopy (CLSM) and high energy X-ray microtomography were used to investigate the microstructure evolution of several steel grades (M2, 100Cr6 and C38LTT) during the heating process from as-received conditions to the semi-solid state. It was found that the microstructure development of M2 can be directly studied at high temperature via these two techniques. Two types of small carbides (MC and M6C) were present in the as-received state, while totally new interconnected carbides of specific size and composition were formed from liquid zones after cooling. It was also noted using CLSM that the diffusion rate of the alloying elements during the cooling of M2 was very low. This confirms that the volume fraction of the liquid phase of M2 at high temperature can be evaluated by three-dimensional X-ray microtomography in situ at high temperature and on quenched specimens. Contrary to M2, the microstructure of the steel grades 100Cr6 and C38LTT in the semi-solid state can only be revealed by CLSM at high temperature. All these observations are discussed in terms of microstructural development and liquid fraction during heating.

Co-Dispersion Behavior of ZrB₂-SiC-B₄C-C Powders with Polyethyleneimine.

The aqueous dispersion behavior of ZrB2, SiC powders with B4C and C as sintering aids was investigated. Well co-dispersed suspension can be obtained in acidic solutions in presence of polyethyleneimine (PEI). The adsorption of PEI on the powder surface was measured by thermal gravimetric (TG) analysis. Rheological measurements displayed the effect of dispersant on the flow behavior of as-prepared slurries. An optimum condition was obtained with 1 wt % PEI. The viscosity of 40 vol % ZrB2–SiC–B4C–C (ZSBC) suspension at 100 s−1 was as low as 0.74 Pa·s, which was suitable for aqueous processing.

Characterization of flow behavior of semi-solid slurries containing low solid fractions in high-pressure die casting

Understanding the flow behavior of semi-solid slurries containing low solid fractions is key to the success in applying this process in the die casting industry. With these low initial solid fractions, the flow behavior of semi-solid slurries is quite complicated, making it difficult to model accurately. This present work developed and studied characterization methods for the flow behavior of semi-solid slurries at low solid fractions in high-pressure die casting. A new parameter, the ratio of gate speed to initial solid fraction (Vg/fs), was proposed to be correlated to the normalized flow interface length, blister area and tensile properties. Results from the flow pattern analysis suggest that the flow behavior can be controlled to achieve laminar flow by varying the initial solid fraction. Blister test results show the trend that slurry die casting conditions with high Vg/fs values exhibit high blister areas. Die casting conditions with excessively high gate speeds and insufficient solid fractions result in turbulent flow patterns and high levels of blister defect. The results of tensile test and fracture surface analysis are consistent with other analysis results. The samples formed by liquid die casting and slurry die casting with high Vg/fs values have gas porosity due to turbulent flow pattern during die filling. On the other hand, the samples formed by slurry die casting with too low Vg/fs values contain shrinkage porosity. This is because of insufficient time for shrinkage feeding due to a combination of a high solid fraction and a low gate speed. This study has demonstrated that die casting with slurries containing low initial solid fractions gives die casters another process parameter to adjust, which can help reduce and control the gas and shrinkage porosities.

Characterization of Flow Behavior of Semi-Solid Slurries with Low Solid Fractions

Semi-solid slurry casting is a metal-forming process that involves transforming liquid metal into slurry having a low solid fraction and then forming the slurry into solid parts. To successfully apply this slurry-forming process, it is necessary to fully understand the flow behavior of semi-solid slurries. This present work applied the rapid quenching method and the modified gravity fluidity casting to investigate the flow behavior, which involves characterizations of the initial solid fraction, fluidity, and microstructure of semi-solid slurries. Three commercial aluminum alloys were used in this study: 383 (Al-Si11Cu), 356 (Al-Si7MgFe), and 7075 (Al-Zn6MgCu) alloys. The results show that the initial solid fractions can be controlled by varying the rheocasting time. The rapid quenching mold can be used to determine the initial solid fractions. In this method, it is important to apply the correcting procedure to account for growth during quenching and to include all the solid phases. Results from the fluidity study of semi-solid slurries show that the fluidity decreases as the initial solid fraction increases. The decrease is relatively rapid near the low end of the initial solid fraction curves, but is quite slow near the high end of the curves. All the three alloys follow this trend. The results also demonstrate that the slurries that contain high solid fractions of up to 30 pct can still flow well. The microstructure characterization results show that the solid particles in the slurries flow uniformly in the channel. A uniform and fine microstructure with limited phase segregation is observed in the slurry cast samples.

Shear thickening of corn starch suspensions: Does concentration matter?

Suspensions of corn starch and water are the most common example of a shear thickening system. Investigations into the non-Newtonian flow behavior of corn starch slurries have ranged from simplistic elementary school demonstrations to in-depth rheological examinations that use corn starch to further elucidate the mechanisms that drive shear thickening. Here, we determine how much corn starch is required for the average person to “walk on water” (or in this case, run across a pool filled with corn starch and water). Steady shear rate rheological measurements were employed to monitor the thickening of corn starch slurries at concentrations ranging from 0 to 55wt.% (0–44vol.%). The steady state shear rate ramp experiments revealed a transition from continuous to discontinuous thickening behavior that exists at 52.5wt.%. The rheological data was then compared to macro-scopic (∼5gallon) pool experiments, in which thickening behavior was tested by dropping a 2.1kg rock onto the suspension surface. Impact-induced thickening in the “rock drop” study was not observed until the corn starch concentration reached at least 50wt.%. At 52.5wt.%, the corn starch slurry displayed true solid-like behavior and the falling rock “bounced” as it impacted the surface. The corn starch pool studies were fortified by steady state stress ramps which were extrapolated out to a critical stress value of 67,000Pa (i.e., the force generated by an 80kg adult while running). Only the suspensions containing at least 52.5wt.% (42vol.%) thickened to high enough viscosities (50–250Pas) that could reasonably be believed to support the impact of a man’s foot while running. Therefore, we conclude that at least 52.5wt.% corn starch is required to induce strong enough thickening behavior to safely allow the average person to “walk on water”.

Flow Behavior and Heat Transfer Characteristics of Ice Slurry along a Heated Cylinder

Flow Behavior and Heat Transfer Characteristics of Ice Slurry along a Heated Cylinder

The slurrying properties of slurry fuels made of petroleum coke and petrochemical sludge

Petroleum coke and petrochemical sludge are the two main by-products of the petroleum chemical industry. They can be disposed and utilized efficiently and cheaply in the form of petroleum coke–sludge slurry (PCSS). The high-quality slurry fuels of low viscosity and good stability can be prepared by petroleum coke and petrochemical sludge, making use of their complementary advantages during the slurrying process. The properties of slurryability, rheology, stability and fluidity were analyzed. The results showed that the fixed-viscosity solid concentration (SCfv) decreased obviously with increasing the sludge mixing proportion (SMP). SC1000, the solid concentration corresponding to 1000mPas, and SC1500, corresponding to 1500mPas, of petroleum coke–water slurry (PCWS) was 69.04% and 70.51% respectively when no sludge was added, whereas they decreased 8.42 and 8.54 percentage point when SMP=6.5wt.%, and further decreased to 51.98% and 53.81% respectively when SMP=26wt.%. The flow behavior of slurry was changed from shear-thickening to shear-thinning after adding petrochemical sludge, and the pseudoplastic behavior was enhanced with increasing either the solid content or SMP. The rheological characteristics fitted perfectly the Herschel–Bulkley model (R2>0.998). Moreover, the sludge produced a significant effect to improve slurry stability.

Flow Structure of Coarse-Grained Slurry in A Horizontal Pipe

Flow Structure of Coarse-Grained Slurry in A Horizontal Pipe The flow behaviour of coarse-grained slurry depends on particle size, shape, density and concentration, and on the density and rheological properties of the carrier liquid. The present paper describes the results of an experimental investigation and flow visualisation of model coarse-grained particle-water mixtures in a closed pipe loop with smooth stainless steel pipes of inner diameter 36 mm. Glass balls and washed graded pebble gravel of mean diameter d50= 6 mm were used as model coarse-grained material. The effect of slurry velocity and particle concentration on the slurry flow behaviour and pressure drop in the turbulent regime was evaluated. Particle distribution in the pipe cross-section and motion of particles along the pipe invert, particle saltation and particle conveying in the carrier liquid were investigated in a transparent pipe viewing section and motion of individual particles was described. Velocity profiles of the carrier liquid and conveyed particles were determined.

Effect of Groove Pattern of Chemical Mechanical Polishing Pad on Slurry Flow Behavior

In chemical mechanical polishing (CMP), the slurry flow behavior on the polishing pad is very important both for improving polishing effectiveness and for reducing the slurry consumption. In this study, we aim to evaluate two types of CMP pad that have unique special groove patterns, slurry outflow and inflow pads, for controlling the slurry flow behavior. We describe the effect of the groove patterns on the slurry flow behavior observed using images recorded using a high-speed digital camera. The results of the study indicate several advantages of the proposed pads over the conventional pads from the viewpoint of slurry flow behavior.

Effect of Groove Pattern of Chemical Mechanical Polishing Pad on Slurry Flow Behavior

In chemical mechanical polishing (CMP), the slurry flow behavior on the polishing pad is very important both for improving polishing effectiveness and for reducing the slurry consumption. In this study, we aim to evaluate two types of CMP pad that have unique special groove patterns, slurry outflow and inflow pads, for controlling the slurry flow behavior. We describe the effect of the groove patterns on the slurry flow behavior observed using images recorded using a high-speed digital camera. The results of the study indicate several advantages of the proposed pads over the conventional pads from the viewpoint of slurry flow behavior.

Numerical studies on flow behavior of composite propellant slurry during vacuum casting

Rockets are powered by composite solid propellant, which is a heterogeneous system consisting of solid oxidizer and metallic fuel dispersed in a polymeric fuel binder matrix. The slurry casting technique under vacuum/ gravity condition is well-established for performing a different class of large sized case bonded rocket motors. During propellant casting, the flow rate of slurry is a very critical parameter as it affects the product quality. The casting rate is governed by suficient degassing and viscosity buildup due to the progress of cure reaction. In the present study, casting rate and casting time have been numerically evaluated for fixed and varying percentages of valve opening, different viscosity of slurry, and different pressure drop (driving force). The velocity profile of propellant slurry inside feeding pipe and valve has also been evaluated. Furthermore, to get a flawless grain and to predict the slurry casting rate, a microscopic analysis has been carried out to model the flow behaviour of composite propellant slurry, where the momentum conservation law has been applied to express the mathematical model in an analytical form. The resulting differential and algebraic equations have been solved numerically using MATLAB, computing software. The numerical analysis is useful for designing new casting set-up and for giving the idea of maximum casting rate, which is achievable for given casting set-up and rheological properties of propellant slurry.

Prediction of Tool and Nozzle Flow Behavior in Ultrasonic Machining Process

The use of hard and brittle material has become increasingly more extensive in recent years. Therefore processing of these materials for the parts fabrication has become a challenging problem. However, it is time-consuming to machine the hard brittle materials with the traditional metal-cutting technique that uses abrasive wheels. In addition, the tool would suffer excessive wear as well. However, if ultrasonic energy is applied to the machining process and coupled with the use of hard abrasive grits, hard and brittle materials can be effectively machined. Ultrasonic machining process is mostly used for the brittle materials. The present research work has developed models using finite element approach to predict the mechanical stresses sand strains produced in the tool during ultrasonic machining process. Also the flow behavior of abrasive slurry coming out of the nozzle has been studied for simulation using ANSYS CFX module. The different abrasives of different grit sizes have been used for the experimentation work. Keywords—Stress, MRR, Flow, Ultrasonic Machining

Application of gamma emission imaging in mineral processing industry: case study of slurry transport in a wet laboratory ball mill

The gamma emission imaging technique has been effectively applied for determination of the slurry radial flow pattern and mixing profile within the ball charge in a wet laboratory ball mill. Aqueous technetium, Tc99m radioisotope that emits 140 keV photons with a short half-life of 6.02 h, was utilized as a flow follower while the glycerol–water mixture was used to mimic the motion of the actual slurry as found in full scale systems. Tests were conducted under two different slurry viscosity conditions for two mill speed levels. Both qualitative and quantitative information of the slurry radial flow and mixing behaviour inside the mill were obtained. The slurry flow and mixing behaviour displayed a marked dependence on the mill speed and slurry viscosity. The slurry mixing time in the ball charge varied directly with the slurry viscosity but inversely with the mill rotational speed.

Effect of Particle Size Distribution and Concentration on Flow Behavior of Dense Slurries

The flow behavior of concentrated slurry depends on particle size distribution, shape, density, and concentration. The slurry flow behavior can change from Newtonian to non-Newtonian depending on the concentration, slurry composition, and content of fine and especially colloidal particles, which evoke a complex rheological behavior of the slurry. The present article deals with experimental investigation of the flow behavior and pressure drop of dense complex slurries containing sand of different particle size distribution (five different monodispersed and polydispersed sands with mean diameters ranging from 0.20 to 1.40 mm), stony dust (mean diameters of 8 μm and 33 μm), or clay conveyed in water. The slurries were tested using experimental pipeline loops with inner diameters of 17.5 and 26.8 mm. The slurry concentrations range from 6% to 40% for sand slurries, from 26% to 48% for stony dust slurries, and from 45% to 51% for stony dust-sand slurries. The study revealed the time-independent yield pseudo-plastic behavior of the concentrated fine-grained stony dust slurries and the possibility of reducing their flow resistance by adding coarse-grained material. The flow behavior of the stony dust slurries can be approximated by the Herschel-Bulkley or the Bingham model in the laminar region and by the Wilson model in the turbulent region.

Quantitative Evaluation of Slurry Flow Behavior Using Digital Image Processing

Lapping is generally used in fabricating high-accuracy hard and brittle materials. In lapping, slurry mixed free abrasive grains and water or dispersion oil is used. It is well known that the lapping characteristics are affected by actual slurry flow in the contact surface between the workpiece and lapping platen. Therefore, stabilization of slurry flow is required to improve lapping characteristics. This paper presents both quantitative evaluation method and results of slurry flow behavior at lapping process, and investigates the movement direction and velocity of slurry flow behavior. Single wafer lapping method was used for our experiment. Furthermore, digital image correlation (DIC) method was used for quantification. As a result, the following points were observed. (1) DIC method can evaluate slurry flow behavior among full-field observed photographed area. (2) Slurry flow velocity has not correlation with relative lapping velocity between the workpiece and lapping platen. (3) Slurry flows much into contact surface along a turn of lapping platen.

Rheology of pyrite slurry and its dispersant for the biooxidation process

Rheology of slurry significantly influenced the grindability, fine grinding performance and energy consumption of industrial minerals in wet grinding. The solid concentration, particle size, temperature and the dispersant, which affected the rheological characteristics of pyrite slurry and the biooxidation process were investigated in this study. This research aimed at the wet grinding process improved by the control of slurry rheology and getting a biocompatible dispersant. The results revealed that the viscosity increased with the solid concentration, which was in agreement with the Chong model. There was a critical concentration (40 wt.%) that led to the flow behavior of slurry transformed from Newtonian fluids to shear-thinning non-Newtonian fluids which fitted to the Casson model. It was also found that the apparent viscosity of slurry increased with the decrease of the particle size and the temperature at high solid concentration. Sodium Hexametaphosphate (SH) was selected experimentally as an effective dispersant for the mineral slurry. The appropriate concentration of SH was also determined at the range from 0.005 wt.% to 0.05 wt.%. The addition of dispersants could reduce the viscosity and yield stress, increase the zeta potential ( ζ) of suspension pronouncedly. No negative effects on the growth rate of microorganisms and the pyrite biooxidation were observed. Therefore, dispersant separation and recovery process could be avoided.

Clay, Phosphate Adsorption, Dispersion, and Rheology

Soluble phosphate is a common ingredient of fertilizer used in agriculture production all over the world. This chemical mixed with soil is transported into the water and marine environment via rainfall causing a range of environmental problems such as toxic algae bloom. Kaolin clay is a common material found in soil and is used as a model system to understand the effects of phosphate adsorption on the flocculation/dispersion of the clay slurries. In the topics, torrential downpours are common. The large water flow will easily disperse the unflocculated or weakly flocculated sediments over a wide area including river and marine environments. Phosphate adsorption was found to weaken the interparticle forces between clay platelets in the slurries. At high enough concentration, it will completely deflocculate the clay slurries, i.e. the net interparticle force is repulsive. A deflocculated slurry is characterised by a low viscosity and no yield stress. As a result, it is much easier to disperse this slurry over a wide area possible even in a small downpour. This study will present the flow and yield stress behaviour of kaolin clay slurries under the influence of adsorbed phosphate.