High Chromium Research Articles

Effect of Cr:C ratio on open three-body wear resistance of squeeze cast high chromium cast iron

A series of high chromium white cast iron (HCCI) alloys with varying Cr:C ratios were designed and fabricated through the squeeze casting process. This study investigates the effect of the Cr:C ratio on the mechanical properties, microstructure, phase diagram, and both low-stress and high-stress abrasion performance of HCCIs. Alloys with a very high Cr:C ratio exhibited better impact toughness but poorer hardness. Scanning electron microscopy (SEM) and phase diagram calculations elucidated the influence of the Cr:C ratio on microstructure, carbide volume fraction, and carbide type. Abrasion resistance was evaluated using impact abrasive wear (high-stress) and rubber-wheel (low-stress) abrasion on quartzite in open three-body wear. Comprehensive assessments under impact abrasive wear and rubber-wheel abrasive wear conditions suggest that the alloy achieves optimal abrasion resistance with a Cr:C ratio ranging from 8 to 11. Post-wear analysis reveals that surface damage varies between high-stress and low-stress conditions. The microstructure of squeeze HCCIs is significantly influenced by the Cr:C ratio, resulting in diverse operative wear mechanisms, including micro-cutting and micro-fracture. Successful adjustment of the Cr:C ratio led to the attainment of a nearly eutectic HCCIs composition suitable for squeeze casting.

Normalizing temperature influence on the microstructure characteristics, mechanical and wear performance of a novel high chromium cast iron

The microstructure, mechanical and wear behavior of a high chromium cast iron were studied at different normalizing temperatures (950°C, 1000°C, 1050°C, 1100°C). The martensite content was proportional to the normalizing temperature except at 1100°C because of the appearance of retained austenite. As the temperature increased, the primary carbide downsized whereas the secondary carbide content first increased but then decreased, contributing to the superior mechanical properties observed tempered at 1050°C. The superior hardness and strength improved the surface deformation resistance, including enhanced work-hardening in the matrix and stacking fault locks in carbides, hindering dislocation slipping and material spalling, thus achieving excellent wear properties when normalized at 1050°C. Moreover, the wear mechanism changed from oxidative/fatigue to abrasive/adhesive wear as the temperature increased.

Microstructure, hardness, and wear resistance of high-carbon hypereutectic high chromium irons containing W for use as roller sleeves

High chromium irons (HCI) have rarely been investigated the impact of varying W content on the microstructure and performance of high-carbon irons by scholars. In this study, after calculating by Java-based Materials Properties software (JMatPro), the casting alloying method was applied to explore the effect of adding W (0-15 wt%), Mo 3 wt%, and C 6 wt% on HCI to prepare highly wear-resistant and hard materials. The results showed that the maximum volume fraction of carbide was 38% at C 6 wt%. The addition of W promoted the formation of M6C with a maximum volume fraction of 21%, which increased the hardness to 64.5 HRC and reduced the weight loss to 0.062 g. Since W10 (the iron with W 10 wt%) and W15 (the iron with W 15 wt%) exhibited similar wear resistance but lower impact resistance, the W10 samples were heat-treated. W10 after QT550 (quench and temper heat treatment at 550 °C) sample developed a large number of M6C-type carbides and martensite in the matrix, which improved the properties of the matrix by diffusion strengthening, leading to a hardness of 70.0 HRC and a reduction in weight loss to 0.035 g. Compared to the Cr20 reference iron, W10 after QT550 was 22.8% higher in hardness and 76.8% lower in abrasion. Concurrently, an experiment was conducted on the production of roller sleeves. With the use of W10 after QT550, the lifetime of the roller sleeve was increased by 1.6 times.

Fungi species identified from polluted environment for chromium sequestration and solid state fermentation on tannery shaving waste

Accumulation of hexavalent chromium in the environment affects our ecosystem. Physico-chemical treatment did not solve the problem, due to high requirement of operational costs & energy, insolubility of Cr (VI) at any pH & sludge accumulation. The study aim is screening and evaluating fungi for chromium biosorption for mycoremediation. Soil and effluent sample were collected. PDA media was used for fungi purification. Fungal chromium tolerance evaluation and optimization was conducted at pH (4, 7, 10), T0 (25, 27.5, 35 °C), Cr concentration (5000–25000 ppm) using Full Factorial experimental design. Spore count, biomass production, Cr tolerance index, mycelia growth were evaluated. Flame Absorptive Spectrophotometer was used for quantification of fungal chromium removal. Fungi species were identified by MALDI-TOF. Fungi growth & degradation of tannery shaving waste was evaluated. The result revealed 6 potential fungi, T. longibrachiatum, T, koningii, A. niger, G. candidum, P. rubens, T. orientale were identified. Optimium mean biomass & spore count were 0.514 ± 0.051& 1.39 ± 0.038 at pH4 and 27.5 °C respectively. MTL test indicate that Trichoderma species, A. niger & P. rubens survive up to 10,000 ppm, 15, 000 ppm & 20,000 ppm respectively. FAAS analysis of fungi chromium removal from aqueous media result indicate that A. niger (99%). T. longibrachiatum (85%) and P. ruben (84.6%). These 6 fungi are efficient in tannery shaving waste degradation but A. niger was superior in spore count 15.1 Log/mL and 7 g substrate weight loss. In conclusion three fungi have high chromium tolerance and removal capacity and shaving waste degradation promising for mycoremediation.

Tribo-performance analysis of HVOF sprayed Colmonoy-88 using the Taguchi method

The current investigation examines the wear performance of High-Velocity Oxygen Fuel coated Colmonoy-88 coating on SS 304. An L9 orthogonal array design based on the Taguchi fractional factorial method was used to create the erosive wear tests. The impact of three parameters, such as impact velocity (100, 120, and 140 m/s), angle of impact (30°, 60°, and 90°), and test duration (10, 15 and 20 min), on wear performance was investigated by analysis of variance. Results show that the impact angle is the most vital factor for mass loss in both SS 304 and Colmonoy-88, followed by impact velocity and time duration. It was revealed that the maximum wear takes place at 30° impact angle in both specimens. The outcomes of the XRD and EDS analysis show that the Colmonoy-88 has a high chromium content, which provides it with exceptional erosion resistance. The Colmonoy-88 wear mechanism involved inter-splat micro-cutting, lips, crack initiations, and craters caused by fly ash particles at varying impact angles.

Effects of Impact Energy, Impact Frequency, and Test Time on Impact Wear Characteristics of Zirconia-Toughened Alumina Particles-Iron (ZTAp-Fe) Composites Using Response Surface Methodology

The study aimed to investigate the effects of wear parameters including impact energy, impact frequency, test time, and their interactions on the impact wear characteristics of high chromium white iron (HCWI) and zirconia toughened alumina (ZTA) reinforced HCWI composites fabricated by squeeze casting method using response surface methodology (RSM). The Box-Behnken Design (BBD) method was employed, and a linear model was developed to describe the relationship between wear loss and wear parameters, and to predict the wear behavior of the tested materials. The parameters of energy, frequency, and test time were found to be statistically significant, and positively influencing the wear behavior. Specifically, test time emerged as the most influential factor, followed by energy and frequency. The wear characteristics of HCWI are primarily characterized by shallower plowing and furrows, partial plastic deformation, surface spalling, and inserted abrasives. In contrast, the predominant wear mechanisms for ZTA/HCWI composites include slight breaking of ZTA particles, plowing, and cutting of the metal matrix; breaking and falling of ZTA particles; broken abrasive particles encrusted into the matrix; and the formation of spalling pits.

A High Current Density and Long Cycle Life Iron Chromium Redox Flow Battery Electrolyte

A High Current Density and Long Cycle Life Iron Chromium Redox Flow Battery Electrolyte

First-principle and experimental investigation into the interfacial characters of Ti-doped ZTA and high chromium cast iron

Ti doping can improve the interfacial wettability and bonding condition between ZTA ceramic and high chromium cast iron (HCCI), but the underlying mechanism is still unclear. Therefore, the effects of Ti doping on the interfacial characters between ZTA and HCCI were investigated by experiment and first-principles calculations. Results of XRD, SEM, and high-temperature drop test indicate the presence of Ti at the interface and its effect on the formation of interfacial diffusion layer to improve the interface wettability and bonding obviously. The heat of segregation and work of adhesion obtained by first-principle calculations shows that the improvement in interface wettability and bonding is due to the promotion of dopped Ti atoms on the diffusion of Fe, Al, and Zr elements, but not the diffusion of Ti itself. Further investigation from the electronic level reveals that the doped Ti changes the charge distribution and orbital hybridization, and thus makes the formation or enhancement of strong ionic bonds and covalent bonds at the interface, improving the bonding strength and wettability of interfaces in ZTA/HCCI. The findings of this research can offer new insights into the modification of ceramics and enlarge the application of advanced ceramic materials.

Blood metal concentrations and cardiac structure and function in total joint arthroplasty patients.

There is concern regarding potential long-term cardiotoxicity with systemic distribution of metals in total joint arthroplasty (TJA) patients. To determine the association of commonly used implant metals with echocardiographic measures in TJA patients. The study comprised 110 TJA patients who had a recent history of high chromium, cobalt or titanium concentrations. Patients underwent two-dimensional, three-dimensional, Doppler and speckle-strain transthoracic echocardiography and a blood draw to measure metal concentrations. Age and sex-adjusted linear and logistic regression models were used to examine the association of metal concentrations (exposure) with echocardiographic measures (outcome). Higher cobalt concentrations were associated with increased left ventricular end-diastolic volume (estimate 5.09; 95%CI: 0.02-10.17) as well as left atrial and right ventricular dilation, particularly in men but no changes in cardiac function. Higher titanium concentrations were associated with a reduction in left ventricle global longitudinal strain (estimate 0.38; 95%CI: 0.70 to 0.06) and cardiac index (estimate 0.08; 95%CI, -0.15 to -0.01). Elevated cobalt and titanium concentrations may be associated with structural and functional cardiac changes in some patients. Longitudinal studies are warranted to better understand the systemic effects of metals in TJA patients.

Effect of Combined Addition of Molybdenum and Tungsten on Continuous Cooling Transformation Behavior of High Chromium Cast Iron

Effect of Combined Addition of Molybdenum and Tungsten on Continuous Cooling Transformation Behavior of High Chromium Cast Iron

Exploring the Kinetics of Oxygen Reduction Reaction in Relation to Pitting Corrosion Resistance in Fe-Cr Alloys

Pitting corrosion, a major concern in materials science and engineering, threatens critical metallic structures and components. Its implications reach across daily life and industries such as energy, transportation, and infrastructure, potentially causing environmental harm, economic losses, and even loss of life. This complex process is influenced by factors including material composition, local environment, and mechanical stresses.1 Once initiated, pit propagation rates are largely dependent on the magnitude of the supporting cathodic current available from the oxygen reduction reaction (ORR) occurring on the external passive film.2 In Fe-Cr alloys, the ORR occurs on this film, undergoing a mixed diffusion and kinetic-controlled process. The number of electrons involved and the corrosion rate are determined by the thermodynamically stable state of the passive film.This research studies the ORR kinetics on FeCr alloys fabricated by arc-melting, using both computational and experimental methods. The rotating disc electrode technique was employed across various Fe:Cr alloys in alkaline and neutral electrolytes. The Koutecky-Levich analysis showed a dominant four-electron ORR pathway in all tested Fe-Cr alloys, with the ORR significantly inhibited by higher proportions of Cr2O3 in the film, suggesting a correlation with high chromium content. Experimental ORR overpotentials, when combined with theoretical potential-pH (Pourbaix) diagrams, helped discern the likely characteristics of the passive films on the alloys. It was deduced that the catalytic properties of potential passive films increased in the order Cr2O3 < Fe3O4 < Fe2O3 < FeCr2O4. These findings, excellently aligned with density functional theory (DFT) modelling, underscore the role of increased chromium levels in slowing pitting progression by suppressing the ORR.In summary, this research offers distinctive insights into the correlation between the kinetics of the ORR and the resistance to localized corrosion in Fe-Cr alloys, which enhances our understanding of the underlying mechanisms of pitting corrosion. Keywords FeCr alloy, pitting corrosion, ORR, rotating disc electrode, DFT Reference [1] B. Zhang, J. Wang, B. Wu, X. W. Guo, Y. J. Wang, D. Chen, Y. C. Zhang, K. Du, E. E. Oguzie, and X. L. Ma, Nat. Commun. (2018) 9, 2559.[2] G. T. Burstein, P. C. Pistorius, and S. P. Mattin, Corros. Sci. (1993) 35, 57.

Effects of current intensities on material removal rate, electrode wear rate, and surface roughness of machining high carbon high chromium steel

AbstractThe electrical discharge machining is very successful and generally recognized for producing complicated shapes and small openings with exceptional precision. The objective of this study is to assess the impact of different electrical discharge machining parameters on the attributes of the machining process. The evaluation of the machining process was conducted based on the workpiece‘s material removal rate, the rate at which the electrodes wear, and the level of surface roughness. Simultaneously achieving a high material removal rate, low electrode wear rate, and high surface roughness is not possible with a specific combination of approaches due to their contradicting nature. Frequently, it is necessary to independently apply many measures instantaneously in order to assess their impact on various responses. This research investigates the machining of high carbon high chromium steel making use of electrical discharge machining with aluminum, copper, and graphite electrodes. The study focuses on the impact of different current intensities on the rate of material removal, electrode wear, and surface roughness. The experimental results demonstrate that the highest material removal rate (mmcubicmin−1) is achieved at a current density of 12 A when using a copper electrode (54.67), as opposed to aluminum electrode (22.91) and graphite electrode (29.43).

Effect of tempering temperature on microstructure and properties of low silicon hypereutectic high chromium cast iron

Effect of tempering temperature on microstructure and properties of low silicon hypereutectic high chromium cast iron

Control of paleoclimate and paleoweathering on chromium contents in a non-ultramafic aquifer hosting high chromium groundwater.

Cr(VI) is a carcinogen with proven mutagenic and genotoxic effects. The effects of the depositional environment (e.g., paleoweathering, paleoclimate, and paleoredox condition) on Crenrichment in non-ultramafic aquifer solids are unclear. In this study, we presented the sedimentary characteristics of a borehole from a typical non-ultramafic aquifer with high Cr groundwater in Jingbian, central Ordos Basin, China. Chromium was enriched in the K1h sandstone aquifer, especially at depths of 400-500m, with the highest value of mass transport coefficient (τAl,Cr) up to 92.13% and τAl,Fe up to 33.5%. The provenance of aquifer Cr was predominantly intermediate and felsic igneous rocks with a mafic rock mixture. This mafic source was inferred from Cr-rich granodiorite and mafic/ultramafic rocks in the Yinshan (Daqingshan-Wulashan) Block, northern Ordos Basin. The Cr-rich aquifer in K1h was developed due to a moderate chemical index of alteration (CIA) (mean, 56.7) under relatively warm and humid paleoclimate, as evidenced by high CIA-temperature (CIA-Temp) (mean, 6.79°C) and paleoclimatic index values (mean, 0.40). Fe-Mn redox cycling in the oxic to suboxic environments contributed to aquifer Cr accumulation. Using path analysis, we identified that paleoclimate created favorable weathering conditions and enrichment of Fe contributed to the formation of high-Cr aquifers. The study reveals the formation of positive Cr anomalies in non-ultramafic aquifers, which is the potential source of groundwater Cr, and highlights the effects of depositional factors on Cr accumulation during aquifer deposition or early diagenesis. It can provide new insights into the natural processes of high-Cr sediments occurring in non-ultramafic aquifers.

Processing of Ilmenite Concentrate with High Chromium Content

The results of research on the processing of ilmenite concentrate from the Obukhovskoye deposit are presented in this article. As the concentrate has a high chromium content, the study involved converting the iron into metal and the titanium into slag through the addition of soda. Positive results were obtained during the smelting of the ilmenite concentrate, and a one-stage smelting mode was established. This mode involved an increase in the temperature up to 1700 °C, with a heating step of 10 °C/min and using an argon supply. The holding time at this temperature was 30 min, followed by cooling to 700 °C in argon. The optimal parameters for sintering the non-magnetic fraction with soda and leaching the sinter with water and hydrochloric acid solution were also determined.

From hydratable alumina bonded high chrome castables to shaped product for coal water slurry gasifier

The gasifier is a key equipment of coal gasification technology, enabling efficient and clean utilization of coal resources. However, the aluminum phosphate bonded high chrome brick lining in the gasifier experienced premature failure due to the migration of phosphate in reducing gases such as H2 and CO, as well as increased slag penetration and thermal spalling. In this study, a high chrome castable was prepared using hydratable alumina as a binder and fired at 1600 ℃ to replace the traditional phosphate bonded high chrome brick. The impact of curing temperatures (25℃, 40 ℃, and 60 ℃) on the properties of the high chrome castable was investigated, with corresponding hydrates examined through XRD, FTIR, TG-DSC, and SEM analyses. Results revealed that higher curing temperatures accelerated the hydration process of hydratable alumina. At higher curing temperatures, more well-developed micro-nano sized boehmite and bayerite phases were formed within the castables, filling their pores effectively and enhancing their properties after drying at 110 ℃. Moreover, during heat treatment these micro-nano sized hydrates decomposed into submicron/nano sized alumina which readily reacted with Cr2O3 to form (Cr-Al)2O3 solid solution. This phenomenon facilitated the sintering of castables fired at 1600 ℃ and optimized internal structure, ultimately leading to the enhanced mechanical properties and improved slag resistance.

Increasing Exploitation Durability of Two-Layer Cast Mill Rolls and Assessment of the Applicability of the XGBoost Machine Learning Method to Manage Their Quality.

The increase in exploitation durability of two-layer cast rolls with the working layer made of high chromium cast iron allows one to significantly improve the quality of rolled metal as well as to increase the economic efficiency of the manufacturing process. However, it is severely hindered due to the massiveness of castings, the impossibility of both evaluating mechanical properties along the depth of the working layer, and providing the structural uniformity of the working surface and the decrease in stresses. In our research, aiming to enhance the exploitation durability of sheet rolls, it is recommended to achieve structural uniformity by CuMg alloying, which increases the concentration of copper up to 2.78 wt.% in certain zones and, owing to the accelerated austenite decomposition at a high temperature during the cool-down of the castings, led to the reduction in excessive strength and the level of heat stresses in the castings. We propose the regimes of cyclic heat treatments which, due to the decomposition of retained austenite and the fragmentation of structure, control the level of hardness to reduce and uniformize the level of stresses along the length of a barrel. A further improvement in the predictions of exploitation durability using XGboost method, which was performed based on the chemical composition of the working layer of high-chromium cast iron and heat treatment parameters, requires taking into account the factors characterizing exploitation conditions of specific rolling mills and the transformations of structural-phase state of the surface obtained by a non-destructive control method. As the controlled parameter, the hardness measured on the roll's surface is recommended, while the gradient change in mechanical properties along the working layer depth can be feasibly analyzed by a magnetic method of coercive force measuring.

Molecular Identification of Potent Chromium Reducing Bacteria Isolated from Hydrocarbon-Contaminated Soil within Sokoto Metropolis

Study’s Novelty/Excerpt This study investigates chromium reduction potential of bacteria isolated from hydrocarbon-contaminated soils in the Sokoto metropolis, a specific environment previously underexplored in this context. It uniquely identifies Brucella intermedia and Bacillus sp. as potent chromium-tolerant isolates with significant reduction efficiencies, providing new insights into the bioremediation capabilities of these strains. Additionally, the research demonstrates a high chromium removal efficacy at various concentrations, highlighting the potential application of these isolates for effective bioremediation of chromium-polluted soils and water bodies. Full Abstract Hydrocarbon-contaminated soils are recognised as reservoirs for heavy metal-utilizing bacteria due to the phenomenon of co-selection. These bacteria can have a potential in the biosorption of chromium heavy metal. This research aimed to screen the chromium reduction potential of bacteria isolated from hydrocarbon-contaminated soils. The soil samples used in this study were collected from hydrocarbon-affected sites in the Sokoto metropolis; additionally, a control sample was collected from non-polluted soil. Bacteria were isolated using standard protocols. Variable amounts of chromium were prepared using potassium monochromate (K2CrO4) and then incorporated into a nutrient broth medium. The most potent, molecularly-identified hydrocarbonoclastic bacteria were screened for chromium tolerance, and the percentage reduction in chromium content was also measured. Mean colony counts from the hydrocarbon-contaminated soil ranged from1.00×106 to 1.30×106 CFU/g while the control soil had 2.30×105 CFU/g. From the 14 strains, two, molecularly identified using NCBI BLAST as Brucellaintermedia and Bacillus sp., were shown to be the most potent chromium tolerant isolates. B. intermedia reduced Cr from an initial value of 350 mg/L to 198 mg/L within 72 hours (44 % removal efficiency). At the lowest concentration used in this study (50 mg/L), a removal efficacy of 96% was achieved. Bacillus sp. recorded the highest chromium reduction compared to Brucellaintermedia at the tested concentrations (50, 150, 250, and 350 mg/L). A 100% reduction in Cr was obtained at the 50 mg/L concentration. This study demonstrated that Bacillus sp. and Brucellaintermedia are particularly effective at reducing chromium from chromium metal solutions of different concentrations. These isolates can be used for bioremediation of chromium-polluted soils or water bodies.

Scouring erosion resistance of metallic materials with composite microstructures

Slurry erosion can cause severe damage and often constitutes a significant portion of the total production cost in many industries such as oil sands and mining. The most commonly used materials for such applications are metallic materials having a composite microstructure consisting of hard reinforcement phases in a more ductile metal matrix. Typical examples are high chromium white irons and tungsten carbide welding overlays. The main purpose of this work is to evaluate the scouring erosion resistance of such materials for applications in handling fine sand slurries and to introduce a wear model to help understand the correlation between erosion resistance and the characteristics of microstructures.Five high chromium white cast irons and four spray and fusion coatings composed of cast tungsten carbide particles and Ni–Cr–B–Si–Fe matrix have been studied using a Coriolis scouring erosion tester in a fine sand slurry. The relationship between the erosion resistance and different microstructure parameters was explored. For the chromium white cast irons, the erosion resistance increased with increase in carbide volume fraction but the spray and fusion coatings showed the opposite trend, i.e., their erosion resistance decreased with increase in the carbide volume fraction. No clear correlation was found between erosion resistance and free path for the spray and fusion coatings while for the chromium white cast irons, the erosion resistance was found to increase rather than decrease with increase in free path.To help explain the experimental results, a wear model has been proposed for the wear resistance of composite microstructures composed of a reinforcement phase (RP) and a metal matrix. In the model, the wear surface of the material is distinguished by four different features/regions, each having unique wear resistance. The rule of mixtures (ROM) for wear resistance is applied to formulate the wear resistance of the material with the above four wear surface features. It is shown that the results can be reasonably well explained based on the proposed model by using the total edge length, L, of the RP particles exposed on a unit area of the wear surface.

Spatio-temporal variability of potentially toxic elements' pollution in road-deposited sediments according to health risk thresholds: a meta-analysis.

Road deposited sediments (RDS) are important sinks of potentially toxic elements (PTEs), which may have a significant impact on human health. A systematic review of published papers on the PTEs occurrence in RDS was carried out. The main goal was to assess the global RDS contamination by PTEs and human health risks linked with anthropogenic activities. A systematic search was made to collect information about the most cited PTEs in the published literature and perform a statistical analysis. Subsequently, health risks were assessed for 35 different areas worldwide. PTE concentrations showed high variability, and means were multiple times higher than the corresponding consensus-based threshold effect concentrations (5.2-, 10.3-, 5.3-, 3-, 7.3-, and 3.6-fold higher for Zn, Pb, Ni, Cr, Cu, and Cd, respectively). PTEs concentrations were ranked as Zn > Pb > Cu > Mn > Cr > Ni > Cd. Non carcinogenic risks followed the trend Pb > Cu > Zn > Cd. Lead is responsible for the highest significant non carcinogenic risk to human health. Unacceptable exposition to carcinogenic risks is present in most areas. The top carcinogenic risk areas were Singapore > Beijing > Yixing > Shanghai > Zhuzhou for adult male, Dresden > Singapore > Ulsan > Huludao for adult females, and Dresden > Singapore > Ulsan > Huludao for children. Highest chromium and nickel carcinogenic risks occurred in Singapore, Cd in Dresden, and Cu in Huludao. Highest RDS contamination was seen in industrial areas due to pollutants deposition. Highest Zn, Cu, Cd, and Pb concentrations occur in densely urbanized areas due to heavy-duty vehicular exhausts.