Hot Stage Research Articles

ABOUT THE SINTERING OF HISTORICAL “YELLOW BRICKS” OF SOFIA

The historical “yellow cobblestones” of Sofia are a very well sintered ceramic clinker with practically zero water absorption. However, the high amount of crystal phase formed, which explains the extraordinary mechanical properties of this remarkable material, is in formal contradiction with its low final porosity. In fact, in the modern ceramics clinkers the crystallinity is similar or inferior, but the reached degree of sintering is lower; as a result, the mechanical properties are reduced. The aim of this report is to elucidate some peculiarities of the densification process of “yellow ceramics bricks” because such information is essential for the eventual successful production of replica of this emblematic pavement. The chemical and phase compositions of original “yellow paving bricks” together with those of modern clinker from “Vitosha” boulevard in Sofia were evaluated by XRF and XRD analysis, respectively. The structures of both ceramics were investigated with density measurements and SEM.Their densification behaviour was estimated by re-sintering of milled original samples by Hot Stage Microscopy (HSM) tests. The results elucidate that the sintering temperature of the historical clinker is inferior, and their sintering interval is significantly narrow. This peculiarity is explained by the rapid decreasing of apparent viscosity with temperature rise.Finally, by secondary holding at the sintering temperatures and subsequent fast quenching of a “yellow brick” sample, it is demonstrated that some phase formation occurred during the industrial cooling step. This result explains both the good degree of densification and the better properties of the “yellow cobblestones”.

CHARACTERIZATION OF CLAYS FROM “MINES MARITSA IZTOK” AS RAW MATERIALS FOR CERAMIC INDUSTRY

The chemical and phase compositions of the clays from coal mining were evaluated by XRF and powder XRD method, respectively. Hot Stage Microscope was used to estimate the thermal behaviour. In addition, the thermal losses of the clays after 1 h thermal treatment at different temperatures were measured. This preliminary analysis elucidates potential prospects for using some of clays as raw materials for ceramic industry. It seems that samples which are montmorillonite type are more plastic, while the others, where higher sand content is observed, and the drying shrinkage is negligible could be characterized as less plastic. The initial results for the thermal behaviour and the structure of a brick sample (obtained by mixing two types of clays) and a foamed geopolymer are also reported. The first sample shows a beginning of the firing shrinkage at about 1000°C, while the second demonstrates intensive bloating after 950°C, leading to specimen with about 56 % closed porosity. Finally, X - ray Computed Tomography and SEM was used to highlight the structure of some test samples.

Microstructure development and strengthening behaviour in hot-extruded Ti-Mo alloys with exceptional strength-ductility balance

A series of strong and ductile Ti-Mo alloys containing 2.5, 5, 7.5 and 10 wt% Mo was experimentally investigated by a two-stage blended-elemental powder metallurgy process. This process consisted of a spark plasma sintering stage for powder-consolidation and in-situ-homogenisation, and a hot extrusion stage for densification and microstructure enhancement. Microstructures in the extruded alloys changed from α dominant to β dominant with molybdenum addition. Simultaneously, a grain refinement effect was observed due to suppressed α precipitation and increase β retention. A significant strengthening effect was observed with molybdenum addition. In comparison with similarly processed commercially pure titanium, Ti-10Mo exhibited a yield strength improvement of 290 % to 1382.8 MPa, and an ultimate tensile strength improvement of 239 % to 1496.5 MPa. Meanwhile, Ti-5Mo exhibited a yield strength improvement of 211 % (1007.9 MPa) without any substantial reduction in ductility, resulting in an exceptional tensile toughness of 361.3 MJ.m−3. A quantitative analysis of strengthening mechanisms reveals considerable strengthening effects from solid solution strengthening, dislocation strengthening, and grain refinement effects. These factors arise from the novel multi-modal microstructures formed by thermomechanical processing at super-transus temperatures. The newly achieved balance of strength and ductility appears to be unrivalled amongst all previously reported binary Ti-Mo alloys.

Interface Structure and Properties of Polypropylene/Wood Flour Composites Reinforced with Grafted Polypropylene Compatibilizer

AbstractIn this work, a new compatibilizer, ternary monomer grafted polypropylene (hereafter shorted as: G‐PP), was successfully synthesized by solid phase grafting of maleic anhydride, methyl methacrylate, and butyl‐acrylate onto polypropylene. For all developed polypropylene matrix composites, the prepared G‐PP evidently showed enhancing mechanical properties on PP/wood flour (WF) composites, which is obviously superior to those from maleic anhydride grafted polypropylene (W‐PP) and virgin polypropylene (C‐PP). In particular, the wettability of G‐PP was greatly improved, while the melting temperature and β crystal phase amounts of the WF composites with G‐PP are much higher when compared to that of W‐PP and C‐PP. This can be reasonably explained by the formation of continuous micropores and filaments in WF composites containing G‐PP, as verified by hot stage polarizing optical microscope (POM). Meanwhile, the G‐PP effectively reduced movement of molecular chains of WPC and formed a better interface layer with WF, which contributed to penetrate more deeply and form micro‐crosslinking in the WF layer. We believe that the results reported in this work will increase the added value of polypropylene based wood plastics composites (WPC) and allow WPC to participate in lightweight and environmentally friendly products.

Thermo‐rheological snapshot of melter feed conversion to glass

AbstractSlurry feed charged into an electric melter creates a layer of reacting and melting material (termed cold cap) that floats on the surface of molten glass. The rheological behavior of heated melter feed affects the spreading of slurry at the top of the cold cap and the stability of the primary foam, affecting cold‐cap coverage and melter plenum temperatures. The apparent viscosity of a high‐alumina high‐level waste melter feed was assessed by thermomechanical analysis, high‐temperature viscometer, and the hot stage microscopy method, yielding viscosity estimates from ≈107.5 Pa s at 550°C to ≈102.5 Pa s at 1050°C. As the temperature of feed materials increased, their state changed from rigid solid to dilatant fluid, to pseudoplastic bubbly liquid with dissolving solids, to fully developed foam, and finally to Newtonian glass melt.

Leveraging solid solubility and miscibility of etoricoxib in Soluplus® towards manufacturing of 3D printed etoricoxib tablets by additive manufacturing

This research focuses on exploring the solid solubility and miscibility of Etoricoxib, a poorly water-soluble anti-inflammatory drug, within Soluplus®, a polymer used as a matrix for 3D-printed tablets. By utilizing hot-melt extrusion (HME), the drug was dispersed within Soluplus® to enhance its solubility. The extrudates were then employed in 3D printing to create customized solid oral dosage form. This study’s novelty lies in combining HME and 3D printing, aiming to improve drug incorporation, stability, and effectiveness in the final formulation. Comprehensive characterization techniques, including hot stage microscopy (HSM), scanning electron microscopy (SEM), micro-computed tomography (Micro-CT), florescence microscopy, optical microscopy, X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FT-IR), solubility studies, differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), and aqueous solubility study were utilized to elucidate the physicochemical properties, thermal stability, and structural integrity for the extruded filaments (the printing ink), and 3D printed tablets made thereof. Furthermore, the in vitro drug release profile of the 3D printed tablet was systematically evaluated, revealing a controlled drug release pattern from the finished dosage form. The systematic investigation reported herein, starting from theoretical miscibility to the printing ink development through HME, detailed characterization of the extruded filaments, and further solid oral formulation development by additive manufacturing can be utilized as a platform technology or a pathway for the development of personalized medicine with drugs having similar physicochemical properties.

Solid–Liquid Phase Equilibrium of the n-Nonane + n-Undecane System for Low-Temperature Thermal Energy Storage

The current article presents an exploration of the solid–liquid phase diagram for a binary system comprising n-alkanes with an odd number of carbon atoms, specifically n-nonane (n-C9) and n-undecane (n-C11). This binary system exhibits promising characteristics for application as a phase change material (PCM) in low-temperature thermal energy storage (TES), due to the fusion temperatures of the individual components, thereby motivating an in-depth investigation of the solid–liquid phase diagram of their mixtures. The n-nonane (n-C9) + n-undecane (n-C11) solid–liquid phase equilibrium study herein reported includes the construction of the phase diagram using Differential Scanning Calorimetry (DSC) data, complemented with Hot–Stage Microscopy (HSM) and low-temperature Raman Spectroscopy results. From the DSC analysis, both the temperature and the enthalpy of solid–solid and solid–liquid transitions were obtained. The binary system n-C9 + n-C11 has evidenced a congruent melting solid solution at low temperatures. In particular, the blend with a molar composition xundecane = 0.10 shows to be a congruent melting solid solution with a melting point at 215.84 K and an enthalpy of fusion of 13.6 kJ·mol–1. For this reason, this system has confirmed the initial signs to be a candidate with good potential to be applied as a PCM in low-temperature TES applications. This work aims not only to contribute to gather information on the solid–liquid phase equilibrium on the system n-C9 + n-C11, which presently are not available in the literature, but especially to obtain essential and practical information on the possibility to use this system as PCM at low temperatures. The solid–liquid phase diagram of the system n-C9 + n-C11 is being published for the first time, as far as the authors are aware.

Oxidation mechanism and microstructure evolution of invar alloy with high temperature annealing process

The high temperature oxidation behavior of Fe–36Ni Invar alloy in the forged billet stage and hot rolled rod stage in the compressed air atmosphere has been systematically studied. The results show that the oxide layer can be divided into the external oxide layer composed of Fe2O3, Fe3O4 and NiO, and the inner transition oxide layer composed of FeO, Fe2O3, Fe3O4 and NiO. In addition, hot rolled rod samples treated by solution and rolling have higher oxidation resistance. The mechanism of O diffusion during oxidation is analyzed, and it is found that the O atom adsorbed on the surface of the substrate diffuses into the grain along the grain boundary. The grain boundary is the optimal path for O diffusion to the interior of the material, which results in the degree of intergranular oxidation of the alloy being greater than the degree of intragranular oxidation. In summary, the oxidation resistance of Invar alloy can be improved by proper solution treatment and avoiding the formation of grain boundary cracks during production.

Effects of the nozzle design parameters on turbulent jet development of active pre-chamber

Active pre-chamber turbulent jet ignition is one of the most promising technologies for developing low- or zero-carbon engines. However, the relevant fundamental studies are far from adequate, particularly for the independent impact of the pre-chamber design parameters on the jet characteristics in the absence of combustion in the main chamber. In this study, the hot turbulent jet characteristics of the pre-chamber fueled with the premixed CH4-air are studied by the double-pass Schlieren imaging. The effects of the pre-chamber nozzle design parameters, including the orifice diameter, total orifice cross-sectional area, and orientation are clarified. The results reveal that the pressure difference between the pre-chamber and main chamber depends on the total orifice cross-sectional area. The effects of the orifice diameter and total orifice cross-sectional area on the penetration rate exhibit a trade-off relation, while the orifice diameter has a more pronounced effect on the hot jet projection area than the total orifice cross-sectional area. Compared to the inclined orifice, the penetration velocity of the straight orifice is faster at the initial hot jet ejection stage. These results are expected to be valuable references for the pre-chamber design and understanding of the ignition mechanisms of active pre-chamber.

Flexible multifunctional magnetic-conductive Janus nanocomposite films towards highly-efficient electromagnetic interference shielding and thermal management

The rapid development of aerospace, intelligent wearable electronics and 5G communications puts forward higher demands for electromagnetic interference (EMI) shielding materials. Herein, the flexible multifunctional magnetic-conductive Janus nanocomposite films with magnetic cobalt carbide nanowires/bacterial cellulose (Co@C NW/BC) blends as the upper side, and conductive Ti3C2Tx MXene as the bottom side are obtained via the layer-by-layer (LBL) vacuum assisted filtration-hot pressing method. The two magnetic and conductive sides endow the Janus nanocomposite films with distinctly different performances in EMI shielding and thermal management. When the electromagnetic waves are incident from Co@C NW/BC side, the films exhibit a high EMI shielding effectiveness (EMI SE) of 49.8 dB with an enhanced microwave absorption (SEA) of 33.9 dB at the ultralow thickness of 43 μm. Meanwhile, the Ti3C2Tx side exhibits improved electrical heating performances with a surface temperature of 120 °C at 6 V voltage, increased photothermal conversion temperature of 77.8 °C upon 2.0 kW/m2 light intensity, as well as excellent thermal stealth properties with a low radiation temperature of 88.4 °C on the 240 °C hot stage. Moreover, the Janus nanocomposite films show a high tensile strength of 80.0 MPa. The resultant Janus nanocomposite films possess great application prospects in highly-efficient EMI shielding and thermal management.

Low-temperature synthesis of dense Si-based nitride ceramics for solar thermal storage: Role of cordierite as sintering additive

Direct nitridation method was used to prepare dense Si-based ceramics for solar thermal storage, and the effect of cordierite as sintering additive on the sintering behaviors of the ceramics was studied. The influence priority between densification and nitride content on the properties of thermal storage ceramics was discussed. Cordierite exhibited a good capability of promoting densification, and the densification temperature could reach 1500 °C. The liquid formed by cordierite helped to construct an interlocking structure of well-grown Si2N2O flakes. Results of hot stage microscopy and DTA indicated that the endothermic silicothermic reaction between Si and cordierite proceeded at 1440–1460 °C, and released SiO gas. The SiO gas inhibited the densification, but resulted in the low-temperature synthesis of nano-sized Si3N4 whiskers. Samples added with more cordierite showed the cost-effective merits as the smaller costs of raw materials, lower densification temperature, higher thermal conductivity (1.72 W m−1 K−1 deviation), and higher bending strength (34.3–68.1 MPa deviations), compared with the samples having the larger nitride content. Densification by adding cordierite as sintering additive showed the priority on the properties of thermal storage ceramics than increasing the nitride content.

Effect of particle size distribution on the properties of celsian based glazes

AbstractThe microstructure and surface properties of ceramic glaze are influenced by chemical composition, particle size distribution, glaze application conditions, and firing parameters. This study specifically focused on the influence of glaze particle size distribution on the thermal behavior, microstructure, and surface appearance of barium frit based ceramic glaze in the floor tile firing process. The investigation involved examining the impact of four distinct particle size dimensions (d50: 5.7 μm, 6.8 μm, 7.5 μm, 10.9 μm) on the glaze properties by using hot stage microscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM), color and gloss measurements. The studies indicated that celsian is the dominant phase in the glaze structure. The sintering and softening temperatures of glazes decreased with the increase of milling time. A decrease in the particle size of the glaze slurry increased the whiteness index. As the average particle size (d50) of the glaze decreased, the number of crystals was also increased. The investigation results also suggested a relation between specular reflection and milling time. As the milling time extended, there was a corresponding increase in the magnitude of glossiness.

ALMA-IMF

Context. The star formation process leads to an increased chemical complexity in the interstellar medium. Sites associated with high-mass star and cluster formation exhibit a so-called hot core phase, characterized by high temperatures and column densities of complex organic molecules. Aims. We aim to systematically search for and identify a sample of hot cores toward the 15 Galactic protoclusters of the ALMA-IMF Large Program and investigate their statistical properties. Methods. We built a comprehensive census of hot core candidates toward the ALMA-IMF protoclusters based on the detection of two CH3OCHO emission lines at 216.1 GHz. We used the source extraction algorithm GExt2D to identify peaks of methyl formate (CH3OCHO) emission, a complex species commonly observed toward sites of star formation. We performed a cross-matching with the catalog of thermal dust continuum sources from the ALMA-IMF 1.3 mm continuum data to infer their physical properties. Results. We built a catalog of 76 hot core candidates with masses ranging from ~0.2 M⊙ to ~80 M⊙, of which 56 are new detections. A large majority of these objects, identified from methyl formate emission, are compact and rather circular, with deconvolved full width at half maximum (FWHM) sizes of ~2300 au on average. The central sources of two target fields show more extended, but still rather circular, methyl formate emission with deconvolved FWHM sizes of ~6700 au and 13 400 au. About 30% of our sample of methyl formate sources have core masses above 8 M⊙ and range in size from ~1000 au to 13 400 au, which is in line with measurements of archetypical hot cores. The origin of the CH3OCHO emission toward the lower-mass cores may be explained as a mixture of contributions from shocks or may correspond to objects in a more evolved state (i.e., beyond the hot core stage). We find that the fraction of hot core candidates increases with the core mass, suggesting that the brightest dust cores are all in the hot core phase. Conclusions. Our results suggest that most of these compact methyl formate sources are readily explained by simple symmetric models, while collective effects from radiative heating and shocks from compact protoclusters are needed to explain the observed extended CH3OCHO emission. The large fraction of hot core candidates toward the most massive cores suggests that they rapidly enter the hot core phase and that feedback effects from the forming protostar(s) impact their environment on short timescales.

Synthesis, Characterization and Molecular Docking of Bis-(1-(2,4-dichlorobenzoyl)-3-methylthiourea) Iron (III) Complex as Anticancer Candidate

The Bis-(1-(2,4-dichlorobenzoyl)-3-methylthiourea) iron (III) complex has been synthesized from the reaction between 1-(2,4-dichlorobenzoyl)-3-methylthiourea and Fe (III) metal ion by reflux method with ethanol solvent at a temperature of 75°C for 7 hours. It was characterized by a hot stage microscope (HSM), UV-Vis, FT-IR, and mass spectroscopy. The % yield of the synthesis result was 97.58%. From the docking study on the ribonucleotide reductase enzyme, the binding affinity value was -7.76 kcal/mol, and the inhibition constant was 2.11 mM. The Bis-(1-(2,4-dichlorobenzoyl)-3 methylthiourea) iron (III) complex compounds can be synthesized and predicted as anticancer candidates.

Development of a micro-infrared thermometry method for surface temperature distribution and variation of millimeter particle during high-temperature reaction

Temperature strongly affects the conversion efficiency, local reactivity, and particle stabilization of the reactions, particularly at high temperature. This study integrated infrared thermography with a high-temperature hot stage reactor to develop a methodology of continuous temperature measurement for a single particle reaction at high temperatures. The external optical transmission transmittance and temperature field core were corrected, and the relationship between the measured temperature (Tr) and true temperature (T0) was obtained by adjusting the sample emissivity. Sample temperature with known emissivity at elevated temperature was measured with 1% deviation. The instantaneous temperature measurement for the gasification process was carried out and the overall emissivities of coal particles were corrected. Temperature distribution and variation on the coal particle surface during the gasification process were further obtained and consistent with the previous research results. The proposed online temperature measurement method provides a new approach for gaining insights into particle reaction states.

Polysaccharide Hydro-Gel from Arid Plant Seed

There is a limited information on the structure and gelation process in mucilagepolysaccharides because of the complex conformation and non-homogeneity of the constituent polysaccharides that typically show large molecular weights in excess of 1 MDa. Only a few works have been done in this area of characterizing mucilage structure and rheological behaviour for different gel solutions. Exploring this area would surely open the new horizons for drug delivery, soil conditioning and pharmaceutical industry. In this study, we aimed to extract polysaccharides found in P.ovata Seed (Isabgol) via mucilage extraction controlling molecular weight of polymers in hot water extraction stage and tried to formulate gel formation dissolving different conc. of extracted freeze-dried material along with the characterization of gel network through Rheological studies and Dynamic Light Scattering (DLS) studies in different solvents. The study confirmed the relationship between molecular associations, chain relaxation time and entanglement behaviour of P. ovata hot water extracted (HW) solutions using polydispersity index and shear rheology. Moreover, two power law regions obtained for different concentration solution are of great importance because of their wide applications in the industrial prospective.

Patient-focused programable release indomethacin tablets prepared via conjugation of hot melt extrusion (HME) and fused depositional modeling (FDM) -3D printing technologies

Indomethacin (IND) eases the chronic pain caused by Juvenile idiopathic arthritis (JIA) in clinic, but it was reported that it has dose-related side effects such as gastrointestinal irritations and potential damage to nervous system. So, there is a considerable demand for offering effective, safety, and quality IND dosages for individual pediatric and youth patients. The main aim of this work is to on-demand manufacture personalized and programmable release IND tablets via combining hot melt extrusion (HME) and 3D printing technologies based on the structure-release correlations. IND loaded filaments were extruded and then the tablets were designed and printed. A series of physical and chemical characterization studies were also conducted, including differential scanning calorimetry (DSC), powder X-ray diffraction (PXRD), hot stage polarized light microscopy (PLM), texture analysis, and in vitro drug release studies. The results showed that IND was dispersed in HPMCAS matrix and formed amorphous solid dispersions (ASDs). Additionally, the in vitro drug release studies demonstrated that the release of IND can be programmed via manipulating 3D structure design. The mathematical model to predict the IND from structural designed tablets was obtained and two tablets (T-v1 and T-v2) were printed to validate such model, where the fitting coefficient are 0.9964 and 0.9965, respectively. This study suggested that combining HME and 3D printing technologies could be an optimal approach for personalized and precision drug delivery dosage development.

Optimisation of slag composition (MgO and Basicity) to operate 20% alumina in Blast Furnace slag

Blast furnace (BF) operation depends on the smooth upward movement of gas and its pressure drop. The slag properties like viscosity affects the gas flow inside the furnace. It is well-known that Al2O3 contributes to the increase of slag viscosity. For smooth BF operation, the maximum limit of Al2O3 in the Indian BF slag is around 18.5%. Higher Al2O3 contents make tapping of the BF slag difficult. In the present work, FACTSAGE calculations were carried out to estimate the viscosity and melting temperature of 20% Al2O3 slag varying MgO% between 7 and 13 and basicity (B2, defined as wt% CaO/wt % SiO2) between 0.9 and 1.2 to find an optimum MgO% and basicity for easy tapping of the slag. The results of the calculations provide three combinations of MgO (12,12.5,13%) and B2 (0.95) of slag for operating 20% Al2O3 in slag which were validated through experimental studies involves the inclined plane test, hot stage microscopy and X-ray diffraction.

Influence of nano-CuO modification on crystallization behavior and surface characteristics of P2O5 containing Li2O-ZnO-B2O3-SiO2 glass-ceramics

This paper investigates the impact of nano-CuO addition on the crystallization process and surface properties of phosphate containing lithium zinc borosilicate glass-ceramic coatings. A comprehensive analysis was performed using diverse thermal, structural, and morphological techniques such as hot stage microscope, differential thermal analysis, X-ray diffraction analysis and scanning electron microscopy. Thermal analysis revealed a glass transition temperature of 478.5 °C and a crystallization onset temperature of 595.6 °C. The coefficient of thermal expansion was measured to be 8.94 × 10−6.°C−1. Viscosity measurements indicated a significant decrease in viscosity with increasing temperature, following the Vogel-Fulcher-Tammann equation. Kinetic studies revealed an activation energy of 11.36 kJ/mol for the crystallization process, suggesting potential kinetic hindrance for the reference glass-ceramic coating. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed the formation of a crystalline phases of Li2ZnSiO4 and Li3PO4 at crystallization temperatures above 750 °C. Nano-CuO addition was found to promote crystal formation and increase the inter-crystal spacing according to the SEM analysis. Optical microscopy and 3D surface analysis revealed that nano-CuO addition refined surface texture and reduced the surface roughness of the glass-ceramic coatings at varying crystallization temperatures of 750, 800 and 850 °C. Moreover, contact angle measurements indicated that nano-CuO addition decreased the wetting angle of the coatings around 62 %, suggesting improved hydrophilicity. The findings suggest that nano-CuO addition can enhance the crystallization kinetics and improve the surface quality and hydrophilicity of glass-ceramic coatings.

Influence of PbO/CuO ratio on phase composition, microstructure, melt wettability and recyclability of copper slag

An estimated 30 % (∼11 million metric tons/year) of copper slag is still landfilled globally. Fayalitic copper slags are well-characterized, and they can be recycled into multiple safe end-products. Conversely, the major type of copper slag produced in Europe is lead-rich and warrants a deep understanding of phases present in it, properties, adverse environmental implications, and potential recycling strategies. The objective of this study is to thoroughly investigate such industrial slags by XRF, XRD, Mössbauer spectroscopy, SEM-EDS, novel automated image analysis using Aphelion, hot stage microscopy (HSM) and assess prospects for their valorization. These industrial slags were found to contain 26.1–50.5 wt% PbO, 3.4–5.4 % As2O5 (both hazardous solid wastes), 5.7–42 % CuO (present partly as Cu2O, an irritant), 3.2–18.2 % Fe2O3, 14–15.9 % SiO2 and oxides of chromium, cobalt (both carcinogenic), zinc and nickel (both toxic to aquatic life). The limitation of Rietveld XRD for glass quantification was overcome by newly-developed automated SEM-image processing which revealed that all three slags consisted of a lead silicate glass (36.3–65.8 vol%). Strikingly, rarely published arsenic- and lead-based compounds like (Ca,Pb)4As2O9-x, (Ca,Cu)2PbO4-x and Pb3Ca2Si3O11 were found when slag's PbO/CuO was 0.6, and Ca3As2O8-Pb2SiO4 formed when PbO/CuO equaled 9. The challenge of toxicity and landfilling can be overcome as these slags have high potential to be used for recovery of copper, cobalt, and lead. Radioactive waste immobilization glasses, gamma-ray shielding concrete and glass-ceramic consumer products may also be prepared from them. HSM revealed that a higher PbO/CuO ratio results in lower melting point and smaller melt contact angle indicating such slag can be useful for manufacturing recycled ceramics but corrosive towards refractories in copper converter.