Iron And Steel Research Articles

Investigation of the Effects of Filling Speed, Casting Temperature and Metallurgical Quality on Fluidity of Lamellar Graphite Cast Iron at Different Section Thicknesses

AbstractIn this study, the fluidity properties of the alloy were investigated at different casting temperatures, different section thicknesses, and varying casting parameters of lamellar graphite cast iron materials. To achieve our goal, we utilized sand molds that were created with specific parameters including pouring temperature, metallurgical quality, section thickness, and fluidity test model. These molds were used for casting. Thus, the effect of fluidity properties in changing casting conditions and liquid metal advance distances at determined section thicknesses was investigated. Modeling was carried out with FlowCast casting simulation software by determining the liquid metal advance distance depending on the section thickness in the castings made in sand molds under changing casting conditions. The fluidity and advance distance of the liquid metal was determined comparatively with experimental and modeling techniques under the changing casting conditions in the parameters determined in this study. When the outcomes were examined; it was observed that different liquid metal advance distances occur at different cross-section thicknesses depending on the changing conditions.

Identifying barriers and drivers for energy efficiency in steel and iron industries of Karachi, Pakistan: Insights from executives and professionals

Pakistan has faced a persistent energy deficit over the past few decades, with energy-intensive industries occupying a substantial share of energy consumption. Despite the potential for energy efficiency improvements within the industrial sector, numerous barriers hinder progress. This study identifies the barriers and drivers of energy efficiency practices specifically within the steel and iron industries of the economic hub of Pakistan. Through a questionnaire-based approach and follow-up interviews, responses were gathered from 32 executives and professionals within the steel sector, representing eight firms. Reliability analysis was conducted to ensure the robustness of the data. The analysis reveals that limited awareness and inadequate managerial commitment are significant barriers to energy efficiency initiatives. Moreover, ineffective policies and a lack of government implementation plans contribute to diminishing demand for energy-efficient technologies. However, there is a growing interest among respondents in reducing energy consumption to enhance cost-effectiveness. Key drivers such as long-term economic benefits, improved working conditions, and cost savings emerge as crucial factors motivating the adoption of energy-efficient practices. Positively, some companies have already initiated energy-saving measures, including the adoption of advanced technologies and renewable energy sources. These findings highlight the urgent need for collaborative efforts to overcome barriers and promote sustainability in steel and iron sector of Pakistan.

Development of machine learning models for the prediction of erosion wear of hybrid composites

AbstractThis article reports on development of an adaptive framework for predicting the erosion performance of polymer composites using certain statistical and machine learning (ML) models. For this, ramie‐epoxy composites reinforced with variations (0–30 wt%) of sponge iron slag (an iron industry waste) are considered. The composites are fabricated and then subjected to high temperature solid particle erosion wear trials following Taguchi's L27 orthogonal array. The effects of different control factors on the erosion rate in an interactive environment are appraised by analysis of variance (ANOVA) which reveals the filler content as the most significant factor contributing 66.21%, followed by impact velocity (22.86%) and impingement angle (2.28%). A regression model based on the input–output parameters obtained from experimentation is constructed for prediction of erosion rate. Further, four predictive models using different machine learning algorithms are also proposed to predict the erosion rate of the composites. The feasibility and performance of each ML model is assessed using appropriate performance metrics. Among all the models, the gradient boosting machine model is found to be the most reliable model exhibiting the highest prediction accuracy and least errors.Highlights Development of novel class of composites reinforced with sponge iron slag. Database creation based on erosion wear experimentation on the composites. Data‐driven modeling for prediction of erosion rates using machine learning. Comparison of performance of different models and identifying the best one.

Morin loaded mesoporous molecular sieves as novel devices to the potential treatment of tumor pathologies.

Morin is an antioxidant and anticancer flavonoid, extracted from natural sources, that may exert beneficial effects for several pathologies. Despite this, the administration of morin represents a challenge due to its low aqueous solubility. Mesoporous silica materials have emerged as biocompatible tools for drug delivery, as their pore size can be modulated for maximum surface area to volume ratio. In this contribution, we evaluate the ability of iron-modified mesoporous materials, for morin loading and controlled delivery. The SBA-15 and MCM-41 sieves were synthesized and modified with iron (metal content 4.02 and 6.27 % wt, respectivily). Characterization by transmission electron microscopy, XRD and UV-Vis revealed adequate pore size and agglomerates of very small metallic nanospecies (nanoclusters), without larger iron oxide nanoparticles. FT-IR spectra confirmed the presence of silanol groups in the solid hosts, which can interact with different groups present in morin molecules. SBA-15 materials were more efficient in terms of morin loading capacity (LC) due to their larger pore diameter. LC was more than 35% for SBA-15 materials when adsorptions studies were carried out with 9mg of drug. Antioxidant activity were assayed by using DPPH test. Free iron materials presented a significate improvement as antioxidants after morin incorporation, reaching a scavenging activity of almost a 90%. On the other hand, in iron modified mesoporous materials, the presence of morin did not affect the scavenging activity. The results could be related with the formation of a complex between the flavonoid and the iron. Finally, biosafety studies using normal epithelial cells revealed that neither the loaded nor the unloaded materials exerted toxicity, even at doses of 1mg/ml. These findings expand knowledge about mesoporous materials as suitable carriers of flavonoids with the aim of improving therapies for a wide range of pathologies.

The Effect of Laser Power on the Microstructure and Wear Resistance of a Ni3Al-Based Alloy Cladding Layer Deposited via Laser Cladding

A coating prepared via laser cladding has the advantages of a high-density reinforced layer, a low matrix dilution rate, and combination with matrix metallurgy. In this study, Ni3Al-based alloy cladding layers with Cr7C3 were prepared via laser cladding, and the corresponding microstructures and wear resistance were studied in detail. The results show that the Ni3Al-based cladding layer prepared using laser cladding technology had good metallurgical bonding with the matrix, and there were no pores, cracks, or other defects on the surface. The microstructures of the laser cladding layer were mainly γ′-Ni3Al, β′-NiAl, and in situ C7C3. As the laser power increased, the heat input increased, resulting in an increase in the dilution rate. Simultaneously, the carbide size in the laser cladding layer increased. With the increase in laser power, the hardness of the laser cladding layer of the Ni3Al-based alloy decreased, and the wear resistance of the laser cladding layer first strengthened and then weakened. When the laser power increased to 2.0 kW, the wear rate of the laser cladding layer decreased to 0.480 × 10−5 mm3/N·m. When the laser power increased to 2.4 kW, the wear rate of the laser cladding layer increased to 0.961 × 10−5 mm3/N·m, which was twice the rate at 2.0 kW. This could be attributed to small Cr7C3 particles, which could not effectively separate the wear pairs, resulting in more serious adhesive wear. Large Cr7C3 particles caused the surface of cast iron material with lower hardness to be damaged, which suffered more serious particle wear. The generation of short rod-shaped carbides should be avoided because, in the process of friction and wear, carbides with these shapes are easy to break, thus leading to crack initiation.

Investigation of Polyurethane Primer Coating Paint Based on Local Palm Oil with Antimicrobial and Anticorrotion Agent Formula Bentonite-Chitosan

Paint is a product that is really needed to coat iron or steel materials such as industrial pipes, medical equipment, and so on. The sample formulation used was the addition of chitosan bentonite filler 2, 4, 6, 8% w/w. In TGA testing, the sample underwent single decomposition and showed the best results in the Polyurethane/Bentonite/Chitosan 8:8% w/w sample where the sample began to degrade at a temperature of 416.85 (℃). The bacterial test results showed the best results in the Polyurethane/Bentonite/Chitosan 8:8% w/w sample which had the widest inhibition zone with a value of 6.9 mm for E.Coli bacteria. The sample with the composition Polyurethane/Bentonite/Chitosan 8:8% w/w was the best sample where the sample experienced the smallest corrosion rate, namely 5.08 mpy. The application of this paint is to strengthen the durability of the building so that corrosion does not occur in the Hagu Barat Laut of Lhokseumawe because it is close to sea waters which have air levels that are quite susceptible to corrosion.

Performance enhancement of engineered cementitious composite through tailoring recycled iron sand

Engineered cementitious composite (ECC) possesses predominant tensile properties while a relatively low modulus of elasticity (MOE) due to the low sand-to-binder ratio and fine quartz sand (QS, QS-ECC). Further, the excessive consumption of QS in concrete industry has imposed a serious challenge to natural resource preservation. Iron sand (IS), a by-product of the iron industry with high particle modulus, could be a potential alternative in developing ECC (IS-ECC). This research focused on recycling IS as fine aggregate to develop a sustainable ECC with high mechanical performance, especially high MOE. The influences of water-to-binder ratio, sand-to-binder ratio, and IS particle size were systematically investigated. The results indicated that all the IS-ECC demonstrated robust tensile performance with the tensile strength and strain capacity over 5 MPa and 5%, respectively. Compared with the QS-ECC, a comparable or even superior compressive strength was achieved by all the IS-ECC. Impressively, the MOE of IS-ECC with 20–40 and 40–80 mesh of IS particles exhibited 68% and 60% higher than that of QS-ECC, respectively. SEM observations well reflected the macroscopic tensile performances. The cost and environmental effect analysis revealed the sustainability of IS-ECC. This research provides the groundwork for promoting the utilization of IS in developing high performance ECC material.

Preparation and Characterization of Cocoa Shell - Pahae Natural Zeolite as a Metal Adsorption Material for Iron (Fe) and Manganese (Mn) in Water

Research has been conducted on an adsorber made from cocoa shell activated charcoal and Pahae Natural Zeolite, designed as an absorber for Fe and Mn metals in well water purification. The cocoa shell were screened with a 100-mesh sieve, followed by carbonization to generate activated charcoal. In parallel, Pahae Natural Zeolite underwent a similar sieving process with a 100-mesh screen and was subsequently chemically activated using a 2.5 M NaOH solution. The compositions of the cocoa shell activated charcoal - Pahae Natural Zeolite adsorber were varied as follows (wt%): 100:0, 95:5, 90:10, 85:15, 80:20, 75:25. These mixtures were then compressed using a hydraulic press with a load of 6 tons for a duration of 10 minutes. The resulting samples underwent physical activation at different temperatures (300°C, 320°C, 340°C) for 30 minutes. The adsorber was subjected to characterization to ascertain its physical properties (porosity, adsorption capacity, density), mechanical properties (compressive strength and hardness), surface morphology, and elemental composition (SEM-EDX). The outcomes of the tests demonstrated the efficacy of the cocoa shell activated charcoal - zeolite based adsorber in significantly reducing iron (Fe) and manganese (Mn) levels, with a remarkable reduction in Fe content by 99.76% and Mn content by 99.70%.

A molecular dynamics analysis of the influence of iron corrosion products on the healing process of bitumen

Corrosion of iron materials in the asphalt concrete pavement occurs commonly when the bitumen film peels off, and the generation of corrosion products would affect the healing performance of bitumen. To identify the affection, this research focuses on the influence of iron corrosion products on the healing process of bitumen by molecular dynamics simulation. Firstly, bitumen model and iron corrosion products model were built. Then the healing systems of sandwich structure were constructed, and the simulated temperature were applied to reach equilibrium in the healing process with NVT ensemble (constant number of atoms, volume, and temperature). Dynamic movements of bitumen were characterized by appearance qualitatively. Healing rate of crack and healing rate of bitumen aggregation were held to evaluate the healing effect. Diffusion behaviors, internal force of motivation and interaction effect were also analyzed. The results indicate the duplicity of iron corrosion products in the healing process including the ease for bitumen climbing and the obstruction of bitumen movement. The comprehensive healing index demonstrated that iron corrosion products would reduce the healing degree, which was mainly caused by the obstruction effect and large internal stress generated by severe aggregation of bitumen in the limited space. From the perspective of crack closure and bitumen aggregation degree in the corrosion area, FeO healing systems were healed best, followed by Fe3O4, Fe2O3 and FeOOH. Furthermore, diffusion period of bitumen molecules on the surface of iron corrosion products during the healing process should be regarded as the important period affecting healing.

A Comparison of the Fatigue Strength of Repair Welded Nodular Cast Iron Materials for Usage in Wind Energy Components

A Comparison of the Fatigue Strength of Repair Welded Nodular Cast Iron Materials for Usage in Wind Energy Components

Unveiling the effect of different dissolved organic matter (DOM) on catalytic dechlorination of nFe/Ni particles: Corrosion and passivation effect

Dissolved organic matter (DOM), which is ubiquitously distributed in groundwater, has a crucial role in the fate and reactivity of iron materials. However, there is a lack of direct evidence on how different DOMs interact with nFe/Ni in promoting or inhibiting the dechlorination efficiency of chlorinated aromatic contaminants. By comparing humic acid (HA), fulvic acid (FA), and biochar-derived dissolved organic matter (BDOM) at different pyrolysis temperatures, we first demonstrated that the dechlorination effect of nFe/Ni on 2,4-dichlorophenol (2,4-DCP) depended on the nature of DOMs and their adsorption on nFe/Ni. HA showed an enhancing effect on the dechlorination of 2,4-DCP by nFe/Ni, while the inhibition effect of other DOMs resulted in the following dechlorination order: BDOM300 ≈FA>BDOM700 ≈BDOM500. The C2 component with higher aromaticity and molecular weight promoted the corrosion of nFe/Ni and the production of reactive hydrogen atoms (H*). The effects of different DOMs on nFe/Ni include that (1) HA accelerates the corrosion and H* production of nFe/Ni, (2) FA and BDOM300 enhance the corrosion but inhibit H* production, and (3) Both nFe/Ni corrosion and H* formation are suppressed by BDOM500/BDOM700. Therefore, this study will provide a reference for understanding the nature of DOM-nFe/Ni interaction and improving the catalytic activity of nFe/Ni when different DOMs coexist in practical applications.

Assessment for Replacing Coal and Petroleum Product with Green Hydrogen for Steel and Iron Production

Among the leading global contributors to anthropogenic CO<sub>2</sub> emissions, the iron and steel industries are energy-intensive sectors. This is due to the fact that fuel and iron ore are reduced using non-renewable energy sources like coal and charcoal. A tonne of iron is produced, and that produces roughly 1.9 tonnes of CO<sub>2</sub> gas. It is necessary to switch to clean energy sources from conventional carbon-emitting sources in order to lower emissions from the iron and steel industry. Hydrogen is a substitute fuel that has the potential to replace carbon-emitting fuel in the iron and steel sectors, according to the present trend in clean energy development. Hydrogen can be employed as a reducing agent in blast furnaces as an auxiliary or as the only reducing agent in the direct reduction process, which is how iron and steel are produced. Water is the only byproduct of the electrolysis process, which creates green hydrogen using renewable energy sources. In the iron industry, using green hydrogen can lower intensive carbon emissions. Green steel or iron production costs can be competitive and less carbon intensive if the cost of producing green hydrogen is low. In this paper, the steel and iron production from green hydrogen is studied to contribute to developing the conceptual design along with challenges for handling the hydrogen in these industries and compared with the conventional carbon-based process. In addition, the economic assessment for the production of steel from a green hydrogen-based process.

Transformation and Detoxification of Typical Metallurgical Hazardous Waste into a Resource: A Review of the Development of Harmless Treatment and Utilization in China.

The production process of the metallurgical industry generates a significant quantity of hazardous waste. At present, the common disposal method for metallurgical hazardous waste is landfilling, which synchronously leads to the leaching of toxic elements and the loss of valuable metals. This paper presents a comprehensive review of the research progress in the harmless treatment and resource utilization of stainless steel dust/sludge (including stainless steel dust and stainless steel pickling sludge) and aluminum ash (including primary aluminum ash and secondary aluminum dross), which serve as representative hazardous wastes in ferrous metallurgy and nonferrous metallurgy, respectively. Additionally, the general steps involved in the comprehensive utilization of metallurgical hazardous waste are summarized. Finally, this paper provides a prospective analysis on the future development and research trends of comprehensive utilization for metallurgical hazardous waste, aiming to offer a basis for the future harmless, high-value, resource-based treatment of metallurgical hazardous waste and the realization of industrial applications in China.

Eco-Friendly Synthesis of Alstonia scholaris (L.) R. Br. Extract-Mediated Nanostructured Material: Removal of Organic Pollutants from Water Resources

In this modern era, pollution of water resources due to industrial waste effluents is an alarming problem as it can cause various health problems in aquatic animals as well as in humans. Among the industrial pollutants, organic dyes are one of the leading chemicals that cause severe damage to the aquatic environment. These harmful organic dyes are practically omnipresent in various types of industries such as textile, tannery, cosmetic, food industries, etc. Photodegradation of these organic dyes is regarded as a promising technology for industrial waste treatment as it is a cost-effective and environment-friendly process. In this study, a nanostructured material of iron has been synthesized using the Alstonia scholaris (L.) R. Br. extract in an easy and eco-friendly way. The potential of this synthesized nanostructured material to act as a photocatalyst, for the degradation of organic dyes, has been explored. Due to its small size and high dispersion, more than 72 % degradation has been achieved within 90 min. A comparative study of its photocatalytic efficiency in different degradation processes has also been performed.

Techniques, mechanisms, and application of 3D-printed biodegradable metals for bone regeneration

Repairing severe bone defects and restoring complete bone tissue morphology are major challenges in clinical practice. Biodegradable metals (BMs) are bioactive materials with active degradation properties. The gradual improvement of three-dimensional (3D) printing technology holds tremendous potential for development and has spurred on the growing utilization of 3D-printed BM materials in the clinical applications of bone regeneration. In this paper, we review the application of three BM (magnesium, iron, and zinc) materials for use in 3D-printed bone regeneration; define the principle of 3D-printed bone regeneration, including the method and selection of materials; and summarize the characteristics and uses of various printing technologies and the properties, advantages, and disadvantages of BMs. Compared to traditional nondegradable implants, 3D-printed degradable metal implants have the advantages of not leaving residue, avoiding stress shielding, promoting osteogenesis and vascularization, and exhibiting antimicrobial ability. In addition, we summarize the clinical applications of 3D-printed BMs. 3D-printed BMs can be used not only for fracture fixation and bone defect repair but also for osteoporotic fracture repair, cartilage repair, maxillofacial surgery, and other processes. In this article, we discuss the advantages and limitations of the current 3D printing degradable metallic materials and describe future development prospects.

The relationship of polymorphisms of the SOD2, NOS3 and SIRT1 genes with hypertension in employees of the converter workshop of the ferrous metallurgy enterprise

Workers employed in ferrous metallurgy enterprises are affected by various oxidants, which lead to increased formation of free radicals, suppression of the antioxidant system, initiation of oxidative stress and the development of diseases characterized by high blood pressure. In this regard, the identification of polymorphisms of genes encoding enzymes that are associated with the formation and neutralization of free radicals is an important task of personalized medicine.
 The study aims to explore the relationship of polymorphisms rs4880 (SOD2), rs1799983 (NOS3) and rs7069102 (SIRT1) with hypertension in workers of the converter workshop.
 To conduct the research the authors used data from periodic medical examinations of men aged 30 to 59 years, including 116 employees of the converter shop and 169 representatives of administrative and managerial personnel (comparison group). Subsequently, we divided each group according to the principle of the presence or absence of a diagnosis of "hypertensive heart disease" (I11 according to ICD-10), established or confirmed during a periodic medical examination. DNA was isolated from peripheral blood using the Lumiere kit for the isolation of genomic DNA from whole blood and literal epithelium (Lumiprobe, Russia) in accordance with the manufacturer's instructions. The scientists performed genotyping using the optical PCR system with real-time optical detection QuantStudio 3 (Thermo Fisher, USA) and ready-made commercial sets "SNP-Screen" (Syntol, Russia).
 The ratio of the chances of developing hypertension in the personnel of the converter shop was increased in carriers of mutant genotypes of the SOD2 (TT) gene. Also, the values of blood pressure, total cholesterol and glucose levels were higher in carriers of the mutant TT genotype of the SOD2 gene compared with CC/CT, but only in the group of converter shop workers with hypertension. In addition, in the comparison group with hypertension, systolic and diastolic blood pressure significantly differed, the values of which were higher in carriers of the mutant GG genotype of the SIRT1 gene.
 Presumably, an excess of superoxide anion in the TT genotype of the SOD2 gene, together with exposure to harmful environmental factors, may contribute to the development of cardiovascular diseases in workers of the converter workshop.
 Ethics. The study was approved in accordance with Protocol No. 1 dated 02/26/2021 and the conclusion of the Local Ethics Committee of the Federal Budgetary Institution of Science "Yekaterinburg Medical Scientific Center for the Prevention and Health Protection of Industrial Workers" of Rospotrebnadzor.

Analysis of tomatoes showing iron deficiency symptoms in winter under heavy fruit load

Declines in crop productivity that are thought to be due to iron deficiency have been reported even on non-calcareous-alkaline soils. For example, tomatoes exhibit iron deficiency-like symptoms (yellowing of new leaves) if the fruit load is heavy during winter. The objective of this study is to investigate the relationship between fruit load, low temperatures, low sunlight, and iron deficiency, and to explore the possibility of increasing productivity with iron-containing fertilizers. Results of an investigation of the farms experiencing iron deficiency-like symptoms in winter showed low iron concentrations and elevated expression of iron deficiency-inducible genes in yellowing leaves. To investigate the effects of heavy fruit load on iron nutrition, plants were grown in three groups: those with a medium number of fruits per truss (MED), a high number of fruits (heavy fruit load; HEAVY), and a high number of fruits with additional iron fertilization (++Fe). The SPAD leaf-color value of the new leaves and weight of the lower leaves in winter were in the order of HEAVY < ++Fe < MED. In all groups, the iron concentrations in the upper leaves in January were lower than those in October and March. RNA-seq analysis showed that the expression of genes involved in iron absorption was suppressed in the roots in January, which may have contributed to iron deficiency in winter. These results suggest that one of the factors limiting the productivity of tomatoes in winter with heavy fruit load is iron, and that productivity can be restored by iron materials.

Nitrogen removal performance of improved subsurface wastewater infiltration system under various influent carbon-nitrogen ratios.

Subsurface wastewater infiltration system (SWIS) has been recognized as a simple operation and environmentally friendly technology for wastewater purification. However, effectively removing nitrogen (N) remains a challenge, hindering the widespread application of SWIS. In this study, zero-valent iron (ZVI) and porous mineral material (PMM) were applied in SWIS to improve the soil matrix. Our results suggested that the addition of ZVI and PMM could simultaneously enhance N removal efficiency and reduce nitrous oxide emissions. This could be attributed to the abundant electrons generated by ZVI alleviating the electronic limitation of denitrification and the porous structure of PMM providing solid phase support for microbial growth. In addition, the abundance of microbial functional genes increased in modified SWIS, which could further explain the higher pollutant removal efficiency. Overall, this study provides new insights into the mitigation of wastewater pollution and greenhouse gas emissions in SWIS. PRACTITIONER POINTS: ZVI and PMM can adapt to different C loads and enhance pollutant removal efficiency in SWIS. Increasing C-N ratios positively affected the nitrate removal performance and negatively affected ammonium removal performance in SWIS. The amending soil matrix promoted the reduction of the N2 O to N2 and greenhouse gas emissions were well controlled. The abundance of microbial functional genes increased with the improvement of the soil matrix.

Application of the IPCC Methodology to Assess the Spatial Distribution of CO2 Emissions in Russian Ferrous Metallurgy

Application of the IPCC Methodology to Assess the Spatial Distribution of CO2 Emissions in Russian Ferrous Metallurgy

The Influence of Product Quality, Price Perception and Product Variety on Consumer Repurchase Intentions with Consumer Satisfaction as a Mediating Variable (Study pn Solid Surface Performnite Products)

The progress of the Indonesian interior world is growing rapidly following current trends. Consumers tend to look for furniture with a simple, clean and functional style. One material that is often used for furniture is solid surface material. Solid surface can be combined with wood, iron, rattan and other materials. Considering the increasing number of solid surface manufacturers in Indonesia, competition in the solid surface industry is becoming tight. It requires strong repurchase interest from consumers to survive in the solid surface industry. This research was conducted to analyze the factors that influence solid surface consumers repurchase interest using PLS-SEM. The population of this research is consumers of solid surface performnite. The results of this research are that product quality, price perception, product variety have a significant effect on consumer satisfaction. Product quality, price perception, product variety have a significant effect on repurchase intention. Consumer satisfaction partially mediates the relationship between product quality, price perception, product variety and repurchase intention.