Smelting Research Articles

Acoustic emission monitoring of a laser powder bed fusion process

Additive manufacturing (AM) metal parts offers opportunities for various industrial applications. From individual production of spare parts for unique mechanical components to prototyping of complex structures, the possibilities of production using the additive manufacturing process are manifold. One common AM technique is the Laser Powder Bed Fusion (PBF-LB/M) process, where a laser is used to selectively melt metal powder and create the parts layer wise as designed in a model. During manufacturing certain defects like pores, cracks and lack of fusion may be created in the built parts. As AM parts often have complex geometries, a postprocess non-destructive testing is difficult or even not possible. Thus, different optical monitoring techniques are applied to detect flaws during the build process with the aim to detect and repair defects right away during the manufacturing process. However, optical monitoring system require a clear view of the melt pool and quite expensive equipment. Acoustic monitoring by AE sensors attached to the built plate would be a cheaper alternative which also can be used without visual contact to the building chamber. This paper shows a first approach of an AE based process monitoring. The build plate of a PBF-LB/M machine therefore was adapted to hold four AE sensors that are then used to monitor the process. The build process itself creates AE signals caused by the melting and cooling and the mechanical application of powder. The formation of pores and cracks is expected to create additional acoustic emissions that will be distinct from the AE pattern from the printing process. This AE signals can be linked to the different layers of the printed part or in the long run to the laser position. Results from the first tests in a customized LPBF machine will be shown as well as the implementation of AE into the PBF-LB/M machine.

Numerical investigation of arc characteristics and metal properties in ELAMF-assisted WAAM with wire retraction

In this study, a multi-physics integrated model of wire arc additive manufacturing (WAAM) with wire retraction and external longitudinal alternating magnetic field (ELAMF) assistance is proposed and validated, and the effect of ELAMF on the arc plasma characteristics and metal properties are systematically and quantitatively investigated. The model comprehensively takes the arc plasma heating, wire dynamic retraction, droplet transfer, the formation and diffusion of metal vapor, the melting and solidification of molten metal, and the stirring effect of ELAMF into account. The simulated results show that ELAMF has compressed the arc morphology, and decreased the temperature, potential, current density and static pressure, which are most pronounced when the wire is at an elevated position and the transient current is at its peak phase. Meanwhile, the formation of low-temperature and low-velocity cavities in the center of arc column are promoted by ELAMF, consequently diminishing the energy transferred from the arc plasma to molten pool through thermal conduction and mitigating the squeezing of the arc plasma on the surface of molten pool. The results also demonstrate that the ELAMF has reduced the temperature gradient of liquid metal inside the molten pool, and intensified the forced convection for the occurrence of multiple circulations.

Methods of Processing Dental Chromium-Cobalt Alloys for Production of Metal Frameworks Faced with Ceramics to Obtain the Best Mechanical Properties.

BACKGROUND Modern prosthetic technologies make it possible to fabricate prosthetic restorations without material loss and to make prosthetic restorations with complex geometric shapes in a relatively simple way. One such technology is selective laser melting (SLM), or additive manufacturing of metal materials, better known as 3D printing from metal or selective laser melting, but currently the most commonly used method is casting. The present study investigated use of dental chromium-cobalt alloys for prosthetic bridges and compared methods of processing dental chromium-cobalt alloys to obtain the best mechanical properties. MATERIAL AND METHODS We used dental chromium-cobalt alloy (SCHEFTNER GMBH) for laser melting StarbondCoSEeasy Powder with grain size of 10-30 µm and StarbondCoS alloy casting, made in accordance with the European standard EN ISO 22674. SLM-made specimens and induction melted alloy castings were prepared for the study. A centrifugal casting system with induction current melting of the metal alloy was used to produce the samples. The melting and casting process is automatic and limits changes in chemical composition. RESULTS The results show that none of the samples changed their chemical composition, while the samples made by SLM had better mechanical properties. CONCLUSIONS The SLM technique makes it possible to produce restorations faster and cheaper without any loss of quality compared to restorations made with the casting technique. Casting technology reduces mechanical properties, but still provides good mechanical properties.

The Impacts of Carbon Policy and “Dual Carbon” Targets on the Industrial Resilience of Ferrous Metal Melting and Rolling Manufacturing in China

The Impacts of Carbon Policy and “Dual Carbon” Targets on the Industrial Resilience of Ferrous Metal Melting and Rolling Manufacturing in China

Melt Pool Changes Characterization in Laser-Processed H11 Hot Work Tool Steel Using Point-by-Point Scanning Mode towards LPBF Process Optimization.

Additive manufacturing techniques employing laser-based metal melting have garnered significant attention within the scientific community. Despite a decade of comprehensive research on the fundamentals of these techniques, there still remain unexplored facets related to heat flux impact on metallic alloys' properties. Particularly, the effects of point-by-point laser operation on melt pool formation in metallic materials still remain unclear. Thus, this study focuses on the implications of laser metal melting, particularly investigating a point-by-point laser mode operation's influence on melt pool formation and its geometry in the phase-transformation-sensitive material H11 hot work tool steel. To examine the melt pool, singular laser tracks with various laser parameters were scanned across H11 sheet metal, which allowed for the elimination of layer-by-layer heat cycles' influence on the melt pool's microstructure. Samples were examined by means of metallography, revealing significant differences in the melt pool's depth, influenced mostly by exposure time rather than volumetric energy density. Heat-affected zone effects were found to have a limited range and thus potentially marginal effects in layer-by-layer manufacturing conditions. At the same time, retained austenite concentrations near fusion lines have been found within melt pools, suggesting potential micro-segregation of the alloying additions. The results present guidelines towards laser melting processes optimization.

Phase Relationships and Distribution of S, Fe, Co, Ni, Re, Os, and Pt between Metal and Sulfide Melts in the Basalt–Fe–FeS–C System at 1400°C and 4 GPa

Phase Relationships and Distribution of S, Fe, Co, Ni, Re, Os, and Pt between Metal and Sulfide Melts in the Basalt–Fe–FeS–C System at 1400°C and 4 GPa

Interdependence of metal vapor plume and melt pool dynamics during laser beam welding under vacuum

Deep penetration laser beam welding involves the emission of hot metal vapor and particles from the keyhole, which interact with the laser beam by means of scattering, absorption, and phase front deformation. The combination of scattering and absorption leads to an extinction of the laser beam, while the phase front deformation adversely affects the beam quality. The capillary formation depends on the local distribution of the absorbed irradiance of the laser beam, which in turn is related to the material process emissions. Additionally, the process atmosphere, in particular the oxygen content, and the working pressure influence the capillary fluctuations and cause variations in welding penetration. This study introduces a measurement setup using simultaneous high-speed observation of the melt pool and the keyhole while measuring the interaction mechanisms between the laser beam and the metal vapor plume during laser beam welding under vacuum of stainless steel. The obtained measurement provides a quantification of the various interaction mechanisms between the laser beam, vapor plume, keyhole, and interdepended melt pool dynamics. These quantitative high-frequency measurements at various working pressures and laser parameters provide useful insights that are crucial for understanding the formation of weld defects, resulting in process monitoring and validation of process-oriented welding simulations.

Temperature-induced structure evolution in monocrystalline and polycrystalline cobalt via molecular dynamics simulations

The structure transition of metallic melt strongly depends on temperature and significantly influences the comprehensive properties. However, observing the structure change in experiments is still challenging. Here, molecular dynamics is used to study the melting process and microstructural evolution in single crystal and polycrystal cobalt (Co). The results indicate that the melting process of single crystal structure starts from 1870 K and lasts for a very short period, while the polycrystal melts from about 1760 to 1870 K. In polycrystal Co, the melting initially occurs in grain boundaries, and the melting temperature shows a positive correlation with grain size. An interesting solidification phenomenon occurs on the surface of big grains in the beginning of melting process. The coordination number increasing from 12 to about 13.4 near melting point proves the local expansion of the first coordination shell, indicating the structural evolution from long-range order to short-range order in the continuous heating process. The common neighbor sub-cluster index and Voronoi polyhedron demonstrate the short-range icosahedron structures, while these polyhedrons become polydisperse and isolated in Co liquid. The findings ignite the investigation of the liquid structure origin of crystal materials and extend the understanding of the atomic structure evolution in melting.

Viscosity and structure correlation mechanism of Fe[sbnd]Cr[sbnd]C melt based on MD simulation

The viscosity of FeCCr melt affects the mass transfer behavior during steelmaking processes. Reasonable regulation of viscosity can improve production efficiency. There is a close relationship between melt viscosity and structure. Therefore, it is of great theoretical significance to analyze the correlation between viscosity and structure of chromium-containing iron melt for the optimization of the whole metallurgical process. This study experimentally investigated the viscosity of FeCCr melt and utilized molecular dynamics simulation to analyze the formation and growth behavior of atomic clusters, revealing the correlation mechanism between structure and viscosity. As the Cr content increased from 11 % to 13 %, the melt viscosity increased by 10.05 %. At a temperature range from 1773 K to 1473 K, the viscosity reached a maximum of 15.5 mPa·s, representing a 40.9 % increase. Simulation results indicated that CrC clusters within the melt act as intermediaries, connecting with CrFe and FeC clusters to form FeCrC clusters. The key influence of increased Cr content on viscosity lies in promoting the generation of FeCrC multicomponent clusters, while the key influence of temperature reduction lies in promoting cluster growth. With the increase in Cr content, the number of clusters at 1773 K increased from 154 to 175, and the average volume of clusters increased from 212 Å3 to 224 Å3. When the temperature decreased from 1773 K to 1473 K, the number of clusters increased by 51.2 %, and the average volume of clusters increased by 18.75 %. In comparison, the thermal state change had a greater impact on clusters, where temperature reduction led to rapid cluster growth, reduction of free volume within the melt, and ultimately resulted in increased viscosity due to the combined effects.

Amalgamation and Regeneration

Abstract This article discusses Israel Zangwill's play The Melting Pot (1908) and Horace M. Kallen's essay ‘Democracy versus the Melting Pot’ (1915) as two different visions of future Jewish inclusion. Zangwill's play and Kallen's response reflect social changes at the time, and both visions consider Jewish history exemplary for the world-to-come. Both show how conceptions of Jewishness were turned into universalist teleologies, but of different kinds. Zangwill's play opened in Washington at the height of immigration, urbanisation and social change, and it swiftly exemplified a vision of the American nation in the making, emphasising concepts of amalgamation more than old historical identities. In opposition, Kallen's response in 1915 emphasised historical identities and rejected the metal melting metaphors, replacing them with a Darwin-inspired spontaneous ‘symphony’. Zangwill and Kallen both imagined the future world as profoundly shaped by Jewishness, albeit with different consequences.

Quantification of evaporative loss of volatile metals from planetary cores and metal-rich planetesimals

The processes responsible for the isotopic compositions and abundances of volatile elements in the early solar system remain highly debated. Orders of magnitude variation of (highly) volatile elements exist between different magmatic iron meteorite groups, but it is unclear to what extent their depletions can be explained by evaporation from metal melts during parent body accretion and/or subsequent break up. To this end, we present 86 new evaporation experiments with the aim of constraining the volatility of most volatile metals from metallic melts. The results confirm the previously proposed important effects of S in metal melt on the volatility of the elements of interest governed by their S-loving or S-phobic behavior. Nominally S-loving elements In, Sn, Te, Pb and Bi are significantly more volatile in Fe melt relative to FeS liquid, whereas nominally S-avoiding elements Ga and Sb are more volatile in FeS liquid relative to Fe melt, at a given pressure and temperature. The newly derived volatility sequences for S-free/poor and S-rich metallic melts were also compared with commonly used volatility models based on condensation temperatures. The results indicate significant differences between the latter, including the much more volatile behavior of Te, relative to Se, in both explored bulk compositions, which are traditionally assumed to be equally volatile. The (minimum) degree of volatile element depletion due to evaporation was quantified using the new experimental results and models. A comparison between the volatile element depletions in magmatic iron meteorites and the predicted depletions appropriate for evaporation from Fe melts shows that the latter depletions can be easily reconciled with (an) evaporation event(s). Altogether, the new data and models will provide an important framework when more accurate and precise estimates of magmatic iron meteorite bulk volatile element contents are available.

Thermal properties and microstructure of Al–Sn alloys

The Al–Sn alloys feature excellent wear and corrosion resistance, along with good mechanical properties. They are mostly used as bearing materials. However, the application of these alloys as phase change materials (PCMs) for thermal energy storage (TES) has recently been suggested. To assess the adequacy of these alloys in a given area, a detailed evaluation of their thermal properties is required. In the present study, Al–Sn alloys with 11.7, 22.4, 32.8, 41.1, and 53.4 at.% Sn were produced by melting of pure metals. The melt was continuously stirred to avoid segregation, after which casting was carried out in a stainless steel mold. The obtained ingots had a homogeneous microstructure without the appearance of cracks and pores. The thermal diffusivities of the solid Al–Sn alloys in the temperature interval 25–150 °C were measured using the light flash method. The densities at room temperature were measured by the Archimedes method, and the specific heat capacities at different temperatures were calculated using the calculation of phase diagrams (CALPHAD) method. Then the thermal conductivities for studied Al–Sn alloys were obtained by the specific conversion equation. The phase transition temperatures and related heat effects were studied using differential scanning calorimetry (DSC). Variations of thermal conductivity with composition and temperature were determined as well as variation of latent heat of fusion with alloy composition. Moreover, the microstructures and phase compositions of the alloys were examined using scanning electron microscopy (SEM) combined with energy dispersive spectrometry (EDS). The present research results provide important information on the thermal properties and microstructure of the Al–Sn alloys for designing new PCM for thermal energy storage.

Spatial heterogeneity: Necessary and feasible for revealing soil trace elements pollution, sources, risks, and their links

The source diversity and health risk of trace elements (TEs) in soil make it necessary to reveal the relationship between pollution, source, and risk. However, neglect of spatial heterogeneity restricts the reliability of existing identification methods. In this study, spatial heterogeneity is proposed as a necessary and feasible factor for accurately dissecting the pollution-source-risk link of soil TEs. A comprehensive framework is developed by integrating positive matrix factorization, Geodetector, and risk evaluation tools, and successfully applied in a mining-intensive city in northern China. Overall, the TEs are derived from natural background (28.5 %), atmospheric deposition (25.6 %), coal mining (21.8 %), and metal industry (24.1 %). The formation mechanism of heterogeneity for high-variance TEs (Se, Hg, Cd) is first systematically deciphered by revealing the heterogeneous source-sink relationship. Specifically, Se is dominated (76.5 %) by heterogeneous coal mining (q=0.187), Hg is determined (92.6 %) by the heterogeneity of metal mining (q=0.183) and smelting (q=0.363), and Cd is caused (50.9 %) by heterogeneous atmospheric deposition (q>0.254) co-influenced by the terrains and soil properties. Highly heterogeneous sources are also noteworthy for their potential to pose extreme risks (THI=1.122) in local areas. This study highlights the necessity of integrating spatial heterogeneity in pollution and risk assessment of soil TEs.

The reduced alloy in Earth's upper mantle: Experimental constraints on Fe-Ni-S-C(-O) melt compositions and deep mantle oxygen fugacity (5–16 GPa)

High-pressure experiments conducted at upper mantle conditions reveal increased Fe3+ contents in majoritic garnet with increasing pressure. Consequently, at ∼8 GPa, Fe2+ disproportionation is expected to generate Fe0, leading to a higher metal/sulfur ratio of the initially present monosulfidic melt. This study experimentally investigates equilibrium systematics between the reduced Fe-Ni-S-C(-O) melt and mantle silicates at 5–16 GPa and near-adiabatic temperatures (1420–1590∘C), aiming to constrain the alloy melt composition in equilibrium with bulk silicate Earth-like (BSE) mantle silicates. As analysis of unquenchable liquid alloys requires large melt pools, experimental charges were designed towards a 50:50 ratio of alloy:silicates, with Fe/Ni ratios, sulfur and carbon scaled to correspond to a BSE with 200–250 ppm S and 100–150 ppm C.Observed phase assemblages consist of Fe-Ni-S-C(-O) melt (metal/(S+O): 0.9–3.5, Ni/(Fe+Ni): ∼0.3–0.6 and 0.2–1.6 wt.% oxygen) saturated with graphite/diamond and coexisting with olivine/wadsleyite (XMg: 0.76–0.91), garnet and cpx ± low-Ca pyroxene. Oxygen fugacities (fO2) range from -0.5 to +4.0 relative to the iron-wüstite (IW) buffer. In most runs, Fe0–Fe2+ redox equilibration affected silicate XMg's, resulting in values <0.90. Therefore, an empirical model was developed to predict KDNi-Fealloy-olivine, allowing to recalculate the experimental results for a primitive BSE mantle composition with XMg of 0.90.Modeling BSE, the alloy's metal/(S+O) increases from 1.1 to ∼7 while Ni/(Fe+Ni) decreases from 0.35 to 0.19 at 5–16 GPa. With BSE-like S concentrations, the abundance of the Fe-Ni-S-C(-O) melt increases from 600–750 ppm at 5 GPa to ∼3800 ppm at 16 GPa, 100–150 ppm bulk carbon lead to graphite/diamond saturation to ∼14 GPa. Finally, a method is presented to derive fO2 from modeled liquid alloy compositions, which act as a “redox-sensor”. For a BSE-like mantle with 250 ppm S, fO2 decreases from IW+2.6 at 5 GPa to IW at 8 GPa, further decreasing to IW-1.0 at 12–16 GPa.

Simultaneous utilization of copper and non-metals from waste integrated circuits for precious metal melting capture and organics thermal detoxification

Waste integrated circuits, with underlying resource attributes and environmental risks, are complex in composition. Current processes suffer from high resource inputs, excessive pollutant emissions and incomplete treatment of varied species. Therefore, a comprehensive resource recycling and safe disposal process integrated with precious metal enrichment, non-metal resource utilization, and organic detoxification was proposed. The copper and non-metals from waste ICs served as in-situ precious metal collector, slagging former and reducing agent for alternative to partial chemical inputs. Batch experiments indicated that optimized parameters enabled the recycling efficiencies of 94.3 %, 96.8 % and 98.4 % for copper, gold and silver, respectively. Meanwhile, oxide component, yielded as silicate slag, was synthesized into glass ceramics via high-temperature sintering. Furthermore, organic conversion process revealed that high-temperature smelting catalyzed bromine removal and contaminant detoxification, with decomposed reductive hydrocarbons facilitating metal capture in turn. And the capture mechanism was disclosed form thermodynamics and microdroplet motion perspectives. As process evaluation indicates, proposed recycling route allows remarkable reductions in negative environmental response and economic investment. In this work, metal recycling, waste minimization and pollutant detoxification were attained synergistically without residue, which contributes a novel insight into the disposal of comparable e-wastes.

New magnetic proxies to reveal source and bioavailability of heavy metals in contaminated soils

Environmental magnetism plays an important role in monitoring heavy metal pollution, but most studies are confined to indicating only the levels of heavy metals using magnetic parameters. This study established new magnetic proxies for accurately depicting the sources and bioavailability of heavy metals in contaminated soils. We observed different relationships between χ and SIRM in the soils contaminated by non-ferrous metal smelting compared to those polluted by coal combustion and steel smelting. Furthermore, we found that the soft magnetic components (IRMsoft) in the soils were mainly controlled by the non-ferrous metal smelting activities, while the hard magnetic components (HIRM) might be affected by the iron erosion. These new magnetic proxies enriched the source composition spectrum and improved the accuracy of the source apportionment analyses (principal component analysis and positive matrix factorization), yielding a result that was comparable to that by Pb isotope fingerprinting. We also found strong relationships between magnetic parameters (especially IRMsoft) and bioavailable fractions of heavy metals, indicating that magnetic measurement may be a powerful tool for monitoring the bioavailability of heavy metals. This study expands the application fields of magnetism in environmental science research.

Performance and mechanism of arsenic-metal separation in copper smelting flue gas regulated by chalcopyrite

To reduce the release of arsenic from non-ferrous metal (especially copper) smelting flue gases as well as to recover arsenic, the dry quenching process has been successfully applied to remove arsenic. However, the formation of arsenate hindered the separation of arsenic, thus reducing the collection efficiency. To tackle the bottleneck, the strategy of mineral phase regulation was proposed by the conversion from arsenate to sulfate, metal sulfate and gaseous arsenic were formed and separated each other. Chalcopyrite served as a potential sulfation regulator due to the gradual production of active sulfur (S2 dimer and S monomers) at high temperatures. At a chalcopyrite dosage of 60 %, the separation efficiency of arsenic from the metals reached 93.78 % and the residual arsenic content in the arsenic-copper particulate matter was decreased from 40.38 % to 3.12 % at 700 °C. The separation of arsenic and metal was attributed to the release of active sulfur from chalcopyrite, which enhanced the conversion of arsenate to sulfate. The separated arsenic enters the following section in the form of gaseous As2O3, which is beneficial to the dry quenching collection of arsenic. This provides theoretical and technical support for the clean production of nonferrous metal smelting and the control of arsenic pollution in flue gas.

Interaction of iron melt with tungsten and WFe composite structure evolution

Development of new plasma facing components (PFC) draw attention of numerous scientific groups in fusion energy field. Tungsten as a main PFC material main have poor machinability, thus various designs were proposed to overcome this problem. However, such technologies as functional graded layers, sintering and additive technologies are limited in production size and have low cost-efficiency. This research considers the alternative approach of steel melt injection or melt infiltration of tungsten mesh. The results obtained establish the mechanism of phase evolution during interaction of solid W with liquid steel and iron. Energy dispersive spectroscopy, X-ray diffraction and Thermocalc calculations used to analyze the phase composition of tungsten wetted with various steels and pure iron. Results show that interaction rate significantly depends on melt temperature and overheating above its liquidus. Then the overheating exceeds 150 °C erosion of tungsten occur.

Cadmium contamination in sediments from a mangrove wetland: Insights from lead isotopes

Cadmium (Cd) pollution has gained significant attention in mangrove sediments due to its high toxicity and mobility. However, the sources of Cd and the factors influencing its accumulation in these sediments have remained elusive. In this study, we utilized lead (Pb) isotopic signatures for the first time to assess Cd contamination in mangrove sediments from the northern region of the Beibu Gulf. A strong correlation was observed between Cd and Pb concentrations in the mangrove sediments, suggesting a shared source that can be estimated using Pb isotopic signatures. By employing a Bayesian mixing model, we determined that 70.1 ± 8.2 % of Cd originated from natural sources, while 12.9 ± 4.9 %, 9.8 ± 3.7 %, and 7.1 ± 3.4 % were attributed to agricultural activities, non-ferrous metal smelting, and coal combustion, respectively. Our study clearly suggests that natural Cd could also dominate the high Cd content. Agricultural activities were the most important anthropogenic Cd sources, and the increased anthropogenic Cd accumulation in mangrove sediment was related to organic matter. This study introduces a novel approach for assessing Cd contamination in mangrove sediment, providing useful insights into Cd pollution in coastal wetlands.

Microstructural and elemental analyses of slags excavated from the Gushishan iron‐smelting site, Sichuan Province, China

AbstractThe Shu Commandery was an important iron production center in southwest China during the Han Dynasty (202 BC‐AD 220). In 2007, archaeologists excavated a Han Dynasty smelting furnace (L1) at the Gushishan site and collected large amounts of smelting remains including slags, furnace bricks, and ores. Scientific analysis of the excavated slags was carried out to ascertain that the Gushishan site was a pig iron smelting site. No flux was used at the Gushishan site, and the site is dated no later than the Eastern Han period. No remains related to iron casting of the Han Dynasty was found at or near the iron smelting sites in southwest China, which indicates a separation between iron smelting and iron casting as characteristics of the industrial layout in this region.