Papers by Keyword: Metallurgy

Abstract: Manganese is a key transition metal essential to metallurgy, particularly for strengthening steel. Alloys of manganese including iron-manganese (Fe-Mn), manganese-aluminum (Mn-Al), manganese-titanium (Mn-Ti), and other multi-element systems are increasingly critical in biomedical, aerospace, energy, and marine industries. This review consolidates current knowledge, highlights research gaps, and charts future directions by examining Mn’s chemical and metallurgical properties, major alloy systems, mechanical and corrosion performance, and modern processing methods. In-depth case studies in automotive (TWIP steels), biomedical (biodegradable stents), and aerospace (high-entropy alloys) applications are presented to illustrate real-world performance. A comparative analysis of advanced manufacturing techniques, including Laser Powder Bed Fusion (L-PBF) and Directed Energy Deposition (DED), reveals the profound impact of processing on microstructure and properties. Drawing on over seventy recent studies, this work assesses how microstructure, phase transformations, and alloying behavior influence performance across structural, biodegradable, and functional applications. Despite notable progress, challenges persist in predicting corrosion, ensuring long-term biocompatibility, overcoming low-temperature brittleness, and mitigating the environmental impacts of manganese processing. A critical evaluation of the manganese lifecycle, from mining impacts to recycling challenges, underscores the need for sustainable practices. To address these challenges, we recommend advanced manufacturing for precise microstructural control, surface treatments to improve corrosion resistance, and computational modeling to predict performance. Future research should prioritize corrosion-resistant, biocompatible alloys, refine additive manufacturing for complex designs, gather long-term biocompatibility data, and improve recycling methods. Collaborative efforts integrating simulations, experimental validation, and sustainable practices will ultimately shape manganese’s role in future innovations.

Abstract: Nickel and cobalt recovered from ternary leaching solutions have high market value and stability. In addition to preventing environmental damage, this recovery process is also very useful in the application of power energy storage and electric vehicles. Solvent extraction is an effective and selective method for separating elements in ternary leaching solutions. This research focuses on the separation stage of feed solution impurities, especially Cu, by optimizing the extraction process using multi-stage extraction. This method, which is adapted to a laboratory scale, mixes the feed solution with saponified P204 (prepared with NaOH) and then stirred until phase separation into a loaded organic phase and raffinate occurs. The use of P204 with 3-stage extractions with O/A= 1.5/1 and pH= 4.5 succeeded in separating 99.96% extraction of Cu with a primary yield of Cu value of 99.999%. This solvent extraction also successfully separated 99.23% of Mn, Ca=95.62%, and other impurity metals such as Fe, Zn, Li, and Si reaching a final concentration in the raffinate solution of only 10^-3 g/L. The results of this research are very useful in the subsequent extraction process in the form of separating the valuable elements nickel and cobalt. This method can potentially overcome environmental problems resulting from the disposal of NCM battery waste in the metallurgical field.

Abstract: Corten steel is a type of weathering steel possessing high strength with low alloying elements content. The uniqueness of Corten steel lies in its excellent corrosion resistance to elements of nature, and having high strength to weight ratio among the carbon steels. The Corten steel is widely used in fabricating railway coaches, structures like bridges, etc. Even though the Corten steel is weldable, its inherent properties are lost during welding and other thermal processes. The behavior is due to the change in metallurgical and mechanical properties of Corten steel when undergoing processes exceeding the recrystallization temperature. Hence, necessitating the need for this research work. In this research work, the micro hardness, microstructure and grain size of Corten ASTM A242 Grade Steel was evaluated in as received normal condition and at recrystallization temperature. When the material is heated up to recrystallization temperature the formation of new grains is observed. Recrystallization had a positive impact on the microstructure and micro hardness of the Corten steel.

Abstract: Aluminium metal matrix composites (AMC) are perspective materials for a wide range of applications in automotive, aerospace and other industries where material mechanical properties and weight ratio is crucial. In AMC manufacturing through metallurgical process the main obstacle for particle introduction into the melt is poor particle wettability and their tendency to form agglomerates due to van der Waals and interfacial forces. Most of currently used AMC manufacturing methods through metallurgical route are effective only for small quantities or are time consuming, even though metallurgical AMC production route would promise significant cost savings. In this study we propose a permanent magnet stirring technology developed by IP UL as tool for alternative realization of stir- and compo-casting methods for AMC production. First results of contactless stirred semi-solid aluminium alloys show effective alloy stirring in melt volume and intense surface deformations that can break the oxide layer and stir in the reinforcement material from the melt surface.

Abstract: The article discusses the experience of recycling industrial waste from the electric power industry and metallurgy. Based on the experience of Ecostroy NII-PV LLP. The proposed technology for manufacturing building products from ash and slag waste provides innovative compositions of raw mixtures. What provides an increase in operational characteristics and labor productivity in construction. The applied technology, in comparison with the existing analogues, provides for the use of local waste (ash and slag waste from the combustion of Ekibastuz coal, bauxite sludge from the Pavlodar aluminum plant, steel-making slags), differing in chemical and granulometric composition. as well as binding properties from other analogs and prototypes. In the manufacture of building products introduced mixture, including, wt %: slag Portland cement - 14.32-17.00; sand - 18.74-25.52, crushed stone - 46.50-49.71, sludge from alumina production obtained during the recycling of bauxite from Kazakhstan - 5-7; self-disintegrating steelmaking slag - 5-7; ash and slag waste from thermal power plants from burning Ekibastuz coals - 5-7. According to the test results, the average tensile strength of building products (paving slabs, curbs, hollow bricks) is 3.2 - 3.8 MPa (strength class V2.5).

Abstract: The article presents a method for eliminating the crystallization of thermal nodes and shrinkage defects in the form of micro-friable cavities. The method of soldering on castings from steel grades VNL-1 and VNL-6 using 5VA powder solder has been investigated. Also, the optimal soldering modes were determined, the effects of soldering modes on the properties of the base material and the soldered joint were studied, the corrosion resistance was investigated, the corrosion resistance of the soldered joints in corrosive environments. The conducted studies of sealing by soldering cast parts with microdefects lead to the following results: increased corrosion resistance; ensuring increased tightness; improving the presentation; elimination of surface microdefects.

Abstract: One of steel 08H14N5M2DL scopes in the industry is an aircraft industry, to be exact, production of racks of the chassis for airplanes and helicopters which test cyclic types of loadings (take-off/landing). Despite the margin of safety which is put at the design of the aircraft, an important role plays, both quality of the material and its ability to save the mechanical properties during all assigned resource for the aircraft. Therefore the development of necessary conditions of production of steel under which the highest mechanical properties and also the ability to save them on the maximum period will be received becomes relevant and today. Work purpose: Identification and prevention of the most significant negative factors having an impact on mechanical properties of steel 08H14N5M2DL in the course of its receiving. In the work, 257 melting of steel of VNL-3 brand in the open IST-0.16 induction furnace with lining from a ground, magnesite brick is investigated. Methods of research are control of the content of austenite and existence of δ - ferrite in structure there were by measurement of values of a magnetic flux density cold and hot tests on the IFSS-1 device and also calculations of the number of products of wear, the solubility of nitrogen in steel VNL-3 and saturation nitrogen. It is revealed that negative impact on mechanical properties of VNL steel – 3 is rendered by nonmetallic inclusions, the maintenance of δ-ferrite and nitrogen. It is established that for stabilization of mechanical properties of steel, aging temperature after tempering in 500 °C allows to support and save steady indicators of mechanical properties. The fact that δ the ferrite exception of solid steel will allow reducing the oxygen content in it not less, than for 0.019% is confirmed owing to what iron crystallizes in γ-phase, passing δ-modification. The presented results confirm prospects of the developed approach in receiving the high-quality steel intended for use in the aviation industry.

Abstract: Analysis of forming chromium-bearing ferroalloys production waste in Russian Federation was performed. Chemical, phase, fractional compositions and physico-chemical, technological properties of high-carbon ferrochromium slag were defined. Physico-chemical, thermo-mechanical and thermo-physical properties of fire-resistant materials, obtained from ferrochromium production slag and dust, were researched. It was shown that researched waste may be utilized as raw for fire-resistant materials production. Because of their chemical and phase composition, researched materials may be utilized for production of forsterite-spinel-based and forsterite-spinel-periclase-based fire-resistant materials. Technological properties of researched materials allow obtaining dense strength fire-resistant materials. Such fire-resistant materials are promising in the field of ferrous metallurgy (lining up furnaces, ladles and overflow launders in ferroalloys production).

Abstract: Three tasks have been consistently solved in this paper. A thermodynamic analysis of the high-carbon ferromanganese smelting was carried out. The associated solutions theory was used to describe a thermodynamic activity of components in the metal and slag. Comparison of the calculated and technological data shows that the melting ends in conditions close to chemical equilibrium. The mineral phases in the slag, the relative amount and chemical composition of the phases are determined by X-ray diffraction analysis and X-ray spectral microanalysis. The method of converting the phase volume fraction to phase mass fraction (without using weight density) was suggested. It is established that there is no unambiguous relationship between the total content of MnO by chemical analysis and the MnO content in slag oxide phases. Also, there is no correspondence between the total content of MnO by chemical analysis and the amount of ferromanganese inclusions in the slag. A calculation-experimental method for description of manganese losses in the slag has been created. Correlation equations allow calculating the manganese distribution between the ferromanganese inclusions and slag phases by chemical analysis data only, without microscopic analysis of the structure.

Abstract: The increasing demand for lightweight materials capable to absorb impact energy has driven the growth of scientific research in the metallic foams field. This paper aims to investigate the possibility to obtain Al foams from recycled aluminium alloy through the sintering dissolution process (SDP) with sodium chloride (NaCl) as space holder. Aluminium scraps from AA 3104 alloy were powdered by high energy ball milling. Alloy powder was mixed with variable weight fraction of NaCl. The mixtures were die-pressed at room temperature and then sintered at 680°C. In the following step sintered parts were immersed in boiling water to obtain the aluminium foam. Foam microstructure was characterized by scanning electron microscopy and chemical composition was analyzed by energy dispersive spectroscopy. In addition, the residual NaCl was quantified and the foam density was determined by hydrostatic method. Best result was obtained with 60 wt% of NaCl, given a relative foam density of 30%, which in turn justifies further studies with metallic foams from aluminium scraps.