Interfacial Phenomena between Liquid Si-rich Si-Zr Alloys and Glassy Carbon

To succeed in the design and optimization of liquid-assisted processes such as reactive infiltration for the fabrication of tailored refractory SiC/ZrSi2 composites, the interfacial phenomena that occur when Si-rich Si-Zr alloys are in contact with glassy carbon (GC) were investigated for the first time by the sessile drop method at T = 1450 °C. Specifically, two different Si-rich Si-Zr alloys were selected, and the obtained results in terms of wettability, spreading kinetics, reactivity, and developed interface microstructures were compared with experimental observations that were previously obtained for the liquid Si-rich, Si-Zr, near-eutectic composition (i.e., Si-10 at.%Zr) that was processed under the same operating conditions. The increase of the Si content only weakly affected the overall phenomena that were observed at the interface. From the practical point of view, this means that even Si-Zr alloys with a higher Si content, with respect to the near eutectic alloy, may be potentially used as infiltrant materials.The work performed at CNR-ICMATE was supported by National Science Center of Poland through POLONEZ project number UMO-2016/23/P/ST8/01916. This project is carried out under POLONEZ-3 program which has received funding from European Union’s Horizon 2020 research and innovation program under Marie Skłodowska-Curie grant agreement. No 665778. The work performed by JN was funded by the Spanish “Ministerio de Economía y Competitividad” (Grant MAT2017-86992-R) and action Mobility of Alicante University

Improvements in experimental investigation of molten Mg-based materials

In this paper, the experimental performance of a new testing device designed for investigating the high temperature properties of molten Mg is presented. The newly developed device allows examining high temperature wetting behavior and thermophysical properties of molten Mg (and Mg alloys) by using various experimental procedures (e.g. classical sessile drop, pendant drop, dispensed drop and drop sucking). High temperature wettability tests at temperatures up to 1000 °C in an inert gas atmosphere or under high vacuum (up to 10−7 hPa) are now possible. It has been documented that the application of the classical sessile drop method combined with a capillary purification procedure successfully eliminates the problem of magnesium oxidation that traditionally affects obtained results. Selected examples of high temperature experiments carried out for molten Mg in contact with various refractories are presented in order to show a wide range of analytical possibilities of the new device. The results obtained by using the new device are important from both a high theoretical and practical perspective regarding liquid phase assisted fabrication and processing of Mg-based alloys and metal-matrix composites. Keywords: Equipment design, Sessile drop method, Reactivity, Mg composites, Mg alloy

Improved methodological concepts for processing liquid Mg at high temperature

Abstract In this paper, new improvements of methodological concepts upon examining wettability of high vapor pressure liquid metal systems (e.g. Mg-based alloys) in contact with refractory materials, are presented and discussed. In this regard, high-temperature experiments on molten magnesium (Mg) in contact with graphite as a refractory substrate, were performed by utilizing a newly developed testing device and by applying a suitable experimental procedure. The wetting experiments were carried out by the sessile drop method and under identical testing conditions (700 °C/10 min under a protective gas atmosphere). Two different procedures were applied: the classical contact heating (CH) or a newly introduced capillary purification (CP) one. The contact angle behaviors observed under the same conditions were strongly influenced by the applied procedure. Specifically, in the case of using the CH procedure, a presence of native surface oxide layer on the metal surface hinders the observations of melting process, making not possible to experimentally determine the wetting kinetics curve θ=f(t). Contrarily, during the wetting test performed on the Mg/graphite couple by applying the CP procedure, the native surface oxide layer was mechanically removed during the squeezing of the molten Mg through the hole of a capillary. Indeed, an oxide-free squeezed Mg-drop with regular and spherical shape was successfully obtained and dispensed on the graphite substrate. Consequently, the reliable contact angle value around θ=150° for the Mg/graphite system, was measured within the wetting test

The Effect of Boron Content on Wetting Kinetics in Si-B Alloy/h-BN System

In this work, the effect of boron content on the high-temperature wetting behavior in the Si-B alloy/h-BN systems was experimentally examined. For this reason, hypoeutectic, eutectic and hypereutectic Si-B alloys (Si-1B, Si-3.2B and Si-5.7B wt.%, respectively) were produced by electric arc melting method and then subjected to sessile drop/contact heating experiments with polycrystalline h-BN substrates, at temperatures up to 1750 °C. Similar to pure Si/h-BN system, wetting kinetics curves calculated on a basis of in situ recorded drop/substrate images point toward non-wetting behavior of all selected Si-B alloy/h-BN couples. The highest contact angle values of ~ 150° were obtained for hypoeutectic and eutectic Si-B alloys in the whole examined temperature range. © 2018, The Author(s)

Manganese and Aluminium Recovery from Ferromanganese Slag and Al White Dross by a High Temperature Smelting-Reduction Process

The recovery of Mn and Al from two industrial waste of ferromanganese and aluminum production processes was investigated via implementing a high temperature smelting—aluminothermic reduction process. The experiments were carried out with or without CaO flux addition, and two dross qualities. It was observed that the prepared mixtures of the materials yield homogeneous metal and slag products in terms of chemical composition and the distribution of phases. However, the separation of produced metal phase from the slag at elevated temperatures occurs when a higher amount of CaO is added. Viscosity calculations and equilibrium study indicated that the better metal and slag separation is obtained when the produced slag has lower viscosity and lower liquidus. It was found that the process yields Al-Mn-Si alloys, and it is accompanied with complete recovery of Mn, Si and Fe and the unreacted Al in the process. Moreover, the quality of metal product was less dependent on the slightly different dross quality, and the concentration of minor Ca in metal is slightly increased with significant increase of CaO in the slag phase

Aluminothermic reduction of manganese oxide from selected mno-containing slags

The aluminothermic reduction process of manganese oxide from different slags by aluminum was investigated using pure Al and two types of industrial Al dross. Two types of MnO-containing slags were used: a synthetic highly pure CaO-MnO slag and an industrial high carbon ferromanganese slag. Mixtures of Al and slag with more Al than the stoichiometry were heated and interacted in an induction furnace up to 1873 K, yielding molten metal and slag products. The characterization of the produced metal and slag phases indicated that the complete reduction of MnO occurs via the aluminothermic process. Moreover, as the Al content in the charge was high, it also completely reduced SiO2 in the industrial ferromanganese slag. A small mass transport of Ca and Mg into the metal phase was also observed, which was shown to be affected by the slag chemistry. The obtained results indicated that the valorization of both Al dross and FeMn slag in a single process for the production of Mn, Mn-Al, and Mn-Al-Si alloys is possible. Moreover, the energy balance for the process indicated that the energy consumption of the process to produce Mn-Al alloys via the proposed process is insignificant due to the highly exothermic reactions at high temperatures

Valorization of aluminum dross with copper via high temperature melting to produce al-cu alloys

The valorization of aluminum dross for Al recovery was performed via its mixing with metallic copper to produce Al-Cu alloys. This approach was with the intention of establishing a new smelting process to treat the dross with Cu scrap use. To evaluate the high temperature interaction of the materials, the wettability of a Cu-containing aluminum alloy with the non-metallic components of the dross was studied by the sessile drop method. It was found that the wetting was weak via temperature changes at 973–1373 K, and consequently no proper metal separation occurred. To better separate the metallic and non-metallic phases with larger density differences, a higher Cu portion was considered to obtain a significantly denser metallic phase, and it was found that partial separation of the Al in an Al-Cu alloy is possible. The complete separation of the metallic components of the dross was, however, experienced by the dross and copper melting with the addition of pre-melted calcium aluminate slags at elevated temperatures. It was found that Al-Cu alloys were produced and separated from the adjacent slags, and the aluminum oxide of the dross ended up in the slag phase. Moreover, the characteristics of the produced slags depend on the process charge

Aluminothermic Reduction of Manganese Oxide from Selected MnO-Containing Slags

The aluminothermic reduction process of manganese oxide from different slags by aluminum was investigated using pure Al and two types of industrial Al dross. Two types of MnO-containing slags were used: a synthetic highly pure CaO-MnO slag and an industrial high carbon ferromanganese slag. Mixtures of Al and slag with more Al than the stoichiometry were heated and interacted in an induction furnace up to 1873 K, yielding molten metal and slag products. The characterization of the produced metal and slag phases indicated that the complete reduction of MnO occurs via the aluminothermic process. Moreover, as the Al content in the charge was high, it also completely reduced SiO2 in the industrial ferromanganese slag. A small mass transport of Ca and Mg into the metal phase was also observed, which was shown to be affected by the slag chemistry. The obtained results indicated that the valorization of both Al dross and FeMn slag in a single process for the production of Mn, Mn-Al, and Mn-Al-Si alloys is possible. Moreover, the energy balance for the process indicated that the energy consumption of the process to produce Mn-Al alloys via the proposed process is insignificant due to the highly exothermic reactions at high temperatures

Aluminum Recovery from White Aluminum Dross by a Mechanically Activated Phase Separation and Remelting Process

The aluminum recovery from white aluminum dross by a mechanical treatment and sizing followed by remelting process was investigated. The dross was subjected to a ball mill, and the obtained particles were sized in different ranges. They were studied by advanced materials characterization techniques. It was found that the larger particles contain high metallic portions, and most non-metallic components of the dross are in the fine fraction 1 mm) were remelted at 900°C to recover aluminum. It was found that the metal structure after remelting is homogeneous and consisted of a dominant metallic aluminum matrix, containing an average of > 96% Al with around 99% total metallic components. The results show that the applied method is a good economic alternative for the aluminum recovery from white dross, which is important for the valorization/recycling of industrial waste and circular economy

Investigation of Two Immiscible Liquids Wetting at Elevated Temperature: Interaction Between Liquid FeMn Alloy and Liquid Slag

The goal of the current work is to develop a methodology to study the wetting behaviour of two immiscible liquids at high temperatures, and to investigate the parameters which influence the wetting properties. The wetting behaviour between synthetic FeMn alloy and synthetic slag has been investigated using the sessile drop technique. Two experimental procedures were implemented under both Ar and CO atmospheres: (a) FeMn alloy and slag placed next to each other on a graphite substrate; and (b) one droplet dropped on top of the other. FactSage is applied to calculate reactions and their equilibrium. The current work presents and demonstrates the suggested methodologies. The results indicate that the wetting between slag and FeMn alloy is relatively stable at temperatures up to 100 K above their melting points, regardless of the droplet size and atmosphere. MnO reduction is accelerated at higher temperature, especially in CO, thus increasing the wetting between FeMn alloy and slag, eventually fusing together. At even higher temperature, slag separates from FeMn alloy due to changing chemical composition during non-equilibrium MnO reduction.publishedVersio