Ceramics composites from iron ore tailings and blast furnace slag

The search for materials and methods capable of reducing human impacts on the environment is of utmost importance nowadays. This study's primary purpose was to analyze the technical feasibility of ceramic composites production utilizing Fundão Dam's Iron Ore Tailings (IOT), Blast Furnace Slag (BFS) from charcoal, and Foundry Sand (FS) as partial substitutes for the traditional raw materials – sand and clay – for application in building industry materials. The composites were molded in rectangular specimens and fired at temperatures of 900, 950, 1000, 1050, and 1200 °C. The developed materials were analyzed and characterized by X-Ray Diffraction (XRD), Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), Thermogravimetry (TGA), and Differential Thermal Analysis (DTA). The obtained materials had flexural strength modulus of up to 12.19 MPa, water absorption ranging from 2 to 22%, linear shrinkage ranging from 0.02 to 6.50%, and apparent density ranging from 2.03 to 1.63 g/cm³. The study of the internal structure formation process revealed the formation of amorphous structures in the composites. The results demonstrated that these waste materials may be jointly used in construction materials, contributing to the reduction of natural resource extraction, besides enabling their correct disposal, minimizing environmental impacts, and improving the life quality of the surrounding communities.     

基于数值模拟的挤压参数对AZ91镁合金管转角焊合室分流挤压焊合压力的影响规律研究

提出了一种镁合金管材转角焊合室分流挤压新工艺，该工艺可在有效延长焊合室长度和焊合时间前提下保证舌针刚度，从而保证管材尺寸精度，并且可通过转角剪切变形机制增加预焊合金属变形量和动态再结晶程度，从而有利于提高管材性能和焊缝焊合性能。利用有限元法揭示了转角焊合室分流挤压成形过程中金属的流动特征，应变分布特征和焊合室内的静水压力分布特征。结果表明，整个挤压过程无金属折叠，从而保证管材的表面质量；流经转角后预焊合金属变形量明显增加，有利于提高管材质量和焊缝质量。最后，研究揭示了坯料初始温度，挤压速度和模具转角对焊合室内静水压力的影响规律。结果表明，随着挤压速度的增加和模具转角的增大，转角焊合室内静水压力增大；随着坯料预热温度的增加，转角焊合室内静水压力呈先增大后减小的趋势。     

Chromium-promoted preparation of forsterite refractory materials from ferronickel slag by microwave sintering

The chromium-promoted preparation of forsterite refractory materials from ferronickel slag was investigated by microwave sintering of the slag with the additions of sintered magnesia and 0–10 wt% chromium oxide (Cr₂O₃). The thermodynamic calculations revealed that the addition of Cr₂O₃ can promote the formations of spinel and liquid phase and maintain high content of forsterite below 1500 °C. The experimental results showed that there existed a stronger promoting effect of Cr₂O₃ additive on the properties of refractory materials in the microwave field than that in conventional sintering. It was attributed to the preferential formation and growth of spinel with stronger microwave absorption than other phases (e.g., enstatite), the existence of more forsterite, and the enhanced densification in association with the presence of more liquid phase at the same temperature. By microwave sintering of the mixture of ferronickel slag, 25 wt% sintered magnesia, and 4 wt% Cr₂O₃ at 1350 °C for 20 min, a superior refractory material with refractoriness of 1801 °C, thermal shock resistance of 6 times, bulk density of 2.97 g/cm³, apparent porosity of 1.4%, and compressive strength of 197 MPa was obtained. Compared with that prepared by conventional sintering at 1350 °C for 2 h, the refractoriness and thermal shock resistance were increased by 175 °C and 100%, respectively. The present study provided a novel method for preparing high-quality refractory materials from ferronickel slag and relevant industrial wastes.     

Fabrication and properties of the superhydrophobic ceria-based composite coating on magnesium alloy

A superhydrophobic ceria-based composite coating is developed to improve anticorrosion properties of AZ61 magnesium alloy, fabricating via chemical conversion method followed by hydrothermal treatment. The cerium conversion coating has a block structure with microcracks. After the hydrothermal treatment, a dense CeO₂ layer, porous CeO₂ nanorods, and stearic absorbing layers are grown stepwise on the conversion coating. And the composite coating is hydrophobic or even superhydrophobic and has almost no microcracks. As the hydrothermal reaction time increases, the water contact angle of the composite coating first increases and then decreases, and it reaches the maximum value of 152° after hydrothermal treatment for 4 h. Both the dense CeO₂ layer and the superhydrophobic stearic absorbing layer can effectively prevent the electrolyte from contacting the substrate; the corrosion current density of the superhydrophobic composite coating is lower than that of the hydrophilic composite coating and the cerium conversion coating, and has the best corrosion resistance.     

蒸压建材生产过程中钢渣安定性处理与活性化利用

钢渣安定性处理过程常常造成胶凝活性的损失。为此，本文利用改性助剂消除钢渣水化过程中产生的氢氧化物并生成胶凝产物，在蒸压建材的生产过程中实现钢渣安定性处理和游离氧化物的活性化利用，并避免单独处置钢渣造成的活性物质损失。研究表明，8%秸秆灰和3%磷酸二氢铵作为复合助剂制备的尾矿-钢渣蒸压试块体积稳定，抗压强度达24.0MPa。通过对蒸压样品游离氧化物消解率、化学结合水量及热重、XRD分析，得出钢渣安定性处理与活性化利用机制：硅质材料与钢渣中f-CaO水化生成的Ca(OH)₂结合迅速生成对体系力学强度有益的水化硅酸钙，避免因大量Ca(OH)₂积累造成体积膨胀；磷酸盐中的NH₄⁺、H₂PO₄^-与f-MgO结合生成磷酸铵镁及其他低溶度积复盐类矿物，进而消除因f-MgO水化生成Mg(OH)₂造成体积膨胀的隐患。试样在180℃蒸压4h后，f-CaO及f-MgO消解率分别可达86.28%、89.73%。本文将为利用钢渣大比例取代水泥和石灰生产蒸压建筑材料提供理论基础，对于提高钢渣利用率、减少碳排放具有重要价值。     

水氯镁石制备金属镁的过程集成与能量分析

以无水氯化镁和氧化镁作为中间产物，电解和热还原为两个关键方法，集成各种相关过程，构建了从水氯镁石到金属镁的综合过程网络，其中涉及24个物种、20个化学过程和25个工艺路线；建立了最低能耗分析模型用于简单和复合过程的能量分析；利用物质的标准生成焓和多温等压摩尔热容，计算得出全部反应过程及工艺过程的能量消耗和热量移除。结果表明基于还原法的最优路径是水氯镁石用石灰法转为氢氧化镁，进而煅烧成氧化镁，再铝热还原成金属镁，该过程能耗360.15 kJ/mol，放出热量–315.46 kJ/mol；基于电解法的最优路径是石灰乳法生成氢氧化镁，再煅烧成氧化镁，通过在熔融电解质中电解生成金属镁，该过程能耗738.54 kJ/mol，放出热量–135.42 kJ/mol。无水氯化镁制备耗能高，不在最优路径中。     

镁合金网格壁板压弯成形数值模拟及实验研究

为探索镁合金整体壁板压弯成形的可行性,以及镁合金壁板压弯成形过程中金属的流动规律,对AZ31镁合金网格壁板压弯成形进行了数值模拟和实验研究。建立了有限元数值模拟的几何模型,采用有限元计算软件对AZ31镁合金网格壁板压弯成形过程进行了数值模拟研究,分析了镁合金网格壁板压弯成形中的温度场、应变场、应力场、破坏系数等的分布规律。确定了合适的AZ31镁合金壁板压弯成形工艺参数,并对镁合金网格壁板压弯成形进行了实验研究,获得了合格的镁合金网格壁板弯曲件,并分析了镁合金网格壁板成形件尺寸精度,模拟结果与实验结果相吻合,最大相对误差为16.7%。     

直缝埋弧焊钢管焊缝点状缺陷原因分析及改进

为了解决壁厚23 mm直缝埋弧焊管出现的焊缝点状缺陷问题，通过超声波探伤和宏观金相检测对实际生产过程中出现的焊缝点状缺陷不合格试样进行了分析，对铣边坡口形状、焊接工艺参数、焊接材料、焊接设备及焊件清理等方面给出了相应的优化改进措施。现场应用效果表明:这些措施的实施有效控制了此类直缝埋弧焊管焊缝中的点状缺陷，保证了直缝埋弧焊管焊缝形貌及各项力学性能指标，提高了焊接质量。     

FCC废催化剂镁改性催化裂化性能再生研究

提出并证实了高的强酸性位可接近性导致FCC废催化剂失活的机制。基于所提出的失活机制，采用浸渍法对FCC废催化剂进行镁改性再生。对所制备的再生FCC废催化剂进行了表征并考察了其重油催化裂化性能。表征结果表明，与未改性的FCC废催化剂相比，再生FCC废催化剂表面酸强度被一定程度地削弱，而表面总酸量和结构性质参数未出现显著改变。重油催化裂化结果表明，得益于适宜的表面酸性，再生FCC废催化剂的催化裂化反应性能得到极大改善。与未改性的FCC废催化剂相比，再生FCC废催化剂的汽油产率显著增加了3.04个百分点，同时干气、液化气、焦炭和重油产率则分别下降了0.36、0.81、1.28和0.87个百分点，这使得所制备的再生FCC废催化剂可以代替部分新鲜FCC催化剂使用。最后，探讨了再生FCC废催化剂表面酸性改变机理。     

水电站大型竖井施工安全风险控制措施研究

竖井是大型水电工程中广泛采用的重要建筑物,但竖井的传统施工方法存在施工程序复杂、人工劳动强度大、施工效率不高等特点,同时还存在较大的安全风险。通过对杨房沟水电站大型竖井施工过程的研究,总结出精细化控制爆破、小溜渣井施工方式,同时也设计了一套用于运输的综合提升系统。采用上述创新方法不仅减少了繁琐的施工程序,降低了安全施工风险,而且大量采用机械化手段进一步提高了施工效率,确保了该工程竖井施工的安全风险可控。相关措施可为类似工程的竖井施工提供较好的借鉴作用。