High-temperature properties and microstructural stability of hot-work tool steels

Indexable insert tools for machining operations are in service exposed to high temperatures and cyclic mechanical loads. Secondary hardening steels such as hot-work steels are commonly used for tools subjected to thermal exposure. However, these steels, highly alloyed with strong carbide forming elements as Cr, V and Mo, are generally difficult to machine and machining represents a large fraction of the production cost of a tool. Thus, the present study concerns the development of a new steel with improved machinability and meeting the requirements for high-temperature properties.Softening resistance of the THG2000 and QRO90 tool steels, commonly used in hot-work applications, and a newly developed tool steel MCG2006 with lower alloying content of carbide forming elements, was investigated by tempering and isothermal fatigue testing. Mechanisms of high-temperature softening of the tested tool steels were discussed with respect to their microstructure and high-temperature mechanical properties. Carbide morphology and precipitation as well as dislocation structure were determined using transmission electron microscopy and X-ray line broadening analysis.No difference in softening behaviour was found among the QRO90 and MCG2006 regarding hot hardness measurements. The THG2000 indicated some stabilization of the hardness between 450 and 550 °C and a considerable hardness decrease at higher temperatures.The short-time cyclic softening in isothermal fatigue was controlled by dislocation rearrangement and annihilation. The alloying composition of the steels presently tested had no influence on the dislocation density decrease.The long-time softening was affected by the material's temper resistance and strongly depended on the carbide morphology and their over-ageing resistance. The QRO90 with greater molybdenum and lower chromium contents than in the THG2000 show the best resistance to softening among the tested grades at all temperatures. The MCG2006, leaner alloyed with the carbide forming elements and alloyed with 4 wt% nickel, has better temper resistance than THG2000 at higher temperatures and longer tempering times.     

Removal of chloride from electric arc furnace dust

Electric arc furnace (EAF) dust with high chloride content increases the threat of dioxin emissions and the high chloride content reduces the value of recycled zinc oxide produced by EAF dust recycling plants. This study conducts a number of laboratory experiments to determine the technical feasibility of a new dechlorination method. These methods consist of a series of roasting processes and water washing processes. In the roasting process, EAF dust was heated in a tube furnace to evaluate the parameters of atmospheric conditions, roasting temperature, and roasting time. Results indicate that sulfation roasting is more efficient in reducing chloride content than other roasting processes. The water washing process can totally remove water-soluble chloride at a solid to liquid ratio of 1:10. However, the remaining water-insoluble substance is difficult to dechlorinate. For example, lead chloride forms a hydroxyl-halide (PbOHCl) and lead chloride carbonate (Pb(2)CO(3)Cl(2)) agglutinative matrix that is hard to wash away.     

Integrated hydrometallurgical process for production of zinc from electric arc furnace dust in alkaline medium

In this study, a novel and integrated hydrometallurgical process for the production of zinc powder from electric arc furnace (EAF) dust in alkaline medium is reported. The dust is firstly hydrolysed in water, and then fused in caustic soda at 350°C for 1 h, followed by leaching in alkaline solution in which both zinc and lead are effectively extracted. Zinc powder is then produced by electrowinning from the leach solution after the lead is selectively removed by precipitation using sodium sulphide as precipitant. The EAF dust tested contained 25% Zn, 1.8% Pb and 33% Fe. It was found that 38% of zinc and 68% of lead could be extracted from the dust when leached directly in caustic soda solution. Leaching of zinc increased to 80% when dust was directly fused with caustic soda followed by alkaline leaching. However, the leaching further increased to 95% when the dust was hydrolysed first with water before fusion. Zinc powder with a purity of 99.95% was then produced by electrowinning from the lead depleted solution. Stainless electrodes were used as both anode and cathode.     

NO x emission from electric arc furnace in steel industry: contribution from electric arc and co-combustion reactions

Off-gas measurements were conducted at industrial electric arc furnaces (EAF) in Germany in order to investigate the interrelation of NO _x emission with installed plant equipment (e.g. gas burner) and process data (e.g. carbon input). Off-gas data monitor rapid changes in off-gas composition, temperature, and volume flow rates of air into the furnace indicating the transient state batch process of scrap melting. From the measurements two distinct sources of NO _x emission are clearly distinguished: (1) NO _x formation in the electric arc plasma during the start-up period of the melting process in an oxidizing furnace atmosphere after the charging of the furnace. (2) NO _x formation from post-combustion of CO/CO₂/H₂ gas with air inside and outside the furnace. Whereas the contribution from arc ignition is similar for different types of EAFs, other contributions depend on furnace equipment and operation, e.g. gas burners, use of air as carrier medium for carbon or dust injection, air-tightness of furnace, and parameters of off-gas extraction by EAF dedusting system. The positive effect of the minimum volume flow rate of air into the furnace by controlled off-gas extraction to total NO _x emission is shown.     

Minimizing the three-phase unbalance in an electric arc furnace

A method is proposed to reduce impedance imbalance in the electrode arms of an arc furnace. Conducting plates or tubes are used to shield the magnetic fields around busbars in order to minimize the mutual inductance. The volume integral equation method is used to calculate bus impedances, current distribution, and eddy current losses. The numerical results indicate a significant improvement in system balance even during bus movement. Two types of shields are investigated. Shielding the center phase by using a large tube reduces the unbalance at the coplanar bus positions, but it has little effect when one bus is offset. Shielding by two conducting plates standing between buses yields good balance and constant reactance for all bus positions. The power loss in the shields is only a small percentage of the bus loss, the shields can be replaced by parallel conducting bars bounded at ends. By combining the new method with a smaller center bus diameter, better results have been achieved     

Influence of nickel content on machinability of a hot-work tool steel in prehardened condition

In the present study, the influence of nickel content on the machinability of a prehardened hot-work tool steel was investigated. The machinability with varying nickel content from 1 to 5 wt.% was characterized in end milling and drilling by evaluating tool life, cutting forces, and tool/chip interface temperature.     

Microstructure evolution of hot-work tool steels during tempering and definition of a kinetic law based on hardness measurements

Microstructural evolutions of the 55NiCrMoV7 steel during tempering were investigated by transmission electron microscopy, scanning electron microscopy and X-ray diffraction in order to describe the main mechanisms of softening. The softening resistance is strongly associated with evolution of obstacles to the movement of dislocations (prior austenitic grain boundary, lath boundary, secondary carbides, etc.). Only the average size of carbides was found to be influenced by tempering conditions. Moreover, a strong correlation observed between the hardness measured after tempering and the average size of carbides showing that this easy test could in this case partially characterize the state of the microstructure after tempering. Performing hardness measurements at the as-quenched, tempered and annealed states, a kinetic law of tempering based on the work of Johnson, Mehl and Avrami has been proposed. This law was validated in the case of complex tempering and for other steels and can well describe the evolution of hardness during tempering.     

Solidification/stabilization of electric arc furnace dust using coal fly ash. Analysis of the stabilization process

In this paper, the stabilization of electric arc furnace (EAF) dust containing hazardous metals such as Pb, Cd, Cr or Zn is described. The treatment involves a waste solidification/stabilization (S/S) process, using coal fly ash as the fundamental raw material and main binder. The article also contains a brief review of the most important recent publications related to the use of fly ash as S/S agents.The efficacy of the process has been evaluated mainly through leaching tests on the solidified products and compliance with some imposed leachate limits. The concentration of metals leaching from the S/S products was strongly leachate pH dependent; thus, the final pH of the leachate is the most important variable in reaching the limits and, therefore, in meeting the stabilization goals.In this study, the dependence relationship between the leachate pH and the concentrations of metals in the leachate are analyzed; in some cases, this allows us to estimate the speciation of contaminants in the S/S solids and to understand the mechanism responsible for reduced leachability of heavy metals from solidified wastes.     

Characterization and leachability of electric arc furnace dust made from remelting of stainless steel

Electric arc furnace dust (EAFD) is a toxic waste product made in the remelting of scrap steel. The results of a Toxicity Characteristic Leaching Procedure (TCLP) conducted on a sample of EAFD originating from the remelting of stainless steel scrap showed that the total Cr and Cr (VI) liquor concentrations (9.7 and 6.1 mg/L, respectively) exceeded the Toxicity Characteristic Regulatory Level (TCRL). The EAFD showed a complex heterogeneous mineralogy with spinel minerals group predominance. A sequential extractions method has permitted the determination of the amount of available metals (potentially mobile component) from the EAFD as follows: Cr (3%), Ni (6%), Pb (49%) and Zn (40%). Solubility controls on Cr, Pb, Zn and Ni were identified in the EAFD. This means that the Cr, Pb, Zn and Ni concentrations in solution were controlled by the solubility of some phases from EAFD. The concentrations of Ni and Zn, which are metals not regulated by TCRL were below 0.41 and 1.3 mg/L, respectively. The solubility control on Pb was sufficient to decrease its concentration (<0.24 mg/L) to a level below the TCRL. However, the control on Cr was not sufficient to decrease its concentration (between 117 and 331 mg/L) to below the TCRL.     

Modeling of zinc solubility in stabilized/solidified electric arc furnace dust

Equilibrium models which attempt for the influence of pH on the solubility of metals can improve the dynamic leaching models developed to describe the long-term behavior of waste-derived forms. In addition, such models can be used to predict the concentration of metals in equilibrium leaching tests at a given pH. The aim of this work is to model the equilibrium concentration of Zn from untreated and stabilized/solidified (S/S) electric arc furnace dust (EAFD) using experimental data obtained from a pH-dependence leaching test (acid neutralization capacity, ANC). EAFD is a hazardous waste generated in electric arc furnace steel factories; it contains significant amounts of heavy metals such as Zn, Pb, Cr or Cd. EAFD from a local factory was characterized by X-ray fluorescence (XRF), acid digestion and X-ray diffraction (XRD). Zn and Fe were the main components while the XRD analysis revealed that zincite, zinc ferrite and hematite were the main crystalline phases. Different cement/EAFD formulations ranging from 7 to 20% dry weight of cement were prepared and subjected to the ANC leaching test. An amphoteric behavior of Zn was found from the pH dependence test. To model this behavior, the geochemical model Visual MINTEQ (VMINTEQ) was used. In addition to the geochemical model, an empirical model based on the dissolution of Zn in the acidic zone and the re-dissolution of zinc compounds in the alkaline zone was considered showing a similar prediction than that obtained with VMINTEQ. This empirical model seems to be more appropriate when the metal speciation is unknown, or when if known, the theoretical solid phases included in the database of VMINTEQ do not allow to describe the experimental data.     

Modeling of zinc solubility in stabilized/solidified electric arc furnace dust

The bacteria that could grow on media containing olive mill wastewater (OMW) were isolated and their lipase production capacities were investigated. The strain possessing the highest lipase activity among 17 strains grown on tributyrin agar medium was identified as Bacillus sp. The effect of initial pH on the lipase activity was investigated in tributyrin medium and pH 6 was found to be the optimal. The liquid medium composition was improved by replacing tributyrin with various carbon sources. Among the media containing different compositions of triolein, trimyristin, trilaurin, tricaprin, tricaprylin, tributyrin, triacetin, Tween 80, OMW, glucose, and whey; the medium contained 20% whey +1% triolein was found to give the highest lipase activity. Cultivation of Bacillus sp. in the optimal medium at pH 6 and 30 degrees C for 64h resulted in the extracellular and intracellular lipase activities of 15 and 168U/ml, respectively.     

影响真空自耗电极电弧炉电弧稳定性的因素及对策

本文总结了影响真空自耗电极电弧炉电弧稳定的多种因素。通过理论分析，总结出在设计和控制方面采取的应对方案和方法。     

Utilization of electric arc furnace dust as a solid catalyst in biodiesel production

Clean Technologies and Environmental Policy - World’s energy sources like petrochemical oils, natural gas and coal cause global warming and environmental pollution. Therefore, the traditional...     

Chemical, physical, structural and morphological characterization of the electric arc furnace dust

Electric arc furnace dust (EAFD) is a hazardous industrial waste generated in the collection of particulate material during steelmaking process via electric arc furnace. Important elements to the industry such as, Fe and Zn are the main ones in EAFD. Due to their presence, it becomes very important to know how these elements are combined before studying new technologies for its processing. The aim of this work was to carry out a chemical, physical, structural and morphological characterization of the EAFD. The investigation was carried out by using granulometry analysis, chemical analysis, scanning electron microscopy (SEM), energy dispersive spectroscopy via SEM (EDS), X-ray mapping analysis via SEM, X-ray diffraction (XRD) and Mössbauer spectroscopy. By XRD the following phases were detected: ZnFe₂O₄, Fe₃O₄, MgFe₂O₄, FeCr₂O ₄, Ca_0.15Fe_2.85O₄, MgO, Mn₃O₄, SiO₂ and ZnO. On the other hand, the phases detected by Mössbauer spectroscopy were: ZnFe₂O₄, Fe₃O₄, Ca_0.15Fe_2.85O₄ and FeCr₂O₄. Magnesium ferrite (MgFe₂O₄), observed in the XRD pattern as overlapped peaks, was not identified in the Mössbauer spectroscopy analysis.     

The influence of heat treatment and resulting microstructures on the thermophysical properties of martensitic steels

This research study investigates the influence of heat treatment on the thermal conductivities of three different tool steels at room temperature. The results reveal not only that tempering plays a decisive role in their thermophysical properties, but also that the changes in thermal conductivity due to heat treatment are dependent on the degree of alloying. Isobaric heat capacities c _p are found to be less dependent on heat treatment than thermal diffusivities a. The results are discussed with respect to the resulting microstructures and, for high-tempered conditions, under consideration of Calphad calculations. The results are relevant for the thermal design of tools, in particular, for tailored tempering of tools used for press hardening.