Separation of Fine Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Inclusion from Liquid Steel with Super Gravity

An innovative approach of super gravity was proposed to separate fine Al₂O₃ inclusions from liquid steel in this study. To investigate the removal behaviors of inclusions, the effects of different gravity coefficients and time on separating the inclusions were studied. The results show that a large amount of Al₂O₃ inclusions gathered at the top of the sample obtained by super gravity, whereas there were almost no inclusions appearing at the bottom. The volume fraction and number density of inclusions presented a gradient distribution along the direction of the super gravity, which became steeper with increasing gravity coefficient and separating time. As a result of the collision between inclusions, a large amount of inclusions aggregated and grew during the moving process, which further decreased the removal time. The experimental required removal time of inclusions is close to the theoretical values calculated by Stokes law under gravity coefficient G ≤ 80, t ≤ 15 minutes, and the small deviation may be because the inclusion particles are not truly spherical. Under the condition of gravity coefficient G = 80, t = 15 minutes, the total oxygen content at the bottom of the sample (position of 5 cm) is only 8.4 ppm, and the removal rate is up to 95.6 pct compared with that under normal gravity.     

Wear of Plasma Sprayed Conventional and Nanostructured Al<Subscript>2</Subscript>O<Subscript>3</Subscript> and Cr<Subscript>2</Subscript>O<Subscript>3</Subscript>, Based Coatings

An ever increasing demand for high-performance ceramic coatings has made it inevitable for developing techniques with precise control over the process parameters to enable the fabrication of coatings with the desired microstructure and improved structural properties. The literature on plasma sprayed nanostructured ceramic coatings such as of Al₂O₃, Cr₂O₃, and their composites obtained using reconstituted nano sized ceramic powders has been reviewed in this study. Ceramic coatings due to their enhanced properties are on the verge of replacing conventional ceramic coatings used for various applications like automotive systems, boiler components, power generation equipment, chemical process equipment, aircraft engines, pulp and paper processing equipment, land-based and marine engine components, turbine blades etc. In such cases, the advantage is greater longevity and reliability for realizing the improved performance of ceramic coatings. It has been observed that the plasma sprayed nanostructured ceramic coatings show improvement in resistance to wear, erosion, corrosion, and mechanical properties as compared to their conventional counterparts. This article reviews various aspects concerning the plasma sprayed ceramic coatings such as (i) the present understanding of formation of plasma-spray coatings and factors affecting them, (ii) wear performance of nanostructured Al₂O₃, Cr₂O₃ and their composite ceramic coatings in comparison to their conventional counterparts, and (iii) mechanisms of wear observed for these coatings under various conditions of testing.     

Effect of Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Concentration on Density and Structure of (CaO-SiO<Subscript>2</Subscript>)-xAl<Subscript>2</Subscript>O<Subscript>3</Subscript> Slag

The effect of Al₂O₃ concentration on the density and structure of CaO-SiO₂-Al₂O₃ slag was investigated at multiple Al₂O₃ mole percentages and at a fixed CaO/SiO₂ ratio of 1. The experiments were conducted in the temperature range of 2154 K to 2423 K (1881 °C to 2150 °C) using the aerodynamic levitation technique. In order to understand the relationship between density and structure, structural analysis of the silicate melts was carried out using Raman spectroscopy. The density of each slag sample investigated in this study decreased linearly with increasing temperature. When the Al₂O₃ content was less than 15 mole pct, density decreased with increasing Al₂O₃ content due to the coupling of Si (Al), whereas above 20 mole pct density of the slag increased due to the role of Al³⁺ ion as a network modifier.     

Oxidation of Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Scale-Forming MAX Phases in Turbine Environments

High temperature oxidation of alumina-forming MAX phases, Ti₂AlC and Cr₂AlC, were examined under turbine engine environments and coating configurations. Thermogravimetric furnace tests of Ti₂AlC showed a rapid initial transient due to non-protective TiO₂ growth. Subsequent well-behaved cubic kinetics for alumina scale growth were shown from 1273 K to 1673 K (1000 °C to 1400 °C). These possessed an activation energy of 335 kJ/mol, consistent with estimates of grain boundary diffusivity of oxygen (~375 kJ/mol). The durability of Ti₂AlC under combustion conditions was demonstrated by high pressure burner rig testing at 1373 K to 1573 K (1100 °C to 1300 °C). Here good stability and cubic kinetics also applied, but produced lower weight gains due to volatile TiO(OH)₂ formation in water vapor combustion gas. Excellent thermal stability was also shown for yttria-stabilized zirconia thermal barrier coatings deposited on Ti₂AlC substrates in 2500-hour furnace tests at 1373 K to 1573 K (1100 °C to 1300 °C). These sustained a record 35 µm of scale as compared to 7 μm observed at failure for typical superalloy systems. In contrast, scale and TBC spallation became prevalent on Cr₂AlC substrates above 1423 K (1150 °C). Cr₂AlC diffusion couples with superalloys exhibited good long-term mechanical/oxidative stability at 1073 K (800 °C), as would be needed for corrosion-resistant coatings. However, diffusion zones containing a NiAl-Cr₇C₃ matrix with MC and M₃B₂ particulates were commonly formed and became extensive at 1423 K (1150 °C).     

A reinvestigation of phase equilibria in the system Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-SiO<Subscript>2</Subscript>-ZnO

The phase equilibria and liquidus temperatures in the binary SiO₂-ZnO system and in the ternary Al₂O₃-SiO₂-ZnO system at low Al₂O₃ concentrations have been experimentally determined using the equilibration and quenching technique followed by electron probe X-ray microanalysis. In the SiO₂-ZnO system, two binary eutectics involving the congruently melting willemite (Zn₂SiO₄) were found at 1448±5 °C and 0.52±0.01 mole fraction ZnO and at 1502±5 °C and 0.71±0.01 mole fraction ZnO, respectively. The two ternary eutectics involving willemite previously reported in the Al₂O₃-SiO₂-ZnO system were found to be at 1315±5 °C and 1425±25 °C, respectively. The compositions of the eutectics are 0.07, 0.52, and 0.41 and 0.05, 0.28, and 0.67 mole fraction Al₂O₃, SiO₂, and ZnO, respectively. The results of the present investigation are significantly different from the results of previous studies.     

Phase-equilibrium data and liquidus for the system “MnO”-CaO-Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-SiO<Subscript>2</Subscript> at Al<Subscript>2</Subscript>O<Subscript>3</Subscript>/SiO<Subscript>2</Subscript> of 0.55 and 0.65

Phase-equilibrium data and liquidus isotherms for the system “MnO”-CaO-(Al₂O₃+SiO₂) at silicomanganese alloy saturation have been determined in the temperature range of 1373 to 1723 K. The results are presented in the form of the pseudoternary sections “MnO”-CaO-(Al₂O₃+SiO₂) with Al₂O₃/SiO₂ weight ratios of 0.55 and 0.65. The primary-phase fields have been identified in this range of conditions.     

Phase composition and some properties of titanium carbonitride-titanium nickelide alloys with Al<Subscript>2</Subscript>O<Subscript>3</Subscript> nanoparticles

The phase formation in and the microstructure of titanium carbonitride-titanium nickelide alloys with aluminum oxide Al₂O₃ nanopowder additions are studied by X-ray diffraction, electron-microscopic, and electron-probe microanalyses. The phase interaction is characterized by the redistribution of nonmetallic elements and aluminum between refractory and binding phases with the formation of a nonstoichiometric titanium-aluminum (Ti,Al)(C,N) carbonitride and a titanium-aluminum nickelide. The number of forming phases and their compositions are controlled by the kinetic parameters of the process.     

Effect of Ce<Subscript>2</Subscript>O<Subscript>3</Subscript> on Structure,Viscosity, and Crystalline Phase of CaO-Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-Li<Subscript>2</Subscript>O-Ce<Subscript>2</Subscript>O<Subscript>3</Subscript> Slags

Aiming at devising new mold flux for Ce-bearing stainless steel, a fundamental investigation on the effect of Ce₂O₃ on properties of the CaO-Al₂O₃-Li₂O-Ce₂O₃ slag was provided by the present work. The results show that adding Ce₂O₃ could decrease the viscosity of the slag due to its effects on decreasing the polymerization of the slag. The crystalline process was restrained by increasing the content of Ce₂O₃, and the crystalline phases also can be influenced by the slag structure. The crystalline phases were transferred from LiAlO₂ and CaO to LiAlO₂ and CaCeAlO₄ with the addition of Ce₂O₃ to the slag, which could be well confirmed by the structure of the unit cell of the crystals.     

Formation of CaS on Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-CaO inclusions during solidification of steels

In this article, the effect of CaS formation on the evolution of Al₂O₃-CaO inclusions in low-carbon Al-killed and Ca-treated steel during the solidification process is investigated through high-temperature confocal scanning laser microscopy (CSLM). The inclusions started as mostly liquid-globular inclusions that did not agglomerate with each other on the melt surface but during solidification were seen to change shape into an irregular morphology. The shape change was found to be due to the reaction between the Al₂O₃-CaO inclusions with the dissolved S and Al in the melt, resulting in the formation of dense CaS shells around the inclusions. The melt composition during solidification, estimated from the observed solid δ-front advance rate, was compared to the thermodynamic limit for CaS precipitation. The observed growth rate of the CaS shell was found to initially increase with decreasing temperature because of the higher, solid δ-front advance rates at lower temperatures, which results in higher rates of S and Al partitioning. Once CaS had precipitated, the inclusions were found to form agglomerates on the melt surface because of fluid flow, initially, and later, the capillary depression.     

Deformation and fracture behavior of beams composed of alumium foam core and ceramic Al<Subscript>2</Subscript>O<Subscript>3</Subscript> under monolithic bending

Deformation and fracture mechanisms of sandwich and multilayer beams composed of aluminum foam core and ceramic face sheets under four-point bending condition were investigated in situ by surface displacement analysis (SDA) software. The toughening mechanism of the beams was discussed and a model was given for the computation of the fracture energy of the beams. Beams containing foam core with 5-, 10-, and 20-mm thickness and Al₂O₃ face sheets of 0.5-and 1-mm thickness were prepared. The results show that collapse of the beams is by two basic modes, indentation (ID) and face plate failure (PF). The SDA results illustrated that indentation is localized compression on the portion of the beam adjacent to the loading rollers, where displacement and strain are at the maximum. In PF, the beam entirely bends. It is also found that before collapse of the beams with pure PF mode, the foam core undergoes uniform compressive deformation, which contributes most to the fracture energy of the beams. As for the beams with ID characteristic, the localized compressive deformation plays a key role rather than the uniform compressive deformation in the fracture energy of the beam. The total fracture energy W of a beam under bending condition is proposed as W=W _UC+W _LC+W _CB+W _PF where W _UCis the energy of uniform compressive deformation of the foam core, W _LCis the energy of localized compression of the foam core and W _CBand W _PFare the bending fracture energy of the monolithic foam core and ceramic face sheet, respectively. For the beams with pure PF mode, W _LCis zero. The estimated values of the fracture energy are in good agreement with the measured fracture energy of the beams.     

Deformation and fracture behavior of beams composed of aluminum foam core and ceramic Al<Subscript>2</Subscript>O<Subscript>3</Subscript> under monolithic bending

Deformation and fracture mechanisms of sandwich and multilayer beams composed of aluminum foam core and ceramic face sheets under four-point bending condition were investigated in situ by surface displacement analysis (SDA) software. The toughening mechanism of the beams was discussed and a model was given for the computation of the fracture energy of the beams. Beams containing foam core with 5-, 10-, and 20-mm thickness and Al₂O₃ face sheets of 0.5- and 1-mm thickness were prepared. The results show that collapse of the beams is by two basic modes, indentation (ID) and face plate failure (PF). The SDA results illustrated that indentation is localized compression on the portion of the beam adjacent to the loading rollers, where displacement and strain are at the maximum. In PF, the beam entirely bends. It is also found that before collapse of the beams with pure PF mode, the foam core undergoes uniform compressive deformation, which contributes most to the fracture energy of the beams. As for the beams with ID characteristic, the localized compressive deformation plays a key role rather than the uniform compressive deformation in the fracture energy of the beam. The total fracture energy W of a beam under bending condition is proposed as

Deoxidation of Liquid Copper with Reducing O<Subscript>2</Subscript>/CH<Subscript>4</Subscript> Flames

The rate of deoxidation of molten copper during top blowing with various reducing gases has been investigated using thermogravimetry. It was observed that the rate of deoxidation increases with an increasing flow rate of H₂ or CO and that H₂ is a more effective reducing reagent than CO. The rate of deoxidation using methane was measured for O₂/CH₄ ratios from 1.5 to 2.0. As expected, the deoxidation rate decreased with an increasing O₂/CH₄ feed ratio because the flame became less reducing. For all tests, initially there is a linear decrease in mass as oxygen is removed. However, for some experiments, after some time, a sudden acceleration in the rate of mass loss occurs. Using video and X-ray imaging, it was found that this pattern corresponded to gas evolution from within the molten copper. This finding can be explained by the sudden water vapor evolution because the hydrogen dissolved in the copper reacts with the remaining oxygen, and “boiling” takes place, leading to an enhanced stirring of the copper.     

Peculiarities of the technology and physicomechanical properties of a laminated Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-Al cermet

A technological approach permitting one to obtain laminated Al₂O₃-Al cermet is considered. The industrial PAP-2 powder with laminated particles served as the starting crude. The powder billets were obtained by compaction under pressure (P) from 100 to 1000 MPa and thermally treated in air by heating in the furnace to 600°C. It is established that either the solid-phase sintering or reaction sintering of the billets in the mode of filtration combustion can be achieved depending on the value of P. In the produced composite, the content of the oxide phase varies from 5 to 40%, while the density and strength upon bending vary in the limits 2.53–2.00 g/cm³ and 330-98 MPa, respectively. The laminated structure of the material is retained after thermal aging in air at t= 600°C for no less than 1000 h.     

Gas release from the ZrO<Subscript>2</Subscript>-Y<Subscript>2</Subscript>O<Subscript>3</Subscript> ceramics used in the seeded growth of diamond single crystals

Gas release from the ZrO₂-Y₂O₃ ceramics used for the seeded growth of diamond single crystals in a temperature range from 100 to 700°C and a pressure of 10^?4 Pa is investigated. It is experimentally found that the air content in the pores of ceramic elements of the container is 0.086 sccm³/g. The coefficient of the gas release and diffusivity are determined; this allows one to determine the degassing time for which the gas fraction from the sample attains a definite value from the starting amount. It is revealed that vacuum annealing at a temperature no lower than 700°C and P = 10^?4 Pa provides a decrease in the content of the adsorbed gas on the parts of the reaction cell by an order of magnitude.     

Effect of LiF as Sintering Agent on the Densification and Phase Formation in Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-4 Wt Pct Nb<Subscript>2</Subscript>O<Subscript>5</Subscript> Ceramic Compound

Different amounts of LiF were added to an Al₂O₃-4 pct Nb₂O₅ basic ceramic, as sintering agent. Improved new ceramics were obtained with LiF concentrations varying from 0.25 to 1.50 wt pct and three sintering temperatures of 1573 K, 1623 K, and 1673 K (1300 °C, 1350 °C, and 1400 °C). The addition of 0.5 wt pct LiF yielded the highest densification, 94 pct of the theoretical density, in association with a sintering temperature of 1673 K (1400 °C). Based on X-ray diffraction (XRD), this improvement was due not only to the presence of transformed phases, more precisely Nb₃O₇F, but also to the absence of LiAl₅O₈. The preferential interaction of LiF with Nb₂O₅, instead of Al₂O₃, contributed to increase the alumina sintering ability by liquid phase formation. Scanning electron microscopy (SEM) results revealed well-connected grains and isolated pores, whereas the chemical composition analysis by energy dispersive energy (EDX) indicated a preferential interaction of fluorine with niobium, in agreement with the results of XRD. It was also observed from thermal analysis that the polyethylene glycol binder burnout temperature increased for all LiF concentrations. This may be related to the formation of hydrogen bridge bonds.