Synthesis of WC powder through microwave heating of WO3-C mixture

A simple, easy, and low-cost process for the fabrication of tungsten carbide (WC) powder through microwave heating of WO₃-C mixtures was developed. Thermodynamic calculations and experimental investigations were carried out for WO₃-C and W-C systems, and a formation mechanism was proposed. In the results, for the synthesis of WC, the use of over stoichiometric amount of C together with a specially assembled experimental setup (which effectively retains heat in the system) is necessary. The WC powder is successfully obtained by heating WO₃:5C mixture for 900s in a domestic microwave oven.     

Synthesis of aluminum nitride in a coke – calcium reduction bed using nitrogen in air

An experimental study on the heating of a mixture of aluminum and lithium hydroxide(LiOH) powders in a reductive bed under air atmosphere is reported. The formation of aluminum nitride(AlN) during this process was the focus of this study. The formation of Al N was achieved using LiOH as an additive and heating the sample in a resistance furnace in a specially designed double crucible within a bed of a mixture of coke and filamentous calcium. The temperature range of the reaction was between 700°C and 1100°C. The optimum temperature of 1100°C and the optimum Li OH amount(5wt%) required to achieve maximum yield were determined by powder X-ray diffraction(XRD) analysis. Scanning electron microscopy(SEM) micrographs clearly indicated the transformation of grain structures from rods(700°C) to cauliflower shapes(1100°C).     

Microwave sintering effects on the microstructure and mechanical properties of Ti–51at%Ni shape memory alloys

Ti–51at%Ni shape memory alloys(SMAs) were successfully produced via a powder metallurgy and microwave sintering technique.The influence of sintering parameters on porosity reduction,microstructure,phase transformation temperatures,and mechanical properties were investigated by optical microscopy,field-emission scanning electron microscopy(FE-SEM),X-ray diffraction(XRD),differential scanning calorimetry(DSC),compression tests,and microhardness tests.Varying the microwave temperature and holding time was found to strongly affect the density of porosity,presence of precipitates,transformation temperatures,and mechanical properties.The lowest density and smallest pore size were observed in the Ti–51at%Ni samples sintered at 900°C for 5 min or at 900°C for 30 min.The predominant martensite phases of β2 and β19′ were observed in the microstructure of Ti–51at%Ni,and their existence varied in accordance with the sintering temperature and the holding time.In the DSC thermograms,multi-transformation peaks were observed during heating,whereas a single peak was observed during cooling;these peaks correspond to the presence of the β2,R,and β19′ phases.The maximum strength and strain among the Ti–51at%Ni SMAs were 1376 MPa and 29%,respectively,for the sample sintered at 900°C for 30 min because of this sample's minimal porosity.     

Synthesis of aluminum nitride in a coke-calcium reduction bed using nitrogen in air

An experimental study on the heating of a mixture of aluminum and lithium hydroxide (LiOH) powders in a reductive bed under air atmosphere is reported. The formation of aluminum nitride (AlN) during this process was the focus of this study. The formation of AlN was achieved using LiOH as an additive and heating the sample in a resistance furnace in a specially designed double crucible within a bed of a mixture of coke and filamentous calcium. The temperature range of the reaction was between 700°C and 1100°C. The optimum tem-perature of 1100°C and the optimum LiOH amount (5wt%) required to achieve maximum yield were determined by powder X-ray diffrac-tion (XRD) analysis. Scanning electron microscopy (SEM) micrographs clearly indicated the transformation of grain structures from rods (700°C) to cauliflower shapes (1100°C).     

Synergistic effect of microwave irradiation and CaF_2 on vanadium leaching

The effect and mechanism of microwave irradiation on vanadium leaching were studied via a comparison between microwave heating and conventional heating. The results show a synergistic effect of microwave irradiation and calcium fluoride(Ca F_2) on the vanadium leaching efficiency. It is confirmed that the vanadium leaching process can be improved by microwave irradiation when Ca F_2 is present. The leaching rate of vanadium under microwave irradiation is increased by 8%–15% when 5wt% Ca F_2 is added; by contrast,in the absence of Ca F_2,the leaching rate is almost unaffected compared to that by conventional heating. Morphological analysis reveals that the particles are gradually eroded by acid under microwave irradiation,whereas some of the fine particles in samples subjected to conventional heating are tightly covered by a flocculent silicate product. Moreover,a large amount of Al and V and a small amount of Si are dissolved from samples under microwave heating,as revealed by the elemental analysis of leachates. Fourier transform infrared spectroscopic analysis also indicates a higher mass transfer coefficient in the diffusion layer of the raw material by microwave irradiation. When Ca F_2 is present,the reaction energy barrier is lowered and the leaching process is controlled by the tightly covered product layer,resulting in a prominent effect of microwave irradiation.     

Preparation of in situ and ex situ reinforced Fe–10Cr–1Cu–1Ni–1Mo–2C containing NbC particles by milling and hot pressing

An in situ and ex situ reinforced powder metallurgy(PM) steel was prepared by the combination of high-energy ball milling and subsequent hot pressing of elemental mixed powders of Fe–10Cr–1Cu–1Ni–1Mo–2C by mass with the addition of Nb C particles. A 40-h milling pretreatment makes the powder particles nearly equiaxed with an average diameter of ~8 μm, and the ferrite grain size is refined to ~6 nm. The sintered density reaches 99.0%–99.7% of the theoretical value when the sintering is conducted at temperatures greater than 1000°C for 30 min. In the sintered bulk specimens, the formation of an in situ M7C3(M = Cr, Fe, Mo) phase is confirmed. M7C3 carbides with several hundred nanometers in size are uniformly distributed in the matrix. Some ultra-fine second phases of 50–200 nm form around the ex situ Nb C and in situ M7C3 particles. The sintered steel exhibits an excellent combination of hardness( Hv 500) and compressive strength(2100–2420 MPa).     

Microstructure and oxidation resistance of SiC–MoSi2 multi-phase coating for SiC coated C/C composites

In order to improve the anti-oxidation of C/C composites, a SiC–MoSi2multi-phase coating for SiC coated carbon/carbon composites(C/C)was prepared by low pressure chemical vapor deposition(LPCVD) using methyltrichlorosilane(MTS) as precursor, combined with slurry painting from MoSi2 powder. The phase composition and morphology were analyzed by scanning electron microscope(SEM) and X-ray diffraction(XRD) methods, and the deposition mechanism was discussed. The isothermal oxidation and thermal shock resistance were investigated in a furnace containing air environment at 1500 1C. The results show that the as-prepared SiC–MoSi2coating consists of MoSi2 particles as a dispersing phase and CVD–SiC as a continuous phase. The weight loss of the coated samples is 1.51% after oxidation at 1500 1C for 90 h, and 4.79% after 30 thermal cycles between 1500 1C and room temperature. The penetrable cracks and cavities in the coating served as the diffusion channel of oxygen, resulted in the oxidation of C/C composites, and led to the weight loss in oxidation.     

Characterization and in-situ formation mechanism of tungsten carbide reinforced Fe-based alloy coating by plasma cladding

The precursor carbonization method was first applied to prepare W–C compound powder to perform the in-situ synthesis of the WC phase in a Fe-based alloy coating. The in-situ formation mechanism during the cladding process is discussed in detail. The results reveal that fine and obtuse WC particles were successfully generated and distributed in Fe-based alloy coating via Fe/W–C compound powders. The WC particles were either surrounded by or were semi-enclosed in blocky M_7C_3 carbides. Moreover, net-like structures were confirmed as mixtures of M_(23)C_6 and α-Fe; these structures were transformed from M_7C_3. The coarse herringbone M_6C carbides did not only derive from the decomposition of M_7C_3 but also partly originated from the chemical reaction at the α-Fe/M_(23)C_6 interface. During the cladding process, the phase evolution of the precipitated carbides was WC → M_7C_3 → M_(23)C_6 + M6_C.     

Microstructure and properties of Ag–Ti_3SiC_2 contact materials prepared by pressureless sintering

Ti_3SiC_2-reinforced Ag-matrix composites are expected to serve as electrical contacts. In this study, the wettability of Ag on a Ti_3SiC_2 substrate was measured by the sessile drop method. The Ag–Ti_3SiC_2 composites were prepared from Ag and Ti_3SiC_2 powder mixtures by pressureless sintering. The effects of compacting pressure(100–800 MPa), sintering temperature(850–950°C), and soaking time(0.5–2 h) on the microstructure and properties of the Ag–Ti_3SiC_2 composites were investigated. The experimental results indicated that Ti_3SiC_2 particulates were uniformly distributed in the Ag matrix, without reactions at the interfaces between the two phases. The prepared Ag–10 wt%Ti_3SiC_2 had a relative density of 95% and an electrical resistivity of 2.76 × 10-3 mΩ?cm when compacted at 800 MPa and sintered at 950°C for 1 h. The incorporation of Ti_3SiC_2 into Ag was found to improve its hardness without substantially compromising its electrical conductivity; this behavior was attributed to the combination of ceramic and metallic properties of the Ti_3SiC_2 reinforcement, suggesting its potential application in electrical contacts.     

Microstructure evolution and reaction behavior of Cu–Ni alloy and B_4C powder system

Microstructure evolution and reaction behavior of Cu–Ni alloy and B_4C power system was studied by in-situ and static experimental investigations along with theoretical calculations. The reaction process was as follows. Firstly,B_4C decomposed into B and C atoms, and then B atoms diffused into Cu–Ni matrix, leading to the formation of Ni_2B particles. Subsequently, Ni atoms diffused into B_4C, forming a loose mixture of Ni_2B and amorphous C at the initial powder boundary. Finally, with the completion of reaction, Ni_2B particles at the powder boundary grew into a monolithic block, and then C substance was excluded out and accumulated at the edge of this monolithic Ni_2B block. It is believed that the formation of Ni_2B phase is caused by the most negative change of Gibbs free energy among all the potential reactions between Ni–B and Ni–B_4C systems.     

传统加热和微波加热下氧化锰矿的碳热还原行为研究

For the purpose of exploring a potential process to produce FeMn, the effects of microwave heating on the carbothermal reduction characteristics of oxidized Mn ore was investigated. The microwave heating curve of the mixture of oxidized Mn ore and coke was analyzed in association with the characterization of dielectric properties. The comparative experiments were conducted on the carbothermal reductions through conventional and microwave heatings at temperatures ranging from 973 to 1373 K. The thermogravimetric analysis showed that carbothermal reactions under microwave heating proceeded to a greater extent and at a faster pace compared with those under conventional heating. The metal phases were observed in the microstructures only under microwave heating. The carbothermal reduction process under microwave heating was discussed. The electric and magnetic susceptibility differences were introduced into the thermodynamics analysis for the formation of metal Mn. The developed thermodynamics considered that microwave heating could make the reduction of MnO to Mn more accessible and increase the reduction extent.     

Effect of initial microstructure on austenite formation kinetics in high-strength experimental microalloyed steels

Austenite formation kinetics in two high-strength experimental microalloyed steels with different initial microstructures compris-ing bainite–martensite and ferrite–martensite/austenite microconstituents was studied during continuous heating by dilatometric analysis. Austenite formation occurred in two steps:(1) carbide dissolution and precipitation and (2) transformation of residual ferrite to austenite. Di-latometric analysis was used to determine the critical temperatures of austenite formation and continuous heating transformation diagrams for heating rates ranging from 0.03°C×s?1 to 0.67°C×s?1. The austenite volume fraction was fitted using the Johnson–Mehl–Avrami–Kolmogorov equation to determine the kinetic parameters k and n as functions of the heating rate. Both n and k parameters increased with increasing heat-ing rate, which suggests an increase in the nucleation and growth rates of austenite. The activation energy of austenite formation was deter-mined by the Kissinger method. Two activation energies were associated with each of the two austenite formation steps. In the first step, the austenite growth rate was controlled by carbon diffusion from carbide dissolution and precipitation;in the second step, it was controlled by the dissolution of residual ferrite to austenite.     

Synthesis of PbS–K2La2Ti3O10 composite and its photocatalytic activity for hydrogen production

Photocatalyst, lead sulfide (PbS )-intercalated layer perovskite-type compound (K2La2Ti3O10), was synthesized via ion-exchange reaction, butylamine pillaring and sulfuration processes under the assistance of the microwave irradiation. The structure of the photoc atalysts was determined by means of powder X-ray diffraction, scanning electron microscope, ultraviolet- visible diffuse reflection spectra and photoluminescence measu rement. And the photocatalytic activity of the composite compound for hydrogen production was also investigated. The experimental results showed that the intercalation of PbS in the layered space of K2La2Ti3O10 greatly improved the absorption edge and the photocatalytic activity. Hydrogen production of the PbS–K2La2Ti3O10 was 127.19 mmol/(g cat) after 3 h irradiation of ultraviolet light.     

Investigation on microwave heating for direct leaching of chalcopyrite ores and concentrates

The use of microwave energy in materials processing is a relatively new development presenting numerous advantages because of the rapid heating feature. Microwave technology has great potential to improve the extraction efficiency of metals in terms of both a reduction in required leaching time and an increase in the recovery of valuable metals. This method is especially pertinent in view of the increased demand for environment-friendly processes. In the present study, the influence of microwave heating on the direct leaching of chalcopyrite ores and concentrates were investigated. The results of microwave leaching experiments were compared with those obtained under conventional conditions. During these processes, parameters such as leaching media, temperature, and time have been worked to determine the optimum conditions for proper copper dissolution. Experimental results show that microwave leaching is more efficient than conventional leaching. The optimum leaching conditions for microwave leaching are the solid-to-liquid ratio of 1:100 g/mL, the temperature of 140℃, the solution of 0.5 M H₂SO₄ + 0.05 M Fe₂(SO₄)₃, and the time of 1 h.     

Numerical simulation of the temperature field of titania-bearing BF slag heated in a microwave oven

Considering the characteristic of selective heating of microwave and the treatment of titania-bearing BF slag, a mathematical model for the heating of a slag specimen is developed. The temperature distribution in the specimen is studied by numerical simulation. The temperature in the center of the cylindrical slag specimen is the highest and the temperature decreases when the radius increases rapidly. In this case, the temperature rising rate decreases with heating time rapidly, and it tends to zero when the heating time is up to 150 s.     

Mechanical characterization of Mg-B_4C nanocomposite fabricated at different strain rates

Magnesium has wide application in industry. The main purpose of this investigation was to improve the properties of magnesium by reinforcing it using B_4C nanoparticles. The reinforced nanocomposites were fabricated using a powder compaction technique for 0, 1.5 vol%, 3 vol%,5 vol%, and 10 vol% of B_4C. Powder compaction was conducted using a split Hopkinson bar(SHB), drop hammer(DH), and Instron to reach different compaction loading rates. The compressive stress–strain curves of the samples were captured from quasi-static and dynamic tests carried out using an Instron and split Hopkinson pressure bar, respectively. Results revealed that, to achieve the highest improvement in ultimate strength, the contents of B_4C were 1.5 vol%, 3 vol%, and 3 vol% for Instron, DH, and SHB, respectively. These results also indicated that the effect of compaction type on the quasi-static strength of the samples was not as significant, although its effect on the dynamic strength of the samples was remarkable. The improvement in ultimate strength obtained from the quasi-static stress–strain curves of the samples(compared to pure Mg) varied from9.9% for DH to 24% for SHB. The dynamic strength of the samples was improved(with respect to pure Mg) by 73%, 116%, and 141% for the specimens compacted by Instron, DH, and SHB, respectively. The improvement in strength was believed to be due to strengthening mechanisms,friction, adiabatic heating, and shock waves.     

Effect of continuous induction annealing on the microstructure and mechanical properties of copper-clad aluminum flat bars

Copper-clad aluminum (CCA) flat bars produced by the continuous casting–rolling process were subjected to continuous induction heating annealing (CIHA), and the effects of induction heating temperature and holding time on the microstructure, interface, and mechanical properties of the flat bars were investigated. The results showed that complete recrystallization of the copper sheath occurred under CIHA at 460°C for 5 s, 480°C for 3 s, or 500°C for 1 s and that the average grain size in the copper sheath was approximately 10.0 μm. In the case of specimens subjected to CIHA at 460–500°C for longer than 1 s, complete recrystallization occurred in the aluminum core. In the case of CIHA at 460–500°C for 1–5 s, a continuous interfacial layer with a thickness of 2.5–5.5 μm formed and the thickness mainly increased with increasing annealing temperature. After CIHA, the interfacial layer consisted primarily of a Cu₉Al₄ layer and a CuAl₂ layer; the average interface shear strength of the CCA flat bars treated by CIHA at 460–500°C for 1–5 s was 45–52 MPa. After full softening annealing, the hardness values of the copper sheath and the aluminum core were HV 65 and HV 24, respectively, and the hardness along the cross section of the CCA flat bar was uniform.     

Synergistic effect of microwave irradiation and CaF<Subscript>2</Subscript> on vanadium leaching

The effect and mechanism of microwave irradiation on vanadium leaching were studied via a comparison between microwave heating and conventional heating. The results show a synergistic effect of microwave irradiation and calcium fluoride (CaF₂) on the vanadium leaching efficiency. It is confirmed that the vanadium leaching process can be improved by microwave irradiation when CaF₂ is present. The leaching rate of vanadium under microwave irradiation is increased by 8%-15% when 5wt% CaF₂ is added; by contrast, in the absence of CaF₂, the leaching rate is almost unaffected compared to that by conventional heating. Morphological analysis reveals that the particles are gradually eroded by acid under microwave irradiation, whereas some of the fine particles in samples subjected to conventional heating are tightly covered by a flocculent silicate product. Moreover, a large amount of Al and V and a small amount of Si are dissolved from samples under microwave heating, as revealed by the elemental analysis of leachates. Fourier transform infrared spectroscopic analysis also indicates a higher mass transfer coefficient in the diffusion layer of the raw material by microwave irradiation. When CaF₂ is present, the reaction energy barrier is lowered and the leaching process is controlled by the tightly covered product layer, resulting in a prominent effect of microwave irradiation.     

Investigation of the stable and the metastable liquidus miscibility gaps in Fe-Sn and Fe-Cu binary systems

Two kinds of experimental methods were tried in the present work:(i) the powder metallurgy method combined with differential thermal analysis (DTA) to determine the metastable liquidus miscibility gap for a Fe-Cu binary system and (ii) the high-temperature melting method combined with isothermal treatment to determine the stable liquidus miscibility gap for a Fe-Sn binary system. The experimental method was adopted according to the characteristics of the liquidus miscibility gap of the specific system. Using the powder metallurgy method, a uniform microstructure morphology and chemical composition was obtained in the DTA specimen, and the phase-separation temperature of the supercooled metastable liquid was measured. The isothermal treatment was applied for the samples inside the stable liquidus miscibility gap; here, equilibrated compositions were reached, and a layered morphology was formed after rapid cooling. The liquid miscibility gaps of the Fe-Cu and Fe-Sn binary systems were measured, and the peak temperatures of the corresponding miscibility gaps were determined to be about 1417℃ at x(Cu)=0.465at% and 1350℃ at x(Sn)=0.487at%, respectively. On the basis of the experimental results, both the Fe-Cu and the Fe-Sn binary systems were thermodynamically assessed.     

Erosion–corrosion behavior of austenitic cast iron in an acidic slurry medium

A series of austenitic cast iron samples with different compositions were cast and a part of nickel in the samples was replaced by manganese for economic reason. Erosion–corrosion tests were conducted under 2wt% sulfuric acid and 15wt% quartz sand. The results show that the matrix of cast irons remains austenite after a portion of nickel is replaced with manganese.(Fe,Cr)3C is a common phase in the cast irons, and nickel is the main alloying element in high-nickel cast iron; whereas,(Fe,Mn)3C is observed with the increased manganese content in low-nickel cast iron. Under erosion–corrosion tests, the weight-loss rates of the cast irons increase with increasing time. Wear plays a more important role than corrosion in determining the weight loss. It is indicated that the processes of weight loss for the cast irons with high and low nickel contents are different. The erosion resistance of the cast iron containing 7.29wt% nickel and 6.94wt% manganese is equivalent to that of the cast iron containing 13.29wt% nickel.