Effects of Zn content on the microstructure and the mechanical and corrosion properties of as-cast low-alloyed Mg–Zn–Ca alloys

The effects of Zn content on the microstructure and the mechanical and corrosion properties of as-cast low-alloyed Mg–xZn–0.2Ca alloys (x=0.6wt%, 2.0wt%, 2.5wt%, hereafter denoted as 0.6Zn, 2.0Zn, and 2.5Zn alloys, respectively) are investigated. The results show that the Zn content not only influences grain refinement but also induces different phase precipitation behaviors. The as-cast microstructure of the 0.6Zn alloy is composed of α-Mg, Mg₂Ca, and Ca₂Mg₆Zn₃ phases, whereas 2.0Zn and 2.5Zn alloys only contain α-Mg and Ca₂Mg₆Zn₃ phases, as revealed by X-ray diffraction (XRD) and transmission electron microscopy (TEM) analyses. Moreover, with increasing Zn content, both the ultimate tensile strength (UTS) and the elongation to fracture first increase and then decrease. Among the three investigated alloys, the largest UTS (178 MPa) and the highest elongation to fracture (6.5%) are obtained for the 2.0Zn alloy. In addition, the corrosion rate increases with increasing Zn content. This paper provides an updated investigation of the alloy composition–microstructure–property relationships of different Zn-containing Mg–Zn–Ca alloys.     

Microstructure and corrosion behavior of Al<Subscript>3</Subscript>Ti/ADC12 composite modified with Sr

In this study, we investigated the effect of the addition of Sr (0wt%, 0.1wt%, 0.2wt%, and 0.3wt%) on the microstructure and corrosion behavior of Al₃Ti/ADC12 composite by optical microscopy, X-ray diffraction, scanning electron microscopy, and energy diffraction spectroscopy. The results reveal that the α-Al phases were nearly spherical and 40 μm in size and that the eutectic Si phases became round in the composite when the Sr content reached 0.2wt%. The Al₃Ti particles were distributed uniformly at the grain boundary. The results of the corrosion examination reveal that the Al₃Ti/ADC12 composite exhibited a minimum corrosion rate of 0.081 g·m–2·h–1 for an Sr content of 0.2wt%, which is two thirds of that of unmodified composite (0.134 g·m–2·h–1). This improved corrosion resistance was due to galvanic corrosion, which resulted from the low area ratio of the cathode to anode regions. This caused a low-density corrosion current in the composite, thereby yielding optimum corrosion resistance.     

Preparation and performance of a cold gas dynamic sprayed high-aluminum bronze coating

By mixing preheated high-aluminum bronze powders with different amounts of Al₂O₃ powder, a low-pressure cold-sprayed coating was prepared and sprayed onto a Cr12MoV steel substrate. The hardness of the coating and the bonding strength between the coating and the substrate were tested with a HV-1000 microhardness tester and a mechanical universal testing machine. The surface microstructure, cross-section and tensile fracture surface of the coating were observed with a scanning electron microscope (SEM). Correspondingly, the influences of the preheat treatment temperature of the bronze powder and the Al₂O₃ content on the coating performance were investigated. The results indicate that the hardness of bronze powders decreased and the coating deposition rate increased after the preheating treatment of the bronze powder. The Al₂O₃ content in the mixed powders contributed to the deformation of bronze powders during the spraying process. This trend resulted in varied performance of the coating.     

Electrochemical behavior of gold and its associated minerals in alkaline thiourea solutions

Electrochemical measurements were conducted to study the electrochemical behavior of gold (Au) and its commonly associated minerals in alkaline thiourea solutions. The results indicated that without addition of any stabilizer, selective dissolution of Au from stibnite and pyrite was only possible at relatively low thiourea concentrations. As Na₂SiO₃ was added, pyrite started to become active and an oxidation peak appeared; the oxidation peaks of arsenopyrite and chalcocite appeared earlier than that of Au. The chalcocite peak shifted in the positive direction and the peak current increased. Stibnite did not show an oxidation peak and its current was nearly zero. Adding Na₂SiO₃ favored the selective dissolution of Au when its minerals were associated with chalcocite and stibnite. At pH 12, the Au anode dissolution peak current increased with stabilizer concentration. At 0.38 and 0.42 V and for Na₂SiO₃ concentration below 0.09 M, the current density continuously increased with Na₂SiO₃ concentration. The Na₂SiO₃ concentration had to be adequate to stabilize thiourea. When the potential was higher than 0.42 V, the surface of the Au electrode started to passivate. With an additional increase in potential, the presence of Na₂SiO₃ could not stop the inevitable decomposition of thiourea.     

Corrosion behavior of high-strength spring steel for high-speed railway

The corrosion resistance and evolution of corrosion products in medium-carbon high-strength spring steels were investigated in a neutral salt spray (5wt% NaCl solution). A formation model of γ-FeOOH and a transformation model describing the conversion of γ-FeOOH to α-FeOOH were constructed. The results indicated that, at the initial corrosion stage, the corrosion resistance was gradually improved with the addition of Cr; however, with the addition of alloying element V, the corrosion resistance decreased. These results were attributed mainly to the initial corrosion stage being closely related to the matrix microstructure parameters such as grain-boundary character and dislocation density. After the rust layer was formed at a later corrosion stage, the corrosion resistance was reinforced with the addition of Cr and V because Cr strongly influenced the composition, structure, and morphology of the corrosion products. The results presented herein show that Cr was conducive to the transformation of γ-FeOOH into α-FeOOH. Moreover, V and Cr exhibited obvious synergy and were enriched in the inner layer of the corrosion products.     

Improvement of microstructure and corrosion properties of friction stir welded AA5754 by adding Zn interlayer

This study investigated the effect of Zn foil layers on the microstructure and corrosion characteristics of friction stir welded aluminum alloy 5754. Samples of various joints were prepared by applying different rotational and welding speeds, and their microstructures were evaluated via a metallographic technique and scanning electron microscopy equipped with energy-dispersive X-ray spectroscopy elemental analysis. The anticorrosion behavior of joints in the absence and presence of a Zn interlayer was studied by cyclic potentiodynamic polarization test in 3.5wt% NaCl aqueous solution, and sound welds were obtained in the presence of the Zn interlayer foil. The results revealed that the joint made at a rotational speed of 800 r/min and traveling speed of 15 mm/min achieved a chemical composition identical to that of aluminum alloy 7xxx series, and as such, it showed the best resistance to corrosion.     

Alkaline digestion behavior and alumina extraction from sodium aluminosilicate generated in pyrometallurgical process

In pyrometallurgical process, Al-and Si-bearing minerals in iron and aluminum ores are easily transformed into sodium aluminosilicates in the presence of Na₂O constituents, which alters the leaching behaviors of Al₂O₃ and SiO₂. It was confirmed that sodium aluminosilicates with different phase compositions synthesized at various roasting conditions were effectively digested in the alkaline digestion process. Under the optimum conditions at temperature of 100-120℃, liquid-to-solid ratio (L/S) of 10:2 mL/g, caustic ratio of 4, and Na₂O concentration of 240 g/L, the actual and relative digestion ratio of Al₂O₃ from the synthesized sodium aluminosilicates reached maximums of about 65% and 95%, respectively, while SiO₂ was barely leached out. To validate the superior digestion property of sodium aluminosilicate generated via an actual process, the Bayer digestion of an Al₂O₃-rich material derived from reductive roasting of bauxite and comprising Na_1.75Al_1.75Si_0.25O₄ was conducted; the relative digestion ratio of Al₂O₃ attained 90% at 200℃.     

Process mineralogy characteristics of acid leaching residue produced in low-temperature roasting-acid leaching pretreatment process of refractory gold concentrates

To provide a theoretical basis for a suitable process to extract gold from refractory gold concentrates, process mineralogy on the acid leaching residue of gold calcine was studied by chemical composition, X-ray diffraction, scanning electron microscopy-energy spectrum, and mineral dissociation analysis. The results showed that the acid leaching residue contained Au 68.22 g/t, Ag 92.71 g/t, Fe 0.44%, As 0.10%, and S 0.55%. Gold and silver minerals existed as native gold, argentite, and proustite. Quartz, the main gangue mineral, accounted for 78.33wt/%. The dissociation degree analysis showed that the proportions of monomer and exposed gold in acid leaching residue were 96.66wt%. The cyanidation results showed that the cyanide gold leaching rate of acid leaching residues was close to 100wt%. However, the maximum cyanide gold leaching rate of gold calcine was only 85.31wt%. This suggests that acid leaching can increase the gold dissolution rate in the cyanide process.     

Effect of Ce addition on microstructures and mechanical properties of A380 aluminum alloy prepared by squeeze-casting

The effect of cerium (Ce) addition on the eutectic Si, β-Al₅FeSi phase, and the tensile properties of A380 alloy specimens prepared by squeeze-casting were studied by optical microscopy (OM), scanning electron microscopy (SEM), and X-ray diffraction (XRD). The experimental results showed that Ce more effectively modified the eutectic Si and refined the β-Al₅FeSi. The refinement effect significantly increased under a specific pressure of 100 MPa with the addition of Ce from 0.1wt% to 0.9wt%. In contrast, the average length and the aspect ratio of the eutectic Si and β-Al₅FeSi exhibited their optimal values when the content of the added Ce was greater than 0.5wt%. Needle-like Al8Cu4Ce was precipitated with the addition of excessive Ce; hence, the mechanical properties of A380 gradually decreased with increasing Ce content in the range from 0.3wt% to 0.9wt%.     

New testing methodology for the quantification of rock crushability: Compressive crushing value (CCV)

Crushing is a size reduction process that plays a key role in both mineral processing and crushing-screening plant design. Investigations on rock crushability have become an important issue in mining operations and the manufacture of industrial crusher equipment. The main objective of this research is to quantify the crushability of hard rocks based on their mineralogical and mechanical properties. For this purpose, the mineralogical, physical, and mechanical properties of various hard rocks were determined. A new compressive crushing value (CCV) testing methodology was proposed. The results obtained from CCV tests were compared with those from mineralogical inspections, rock strength as well as mechanical aggregate tests. Strong correlations were found between CCV and several rock and aggregate properties such as uniaxial compressive strength (UCS), the brittleness index (S₂₀), and aggregate impact value (AIV). Furthermore, the relationship between the mineralogical properties of the rocks and their CCVs were established. It is concluded that the proposed testing methodology is simple and highly repeatable and could be utilized as a pre-design tool in the design stage of the crushing process for rock quarries.