Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “SLAG”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Nitinol Electroslag Remelting: Initial Slag Study

Nitinol’s unique shape memory and super-elastic properties make it attractive for many applications in biomedical, automotive, aerospace, industrial refrigeration, and waste heat reclamation industries. The fatigue performance is limited however, by non-metallic inclusions (NMI) formed during the traditional VIM/VAR or multi-VAR process. ESR is a potential alternative melt process and is commonly used to refine ingot chemistry and enhance the metallurgical structure of many superalloys and specialty steels, but no study on ESR of Nitinol has been reported to date. The key to establishing a successful ESR process is selecting a compatible slag. In this study, several different slag chemistries are evaluated for their compatibility with Nitinol. One slag chemistry is chosen, along with a control, to produce four Nitinol ESR ingots. Pursuit of a novel slag chemistry for adequate Nitinol refinement is discussed.

Fezi, Kyle↗
DOE OSTI2018

Removal of Non-metallic Inclusions from Nickel Base Superalloys by Electromagnetic Levitation Melting in a Slag

Samples of INCONEL 718 were levitated and melted in a slag by the application of an electromagnetic field. The effects of temperature, time, and slag composition on the inclusion content of the samples were studied thoroughly. Samples were compared with the original alloy to study the effect of the process on inclusions. Size, shape, and chemical composition of remaining non-metallic inclusions were investigated. The samples were prepared by Standard Guide for Preparing and Evaluating Specimens for Automatic Inclusion Assessment of Steel (ASTM E 768-99) method and the results were reported by means of the Standard Test Methods for Determining the Inclusion Content of Steel (ASTM E 45-97). Results indicated that by increasing temperature and processing time, greater level of cleanliness could be achieved, and numbers and size of the remaining inclusions decreased significantly. It was also observed that increasing calcium fluoride content of the slag helped reduce inclusion content.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Effect of CaO on Gas/Slag/Matte/Tridymite Equilibria in Fayalite-Based Copper Smelting Slags at 1473 K (1200 °C) and P(SO{sub 2}) = 0.25 Atm

Fundamental experimental studies have been undertaken to determine the effect of CaO on the equilibria between the gas phase (CO/CO{sub 2}/SO{sub 2}/Ar) and slag/matte/tridymite phases in the Cu-Fe-O-S-Si-Ca system at 1473 K (1200 °C) and P(SO{sub 2}) = 0.25 atm. The experimental methodology developed in the Pyrometallurgy Innovation Centre was used. New experimental data have been obtained for the four-phase equilibria system for fixed concentrations of CaO (up to 4 wt pct) in the slag phase as a function of copper concentration in matte, including the concentrations of dissolved sulfur and copper in slag, and Fe/SiO{sub 2} ratios in slag at tridymite saturation. The new data provided in the present study are of direct relevance to the pyrometallurgical processing of copper and will be used as an input to optimize the thermodynamic database for the copper-containing multi-component multi-phase system.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Reduction of CaO and MgO Slag Components by Al in Liquid Fe

This study documents laboratory-scale observations of reactions between Fe-Al alloys (0.1 to 2 wt pct Al) with slags and refractories. Al in steels is known to reduce oxide components in slag and refractory. With continued development of Al-containing Advanced High-Strength Steel (AHSS) grade, the effects of higher Al must be examined because reduction of components such as CaO and MgO could lead to uncontrolled modification of non-metallic inclusions. This may lead to castability or in-service performance problems. In this work, Fe-Al alloys and CaO-MgO-Al{sub 2}O{sub 3} slags were melted in an MgO crucible and samples were taken at various times up to 60 minutes. Inclusions from these samples were characterized using an automated scanning electron microscope equipped with energy dispersive x-ray analysis (SEM/EDS). Initially Al{sub 2}O{sub 3} inclusions were modified to MgAl{sub 2}O{sub 4}, then MgO, then MgO + CaO-Al{sub 2}O{sub 3}-MgO liquid inclusions. Modification of the inclusions was faster at higher Al levels. Very little Ca modification was observed except at 2 wt pct Al level. The thermodynamic feasibility of inclusion modification and some of the mass transfer considerations that may have led to the differences in the Mg and Ca modification behavior were discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Transition of Blast Furnace Slag from Silicate Based to Aluminate Based: Electrical Conductivity

The electrical conductivity of the CaO-SiO{sub 2}-Al{sub 2}O{sub 3}-MgO-TiO{sub 2} slag was determined using the four-electrode method. The effect of the Al{sub 2}O{sub 3} and Al{sub 2}O{sub 3}/SiO{sub 2} mass ratio on the electrical conductivity was studied. At a fixed CaO/SiO{sub 2} ratio of 1.20, the electrical conductivity decreases with increasing Al{sub 2}O{sub 3} from 16 mass pct to 24 mass pct because of the increased polymerization of aluminosilicate structures and the reduced amount of conductive ions. However, it increases with Al{sub 2}O{sub 3} of more than 24 mass pct because of the difference in the stable energy between [AlO{sub 4}]{sup 5−} and [SiO{sub 4}]{sup 4−}. Increasing the Al{sub 2}O{sub 3}/SiO{sub 2} ratio from 0.47 to 0.79 causes the electrical conductivity to increase and has an opposite effect when the ratio is greater than 0.79. Furthermore, Raman spectroscopy of the quenched slags was analyzed to understand the structural role of Al{sub 2}O{sub 3} and Al{sub 2}O{sub 3}/SiO{sub 2} mass ratio in the network. The Raman spectroscopy results indirectly supported the variations of electrical conductivity with the composition of the slags.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Molecular Dynamics Simulation of the Structure and Properties of CaO-SiO{sub 2}-CaF{sub 2} Slag Systems

As a fundamental slag system in metallurgical processes, the CaO-SiO{sub 2}-CaF{sub 2} system, its properties, and related microstructures are of critical importance. The effect of the binary basicity and addition of CaF{sub 2} on the structure and viscosity of CaO-SiO{sub 2}-CaF{sub 2} slag were investigated using molecular dynamics simulations and Fourier transform infrared spectrometry. The average bond lengths of Si-O, Ca-O, and O-O were 1.61, 2.31, and 2.61 Å, respectively, and the coordinate number of Si remained constant. O-Si-O maintained an angle of 109.2, which was considered to be unaffected by the basicity changes. With increasing basicity, the network connectivity degrees Q{sup 3} and Q{sup 4} decreased, and the microstructure of the melt was significantly simpler. The effect of CaF{sub 2} on the depolymerization of the network structure was not obvious, and CaF{sub 2} acted mainly as a diluent. The calculations showed that the viscosity decreased upon setting up a ratio of nonbridging oxygen over tetrahedrally coordinated atoms (NBO/T). A good linear relationship was confirmed between the viscosity of the molten slag and the NBO/T.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Motion and Detachment Behaviors of Liquid Inclusion at Molten Steel–Slag Interfaces

The fundamental physics of particles adsorbed at the liquid interfaces has numerous applications in a wide field. In the current study, the motion and detachment behaviors of the liquid nonmetallic inclusion from molten steel–slag interfaces were theoretically studied by developing a force balance model. According to the model calculations, the thin-film drainage is the main stage of the inclusion separation. The capillary force is the main driving force of the inclusion rebounding at the drainage stage. The effect of triple interface among the steel, slag, and inclusion after the film rupture does not seem to be the main factor for the inclusion detachment. The current model can predict the critical inclusion size of the detachment. The vertical terminal velocities of the inclusion, inclusion size, and slag surface tension are the key factors of the detachment.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Al{sub 2}O{sub 3} Level in CaO-SiO{sub 2}-MgO-Al{sub 2}O{sub 3} Refining Slags on Slag/Magnesia-Doloma Refractory Interactions

The influence of the Al{sub 2}O{sub 3} level in CaO-SiO{sub 2}-MgO-Al{sub 2}O{sub 3} (CSMA) stainless steel refining slags on the degradation of magnesia-doloma refractories was investigated through static refractory finger corrosion tests. The tests were performed at 1620 °C under Ar atmosphere, using slags with Al{sub 2}O{sub 3} contents of 5, 10, and 20 wt pct, respectively. The results indicate that the formation of 2CaO·SiO{sub 2} at the slag/refractory interface was suppressed by increasing the Al{sub 2}O{sub 3} content to 20 wt pct, thereby changing the corrosion mechanism from an indirect dissolution to a direct dissolution of CaO and MgO from the refractories. The increased solubility limit of MgO by the Al{sub 2}O{sub 3}-rich CSMA slags results in an overall higher corrosion rate of the MgO-doloma refractory.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Experimental Investigation on Metallic Droplet Behavior in Molten BOF Slag

In order to better understand the metallic droplet behavior during a slag treatment process, a physical modeling based on the similarity principle was performed in a transparent scaled-down vessel at room temperature. Paraffin oil, 20 wt pct copper sulfate solution, and compressed air were used to simulate the molten slag, metallic droplet, and carrier gas, respectively. The droplets injected into paraffin oil during the experiment were captured by a high speed camera and were analyzed by Image Pro Plus software to obtain the droplet size distribution. The critical droplet size in the physical modeling and slag treatment process is quantitatively correlated. The results show that droplet breakage phenomenon is dominant over its coalescence in the current industrial practice, and droplet breakage is enhanced with increasing gas flow rate and/or lance depth. No significant effect of the nozzle configuration was found on the droplet breakage and coalescence. The droplet size distribution varies with the lance position. Gas flow rate and lance depth are the most important factors for droplet breakage, the extent of which can be reduced through a proper selection of the operational conditions. A linear relationship between the droplet size and the input energy flux is obtained.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Kinetics of the Carbothermic Reduction of Manganese Oxide from Slag

Experiments were performed using a range of test conditions to elucidate the rate controlling step during the reaction of liquid iron-carbon droplets and slags containing manganese oxide. Four conditions were tested in the system: initial MnO content in the slag (5, 10, and 15 wt pct), initial carbon content of the metal (1, 2.5, 4.3 wt pct), initial droplet mass (0.5, 1.0, and 1.5 g), and reaction temperature (1823 K [1550 °C], 1873 K [1600 °C], and 1923 K [1650 °C]). Data were collected using the Constant Volume Pressure Increase (CVPI) technique which tracked the continuous pressure increase in the sealed furnace over time. Samples were quenched at the end of each experiment and chemistry was checked using LECO Carbon Analysis and ICP (Inductively Coupled Plasma) for manganese. The rate of reaction can be broken into a faster initial period related to internal CO formation, and a slower second reaction controlled by a complex mechanism involving transport of oxygen from slag to metal via CO{sub 2} and decomposition of the CO{sub 2} at the gas–metal interface.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Characterisation of Ba(OH){sub 2}–Na{sub 2}SO{sub 4}–blast furnace slag cement-like composites for the immobilisation of sulfate bearing nuclear wastes

Soluble sulfate ions in nuclear waste can have detrimental effects on cementitious wasteforms and disposal facilities based on Portland cement. As an alternative, Ba(OH){sub 2}–Na{sub 2}SO{sub 4}–blast furnace slag composites are studied for immobilisation of sulfate-bearing nuclear wastes. Calcium aluminosilicate hydrate (C–A–S–H) with some barium substitution is the main binder phase, with barium also present in the low solubility salts BaSO{sub 4} and BaCO{sub 3}, along with Ba-substituted calcium sulfoaluminate hydrates, and a hydrotalcite-type layered double hydroxide. This reaction product assemblage indicates that Ba(OH){sub 2} and Na{sub 2}SO{sub 4} act as alkaline activators and control the reaction of the slag in addition to forming insoluble BaSO{sub 4}, and this restricts sulfate availability for further reaction as long as sufficient Ba(OH){sub 2} is added. An increased content of Ba(OH){sub 2} promotes a higher degree of reaction, and the formation of a highly cross-linked C–A–S–H gel. These Ba(OH){sub 2}–Na{sub 2}SO{sub 4}–blast furnace slag composite binders could be effective in the immobilisation of sulfate-bearing nuclear wastes.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Chemical acceleration of a neutral granulated blast-furnace slag activated by sodium carbonate

This paper presents results of a study on chemical acceleration of a neutral granulated blast-furnace slag activated using sodium carbonate. As strength development of alkali-activated slag cements containing neutral GBFS and sodium carbonate as activator at room temperature is known to be slow, three accelerators were investigated: sodium hydroxide, ordinary Portland cement and a combination of silica fume and slaked lime. In all cements, the main hydration product is C–(A)–S–H, but its structure varies between tobermorite and riversideite depending on the accelerator used. Calcite and gaylussite are present in all systems and they were formed due to either cation exchange reaction between the slag and the activator, or carbonation. With accelerators, compressive strength up to 15 MPa can be achieved within 24 h in comparison to 2.5 MPa after 48 h for a mix without an accelerator.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Utilisation of steel furnace slag coarse aggregate in a low calcium fly ash geopolymer concrete

This paper evaluates the performance of steel furnace slag (SFS) coarse aggregate in blended slag and low calcium fly ash geopolymer concrete (GPC). The geopolymer binder is composed of 90% of low calcium fly ash and 10% of ground granulated blast furnace slag (GGBFS). Mechanical and physical properties, shrinkage, and detailed microstructure analysis were carried out. The results showed that geopolymer concrete with SFS aggregate offered higher compressive strength, surface resistivity and pulse velocity than that of GPC with traditional aggregate. The shrinkage results showed no expansion or swelling due to delayed calcium oxide (CaO) hydration after 320 days. No traditional porous interfacial transition zone (ITZ) was detected using scanning electron microscopy, indicating a better bond between SFS aggregate and geopolymer matrix. Energy dispersive spectroscopy results further revealed calcium (Ca) diffusion at the vicinity of ITZ. Raman spectroscopy results showed no new crystalline phase formed due to Ca diffusion. X-ray fluorescence result showed Mg diffusion from SFS aggregate towards geopolymer matrix. The incorporation of Ca and Mg into the geopolymer structure and better bond between SFS aggregate and geopolymer matrix are the most likely reasons for the higher compressive strength observed in GPC with SFS aggregate.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Characterization of novel blast-furnace slag cement pastes and mortars activated with a reactive mixture of MgO-NaOH

This paper reports results of strength and reaction products of blast-furnace slag cements activated using a mixture of MgO-NaOH with a ratio 50/50 incorporated at 4, 6 and 8% relative to the slag mass. Pastes and mortars were prepared and cured at 20 °C and 60 °C-24 h-20 °C up to 90 days. The results indicated that the combination of MgO-NaOH acts as an effective alkaline activator of the slag, as samples cured at 20 °C developed 54 MPa at 90 days, while those at 60 °C-24 h-20 °C had a rapid strength gain at early ages but in the long run strengths of ~42 MPa at 90 days were observed. The microstructures consisted of (C-(A)-S-H), third aluminate hydrates and hydrotalcite. The formation of the latter increased at higher MgO:NaOH concentration lowering the Al uptake by C-S-H. MgO and Mg(OH){sub 2} were not detected, indicating an effective incorporation of Mg{sup 2+} ions into the atomic structure of the reaction products.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A parametric study of accelerated carbonation in alkali-activated slag

Resistance to carbonation is one important attribute that low-CO{sub 2} cement alternatives must possess, and is particularly crucial for cement alternatives subjected to aggressive CO{sub 2} concentrations such as those used in construction of oil wells and wells for below ground carbon sequestration. Here, a parametric study of alkali-activated slag (AAS) carbonation in aggressive environments has been conducted to examine (i) calcium carbonate polymorphism using X-ray diffraction (XRD) and Fourier-transform infrared (FTIR) spectroscopy, and (ii) the extent of calcium carbonate formation and CO{sub 2} adsorption using thermogravimetric analysis (TGA). A range of AASs have been studied by varying the magnesium content of the slag, the activator type (sodium hydroxide and sodium silicate), the activator concentration, and the curing time prior to carbonation. It was uncovered that both (i) magnesium from the slag and (ii) silica from the activating solution are needed to reduce the propensity for the sodium-containing calcium-alumino-silicate-hydrate gel to undergo decalcification.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effects of carbonation on the retention of heavy metals in chemically activated BOF slag pastes

Basic Oxygen Furnace slag contains heavy metals, including vanadium, chromium and molybdenum. The leachability of these elements determines the industrial applicability of slag-based building products. This study investigates the post‑carbonation leaching of heavy metals from activated BOF slag pastes with the focus on the activator dosage and type (sodium and potassium citrate). Results reveal that the high degree of brownmillerite hydration boosts the leachability of heavy metals as its hydration product- hydrogarnet is less stable upon carbonation. With two leaching procedures, it is demonstrated that the carbonation resistance of pastes becomes the main attribute in preventing the leaching of heavy metals. It can be enhanced by optimising the activator dosage to facilitate the hydration of C{sub 2}S and consequent structural densification.

36 MATERIALS SCIENCE↗
DOE OSTI2018

AOI [3]: Smart Refractory Sensor Systems for Wireless Monitoring of Temperature, Health, and Degradation of Slagging Gasifiers

The objective of the work was to develop refractory “smart bricks”, which would contain embedded temperature, strain/stress, and spallation sensors throughout the volume of highchromia (-Cr 2 O 3 ) refractory brick. The proposed work included work to interconnect the sensors to the reactor exterior, where the sensor signals may be processed by low-power electronics and transmitted wirelessly to a central processing hub. The data processing and wireless transmitter hardware was specifically designed to be isolated (with low power consumption) and to be adaptable to future implementation of energy-harvesting strategies for extended life. Finally, the collected data was incorporated into a model to estimate refractory degradation, a technique that could help monitor the health of the refractory in real-time. The long-term goal of this program was to demonstrate high-temperature, wireless sensor arrays for in situ three-dimensional (3-D) refractory monitoring or mapping for slagging gasification systems. The research was in collaboration with HarbisonWalker International (HWI) Technology Center in West Mifflin, PA. HWI is a leading developer and manufacturer of ceramic refractory products for high-temperature applications. The work completed focused on the following areas: 1) Investigation of the chemical stability, microstructural evolution, grain growth kinetics, degree of homogeneity (quantitative image analysis), and electrical properties of refractory oxide-silicide composites at temperatures between 750-1450ºC; 2) Fabrication of silicide-alumina composite and oxide thermocouples and thermistor preforms and the development of techniques to embed them into high-chromia refractory bricks to form “smart bricks”; 3) Utilization of commercial off-the-shelf discrete components to prototype circuits for interfacing between smart brick sensors and the wireless sensor network. The prototypes were then used to design an integrated circuit for thermistor, thermocouple, and capacitive-based smart brick sensor interfacing; 4) Interfacing of the smart bricks with embedded sensors with wireless motes thus yielding a complete signal chain. This end-to-end data collection system was tested on a furnace heated to 1350°C; 5) Development of a slag penetration model and a nonlinear unknown input filter for the data from the embedded sensors for estimating temperature and extent of slag penetration.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Selection and Validation of Alternate Slag Sources for Saltstone Production - 16145

To stabilize low activity salt solution produced at the Savannah River Site (SRS) the salt waste is mixed with a combination of fly ash (FA), ground granulated blast furnace slag (GGBFS), and ordinary Portland cement (OPC) to form a grout termed saltstone. Upon curing, the low activity waste is encapsulated within the hardened cementitious matrix. While the sources of the dry feed components have remained unchanged for several years, SRS was recently notified that its domestic source of GGBFS would no longer be available due to the shutdown of the steel making plant that produced the ferrous slag as a by-product. This shut-down follows a trend in the reduction of domestic ferrous slag sources. Alternate GGBFS vendors were sought and a program developed to validate the alternate sources for use in saltstone. GGBFS is primarily utilized in the construction industry as a replacement for OPC and the requirements of a GGBFS source, based on an American Society for Testing and Materials (ASTM) standard, are predominantly limited to demonstrating that the GGBFS replacement will provide equivalent strength in comparison to the baseline OPC-based concrete. This affords the construction industry significant flexibility with respect to the GGBFS source that can be used. In contrast, GGBFS has a role of significantly more importance when utilized in saltstone. In particular, the reducing blast furnace environment under which GGBFS is produced yields reducing species, such as sulfide (S{sup 2-}) and ferrous iron (Fe{sup 2+}), which are believed to facilitate the long-term immobilization of redox sensitive contaminants (e.g. technetium-99 ({sup 99}Tc)). In addition, a change in GGBFS source has the potential to impact the rheological properties and the reactive heat generation of the grout, which may adversely affect the ability to pump the grout to a Saltstone Disposal Unit (SDU) and the temperatures attained within an SDU, respectively. As such, alternate GGBFS sources for the processing of saltstone require significantly more scrutiny than is prescribed by the ASTM standard. Four alternate GGBFS sources were evaluated. All four sources met the ASTM requirements, only one source was considered viable for use in saltstone based on preliminary evaluation. The other three sources will require a more intensive assessment to determine their potential applicability. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗