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Journal of Materials & Metallurgical Engineering
Contents
1. Effect of Pin Profile on Microstructure and Mechanical Properties of Friction Stir Welded AZ31B Magnesium Alloy Piyush Gulati, Dinesh Kumar Shukla
1
2. Effect of Pulse Current Micro Plasma Arc Welding Parameters on Pitting Corrosion Rate of AISI 316Ti Sheets in 3.5 N NaCl Medium Kondapalli Siva Prasad
12
3. Recovery of Iron Values from Waste Iron Ore Slime Jyolsna Jerin, Rajendra Kumar Rath, Anil Kumar
25
4. Recovery of Iron Values from Iron Ore Slimes using Reagents Rajesh Chintala, R.K. Rath, Anil Kumar
32
5. Solidification Curve Analysis of Cylindrical Casting by FEM Dharmesh Barodiya, M.D. Mahajan, Shaheen Beg Mughal
44
Journal of Materials & Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print) Volume 6, Issue 3 www.stmjournals.com
Effect of Pin Profile on Microstructure and Mechanical Properties of Friction Stir Welded AZ31B Magnesium Alloy Piyush Gulati1,2,*, Dinesh Kumar Shukla1
1
Department of Mechanical Engineering, Dr. B.R. Ambedkar National Institute of Technology, Jalandhar, Punjab, India 2 School of Mechanical Engineering, Lovely Professional University, Phagwara, Punjab, India
Abstract
Friction Stir Welding (FSW) is a solid state welding technique which was developed primarily for joining soft metal alloys. The aim of the present work was to develop a defect free friction stir joint of magnesium AZ31B sheets and to investigate the microstructural and mechanical properties of the weld. Two types of tool pins namely cylindrical and truncated conical pin profiled tools have been used to analyze its effect on the weld quality. Mechanical properties of different zones were determined by Vickers hardness test and Impact energy absorption test. Microstructure of the welded specimens was analyzed and mean grain size and grain number were measured. Keywords: Friction stir welding, grain size, mechanical properties, microstructure
INTRODUCTION
The main concern of automobile and aero engine industry is to use lightweight materials which would lead to increased efficiency, fuel savings and reduction in emissions. This leads to considerable attention on materials like Aluminum and Magnesium. Magnesium and its alloys are the lightest of all metal alloys, one third in weight in comparison to aluminum alloys, and also possess good mechanical properties such as high strength and stiffness and also good machinability, therefore, is an excellent choice for engineering applications when weight is a critical design element [1–3]. However, joining of magnesium alloys is a big challenge, if done by conventional methods such as GTAW, as it leads to defects like hot cracks and porosity deteriorating joint’s mechanical properties. These defects produced by fusion welding processes can be overcome by solid state joining processes [4–6]. Friction Stir welding (FSW) welding technique, which producing defect free joints melting materials [7–9]. In
is a solid state is capable of especially low FSW, a solid
rotating tool, harder than the workpiece, is used to permanently join the plates. The tool consisting of a shoulder and a pin is plunged at a constant rotational speed and feed into the joint line between two butted pieces of plate material which are rigidly clamped and is moved longitudinally at a constant welding speed. The combined rotating and plunging action of tool pin and shoulder produces severe plastic deformation due to frictional heat and hence produces a strong metallurgical joint. The material flows in a stirring motion, thereby elongating the grains and producing a refined grain structure, which effectively responds to this technique to improve the strength and mechanical properties. Another variant of Friction stir welding is Friction Stir processing (FSP) is used to localized refinement of grains by modifying material’s microstructure [10]. Many researchers have worked in the area of FSP studying the thermo-mechanical process [11–17]. In Friction stir welding, tool parameters such as tool pin profile, shoulder diameter; pin diameter and process parameters such as rotational speed, welding speed and plunge depth play a major role in producing defect
JoMME (2016) 1-11 © STM Journals 2016. All Rights Reserved
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Journal of Materials & Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print) Volume 6, Issue 3 www.stmjournals.com
Effect of Pulse Current Micro Plasma Arc Welding Parameters on Pitting Corrosion Rate of AISI 316Ti Sheets in 3.5 N NaCl Medium Kondapalli Siva Prasad* Department of Mechanical Engineering, Anil Neerukonda Institute of Technology and Sciences, Visakhapatnam, Andhra Pradesh, India Abstract
Austenitic stainless steel sheets are used for fabrication of components, which require high temperature resistance and corrosion resistance such as metal bellows used in expansion joints in aircraft, aerospace and petroleum industries. When they are exposed to seawater after welding they are subjected to corrosion as there are changes in properties of the base metal after welding. The corrosion rate depends on the chemical composition of the base metal and the nature of welding process adopted. Corrosion resistance of welded joints can be improved by controlling the process parameters of the welding process. In the present work Pulsed Current Micro Plasma Arc Welding (MPAW) is carried out on AISI 316Ti austenitic stainless steel of 0.3 mm thick. Peak current, Base current, Pulse rate and Pulse width are chosen as the input parameters and pitting corrosion rate of weldment in 3.5 N NaCl solution is considered as output response. Pitting corrosion rate is computed using Linear Polarization method from Tafel plots. Response Surface Method (RSM) is adopted by using Box-Behnken Design and total 27 experiments are performed. Empirical relation between input and output response is developed using statistical software and its adequacy is checked using Analysis of Variance (ANOVA) at 95% confidence level. The main effect and interaction effect of input parameters on output response are also studied. Keywords: Plasma arc welding, austenitic stainless steel, pitting corrosion rate
INTRODUCTION
Austenitic Stainless Steel (ASS), being the widest in use of all the stainless steel groups finds application in the beverages industry, petrochemical, petroleum, food processing and textile industries amongst others. It has good tensile strength, impact resistance and wear resistance properties. In addition, it combines these with excellent corrosion resistant properties [1]. Welding is one of the most employed methods of fabricating ASS components. ASS is largely highly weldable; the higher the carbon content, the harder the SS and so the more difficult it is to weld. The problem commonly encountered in welded ASS joints is intergranular corrosion, pitting and crevice corrosion in severe corrosion environments. Weld metals of ASS may undergo precipitation of (CrFe)23C6 at the grain boundaries, thus depleting Cr and making the SS weldment to be preferentially susceptible to corrosion at the grain
boundaries. There may also be the precipitation of the brittle sigma Fe-Cr phase in their microstructure if they are exposed to high temperatures for a certain length of time as experienced during welding. High heat input welding invariably leads to slow cooling. During this slow cooling time, the temperature range of 700–850°C stretches in time and with it the greater formation of the sigma phase [2]. In Pulsed current MPAW process, the interfuse of metals was produced by heating them with an arc using a nonconsumable electrode. It is widely used welding process finds applications in welding hard to weld metals such as aluminium, stainless steel, magnesium and titanium [3]. The increased use of automated welding urges the welding procedures and selection of welding parameters must be more specific for good weld quality and precision with minimum cost [4]. The bead geometry plays an important
JoMME (2016) 12-24 © STM Journals 2016. All Rights Reserved
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Journal of Materials & Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print) Volume 6, Issue 3 www.stmjournals.com
Recovery of Iron Values from Waste Iron Ore Slime 1
Jyolsna Jerin1, Rajendra Kumar Rath2, Anil Kumar1,*
National Institute of Foundry and Forge Technology, Ranchi, Jharkhand, India 2 CSIR-National Metallurgical Laboratory, Jamshedpur, Jharkhand, India
Abstract
Iron ore slime is a waste material generated after beneficiation of iron ores. Due to limited iron ore resources and fast depleting of high-grade iron ore, iron ore producers are emphasizing on recovery of iron values from iron ore slime. Different beneficiation techniques such as hydrocyclone, Wet High Intensity Magnetic Separator (WHIMS), Dispersionflocculation, and Flotation are some options to recover the lost iron value from the waste. In the present work, an attempt has been made, to beneficiate iron ore slime using Hydrocyclone, WHIMS and dispersion-flocculation. Iron ore slime (-150 μm) was obtained after scrubbing and wet screening of a low-grade iron ore assayed 42.7% Fe with 12.5% Al2O3 and 13.68% SiO2. Size analysis revealed that 90% of the iron ore slime was having size less than 72 μm. The isoelectric point of the iron ore slime was found to be at pH 4.21. The optimum condition was applied for Hydrocyclone to obtain maximum recovery, i.e., 89.2%. The cyclone underflow was enriched to 54.8% Fe with 45% recovery using WHIMS at current intensity of 2 Amp. Dispersion-flocculation could upgrade up to 47% Fe only. The nonmagnetic fraction of WHIMS was upgraded from 37 to ~39% Fe using dispersion-flocculation under the optimized condition. Keywords: Iron ore slime, recovery, Hydrocyclone, WHIMS and dispersion-flocculation
INTRODUCTION
World steel production is increasing steadily over the years leading to increase in the requirement of iron ore. According to information published in the Indian Mineral Yearbook, 2011–2012, the total iron ore resource of the country is estimated to be around 28.52 billion tonnes. This excludes Banded Hematite Jasper (BHJ) and Banded Hematite Quartzite (BHQ) deposits [1]. The main iron ore deposits in India occur in the eastern, central, and southern parts, for example, Jharkhand, Orissa, Karnataka, Chhattisgarh, and Goa. Generation of iron ore slimes in India is estimated to be 10–25% by weight of the total iron ore mined [1–4]. The iron ore values are lost to the tune of 15– 20 million tones every year. These slimes are readily available in finer size typically assaying 55–60% Fe [3]. These slimes are dumped in the tailing ponds in the mine area and cause environmental concern. Iron ore slime is a waste generated after beneficiation of iron ores. Due to limited iron ore resources and depleting high-grade iron ore, iron ore
producers are emphasizing on recovery of iron values from iron ore slimes. Generally, physical beneficiation techniques such as gravity, magnetic, flotation and selectiveflocculation for enriching the iron values from slimes are employed. Rath et al. studied dispersion-flocculation experiments on individual samples of hematite, quartz and kaolinite as a function of different process parameters such as pH, flocculation time and dosages of reagents. They could find out a condition for selective separation of hematite from quartz and kaolinite and applied to ternary synthetic mineral system [5]. Thella et al. conducted beneficiation on iron ore slime using desliming and flotation. The slime assayed 51% Fe. Classification of slimes with two stage Hydrocyclone gives a concentrate containing 61.99% Fe with Fe recovery of 54.55% in Stage I. Concentrate from Stage II Hydrocyclone contains 62.19% Fe with Fe recovery of 47.45% with respect to initial feed [6]. Manna et al. conducted
JoMME (2016) 25-31 © STM Journals 2016. All Rights Reserved
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Journal of Materials & Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print) Volume 6, Issue 3 www.stmjournals.com
Recovery of Iron Values from Iron Ore Slimes using Reagents 1
Rajesh Chintala1, R.K. Rath2, Anil Kumar1
National Institute of Foundry and Forge Technology, Hatia, Ranchi, Jharkhand, India 2 CSIR-National Metallurgical Laboratory, Jamshedpur, Jharkhand, India
Abstract
Mining wastes include waste generated during the extraction, beneficiation or processing of minerals like iron ore fines, slimes and tailings. Approximately 10–20% of the raw material is discarded as slimes in to slime ponds/tailing dams. Recovery of iron values from slimes result in economic benefit by utilization of waste as a resource and minimizes the threat to the environment. The iron ore slime is generally considered as waste due to its ultrafine nature and its processing limitations. The chemical analysis of the present iron ore slime is 34.75% Fe with 21.94% SiO2, and 14.4% Al2O3. This research work presents the route to size enlargement of slime using reagents and enrichment of iron values by various beneficiation techniques for the effective utilization of iron ore slime. Screen analysis revealed that 90% of the particles are smaller than 80.15 µm. In the present investigation, the recovery of lost iron values from iron ore slime waste was attempted using different beneficiation techniques like Enhanced gravity separation (EGS) Falcon concentrator, Gravity separation by Mineral separator and Vanner, and selective flocculation after treatment with various reagents. Mineral separator generated a concentrate assaying 46.3% Fe with 56.2% recovery using polyacrylamide flocculant at 90 sec collection time and similarly Vanner produced a concentrate assaying 54.5% Fe with a recovery of 41.6% using CMC. From selective flocculation studies, a concentrate assaying 45.3% Fe with 42.1 yield % was obtained using modified corn starch at a settling time of 5 min, as starch facilitates the selective adsorption on iron particles, which in turn leads to enhancement in selectivity and recovery. Keywords: Iron ore slime, Tailing dams, Gravity, Enhanced gravity separator, Reagent
INTRODUCTION
India is bestowed with large and rich sources of iron ore in terms of quantity and quality. India occupies sixth position in iron ore resource base and ranks fourth with respect to world iron ore production [1]. The existing reserves of hematite (averaging around 63% Fe) are the only source of iron ore and as such, these reserves may not last beyond 25–30 years at the present rate of consumption. Hence, to meet the future and projected requirement, additional domestic resources like slimes and fines dumped elsewhere in mines have to be utilized, which are available in abundance [2]. In India most of the washing plants located in mines generates lumps as well as fines. During this process, a large quantity about 18–25% of ROM of slime is generated containing around 48–60% Fe content, which are discarded as tailings [3]. According to the latest guidelines issued by
IBM, the cutoff grade for tailings is 45% [4]. This huge accumulation of slimes poses environmental problems particularly during rainy season when these fines get washed away and affect the agricultural fields, water bodies, removal of vegetation cover, deforestation, land slope changes, increased risk of erosion, water pollution and contamination of agricultural goods and risk of human health [5, 6]. The major iron ore mines are located in the states of Jharkhand, Orissa, Goa, Karnataka and Chhattisgarh [7]. Statistics showed that the increase in 1% Fe in the concentrate increases productivity of the hot metal by 2% and reduced thereby coke and limestone requirements by 1.8 and 0.9 %, respectively [8]. As fines and slime forms considerable part of iron ore resources, value addition to the iron ore fines through beneficiation is the need of the hour [9]. Generally, iron ore tailings contain substantial
JoMME (2016) 32-43 © STM Journals 2016. All Rights Reserved
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Journal of Materials & Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print) Volume 6, Issue 3 www.stmjournals.com
Solidification Curve Analysis of Cylindrical Casting by FEM Dharmesh Barodiya*, M.D. Mahajan, Shaheen Beg Mughal
Department of Industrial and Production Engineering, Shri Govindram Seksaria Institute of Technology and Science, Indore, Madhya Pradesh, India
Abstract
In casting process, molten metal is solidified in mould cavity. Solidification process majorly classify into three different sections: (i) liquefaction (ii) solidify (iii) after solidification. In all three processes, one parameter which is called 'IHTC' (Intermediate Heat Transfer Coefficient), is varies with time. IHTC coefficient depends on shape, size, type of casting etc., so, it is continuously varies with all dependent functions. So, establishment of IHTC value is a very difficult task and hot cake between researchers. Various methods are available for establishment of IHTC value, like inverse method. In this study we establish IHTC value via inverse methodology. Solid cylinder of ADC 12 Material and sand casting process taken as part of analysis. K-type thermocouple and Autonix temperature indicator are used for temperature measurement. ADC 12 (Al alloys) material is used in various application such as automotive transmission system, escalator steps barbeque covers, oil pumps. Pro cast is used for simulation purpose. After complete experiment and simulation we are establishing IHTC value which is 2000 w/m2-k. Keywords: Sand casting, ADC 12, solid cylinder, K type thermocouple, Autonix temperature indicator, Procast.
INTRODUCTION
Casting is a manufacturing process by which a molten material is poured into a mold, allowed to solidify in the mold box, and then cast out or broken out to make a fabricated part. Casting is used for making parts of convoluted aspect that would be crucial or uneconomical to make by other methods, such as cutting from solid material (Campbell, 2002). This solidification or heat is transferred by the following equations: Q=h (Tms–Tcs)
(1)
Where, Q is heat flux, Tms is temperature of mould surface, Tcs is temperature of casting surface, and h is called intermediate heat transfer coefficient [1].
LITERATURE REVIEW
As computer technology is becoming popular, computer simulation of metal casting process is becoming an accepted tool. With the help of simulation, we can now produce virtual casting without actually doing experimental
work. This saves time, material, manpower and resources, and hence decrease cost of product also. In this literature review, we present the work done by analyzers in the area of casting solidification simulation with the help of finite element method. A metal casting process is defined as a metal part produced by pouring hot molten metal into a mould box containing a cavity which has the desired shape of the final product, and providing the molten metal to solidify in the mold. According to Taylor et al., 1959), copper was the first metal to be cast; it was used for the production of bells for large cathedrals at the beginning of the 13th century. However, the first authorized casting of aluminum was produced in 1876. The following researchers have used inverse method to find out IHTC value. Kovačević et al. generated a mathematical co-relation for finding out IHTC value of Al alloy casting [2]. Choudhari et.al, (2013) concluded that IHTC value depends on casting mould thickness and
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