DOCSLIB.ORG

Dot 11429 DS1.Pdf

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Dot 11429 DS1.Pdf PREFACE This report was prepared by L. C. Schroeder and D. R. Poirier of the Department of Metallurgical Engineering, The University of Arizona. The technical monitor was Mr. James Morris of the Transportation Systems Center in Cambridge, Massachusetts. Dr. Roger K. Steele, then of the Federal Railroad Administration, Transportation Test Center in Pueblo, Colorado graciously arranged for the thermite-welding at the FAST facility in Pueblo. Messrs. Morris and Steele generously made themselves available for technical consultation for the duration of the project. Their assistance is gratefully acknowledged. Preceding page blank iii METRIC CONVERSION fACTORS App•••I.... c••"••a1... •• M••rlc M....... .. - ~ A" IC••"I••• ,... M"rlc M . s--:: I,.,., •••• ,.. •••• ...111,1, " T. I'.... I,.... •... ,••_ ........, " ,. ,... I'.... = .. fl.. - .. - ~ .. LENGTH a LENGTH -- _ ..iUi_'... .... iRc.... I. :: an e...U...... 0.. inc.... i. - .. _,... 2.2 .... h .. "2.' -,~,.. COlI - == :=.... _,... 1.1 ,.nt. yd II :Ill CIft'O""1II _.. =- .. ki_... •.• mile. .1 .,. ,ant. 0.' _.... "'-=- _ • ";1.. 1.1 ki........... iiL- ::: == AREA AREA _ = :I I • = rJ _ .......,...... '.11 __ .. ..I _ ••• _'" clllti...... rJ = ..1 _ ••_I... 1.2 aq ,ant. .,; "I _. .... _.. .........2 _ ..2 _ .. kil....'.. •.• aq i1.. ",2 .,.,a _-,..... ••• _........ .". • loa hac.....,0.000 .11 2.. •. roil _ .,.. 2.' ell"'" lIil__ ".". _ ... _.. •.• ......... ... - = .. .. ;:;.. MASS (w.I"'1 ...<" MASS (w.i,··1 -::: !2 =-- • .._ 1.031 ounc" .. .. _. 21 .-. e= kt kilogr_ 2.2 pound. .. .. 0." kilogr_ kl ::, _.11000 ktI 1.1 _ '0.. ......, 0.' _... "'-'i:---- IZOOO", • = 0 VOLUME _ a- .. VOLUME = • • onillUiI..... g-.. .milil.. 1.'2 ".dld _. II 01 .... ..._. ,. 2 1 pont. III Tbap "b' 11 Illillilit.....1 - = ... II... .1 01 'Iu':=~ :Ill ..iUili.... "".. ~ I Ii'... 1.111 _rt. ... c c.... 0.2' 'i'... I '-.. 1 10,... 0.2' lIlOlI.on. ~' pi pin,. 0.'7 lit... 1 ;;;;;- ..) cubic l1li'.. 3. cub~c ,... h ) II' "".... 0.95 II,..., -....) cubic 1111'.' 1.2 cubiC ,ani. yd ';' lIlOlIon. U Ill... ') _ ~ .. c.... ~c '"' 0.02 cUb~C 11111.. '" .. TEMPERATURE (IIIC" , ..) cuboc ,lid. 0.1' cubIC mI'''. ",2.. =- _. TEMPERATURE (•••c" - .'c C.,.Iu. .111_ ' ..........1' ", _ ,__ _ 221 '_'.'- " ' ..........1. iI'.1". C.I.iu. 'c __ .. • temper.lUre I""'r.cliot l.mpera'WI .... -- , 221 __ .. I, 22 .... 212 -40 0 !40 .0 l 120 1.0 aoa J con\l'''kJ~ ~.;;; 'ai~ ,~ ,.~I -, In • 2.54 tel&llcllvl. f ... 01"-' ...e' Mtd PlUf. dilla.led '.-bIn. seo NBS MISC. "ubi. 2N. i· =... _I' it '.' l' I 'I' (;0' '. • ' ••' ',' Ito Unl" of ".,ghe. and ....SUf••• 'uc.I2.25. ~ C."IOQ No. Cll.IO.2So. ! _! ~g 31 C Ill. TABLE OF CONTENTS Section 1. I NTRODUCT I ON ••••••••••••••••••••••••••••••••••••• 1 1.1 Statement of the Problem.................... 1 1.2 Objective of this Study..................... 2 2. REVIEW OF RELATED STUDIES •••••••••••••••••••••••• 4 2.1 Application of the Aluminothermic Process... 4 2.2 Alternative Reductants to Aluminum.......... 4 2.3 Additives that Affect the Aluminothermic Process. .................................... 5 2.4 Thermite Rail-Welds......................... 7 2.5 Weld Integrity.............................. 10 2.6 Residual Stresses in Welds.................. 16 3. EXPERIMENTAL PROCEDURES •••••••••••••.•••••••••••• 19 4. RESULTS AND DISCUSSIONS •••.••••••••••.•.••••••••• 23 4.1 Mechanical Properties....................... 23 4.1.1 Hardness Profiles••••••••••••.••••••• 23 4.1.2 Impact Properties ••.••••••••••••••••• 24 4.1.3 Tensile Properties •.••••••••••••••••• 25 4.1. 4 Fractography of Impact and Tensile Specimens .•••.•••.••••••••••. 26 4.1.4.1 Charpy V-Notch Specimens in the HAZ.................. 27 4.1.4.2 Charpy V-Notch Specimens in the Weld Metal........... 28 4.1.4.3 Tensile Specimens in the HAZ 29 4.1.4.4 Tensile Specimens in the Weld Metal.................. 30 4.2 Structural Analyses......................... 31 4.2.1 Macrostructures •••••.•••••.•••••••••• 31 4.2.2 Microstructures •••••••••••••••••••••• 33 4.2.3 Inclusion Evaluation••••••••••••••••• 34 4.3 Thermal Measurements........................ 36 4.4 Residual Stresses........................... 39 v TABLE OF CONTENTS (CONT.) Section Page 5. CONCLUSIONS.................................... 43 6 • REFERENCES. ••••••••••••••••••••••••••••••• .• •••• 47 APPENDIX - THERMITE WELDING (FIELD WELDING).............. 55 vi LIST OF ILLUSTRATIONS Figure 1 RESIDUAL STRESSES IN A NONREINFORCED THERMITE RAIL-WELD.......................................... 59 2 MOLD CONFIGURATION AND FLOW PATTERN OF THE MOLTEN STEEL FOR THE THERMITE RAIL-WELDS •••••••••••••••••• 60 3 THERMOCOUPLE LOCATIONS FOR WELDS 1, 2 AND 4 •••••••• 61 4 LOCATIONS OF THERMOCOUPLES IN THE WELD METAL OF WELD 9.......................................... 62 5 LOCATIONS OF TENSILE AND IMPACT SPECIMENS, HARDNESS PROFILES AND MICROSTRUCTURE SPECIMENS IN WELDS................................. 63 6 LOCATIONS OF STRAIN GAUGE ROSETTES FOR RESIDUAL STRESS MEASUREMENTS................................ 64 7 HARDNESS PROFILES OF WELDS 1, 4 AND 7 ..•••.•..••.•• 65 8 HARDNESS VARIATIONS IN THE HAZs OF ALLOY RAILS RELATIVE TO THE HARDNESS OF PARENT RAIL •••••••••••• 66 9 HARDNESS VARIATIONS IN THE HAZs OF STANDARD AND OF HEAD-HARDENED RAIL RELATIVE TO THE HARDNESS OF PARENT RAIL........................................ 67 10 HARDNESS OF THE WELD METAL AS A FUNCTION OF PREHEAT TIME AND DISTANCE FROM THE WELD CENTERLINE ••••••••• 68 11 FRACTURE OF IMPACT SPECIMEN THROUGH THE REGION OF MINIMUM HARDNESS IN THE HEAT-AFFECTED ZONE ••••••••• 69 12 FRACTURE SURFACE OF FIGURE 11: (a) ORIGINAL RAIL SIDE; (b) HAZ SIDE ...•.••••••••••••••.••••••••••.• 70 13 FRACTURE OF IMPACT SPECIMEN THROUGH THE REGION OF MINIMUM HARDNESS IN THE HAZ OF THE HEAD-HARDENED RAIL OF WELD 8. (a) ORIGINAL RAIL SIDE; (b) HAZ SIDE........................................... 71 14 REGION OF EASY SEPARATION OF THE HAZ SIDE (REGION OF MINIMUM HARDNESS) OF THE IMPACT SPECIMEN FROM THE CrV RAIL OF WELD 4 ..•..•.....•......••.•.. 72 vii LIST OF ILLUSTRATIONS (CONT.) Figure 15 FRACTURES OF IMPACT SPECIMENS FROM THE WELD METAL. (a) WELD 1: ALLOY WELD METAL, (b) WELD 8: STANDARD WELD METAL ••••••••••••••••••••••••••••••• 73 16 LOW DUCTILITY FRACTURES OF TENSILE SPECIMENS IN THE REGION OF MINIMUM HARDNESS. (a) FROM WELD 1 IN THE Cr RAIL, (b) FROM WELD 4 IN THE STANDARD RAIL................................................. 74 17 "CUP AND CONE" FRACTURES OF TENSILE SPECIMENS IN THE REGION OF MINIMUM HARDNESS. (a) FROM WELD 1 IN THE CrMo RAIL: (b) FROM W~~D 8 IN THE HEAD- HARDENED RAIL . 75 18 "CUP AND CONE" FRACTURES WITH RADIAL FEATURES FROM TENSILE SPECIMENS IN THE REGION OF MINIMUM HARDNESS. (a) FROM WELD 4 IN THE CrV RAIL: (b) FROM WELD 8 IN THE erMa RAIL..................................... 76 19 TENSILE FRACTURES OF THE HAZ IN THE REGION OF MINIMUM HARDNESS. (a) FROM WELD 4 IN THE STANDARD RAIL: (b) FROM WELD 4 IN THE CrV RAIL ••••••• 77 20 FRACTURES OF TENSILE SPECIMENS FROM THE WELD METAL. (a) WELD 3, ALLOY WELD METAL: (b) WELD 4, STANDARD WELD METAL •••••••••••••••••••••••••••••••••• 78 21 FRACTURE OF THE TENSILE SPECIMEN FROM THE STANDARD WELD METAL OF WELD 6 •••••••••••••••••••••••• 79 22 MACROSTRUCTURE OF THE HEAD AREA OF WELD 6 •••••••••••• 80 23 TENSILE FRACTURE OF THE ALLOY WELD METAL OF WELD 10 SHOWING MICROPOROSITY ••••••••••••••••••••••••••••• 81 24 MACROSTRUCTURE OF WELD 2, ALLOY WELD METAL ••••••••••• 82 25 MACROSTRUCTURE OF WELD 10 SHOWING THE EFFECT OF A LONG PREHEAT......................................... 83 26 PEARLITIC STRUCTURE (a) AND TRANSITIONAL PEARLITE AND BAINITE (b) IN WELD METAL OF WELD 14 ••••••••••••• 84 27 VERY FINE TRANSITIONAL PEARLITE IN THE HAZ OF THE Cr RAIL OF WELD 1 . 85 viii LIST OF ILLUSTRATIONS Figure 28 PROEUTECTOID FERRITE IN THE WELD METAL OF WELD 6 •••••• 86 29 SPHEROIDITE AND DEGENERATIVE PEARLITE IN THE OUTER EDGE OF THE HAZ OF THE HH RAIL OF WELD 7 •••••••••••••• 87 30 ALUMINA (WITH SILICA) INCLUSIONS IN THE CrV FUSION ZONE OF WELD 6........................................ 88 31 TEMPERATURE AS A FUNCTION OF TIME AND POSITION IN THE RAIL DURING THE WELDING PROCESS FOR WELD 1 ••••• 89 32 TEMPERATURE AS A FUNCTION OF TIME AND POSITION IN THE WELD METAL OF WELD 9.............................. 90 33 RAIL TEMPERATURE DISTRIBUTIONS AT THE END OF PREHEAT •• 91 34 PEAK TEMPERATURES AS A FUNCTION OF DISTANCE FROM THE RAIL END: (a) WELD 1: (b) WELD 2. STANDARD PREHEATS. 92 35 PEAK TEMPERATURES AS A FUNCTION OF DISTANCE FROM THE RAIL END: (a) WELD 4 - STANDARD PREHEAT, (b) WELD 3 - LONG PREHEAT...................................... 93 36 PRINCIPAL RESIDUAL STRESSES IN WELD 11•••••••••••••••• 94 ix LIST OF TABLES Table 1 MECHANICAL PROPERTIES FROM BEND TESTS ON RAIL AND WELDED RAI L. ••••••••••••••••••••••••••••••••••• 95 2 EXPERIMENTAL CONDITIONS FOR WELDS ••••••••••••••.••• 96 3 NOMINAL COMPOSITIONS OF RAILS AND OF WELD METAL •.•• 97 4 HARDNESSES OF THE HEAT-AFFECTED ZONES •••••••••••••. 98 5 IMPACT ENERGIES OF THE WELDS AT 200C ••••••••••.••.• 99 6 TENSILE PROPERTIES OF THE WELDS ..••••..••••...••••• 100 7 FRACTURE CHARACTERISTICS OF TENSILE SPECIMENS OF THE HEAT AFFECTED ZONES ••••••••••••••••••••••••• 103 8 FRACTURE CATEGORIES OF TENSILE SPECIMENS IN THE REGION OF MINIMUM HARDNESS •.••••••••••••••••••••••• 104 9 EDS ANALYSES OF THE SURFACES OF THE AS-CAST COLUMNAR STRUCTURE IN STANDARD WELD METAL ••.•••••.• 105 10 EDS ANALYSES OF THE SURFACES OF DENDRITES IN ALLOY WELD METAL................................... 106 11 INCLUSION CONTENT OF WELD METAL .••••.••.••••.•••••• 107 12 TIME IN THE TRANSFORMATION
Load more

Recommended publications
  • Preparation of Alumina-Chromium Composites by Reactive Hot-Pressing A1 + Cr2o3 Based Powders D
    Preparation of alumina-chromium composites by reactive hot-pressing A1 + Cr2O3 based powders D. Osso, A. Mocellin, Gérard Le Caër, A. Pianelli To cite this version: D. Osso, A. Mocellin, Gérard Le Caër, A. Pianelli. Preparation of alumina-chromium composites by reactive hot-pressing A1 + Cr2O3 based powders. Journal de Physique IV Proceedings, EDP Sciences, 1993, 03 (C7), pp.C7-1311-C7-1316. 10.1051/jp4:19937202. jpa-00251836 HAL Id: jpa-00251836 https://hal.archives-ouvertes.fr/jpa-00251836 Submitted on 1 Jan 1993 HAL is a multi-disciplinary open access L’archive ouverte pluridisciplinaire HAL, est archive for the deposit and dissemination of sci- destinée au dépôt et à la diffusion de documents entific research documents, whether they are pub- scientifiques de niveau recherche, publiés ou non, lished or not. The documents may come from émanant des établissements d’enseignement et de teaching and research institutions in France or recherche français ou étrangers, des laboratoires abroad, or from public or private research centers. publics ou privés. JOURNAL DE PHYSIQUE IV Colloque C7, supplement au Journal de Physique 111, Volume 3, novembre 1993 Preparation of alumina-chromium composites by reactive hot-pressing A1 + Cr203 based powders D. OSSO, A. MOCELLIN, G. LE CAER and A. PIANELLI LSG2M, URA I59 du CNRS, Ecole des Mines, 54042 Nancy cedex, France Chromium-Alumina based composites have been obtained by reactive sintering under load and vacuum of various powder blends. The starting mixtures have been prepared from commercially available aluminium metal, chromium and aluminium oxides, and a thermally unstable titanium compound respectively. Differential thermal analysis (DTA) and differential calorimetry (DSC) as well as X-ray diffraction were used to identify chemical transformations taking place within the system.
    [Show full text]
  • Chromium 28.07.2020.Pdf
    Chromium Chromium is a chemical element with the symbol Cr and atomic number 24. It is the first element in group 6. It is a steely-grey, lustrous, hard and brittle transition metal. Chromium is the main additive in stainless steel, to which it adds anti-corrosive properties. Chromium is also highly valued as a metal that is able to be highly polished while resisting tarnishing. Polished chromium reflects almost 70% of the visible spectrum, with almost 90% of infrared light being reflected. Ferrochromium alloy is commercially produced from chromite by silicothermic or aluminothermic reactions and chromium metal by roasting and leaching processes followed by reduction with carbon and then aluminium. Chromium metal is of high value for its high corrosion resistance and hardness. A major development in steel production was the discovery that steel could be made highly resistant to corrosion and discoloration by adding metallic chromium to form stainless steel. Stainless steel and chrome plating (electroplating with chromium) together comprise 85% of the commercial use. Ores:- Although chromium occurs in many minerals, the only ore exploited commercially is chromite. This spinel mineral is ideally composed of ferrous oxide and chromic oxide with the chemical composition FeO · Cr2O3, but it is often found in nature with magnesia (MgO) substituting for FeO and alumina (A12O3) or ferric oxide (Fe2O3) substituting for Cr2O3. Other minerals such as silica (SiO2) are also present. Extraction:- Chromite, FeCr2O4, is the most commercially useful ore, and is extensively used for extraction of chromium. Chromium is produced in two forms: (a) Ferrochrome by the reduction of chromite with coke in an electric arc furnace.
    [Show full text]
  • The Preparation of Chromium Metal by a Sealed, Cold-Hearth, Plasma-Assisted Aluminothermic Method
    The preparation of chromium metal by a sealed, cold-hearth, plasma-assisted aluminothermic method by L.R. Nelson * applications of aluminothermic-reduction technology to the production of metals. Synopsis Future expansion of aluminothermic metal production depends, in part, on the capability The efficiency and cost-effectiveness of the aluminothennic to prove that metal oxides from new sources reduction process in the production of ferro-alloys and 'pure' are amenable to processing. For evaluation of metals depends strongly on appropriate balancing of the process the suitability to aluminothermic reduction of energy required. Insufficient energy results in a poor metal yield, chromic oxide from a unique source, a sealed, while over-supply can result in excessive fuming and possibly even cold-hearth, plasma-assisted test unit was ejection of the reactor contents in a potentially dangerous 'thennite developed. This provided a means of evaluating bomb' reaction. This situation becomes even more critical when the suitability of limited quantities of oxide from new sources must be the aluminothermic preparation of 'pure' evaluated, dictating smaller-scale testwork. The resulting higher chromium metal from a chromic oxide source. relative heat losses from the system complicates control of the This paper gives details of the technique and energy balance, and usually requires the addition of thermal describes the experimental results. boosters or reactant preheating in order to sustain an autothermic process. This often detracts from the quality of the metal product, Process energy required and adds to the hazards of batch aluminothennic-reduction testing. The development of a small-scale method (producing less than General aluminothermic processes 2,5 kg of metal) for the plasma-assisted aluminothennic reduction of chromium oxide that overcomes such difficulties is described.
    [Show full text]
  • Manufacturer Thermite Weld (Pakistan) EST
    THERMITE WELDING NEW GENERATION WELDING Manufacturer Thermite Weld (Pakistan) EST. Office: Room No. 1, 3rd Floor Raja Chamber, 35-Queens Road, Lahore. Factory: Shadiwal, Moterway, Thokar Niaz Baig, Lahore 0322-4101587, [email protected], [email protected] www.thermiteweld.com thermiteweld THERMITE WELDING EXECOTHERMICWELD NEW GENERATION WELDING Manufacturer Thermite Weld (Pakistan) EST. Office: Room No. 1, 3rd Floor Raja Chamber, 35-Queens Road, Lahore. Factory: Shadiwal, Moterway, Thokar Niaz Baig, Lahore 0322-4101587, [email protected], [email protected] www.thermiteweld.com thermiteweld THERMITE WELDING EXECOTHERMICWELD NEW GENERATION WELDING Manufacturer Thermite Weld (Pakistan) EST. Office: Room No. 1, 3rd Floor Raja Chamber, 35-Queens Road, Lahore. Factory: Shadiwal, Moterway, Thokar Niaz Baig, Lahore 0322-4101587, [email protected], [email protected] www.thermiteweld.com thermiteweld INTRODUCTION The thermite welding system is a miracle of chemistry an easy simple to use in field process for welding copper to copper, copper to steel, without the use of external source. Thermite connections utilize the high temperature reaction of powdered copper oxide and aluminum, which when ignited, produced aluminum oxide (in the form of slag) and super-heated copper. The reaction takes place oxide with molten metal aluminum in various welding applications. The reaction takes place in a graphite crucible. The pieces to be welded are introduced prior to the reaction. After the powder is ignited, molten metal from the aluminothermic reaction flows around the pieces, causing them to melt and fuse into a solid homogeneous piece. When the total mass of powder becomes supper heated molten copper, it flows through the mould into the conductor to be joined by melting a thin steel disc which previously has stopped the powder from dropping through the mould.
    [Show full text]
  • Manufacturer of Exothermic Weld Powder & Graphite
    MANUFACTURER OF EXOTHERMIC WELD POWDER & GRAPHITE MOULDS Exothermic welding, also known as exothermic bonding and is a welding process for joining two electrical conductors, that employs superheated copper alloy to permanently join the conductors. The process employs an exothermic reaction of a copper thermite composition to heat the copper, and requires no external source of heat or current. The chemical reaction that produces the heat is an aluminothermic reaction between aluminum powder and a metal oxide. The reaction reaches very high temperatures, depending on the metal oxide used. The reactants are usually supplied in the form of powders, with the reaction triggered using a spark from a flint lighter. The activation energy for this reaction is very high however, and initiation requires either the use of a “booster” material such as powdered magnesium metal or a very hot flame source. The aluminum oxide slag that it produces is discarded. When welding copper conductors, the process employs a semi- permanent graphite crucible mould, in which the molten copper, produced by the reaction, flows through the mould and over and around the conductors to be welded, forming an electrically conductive weld between them. When the copper cools, the mould is either broken off or left in place. Alternatively, hand-held graphite crucibles can be used. The advantages of these crucibles include portability, lower cost (because they can be reused), and flexibility, especially in field applications. The weld formed has higher mechanical strength than other forms of weld, and excellent corrosion resistance. It is also highly stable when subject to repeated short-circuit pulses, and does not suffer from increased electrical resistance over the lifetime of the installation.
    [Show full text]
  • Aluminothermic Reduction of Anatase Concentrates Lino
    ALUMINOTHERMIC REDUCTION OF ANATASE CONCENTRATES LINO R. FREITAS*, Metallurgical Engineer, M.Sc. and Ph.D. PAULO R. MAZONI*, Metallurgical Engineer MAGID W. SAAB*, Metallurgical Engineer, M.Sc. *Center of Technology, Cornpanhia Vale do Rio Doce, Belo Horizonte-MG, Brazil INFACON 86 PROCEEDINGS 349 ABSTRACT The aluminothermic reduction of anatase concentrates (80-86% Ti0 2 i, from Tapira-MG, Brazil, has been studied in an open, alumina-lined reactor. Thermodynamic calculations, as well as the preliminary experiments, indicated that the reaction is not sufficiently exothermic to enable separation of the products. Therefore, additional heat is necessary and a heat booster such as sodium chlorate (NaC10 3 ) was employed. It was found that NaC10 3 additions in excess of 15% of the Ti0 2 content in the feed charge were required to obtain good metal/slag separation. Batch tests with a maximum charge of 15 kg of concentrate were performed and titanium recoveries up to 74% were obtained. The effect of the following variables on the titanium yield was determined: amount of feed charge, amount of fluxes (lime and fluorspar), particle size of reagents and amount of aluminium in excess of the stoichiometric quantity. Additional tests with Australian rutile and synthetic titanium dioxide as feed materials were performed, with similar results. Also, experiments without boosters, but with external heating were conducted and comparable titanium recoveries were obtained. 350 ALUMINOTHERMIC REDUCTION OF ANATASE INTRODUCTION The aluminothermic reduction, also known as production of titanium by aluminothermic the thermite process, is widely used in the reduction, however, is very limited and preparation of ferro-alloys.
    [Show full text]
  • Semi-Empirical Software for the Aluminothermic and Carbothermic Reactions
    Association of Metallurgical Engineers of Serbia Scientific paper AMES UDC: 544.653.2:004.41 SEMI-EMPIRICAL SOFTWARE FOR THE ALUMINOTHERMIC AND CARBOTHERMIC REACTIONS Milorad Gavrilovski1, Vaso Manojlović2*, Željko Kamberović1, Marija Korać1, Miroslav Sokić2 1 Faculty of technology and metallurgy, Karnegijeva 4, University of Belgrade, Serbia 2 Institute for technology of nuclear and other mineral raw materials, Franše d’ Eperea 86, Belgrade, Serbia Received 23.06.2014 Accepted 03.09.2014 Abstract Understanding the reaction thermochemistry as well as formatting the empirical data about element distribution in gas-metal-slag phases is essential for creating a good model for aluminothermic and carbothermic reaction. In this paper modeling of material and energy balance of these reactions is described with the algorithm. The software, based on this model is basically made for production of high purity ferro alloys through aluminothermic process and then extended for some carbothermic process. Model validation is demonstrated with production of FeTi, FeW, FeB and FeMo in aluminothermic and reduction of mill scale, pyrite cinders and magnetite fines in carbothermic process. Introduction Aluminothermic reactions are thermite reactions in witch aluminum metal reacts with some metal oxide reducing it to the pure metal. These reactions are highly exothermic and self-propagating so only initiation is needed to complete the reaction. However, energy of reaction depends on various parameters and it its adjustment can be done by designing of thermite mixture. Aluminothermic reaction has found many applications in production of metals and alloys, welding and coating [1, 2]. In literature there is a lot of data on production, kinetics of reaction, preparation of thermite mixture, effects of additions on metal yield etc [1, 2].
    [Show full text]
  • Exothermic Welding Catalouge S
    EXOTHERMIC WELDING CATALOUGE S. no. EXOTHERMIC WELDING INDEX Page no. 01 Exothermic Weld Process 03 02 Tools Required for Exothermic Weld Process 04 03 Exothermic Weld Operation Process 06 04 General Safety Instructions 08 05 Mould Selection Chart 09 06 Cable to Cable Connections (CTC) 09 07 Cable to Ground Rod Connections (CGRC) 10 08 Cable to Lug / Tape Connection (CLTC) 11 09 Cable to Steel Connections (CTS) 12 10 Steel to Lug / Tape Connections (SLTC) 13 11 Steel to Rod / Stud Connections (SRSC) 13 12 Ground Rod to Ground Rod Connections (GRGR) 14 13 Ground Rod to Tape Connections (GRTC) 14 14 Cable to Re-Bar Connection (CREC) 15 15 Tape to Re-Bar Connection (TREC) 16 16 Re-Bar to Re-Bar Connection (RERE) 16 17 Rod to Re-Bar Connection (RORE) 16 18 Tape to Tape Connection (TTC) 17 AMIABLE IMPEX.Email – [email protected]. +91-9594899995 URL – www.amiableimpex.com Page 2 of 18 EXOTHERMIC WELDING PROCESS Exothermic welding, also known as exothermic bonding and thermite welding is a welding process for joining two electrical conductors, that employs superheated copper alloy to permanently join the conductors. The process employs an exothermic reaction of a copper thermite composition to heat the copper, and requires no external source of heat or current. The chemical reaction that produces the heat is an aluminothermic reaction between aluminum powder and a metal oxide. The reaction reaches very high temperatures, depending on the metal oxide used. The reactants are usually supplied in the form of powders, with the reaction triggered using a spark from a flint lighter.
    [Show full text]
  • Physico Chemical Aspects of Alumino-Thermic Reduction in the Production of Low Carbon Ferro-Alloys
    Physico Chemical Aspects Of Alumino-Thermic Reduction In The Production Of Low Carbon Ferro-Alloys by D. D. Akerkar Deputy Director (Retired) National Metallurgical Laboratory Jamshedpur 831 007. Introduction No doubt Carbon is the oldest, most extensively used and cheapest reducing agent for the extraction of metals, and ferro-alloys, but due to its high affinity for many metals it results in the formation of undersirable carbides. The growing demand of carbon free alloys has generated considerable interest in aluminothermic reduction of various .oxides. A common example of aluminothermic reduction is the thermit welding of rails and repair of steel castings. As early as in 1898, Goldschmidt (1) demonstrated the use of aluminium as a reducing agent in the production of refractory metals. Subscquently, aluminothermic reduction has been extensively used to pro- duce pure metals such as chromium, manganese and master alloys such as carbon free chromium-aluminium, titanium - aluminium, ferro-chrome, ferro-molybdenum, ferro- columbium, ferro-tungsten and ferro-titanium of high purity. Aluminothermic tech- niques have led to notable developments in the field of high purity special steels. The objective of aluminothermic reduction is to utilise the exothermic heat of the reaction for smelting purposes. Aluminothermic reduction did not generate much interest till 1950's due to various reasons such as high cost of pure aluminium and lack of available means for the removal of residual elements and oxides. The interest in alumino-thermic reduction , revived in 1960's and onwards. Since then extensive research work has been, carried out on aluminothermic reduction for producing low carbon ferro-alloys by obtaining 95-96% pure metals from their pure oxides and also metallic values from their oxides available as secondary sources.
    [Show full text]
  • WO 2014/143553 Al 18 September 2014 (18.09.2014) P O P C T
    (12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT) (19) World Intellectual Property Organization linn il inn International Bureau (10) International Publication Number (43) International Publication Date WO 2014/143553 Al 18 September 2014 (18.09.2014) P O P C T (51) International Patent Classification: (71) Applicant: ATI PROPERTIES, INC. [US/US]; 1600 B22F 3/23 (2006.01) C22B 34/24 (2006.01) N.E. Old Salem Road, Albany, Oregon 97321 (US). C22C 1/04 (2006.01) (72) Inventors: FAJARDO, Arnel M.; 15887 N W Oak Hills (21) International Application Number: Drive, Beaverton, Oregon 97006 (US). FOLTZ, IV, John PCT/US20 14/0 18632 W.; 740 1 1th Avenue SW, Albany, Oregon 97321 (US). (22) International Filing Date: (74) Agents: GROSSELIN, John E., Ill et al; 1000 Six PPG 2 6 February 2014 (26.02.2014) Place, Pittsburgh, Pennsylvania 15222 (US). (25) Filing Language: English (81) Designated States (unless otherwise indicated, for every kind of national protection available): AE, AG, AL, AM, (26) Publication Language: English AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY, (30) Priority Data: BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, 13/844,457 15 March 2013 (15.03.2013) U S DO, DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT, HN, HR, HU, ID, IL, IN, IR, IS, JP, KE, KG, KN, KP, KR, KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD, ME, [Continued on nextpage] (54) Title: PROCESS FOR PRODUCING TANTALUM ALLOYS (57) Abstract: Processes for the production o f tantalum alloys are disclosed.
    [Show full text]
  • Mineral Profiles | Niobium-Tantalum
    Niobium–tantalum April 2011 Definitions, mineralogy and Niobium (Nb) Tantalum (Ta) nt deposits Atomic number 41 73 opme Atomic weight 92.90638 180.9479 vel Definitions and characteristics de Density at 293 K 8.581 16.677 l Niobium (Nb) and tantalum (Ta) are transition metals with 3 ra UK very similar physical and chemical properties, and are (g/cm ) ne mi thus commonly grouped together (Table 1). Niobium was Melting point °C 2468 2996 e bl discovered in 1801 by Charles Hatchett, and was originally Boiling point °C 4930 5425 na ai named ‘columbium’; it was subsequently also recog- Vickers hardness 1320 873 st nised by a German chemist, Heinrich Rose, who named su MPa r it ‘niobium’. The names were used interchangeably for fo Electrical 152 at 0°C 131 at 20°C re some time, before ‘niobium’ was finally accepted in 1949. nt resistivity (nano Tantalum was discovered in 1802 by a Swedish scientist, Ce Minerals ohm-metres) Anders Ekeberg. Crystal structure Body centred Body centred Niobium is a shiny, ductile metal with a white lustre. Nat- cubic cubic urally-occurring niobium consists almost exclusively of the Table 1 Selected properties of niobium and tantalum. isotope 93Nb; natural tantalum is mainly 181Ta, with 0.012 per cent 180Ta. A number of other radioactive isotopes of The columbite-tantalite mineral group (Figure 1) is the both elements have been synthesised. most common group of tantalum- and niobium-bearing minerals. Wodginite is also an important source of The overall abundances of niobium and tantalum in the tantalum. The pyrochlore group (Figure 2) is of great average continental crust are relatively low, niobium economic importance, particularly for niobium.
    [Show full text]
  • Parameter Analysis of Non-Metallic Inclusion Formation in Thermite Alloys
    E3S Web of Conferences 280, 07015 (2021) https://doi.org/10.1051/e3sconf/202128007015 ICSF 2021 Parameter analysis of non-metallic inclusion formation in thermite alloys Ihor Skidin1, Oksana Vodennikova2, Sergii Vodennikov3, Levan Saithareiev1, and Shamil Telkov4 1Kryvyi Rih National University, Metallurgy & Foundry Department of Ferrous Metals, Ukraine 2Zaporizhzhia National University, Department of Metallurgy, Ukraine 3Zaporizhzhia Polytechnic National University, Department of Machines and Foundry Technology, Ukraine 4Satbayev University, Metallurgy and Mineral Processing Department, Kazahstan Abstract. The methodology of calculating parameters of the primary and secondary non-metallic inclusion formation in thermite alloys is offered. The regularities of the growth time of non-metallic inclusion in the form of corundum depending on its size, mass and quantity are analysed. It is shown that in the thermite alloy obtained by self-propagating high-temperature synthesis, the average size of corundum inclusions, surrounding the heterogeneous inclusions of chromium carbide, is 15.4 μm. It is shown that during the process of aluminothermic reactions of the SHS process a significant number of small inclusions of corundum is formed. It is shown that the alumina particles are dissolved in the alloy and they are the centers of crystallization and play the role of inoculating modifier. the inclusion’s total number, but also the inclusion’s Introduction critical size, and the assessment of the compositions; the Today, one of the main indicators of metal quality and, size-based distribution of inclusions [4]. correspondingly, the quality of final products is the One of the unsolved problems of the metallurgical contamination of non-metallic inclusions, and both the processes theory is the reliable calculation of the mass, number of inclusions and their nature and size, and composition of non-metallic inclusions in steel.
    [Show full text]