| 1. |
- Akbarnejad, Shahin, 1978-
(författare)
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Mathematical and Experimental Study on Filtration of Solid Inclusions from Molten Aluminium and Steel
- 2023
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Aluminum and steel have been the most produced metal and alloy, respectively, for many years. Their extensive use in various industries, their fundamental role in our everyday life, and their excellent recycling characteristics are the major driving forces for development of their production towards more sustainable processes. A successful integration and application of molten metal filtration from unwanted inclusions in production processes could result in reducing scrap, rework and would provide a cleaner molten metal which could lead to production of metallic materials with enhanced mechanical properties. Filtration of aluminum melts by ceramic foam filters is an established process in aluminum industry. Ceramic filters are also used in steel foundries to remove inclusions from the melt prior to casting to the mold. However, the use of ceramic filters is either limited to specific types of alloys or casts or to specific filters with large pores and openings. As a result, utilization of ceramic filters in the steel industry has limitations in capturing inclusions, where specifically small size inclusions may not be captured. This research work aims at contributing to the global effort in developing the molten metal production processes to become more sustainable and to increase the quality of the final product. To be specific, it is aimed at shedding more light into filtration applications and the use of ceramic filters for removal of solid non-metallic inclusions from molten aluminum and steel. Thus, permeability characteristics of single 30, 50, and 80 Pore Per Inch (PPI) alumina Ceramic Foam Filter (CFF) grades as well as stacks of three 30, three 50, and three 80 PPI alumina CFF grades were both experimentally and numerically obtained and studied. This provides the information needed to estimate the pressure required to prime and/or push the molten aluminum through the filters. The pressure could either be built up by gravitational or other forces. It has been shown recently that it is possible to prime such filters with electromagnetic forces and filter solid inclusions from molten aluminum. Lastly, physical refining of molten steel from solid alumina inclusions through monolithic extruded square-celled alumina ceramic filter was investigated and studied with a developed mathematical Computational Fluid Dynamics (CFD) model as well as the particle trajectories of inclusions in the size range of 1 to 100 [µm]. The experimentally obtained permeability characteristics as well as the obtained pressure gradient profiles of the single 30, 50, and 80 PPI CFFs were compared to previous research findings from the literature. Overall, a good agreement between the current and previous findings was found. It was also shown that fluid bypassing should be avoided during permeability experiments, otherwise deviations as high as 60% may occur. It was also revealed that similar permeability characteristics for the stacked filters, compared to single filters, could be achieved. However, an about three times higher pressure gradient or pressure needs to be applied when using a stack of three identical PPI filters compared to using single filters. The numerical simulations also validated the experimental findings of the permeability experiments. The CFD simulations and particle trajectories of the solid alumina inclusions in molten steel through the monolithic alumina filter revealed that it was possible to capture all particles larger than 50 [µm]. However, it was not possible to capture all particles smaller than 50 [µm] due to the applied simulation approach as well as current simulation limitations in the software.
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| 2. |
- Arshadi Rastabi, Shahrzad, et al.
(författare)
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Metallurgical investigation of aluminum anode behavior in water-in-salt electrolyte for aqueous aluminum batteries
- 2022
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Ingår i: Journal of Power Sources. - : Elsevier. - 0378-7753 .- 1873-2755. ; 523
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Tidskriftsartikel (refereegranskat)abstract
- Although ionic liquid electrolytes (ILs) are environmentally unfriendly, they are the most common electrolyte used in aluminum-ion batteries (AIB). Aqueous electrolytes offer a more sustainable alternative, but problem with oxide passivating barrier on Al surface becomes more profound. Recently, a new sub-class of aqueous electrolytes, water-in-salt (WIS) of (AlCl3·6H2O), has been considered, but experimental validation of the behavior of the Al electrode over cycling is required. This work investigates aluminum/graphitic cells using WIS electrolytes with a mass ratio of salt to water of 4, 8, and 12 and finds that they show similar trends in cycling performance. The degradation observed over cycling has been attributed to the formation of a detrimental solid electrolyte interphase (SEI) layer on the Al surface. It was found that WIS 4 increased Al corrosion, resulting in a slightly higher capacity and longer cycling life. Metallurgical observation showed that the Al matrix has a tendency to initiate corrosion around Al3Fe intermetallic phases in both WIS and ILs. This implies that the presence of Al3Fe particles allows the electrolyte to break the oxide barrier and access the bulk Al. These results suggests that metallurgical treatments are important to enhance the electrochemical performance of AIB.
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| 3. |
- Bayat, Nazlin, et al.
(författare)
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In-Situ Study of Phase Transformations during Homogenization of 6005 and 6082 Al Alloys
- 2017
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Ingår i: Journal of Alloys and Compounds. - : Elsevier BV. - 0925-8388 .- 1873-4669. ; 725, s. 504-509
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Tidskriftsartikel (refereegranskat)abstract
- Intermetallic β-Al5FeSi phase and coarse Mg2Si particles have negative effects on extrudability and workability of 6xxx Al alloy billets. To achieve extruded products with a high surface quality as-cast billets are therefore heat-treated before extrusion. During heat treatment the undesired intermetallic particles, i.e., β-AlFeSi platelets, are transformed to a rounded α-Al(FeMn)Si intermetallic phase. This transformation was studied in-situ by TEM for 6005 and 6082 Al alloys. It was observed that the Mg2Si particles precipitate in the Al matrix at about 250 °C; this precipitation also occurred at the edge and faces of beta intermetallic particles, and the Mg2Si particles were the preferred sites for α-Al(FeMn)Si particle nucleation. The transformation proceeded faster and at lower temperatures, 350–450 °C, than what has been reported earlier for homogenization studies of bulk samples and industrial billets. This could be associated with the thin characteristic of used samples in TEM giving contribution from fast surface diffusion, but it was also concluded that the phase boundary layer diffusion was important for the understanding of how the transformations proceed.
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| 4. |
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| 5. |
- Bayat, Nazlin, et al.
(författare)
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Influence of Heat Treatment on the Surface Structure of 6082 Al Alloys
- 2017
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Ingår i: Metallurgical and Materials Transactions. A. - : Springer Science and Business Media LLC. - 1073-5623 .- 1543-1940. ; 48A:10, s. 5085-5094
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Tidskriftsartikel (övrigt vetenskapligt/konstnärligt)abstract
- The β-Al5FeSi intermetallic phase and coarse Mg2Si particles have negative effects on extrudability and workability of 6xxx Al alloys billets. To achieve extruded products with a high surface quality, the as-cast billets are heat-treated before extrusion. During heat treatment, the undesired intermetallic particles, i.e., β-AlFeSi platelets are transformed to rounded α-Al(FeMn)Si intermetallic phases. Although the heat treatment of the bulk areas of the 6xxx Al alloys has been the focus of many previous studies, the process of phase transformation at the very surface has not been paid the same attention. In this study, microstructures of a homogenized billet of a 6082 alloy at the area very close to the surface were investigated. By comparing the X-ray diffraction patterns (XRD) of heat-treated samples as a function of different holding times, the gradual phase transformations could be followed, and using GDOES and map analysis by EDX, the alloying elemental redistribution was analyzed. Partial remelting and porosity growth was detected, and transformation rates were faster than in bulk material and from what is known from industrial processes.
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| 6. |
- Bayat, Nazlin
(författare)
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Investigation of Surface Formation in As-Cast and Homogenized 6xxx Aluminium Billets
- 2017
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- The direct chill (DC) casting technique to produce billets for extrusion and ingots for rollingwas developed in the 1930s. The principle, which is still valid, is a two-stage cooling with a primary cooling at a mould surface followed by water spraying directly on the surface. Improvements of this technique have mainly focused on changes to the primary cooling, where a water-cooled metal mould has been replaced by different techniques to minimize cooling at this stage. The drive for development comes from the extrusion industry, which can increase the productivity and quality of extruded profiles by improving the billet surface appearance and structure. Hot top casting supported by airflow against the casting surface during the primary cooling is currently the standard procedure to achieve acceptable billet surfaces. The goal is to minimize the depth of the surface segregation zone, which is the governing factor for the appearance of different phases in the surface region. Billet surface quality is evaluated by quantifying surface appearance, segregation zone thickness, and occurrence of large Mg2Si and β-particles near the surface. The β-Al5FeSi intermetallic phase and coarse Mg2Si particles have negative effects on extrudability and workability of 6xxx Al alloys billets. To achieve extruded products with a high surface quality the as-cast billets are heat-treated before extrusion. During heat treatment the undesired intermetallic particles, i.e., β-AlFeSi platelets are transformed to rounded α-Al(FeMn)Si intermetallic phases.In this research the formation of the surface segregation for smooth defect-free surfaces in both as-cast and homogenized billets was studied. In addition, the surfaces with defects such as wavy, spot and vertical drag defects were investigated and possible mechanisms for initiation of those defects were explained. Moreover, for a better understanding of the homogenization process in-situ studies of the heat treatment of 6082, 6005, 6060 and 6063 Al alloys were carried out by using a transmission electron microscope (TEM). Based on the observations, an explanation of the probable mechanisms taking place during transformation from β-to α-phase was presented.
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| 7. |
- Bayat, Nazlin, 1981-, et al.
(författare)
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On Liquid Metal Wetting of Casting Rings for DC Casting
- 2015
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Ingår i: TMS Light Metals. - Warrendale : Minerals, Metals & Materials Society. - 9781119082446 ; , s. 859-864, s. 855-863
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Konferensbidrag (refereegranskat)abstract
- During air–slip direct chill casting of aluminum alloys, uneven or low air pressure areas at the surface of the porous graphite ring mold, can cause the metal to stick to the graphite ring and produce traces along the billets called vertical drags (VD). To prevent this type of defect, it would be an advantage to decrease the wettability of the graphite ring. It has been shown that nanostructured surfaces can have hydrophobic properties, and a question is weather the same effect can be achieved for molten metals. A TiO2 nanowire structure is proposed to cover the casting ring, and the wetting behavior of such a structure has been studied, and compared to the wetting at a regular graphite ring surface by the dispensed sessile drop method. The results showed that the nanostructured surface very strongly dewetting metal droplets.
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| 8. |
- Bayat, Nazlin, et al.
(författare)
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Surface formation in direct chill (DC) casting of 6082 aluminium alloys
- 2016
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Ingår i: IOP Conference Series. - : Institute of Physics Publishing (IOPP).
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Konferensbidrag (refereegranskat)abstract
- Surface defects in aluminium billet production are a real problem for the subsequent extrusion procedure. Extrusion productivity can be influenced by the surface properties, which is defined as surface appearance, surface segregation zone depth and large Mg2Si and β-particles (Al5FeSi). In this research the surface formation during DC casting of 6082 aluminium billets produced by the air slip technology is studied. The surface microstructures of 6082 aluminium alloys with smooth and wavy surface appearances were investigated, including segregation zone depths and phase formation. The results were discussed based on the exudation of liquid metal through the mushy zone. The specific appearance of the wavy surface of 6082 alloys was correlated to how the oxide skin adheres to the underlying mushy zone and coupled to the dendritic coherency and surface tension of the skin. The occurrence of different phases at the very surface and in the layer just below was explained by variations in solidification directions and subsequent segregation patterns.
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| 9. |
- Bayat, Nazlin, et al.
(författare)
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Surface structure formation in direct chill (DC) casting of al alloys
- 2014
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Ingår i: JOM. - : Springer Science and Business Media LLC. - 1047-4838 .- 1543-1851. ; 66:5, s. 700-710
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Tidskriftsartikel (refereegranskat)abstract
- The aim of this study is to increase the understanding of the surface zone formation during direct chill (DC) casting of aluminum billets produced by the air slip technology. The depth of the shell zone, with compositions deviating from the bulk, is of large importance for the subsequent extrusion productivity and quality of final products. The surface microstructures of 6060 and 6005 aluminum alloys in three different surface appearances - defect free, wavy surface, and spot defects - were studied. The surface microstructures and outer appearance, segregation depth, and phase formation were investigated for the mentioned cases. The results were discussed and explained based on the exudation of liquid metal through the mushy zone and the fact that the exudated liquid is contained within a surface oxide skin. Outward solidification in the surface layer was quantitatively analyzed, and the oxide skin movements explained meniscus line formation. Phases forming at different positions in the segregation zone were analyzed and coupled to a cellular solidification in the exudated layer.
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| 10. |
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