Results of a research on influence of chromium, molybdenum and aluminium on structure and selected mechanical properties of Ni-Mn-Cu cast iron in the as-cast and heat-treated conditions are presented. All raw castings showed austenitic matrix with relatively low hardness, making the material machinable. Additions of chromium and molybdenum resulted in higher inclination to hard spots. However, a small addition of aluminium slightly limited this tendency. Heat treatment consisting in soaking the castings at 500 °C for 4 h resulted in partial transformation of austenite to acicular, carbon-supersaturated ferrite, similar to the bainitic ferrite. A degree of this transformation depended not only on the nickel equivalent value (its lower value resulted in higher transformation degree), but also on concentrations of Cr and Mo (transformation degree increased with increasing total concentration of both elements). The castings with the highest hard spots degree showed the highest hardness, while hardness increase, caused by heat treatment, was the largest in the castings with the highest austenite transformation degree. Addition of Cr and Mo resulted in lower thermodynamic stability of austenite, so it appeared a favourable solution. For this reason, the castings containing the highest total amount of Cr and Mo with an addition of 0.4% Al (to reduce hard spots tendency) showed the highest tensile strength.
The aim of the research conducted in a 2-year pot experiment in an unheated plastic tunnel was to determine suitability of Miscanthus × giganteus for phytoextraction of nickel from soil as well as to assess tolerance of this species on increasing concentrations of this metal in soil. Pots were filled with mineral soil (sand) and a mixture of soil with high-moor peat and three levels of nickel were introduced, i.e. 75 mg dm-3, 150 mg dm-3 and 600 mg dm-3 and the control combinations used substrates without the addition of nickel. Nickel was introduced only in the first year of the experiment in the form of nickel sulfate (NiSO4 · 6H2O). Miscanthus × giganteus accumulated a considerable amount of nickel in biomass. Miscanthus × giganteus growing in contaminated mineral soil turned out to be a species tolerant to high nickel concentrations
FeCl3 bearing etching solution is mainly used for etching of metals used in shadow masks, PCBs and so on. Due course of Invar alloy etching process the FeCl3 bearing etching solution get contaminated with Ni2+ which affect adversely the etching efficiency. Hence, FeCl3 bearing etching solution discarded after several cycle of operation causes an environmental and economic problem. To address both the issues the etching solution was purified through solvent extraction and remained Ni2+ recovered by wet chemical reduction using hydrazine. For optimum Fe3+ extraction efficiency, various extraction parameter were optimized and size and morphology of the recovered pure Ni powder was analyzed. The reported process is a simple process to purify and recover Ni from industry etching solution.
The paper presents the adaptation of the modified pulse method for investigating temperature characteristics of thermal diffusivity in the vicinity of the second-order phase transition points. The principle of the adaptation consists in the modified in relation to the original method, development of the characteristics of temperature changes between boundary surfaces of a flat-parallel specimen after the laser shot onto its front surface. The application of this adaptation was illustrated with investigation into thermal diffusivity of nickel (99.9% wt) in the temperature range of 20-380◦C. In all cases the measurement error was less than 3%, and the averaging interval for the measured values of thermal diffusivity was not greater than 1.2 K.
Serpentine soils from 16 sample points in Serbia as well as the roots and shoots of eight Brassicaceae family species: Aethionema saxatile, Alyssum montanum, Alyssum repens, Cardamine plumieri, Erysimum linariifolium, Erysimum carniolicum, Isatis tinctoria, Rorippa lippizensis, were analyzed with regard to their concentrations of P, K, Fe, Ca, Mg, Ni, Zn, Mn, Cu, Cr, Cd, and Pb. Most of the soil samples were typical of ultramafic sites with low concentrations of P, K and Ca and high concentrations of Mg, Fe, Ni and Zn. Ca/Mg ratio was <1 in most soil samples and Brassicaceae plants. Only in A. montanum, A. repens, E. linariifolium and R. lippizensis was the Ca/Mg ratio >1. The levels of P, K, Fe and Zn were high, Mn and Cu occurred in low amounts, whereas Cr, Cd, Co and Pb were only traceable. In the roots and shoots of A. montanum and A. repens the measured concentrations of Ni were 657 mg kg-1 and 676 mg kg-1 respectively, which is the first instance that such high concentrations of Ni were detected in these two species.
Zinc plant residue is a hazardous waste which contains high quantity of nickel and other valuable metals. Process parameters such as reaction time, acid concentration, solid-liquid ratio, particle size, stirring speed and temperature for nickel extraction from this waste were optimized using factorial design. Main effects and their interactions were obtained by the analysis of variance ANOVA. Empirical regression model was obtained and used to predict nickel extraction with satisfactory results and to describe the relationship between the predicted results and the experiment results. The important parameters for maximizing nickel extraction were identifi ed to be a leaching time solid-liquid ratio and acid concentration. It was found that above 90% of nickel could be extracted in optimum conditions.
Impact of surface and volume modification and double filtration during pouring the moulds on basic mechanical properties and creep resistance of nickel superalloys IN-713C and MAR-247 in conditions of accelerated creep of castings made of post-production scrap of these alloys is evaluated in this paper. The conditions of initiation and propagation of cracks in the specimens were analysed with consideration of stereological properties of material macro- and microstructure. It has been proven that in the conditions of hightemperature creep at 980°C and at stress σ = 150 MPa, creep resistance of superalloy MAR-247 is more than 10 times higher than the creep resistance of IN-713C alloy. In case of IN-713C alloy, the creep resistance negligibly depends on macrograin sizes. But, the macrograin size considerably affects the time to failure of specimens made of alloy MAR-247. Creep resistance of specimens made of coarse grain material was 20% higher than the resistance of fine grain materials.
The paper presents results of research on cobalt and nickel ions removal from monocomponent solutions using Purolite ion exchange resins. It has been shown that C 160 ion exchange resin has the best sorption properties for both ions (Qe – 72.5 mg Co/g and 88.2 mg Ni/g). Regeneration process of this ion exchanger has high efficiency, achieving about 93% for cobalt ions and about 84% in case of nickel ions. It has been shown that the use of ion exchange method with suitable ion exchange resins guarantees effective removal of cobalt and nickel ions from solutions with very high concentrations corresponding to contents of these metals in industrial wastewaters (e.g. galvanic). In case of C 160 ion exchange resin, after the sorption process is carried out in one 50 minute cycle, the cobalt concentration decreased from about 30 000 mg/L to about 9 500 mg/L (approx. 68%), whereas nickel concentration reached about 6 300 mg/L (approx. 79%). Studied chelating resins don’t have such high sorption capacities. In their case, it is required to convert cobalt and nickel ions into complex forms. The kinetics of studied processes were described by pseudo-second order equations.
The paper presents the results of studies of hybrid composite layers Ni/Al2O3/Cgraphite produced by the electrodeposition method. Three variants of hybrid composite layers were prepared in electrolyte solutions with the same amounts of each dispersion phases which were equal to 0.25; 0.50 and 0.75 g/dm3. The structure of Ni/Al2O3/Cgraphite layers as well as the Al2O3 and graphite powders, which were used as dispersion phases was investigated. The results of morphology and surface topography of produced layers are presented. The modulus of elasticity and microhardness of the material of produced layers were determined by DSI method. Tribological and corrosion resistance tests of produced layers were carried out. Realized studies have shown that the material of the produced layers is characterized by a nanocrystalline structure. Incorporation of dispersion phases into the nickiel matrix increases the degree of surface development of layers. Ni/Al2O3/Cgraphite layers are characterized by high hardness and abrasion resistance by friction, furthermore, they provide good corrosion protection for the substrate material.
Nickel alloys belong to the group of most resistant materials when used under the extreme operating conditions, including chemically aggressive environment, high temperature, and high loads applied over a long period of time. Although in the global technology market one can find several standard cast nickel alloys, the vast majority of components operating in machines and equipment are made from alloys processed by the costly metalworking operations. Analysis of the available literature and own studies have shown that the use of casting technology in the manufacture of components from nickel alloys poses a lot of difficulty. This is due to the adverse technological properties of these alloys, like poor fluidity, high casting shrinkage, and above all, high reactivity of liquid metal with the atmospheric air over the bath and with the ceramic material of both the crucible and foundry mold. The scale of these problems increases with the expected growth of performance properties which these alloys should offer to the user. This article presents the results of studies of physico-chemical interactions that occur between theH282alloy melt and selected refractory ceramic materials commonly used in foundry. Own methodology for conducting micro-melts on a laboratory scale was elaborated and discussed. The results obtained have revealed that the alumina-based ceramics exhibits greater reactivity in contact with the H282 alloy melt than the materials based on zirconium compounds. In the conducted experiments, the ceramic materials based on zirconium silicate have proved to be a much better choice than the zirconia-silica mixture. Regardless of the type of the ceramic materials used, the time and temperature of their contact with the nickel alloy melt should always be limited to an absolutely necessary minimum required by the technological regime.
The paper presents a research results concerning impact of volume modification (ceramic filter containning cobalt aluminate and hafniumpowder) and simultaneous surface and volume modification on solidification and stereological parameters of macrostructure of castingsmade from post-production scrap of nickel superalloy IN-713C. Research included investigation of the influence of chemical compositionon the temperature Tliq i Tsol and evaluation of following macrostructure parameters: the number of grains per mm2, average grain area andshape coefficient. Results indicate high influence of carbon content on Tliq. Macrostructure of sample castings indicate positive effect of surface and volume modification, however impact of surface modification is more pronounced.
Superalloys show a good combination of mechanical strength and resistance to surface degradation under the influence of chemically active environments at high temperature. They are characterized by very high heat and creep resistance. Their main application is in gas turbines, chemical industry, and in all those cases where resistance to creep and the aggressive corrosion environment is required. Modern jet engines could never come into use if not for progress in the development of superalloys. Superalloys are based on iron, nickel and cobalt. The most common and the most interesting group includes superalloys based on nickel. They carry loads at temperatures well in excess of the eighty percent of the melting point. This group includes the H282 alloy, whose nominal chemical composition is as follows (wt%): Ni - base, Fe - max. 1.5%, Al - 1.5% Ti - 2.1%, C - 0.06% Co - 10% Cr - 20% Mo - 8.5%. This study shows the results of thermal analysis of the H282 alloy performed on a cast step block with different wall thickness. Using the results of measurements, changes in the temperature of H282 alloy during its solidification were determined, and the relationship dT / dt = f (t) was derived. The results of the measurements taken at different points in the cast step block allowed identifying a number of thermal characteristics of the investigated alloy and linking the size of the dendrites formed in a metal matrix (DAS) with the thermal effect of solidification. It was found that the time of solidification prolonged from less than ome minute at 10 mm wall thickness to over seven minutes at the wall thickness of 44 mm doubled the value of DAS.
Determined was quantitative effect of nickel equivalent value on austenite decomposition degree during cooling-down castings of Ni-MnCu cast iron. Chemical composition of the alloy was 1.8 to 5.0 % C, 1.3 to 3.0 % Si, 3.1 to 7.7 % Ni, 0.4 to 6.3 % Mn, 0.1 to 4.9 % Cu, 0.14 to 0.16 % P and 0.03 to 0.04 % S. Analysed were castings with representative wall thickness 10, 15 and 20 mm. Scope of the examination comprised chemical analysis (including WDS), microscopic observations (optical and scanning microscopy, image analyser), as well as Brinell hardness and HV microhardness measurements of structural components.
Paper presents the results of evaluation of heat resistance and specific heat capacity of MAR-M-200, MAR-M-247 and Rene 80 nickel superalloys. Heat resistance was evaluated using cyclic method. Every cycle included heating in 1100°C for 23 hours and cooling for 1 hour in air. Microstructure of the scale was observed using electron microscope. Specific heat capacity was measured using DSC calorimeter. It was found that under conditions of cyclically changing temperature alloy MAR-M-247 exhibits highest heat resistance. Formed oxide scale is heterophasic mixture of alloying elements, under which an internal oxidation zone was present. MAR-M-200 alloy has higher specific heat capacity compared to MAR-M-247. For tested alloys in the temperature range from 550°C to 800°C precipitation processes (γ′, γ′′) are probably occurring, resulting in a sudden increase in the observed heat capacity.
The article deals with the influence of chemical composition of martensitic stainless steel for castings GXCrNi13-4 (the 1.4317 material) on mechanical properties and structure of as cast steel after heat treatment. Properties of these martensitic stainless steel are heavily influenced by chemical composition and structure of the material after heat treatment. Structure of these steels after quenching is formed with martensite and residual austenite. When tempering the steel the carbon content in martensite is reduced and gently deposited carbides occur. The way of heat treatment has a major impact on structure of martensitic steels with low carbon content and thus on strength, hardness and elongation to fracture of these steels. Chemical composition of the melt has been treated to the desired composition of the lower, middle and upper bounds of the nickel content in the steel within the limits allowed by the standard. Test blocks were gradually cast from the melt. The influence of the nickel equivalent value on structure and properties of the 1.4317 steel was determined from results of mechanical tests.
Inconel 713C is a nickel-based casting alloy characterised by improved heat and creep resistance . It is used e.g. in aircraft engine components, mainly in the form of precision castings. Precision casting enables very good reproduction of complex shapes. However, due to major differences in casting wall thickness and the resultant differences in rigidity, defects can form in precision castings. The most common defects in precision castings are shrinkage porosities and microcracks. Inconel 713C is considered to be a difficult-to-weld or even non-weldable alloy. However, the need to repair precision castings requires attempts to develop technologies for their remelting and pad welding which could be used in industrial practice. This article presents the results of tests consisting in TIG pad welding of defects identified in precision castings intended for the aircraft industry. It was found that the main reason behind failed attempts at repairing precision castings by welding technologies was hot cracking in the fusion zone. Such cracks form as a result of the partial melting of intercrystalline regions along the fusion line. The deformations occurring during the crystallization of the melting-affected zone (fusion zone + partially melted zone + heat affected zone) or pad weld lead to the rupture of the intercrystalline liquid film. Hot cracks form within the so-called high-temperature brittleness range (HTBR) of the alloy. Another type of cracks that was identified were ductility dip cracks (DDC), whose formation is related to the partial melting of carbides.
This work presents the results of a study whose aim was to determine the influence of algal blooms on precipitation of heavy metals. The scope of the study covered culture of a mixed population made up of Scenedesmus and Pseudokirchneriella algae in experimental conditions and initiating a metal biosorption process with the use of culture biomass by administering ions of Zn(II) and Ni(II). The process was controlled by assessing the level of biosorption of metals entered at a one-off basis in the form of Zn(II) and Ni(II) salts or in the form of mixture of both ions, in comparison to the control sample, at different exposure times (2 hours and 24 hours). The presence of metals was determined both in the biomass and in the culture medium. The presented results of the study confirm the effectiveness of Chlorophyta in the process of zinc and nickel biosorption. A phenomenon of competitiveness between the metals was observed when they were administered at the same time.
The paper presents the results of studies to determine the effect of complex surface and bulk modification and double filtration during mould pouring on the stereological parameters of macrostructure and mechanical properties of castings made from the post-production waste IN-713C and the MAR-247 nickel alloys. The evaluation covered the number of grains per 1mm2 of the sample surface area, the average area of grains and the shape index, hardness HB, tensile strength and resistance to high temperature creep. The results indicate the possibility of controlling the stereological parameters of macrostructure through application of several variants of the modification, controlling in this way also different low- and high-temperature properties. The positive effect of double filtration of the alloy during mould pouring on the metallurgical quality and mechanical properties of castings has also been emphasized.
A proper selection of steam reforming catalyst geometry has a direct effect on the efficiency and economy of hydrogen production from natural gas and is a very important technological and engineering issue in terms of process optimisation. This paper determines the influence of widely used seven-hole grain diameter (ranging from 11 to 21 mm), h/d (height/diameter) ratio of catalyst grain and Sh/St (hole surface/total cylinder surface in cross-section) ratio (ranging from 0.13 to 0.37) on the gas load of catalyst bed, gas flow resistance, maximum wall temperature and the risk of catalyst coking. Calculations were based on the one-dimensional pseudo-homogeneous model of a steam reforming tubular reactor, with catalyst parameters derived from our investigations. The process analysis shows that it is advantageous, along the whole reformer tube length, to apply catalyst forms of h/d = 1 ratio, relatively large dimensions, possibly high bed porosity and Sh/St ≈ 0.30-0.37 ratio. It enables a considerable process intensification and the processing of more natural gas at the same flow resistance, despite lower bed activity, without catalyst coking risk. Alternatively, plant pressure drop can be reduced maintaining the same gas load, which translates directly into diminishing the operating costs as a result of lowering power consumption for gas compression.
The safe and reliable operation of pressurized water reactors (PWRs) depends on the integrity of structural material. In particular, the failure of steam generator (SG) tubes on the secondary side is one of the major concerns of operating nuclear power plants. To establish remediation techniques and manage damage, it is necessary to articulate the mechanism through which various impurities affect the SG tubes. This research aims to understand the effect of impurities (e.g., S, Pb, and Cl) on the stress corrosion cracking of Alloy 600 and 690.
In the paper, a relationship between chemical composition of Ni-Mn-Cu cast iron and its structure, hardness and corrosion resistance is determined. The examinations showed a decrease of thermodynamic stability of austenite together with decreasing nickel equivalent value, in cast iron solidifying according to both the stable and the metastable systems. As a result of increasing degree of austenite transformation, the created martensite caused a significant hardness increase, accompanied by small decline of corrosion resistance. It was found at the same time that solidification way of the alloy and its matrix structure affect corrosion resista
Paper presents the results of research on modified surface grain refinement method used in investment casting of hollow, thin-walled parts made of nickel based superalloys. In the current technology, the refining inoculant is applied to the surface of the wax pattern and then, it is transferred to the ceramic mould surface during dewaxing. Because of its chemical activity the inoculant may react with the liquid metal which can cause defects on the external surface of the cast part. The method proposed in the paper aims to reduce the risk of external surface defects by applying the grain refiner only to the ceramic core which shapes the internal surface of the hollow casting. In case of thin-walled parts the grain refinement effect is visible throughout the thickness of the walls. The method is meant to be used when internal surface finish is less important, like for example, aircraft engine turbine blades, where the hollowing of the cast is mainly used to lower the weight and aid in cooling during operation.
Paper presents the results of ATD and DSC analysis of two superalloys used in casting of aircraft engine parts. The main aim of the research was to obtain the solidification parameters, especially Tsol and Tliq, knowledge of which is important for proper selection of casting and heat treatment parameters. Assessment of the metallurgical quality (presence of impurities) of the feed ingots is also a very important step in production of castings. It was found that some of the feed ingots delivered by the superalloy producers are contaminated by oxides located in shrinkage defects. The ATD analysis allows for quite precise interpretation of first stages of solidification at which solid phases with low values of latent heat of solidification are formed from the liquid. Using DSC analysis it is possible to measure precisely the heat values accompanying the phase changes during cooling and heating which, with knowledge of phase composition, permits to calculate the enthalpy of formation of specific phases like γ or γ′.
The paper presents results of calorimetric studies of foundry nickel superalloys: IN100, IN713C, Mar - M247 and ŻS6 U. Particular attention was paid to determination of phase transiti ons temperatures during heating and cooling. The samples were heated to a temperature of 1500°C with a rate of 10°C ⋅ min – 1 and then held at this temperature for 5 min. After a complete melting, the samples were cooled with the same rat e. Argon with a purity of 99.99% constituted the protective atmosphere. The sample was placed in an alundum crucible with a capacity of 0.45 cm 3 . Temperature and heat calibration was carried out based on the mel ting point of high- purity Ni. The tests were carried out by the differential scanning calorimetry (DSC) using a Multi HTC high -temperature calorimeter from Setaram. Based on the DSC curves, the following temperatures were determined: solidus and liquidus, dissolution and precipitation of the γ ’ phase, MC carbides and melting of the γ ’ /γ eutectic. In the temperature range of 100 -1100°C, specific heat capacity of the investigated superalloys was determined. It was found that the IN713C and IN100 alloys exhibit a higher specific heat while compared to the Mar - M247 and ŻS6 U alloys.
Inconel 713C alloy belongs to the group of materials with high application potential in the aerospace industry. This nickel alloy has excellent features such as high strength, good surface stability, high creep and corrosion resistance. The paper presents the results of metallographic examinations of a base material and padding welds made by laser beam on the Inconel 713C alloy. The tests were made on precisely cast test plates imitating low - pressure turbine blades dedicated for the aerospace industry. Observations of the macro- and microstructure of the padding welds, heat-affected zone and base material indicate, that the Inconel 713C alloy should be classified as a hard-to-weld material. In the investigated joint, cracking of the material is disclosed mainly in the heat-affected zone and at the melted zone interface, where pad weld crystals formed on partially melted grains. The results show that phases rich with chromium and molybdenum were formed by high temperature during welding process, which was confirmed by EDS analysis of chemical composition.