Search results for: hooked-end steel fibre (HS)

Authors: Dler Abdullah Ahmed, Zozan Ahmed Mohammed

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Wear as an unavoidable phenomenon in stainless steel contact sliding parts is investigated In this work. Two grades of austenitic AISI 304, and S31254, as well as duplexes of S32205, and AISI 2507, were chosen to compare their wear behavior in temperatures ranging from room temperature to 550°C. The experimental results show that AISI 304 austenitic and AISI 2205 duplex stainless steel had lower wear resistance compared with S31254 and AISI 2507 in various temperatures. When the temperature rose to 140°C, and the wear rate of all grades increased, AISI 304 had the highest at 7.028x10-4 mm3/Nm, and AISI 2507 had the lowest at 4.9033 x 10-4 mm3/Nm. At 300°C, the oxides began to form on the worn surfaces, causing the wear rate to slow. As a result, when temperatures exceeded 300°C, the specific wear rate decreased significantly in all specimens. According to the XRD patterns, the main types of oxides formed on worn surfaces were magnetite, hematite, and chromite.

Keywords: wear, stainless steel, temperature, groove, oxide

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Authors: Dler Abdullah Ahmed, Zozan Ahmed Mohammed

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Wear as an unavoidable phenomenon in stainless steel contact sliding parts is investigated In this work. Two grades of austenitic AISI 304, and S31254, as well as duplexes of S32205, and AISI 2507, were chosen to compare their wear behavior in temperatures ranging from room temperature to 550°C. The experimental results show that AISI 304 austenitic and AISI 2205 duplex stainless steel had lower wear resistance compared with S31254 and AISI 2507 in various temperatures. When the temperature rose to 140°C, and the wear rate of all grades increased, AISI 304 had the highest at 7.028x10-4 mm3/Nm, and AISI 2507 had the lowest at 4.9033 x 10-4 mm3/Nm. At 300°C, the oxides began to form on the worn surfaces, causing the wear rate to slow. As a result, when temperatures exceeded 300°C, the specific wear rate decreased significantly in all specimens. According to the XRD patterns, the main types of oxides formed on worn surfaces were magnetite, hematite, and chromite.

Keywords: wear, stainless steel, temperature, groove, oxide

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Authors: T. Aldeeb, M. Abduelmula

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This study examines the fatigue life of S275 mild steel at room temperature. Mechanical components can fail under cyclic loading during period of time, known as the fatigue phenomenon. In order to prevent fatigue induced failures, material behavior should be investigated to determine the endurance limit of the material for safe design and infinite life, thus leading to reducing the economic cost and loss in human lives. The fatigue behavior of S275 mild steel was studied and investigated. Specimens were prepared in accordance with ASTM E3-11, and fatigue tests of the specimen were conducted in accordance with ASTM E466-07 on a smooth plate, with a continuous radius between ends (hourglass-shaped plate). The method of fatigue testing was applied with constant load amplitude and constant frequency of 4 Hz with load ratio (Fully Reversal R= -1). Surface fractures of specimens were investigated using Scanning Electron Microscope (SEM). The experimental results were compared with the results of a Finite Element Analysis (FEA), using simulation software. The experiment results indicated that the endurance fatigue limit of S275 mild steel was 195.47 MPa.

Keywords: fatigue strength, fatigue life, finite element analysis(FEA), S275 mild steel, scanning electron microscope (SEM)

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Authors: D. Erdenechimeg, T. Bujinlkham, N. Erdenepurev

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The anti-corrosion performance of fatty acid coated mild steel samples is studied. Samples of structural steel coated with collector reagents deposited from surfactant in ethanol solution and overcoated with an epoxy barrier paint. A quantitative corrosion rate was determined by linear polarization resistance method using biopotentiostat/galvanostat 400. Coating morphology was determined by scanning electronic microscopy. A test for hydrophobic surface of steel by surfactant was done. From the samples, the main component or high content iron was determined by chemical method and other metal contents were determined by Inductively Coupled Plasma-Optical Emission Spectrometry (ICP-OES) method. Prior to measuring the corrosion rate, mechanical and chemical treatments were performed to prepare the test specimens. Overcoating the metal samples with epoxy barrier paint after exposing them with surfactant the corrosion rate can be inhibited by 34-35 µm/year.

Keywords: corrosion, linear polarization resistance, coating, surfactant

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Authors: M. Gobinath, S. Balaji

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Assumptions in model inputs: Grade of concrete=40 N/mm2 (for slab), Grade of concrete=40 N/mm2 (for shear wall), Grade of Structural steel (plate girder)=350 N/mm2 (yield strength), Ultimate strength of structural steel=490 N/mm2, Grade of rebar=500 N/mm2 (yield strength), Applied Load=1716 kN (un-factored). Following assumptions are made for the mathematical modelling of RCC with steel embedment: (1) The bond between the structural steel and concrete is neglected. (2) The stiffener is provided with shear studs to transfer the shear force. Hence nodal connectivity is established between solid nodes (concrete) and shell elements (stiffener) at those locations. (3) As the end reinforcements transfer either tension/compression, it is modeled as line element and connected to solid nodes. (4) In order to capture the bearing of bottom flange on to the concrete, the line element of plan size of solid equal to the cross section of line elements is connected between solid and shell elements below for bottom flange and above for top flange. (5) As the concrete cannot resist tension at the interface (i.e., between structural steel and RCC), the tensile stiffness is assigned as zero and only compressive stiffness is enabled to take. Hence, non-linear static analysis option is invoked.

Keywords: structure, construction, signature tower, embedment design concept

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Authors: Sairah Bashir, Liu Yang, John Liggat, James Thomason

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Glass fibre is currently used as reinforcement in over 90% of all fibre-reinforced composites produced. The high rigidity and chemical resistance of these composites are required for optimum performance but unfortunately results in poor recyclability; when such materials are no longer fit for purpose, they are frequently deposited in landfill sites. Recycling technologies, for example, thermal treatment, can be employed to address this issue; temperatures typically between 450 and 600 °C are required to allow degradation of the rigid polymeric matrix and subsequent extraction of fibrous reinforcement. However, due to the severe thermal conditions utilised in the recycling procedure, glass fibres become too weak for reprocessing in second-life composite materials. In addition, more stringent legislation is being put in place regarding disposal of composite waste, and so it is becoming increasingly important to develop long-term recycling solutions for such materials. In particular, the development of a cost-effective method to regenerate strength of thermally recycled glass fibres will have a positive environmental effect as a reduced volume of composite material will be destined for landfill. This research study has demonstrated the positive impact of sodium hydroxide (NaOH) and potassium hydroxide (KOH) solution, prepared at relatively mild temperatures and at concentrations of 1.5 M and above, on the strength of heat-treated glass fibres. As a result, alkaline treatments can potentially be implemented to glass fibres that are recycled from composite waste to allow their reuse in second-life materials. The optimisation of the strength recovery process is being conducted by varying certain reaction parameters such as molarity of alkaline solution and treatment time. It is believed that deep V-shaped surface flaws exist commonly on severely damaged fibre surfaces and are effectively removed to form smooth, U-shaped structures following alkaline treatment. Although these surface flaws are believed to be present on glass fibres they have not in fact been observed, however, they have recently been discovered in this research investigation through analytical techniques such as AFM (atomic force microscopy) and SEM (scanning electron microscopy). Reaction conditions such as molarity of alkaline solution affect the degree of etching of the glass fibre surface, and therefore the extent to which fibre strength is recovered. A novel method in determining the etching rate of glass fibres after alkaline treatment has been developed, and the data acquired can be correlated with strength. By varying reaction conditions such as alkaline solution temperature and molarity, the activation energy of the glass etching process and the reaction order can be calculated respectively. The promising results obtained from NaOH and KOH treatments have opened an exciting route to strength regeneration of thermally recycled glass fibres, and the optimisation of the alkaline treatment process is being continued in order to produce recycled fibres with properties that match original glass fibre products. The reuse of such glass filaments indicates that closed-loop recycling of glass fibre reinforced composite (GFRC) waste can be achieved. In fact, the development of a closed-loop recycling process for GFRC waste is already underway in this research study.

Keywords: glass fibers, glass strengthening, glass structure and properties, surface reactions and corrosion

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Authors: K. Rana, H.A.Saeed, S. Zahir

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Inter Laminar Shear Stress (ILSS) is a main key parameter which quantify the properties of composite materials. These properties can ascertain the use of material for a specific purpose like aerospace, automotive etc. A modelling approach for determination of ILSS is presented in this paper. Geometric modelling of composite material is performed in TEXGEN software where reinforcement, cured matrix and their interfaces are modelled separately as per actual geometry. Mechanical properties of matrix and reinforcements are modelled separately which incorporated anisotropy in the real world composite material. ASTM D2344 is modelled in ANSYS for ILSS. In macroscopic analysis model approximates the anisotropy of the material and uses orthotropic properties by applying homogenization techniques. Shear Stress analysis in that case does not show the actual real world scenario and rather approximates it. In this paper actual geometry and properties of reinforcement and matrix are modelled to capture the actual stress state during the testing of samples as per ASTM standards. Testing of samples is also performed in order to validate the results. Fibre volume fraction of yarn is determined by image analysis of manufactured samples. Fibre volume fraction data is incorporated into the numerical model for correction of transversely isotropic properties of yarn. A comparison between experimental and simulated results is presented.

Keywords: ILSS, FEA, micromechanical, fibre volume fraction, image analysis

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Authors: G. M. Dominguez Almaraz, J. A. Ruiz Vilchez, M. A. Sanchez Miranda

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Ultrasonic fatigue tests have been carried out in the maraging 300 steel. Experimental results show that fatigue endurance under this modality of testing is closely related to the nature and geometrical properties of inclusions present in this alloy. A model was proposed to correlate the ultrasonic fatigue endurance with the nature and geometrical properties of the crack initiation inclusion. Scanning Electron Microscopy analyses were obtained on the fracture surfaces, in order to assess the crack initiation inclusion and to introduce these parameters in the proposed model, with good agreement for the fatigue life prediction.

Keywords: inclusions, ultrasonic fatigue, maraging 300 steel, crack initiation

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Authors: E. A. Krasikov

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Dependence of the materials properties on neutron irradiation intensity (flux) is a key problem while usage data of the accelerated materials irradiation in test reactors for forecasting of their capacity for work in realistic (practical) circumstances of operation. Investigations of the reactor pressure vessel steel radiation degradation dependence on fast neutron fluence (embrittlement kinetics) at low flux reveal the instability in the form of the scatter of the experimental data and wave-like sections of embrittlement kinetics appearance. Disclosure of the steel degradation oscillating is a sign of the steel structure cyclic self-recovery transformation as it take place in self-organization processes. This assumption has received support through the discovery of the similar ‘anomalous’ data in scientific publications and by means of own additional experiments. Data obtained stimulate looking-for ways to management of the structural steel radiation stability (for example, by means of nano - structure modification for radiation defects annihilation intensification) for creation of the intelligent self-recovering material. Expected results: - radiation degradation theory and mechanisms development, - more adequate models of the radiation embrittlement elaboration, - surveillance specimen programs improvement, - methods and facility development for usage data of the accelerated materials irradiation for forecasting of their capacity for work in realistic (practical) circumstances of operation, - search of the ways for creating of the radiation stable self-recovery intelligent materials.

Keywords: degradation, radiation, steel, wave-like kinetics

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Authors: Jason Ting Jing Cheng, Lee Foo Wei, Yew Ming Kun, Chin Ren Jie, Yip Chun Chieh

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The utilization of industrial by-products, such as steel slag in cementitious materials, not only mitigates environmental impact but also enhances material properties. This study investigates the dual influence of steel slag particle size on the compressive strength and carbonation efficiency of cementitious composites. Through a systematic experimental approach, steel slag particles were incorporated into cement at varying sizes, and the resulting composites were subjected to mechanical and carbonation tests. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) are conducted in this paper. The findings reveal a positive correlation between increased particle size and compressive strength, attributed to the improved interfacial transition zone and packing density. Conversely, smaller particle sizes exhibited enhanced carbonation efficiency, likely due to the increased surface area facilitating the carbonation reaction. The presence of higher silica and calcium content in finer particles was confirmed by EDX, which contributed to the accelerated carbonation process. This study underscores the importance of particle size optimization in designing sustainable cementitious materials with balanced mechanical performance and carbon sequestration potential. The insights gained from the advanced analytical techniques offer a comprehensive understanding of the mechanisms at play, paving the way for the strategic use of steel slag in eco-friendly construction practices.

Keywords: steel slag, carbonation efficiency, particle size enhancement, compressive strength

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Authors: A. A. Selaimia, H. Bensouilah, M. A. Yallese, I. Meddour, S. Belhadi, T. Mabrouki

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The objective of this work is to model the output responses namely; surface roughness (Ra), cutting force (Fc), during the face milling of the austenitic stainless steel X2CrNi18-9 with coated carbide tools (GC4040). For raison, response surface methodology (RMS) is used to determine the influence of each technological parameter. A full factorial design (L27) is chosen for the experiments, and the ANOVA is used in order to evaluate the influence of the technological cutting parameters namely; cutting speed (Vc), feed per tooth, and depth of cut (ap) on the out-put responses. The results reveal that (Ra) is mostly influenced by (fz) and (Fc) is found considerably affected by (ap).

Keywords: austenitic stainless steel, ANOVA, coated carbide, response surface methodology (RSM)

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Authors: K. M. Aldossari, W. A. Elsaigh, M. J. Shannag

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An experimental study was conducted to investigate the effect of hooked-end steel fibers on the flexural behavior of normal and high strength concrete matrices. The fiber content appropriate for the concrete matrices investigated was also determined based on flexural tests on standard prisms. Parameters investigated include: Matrix compressive strength ranging from 45 MPa to 70 MPa, corresponding to normal and high strength concrete matrices respectively; Fiber volume fraction including 0, 0.5%, 0.76%, and 1%, equivalent to 0, 40, 60, and 80 kg/m3 of hooked-end steel fibers respectively. Test results indicated that flexural strength and toughness of normal and high strength concrete matrices were significantly improved with the increase in the fiber content added; Whereas a slight improvement in compressive strength was observed for the same matrices. Furthermore, the test results indicated that the effect of increasing the fiber content was more pronounced on increasing the flexural strength of high strength concrete than that of normal concrete.

Keywords: concrete, flexural strength, toughness, steel fibers

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Authors: Amirmozafar Benshams, Saman Shafeinejad, Mohammad Zaman Kabir, Farzad Hatami, Mohammadreza Khedmati, Mesbah Saybani

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Steel bars has been used in concrete structures for more than one hundred years but lack of corrosion resistance of steel reinforcement has resulted in many structural failures. Fiber Reinforced Polymer (FRP) bar is an acceptable solution to replace steel to mitigate corrosion problem. Since FRP is a brittle material its use in seismic region has been a concern. FRP RC structures can be made ductile by employing a ductile material such as Shape Memory Alloy (SMA) at the plastic hinge region and FRP at the other regions on the other hand SMA is highly resistant to corrosion. Shape Memory Alloy has the unique ability to undergo large inelastic deformation and regain its initial shape through stress removal therefore utilizing composite SMA-FRP bars not only have good corrosion resistance but also have good performance in seismic region. The result show indicate that such composite SMA-FRP bars can substantially reduce the residual drift with adequate energy dissipation capacity during earthquake.

Keywords: steel bar, shape memory alloy, FRP, corrosion

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Authors: Pradyumna Mohanty

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The paper aims to explore whether accounting information of Indian companies in the Steel sector are value relevant or not. Ohlson’s model which usually takes into consideration book value per share (BV) and earnings per share (EARN) has been used and the same has been expanded to include two more variables such as cash flow from operations (CFO) and return on equity (ROE). The data were collected from CMIE-Prowess data base in respect of BSE-listed steel companies and the time frame spans from 2010 to 2014. OLS regression has been used to test the value relevance of these accounting numbers. Results indicate that both CFO and BV are having significant influence on the stock price in two out of five years of study. But, BV is emerging as the most significant and highly value relevant of all the four variables during the entire period of study.

Keywords: value relevance, accounting information, book value per share, earnings per share

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Authors: Min Ho Kwon, Woo Young Jung, Hyun Su Seo

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A Polymer Cement Mortar (PCM) has been widely used as the material of repair and restoration work for concrete structure; however a PCM usually induces an environmental pollutant. Therefore, there is a need to develop PCM which is less impact to environments. Usually, UM resin is known to be harmless to the environment. Accordingly, in this paper, the properties of the PCM using UM resin were studied. The general cement mortar and UM resin was mixed in the specified ratio. A certain percentage of PVA fibers, steel fibers and mixed fibers (PVA fiber and steel fiber) were added to enhance the flexural strength. The flexural tests were performed in order to investigate the flexural strength of each PCM. Experimental results showed that the strength of proposed PCM using UM resin is improved when they are compared with general cement mortar.

Keywords: polymer cement mortar, UM resin, compressive strength, PVA fiber, steel fiber

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Authors: Myoung-Jin Lee, Sung-Jin Lee, Young-Kon Park, Jin-Wook Kim, Bo-Kyoung Kim, Song-Hun Chong, Sun-Ii Kim

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The ability to resist the shear strength arises mainly from the web panel of steel girders and as such, the shear buckling strength of these girders has been extensively investigated. For example, Blaser’s reported that when buckling occurs, the tension field has an effect after the buckling strength of the steel is reached. The findings of these studies have been applied by AASHTO, AISC, and to the European Code that provides guidelines for designs aimed at preventing shear buckling. Steel girders are susceptible to corrosion resulting from exposure to natural elements such as rainfall, humidity, and temperature. This corrosion leads to a reduction in the size of the web panel section, thereby resulting in a decrease in the shear strength. The decrease in the panel section has a significant effect on the maintenance section of the bridge. However, in most conventional designs, the influence of corrosion is overlooked during the calculation of the shear buckling strength and hence over-design is common. Therefore, in this study, a steel girder with an A/D of 1:1, as well as a 6-mm-, 16-mm-, and 12-mm-thick web panel, flange, and intermediate reinforcing material, respectively, were used. The total length was set to that (3200 mm) of the default model. The effect of corrosion shear buckling was investigated by determining the volume amount of corrosion, shape of the erosion patterns, and the angular change in the tensile field of the shear buckling strength. This study provides the basic data that will enable designs that incorporate values closer (than those used in most conventional designs) to the actual shear buckling strength.

Keywords: corrosion, shear buckling strength, steel girder, shear strength

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Authors: Roman Kalvin, Anam Nadeem, Shahab Khushnood

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Differential is an integral part of four wheeled vehicle, and its main function is to transmit power from drive shaft to wheels. Differential assembly allows both rear wheels to turn at different speed along curved paths. It consists of four gears which are assembled together namely pinion, ring, spider and bevel gears. This research focused on the spider gear and its static structural analysis using ANSYS. The main aim was to evaluate the distribution of stresses on the teeth of the spider gear. This study also analyzed total deformation that may occur during its working along with bevel gear that is meshed with spider gear. Structural steel was chosen for spider gear in this research. Modeling and assembling were done on SolidWorks for both spider and bevel gear. They were assembled exactly same as in a differential assembly. This assembly was then imported to ANSYS. After observing results that maximum amount of stress and deformation was produced in the spider gear, it was concluded that structural steel material for spider gear possesses greater amount of strength to bear maximum stress.

Keywords: ANSYS, differential, spider gear, structural steel

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Authors: Ng Mei Han, Nu'man Abdul Hadi

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Extraction of ferulic acid from palm pressed fiber using deep eutectic solvent (DES) of choline chloride-acetic acid (ChCl-AA) and choline chloride-citric acid (ChCl-CA) are reported. Influence of water content in DES on the extraction efficiency was investigated. ChCl-AA and ChCl-CA experienced a drop in viscosity from 9.678 to 1.429 and 22.658 ± 1.655 mm2/s, respectively as the water content in the DES increased from 0 to 50 wt% which contributed to higher extraction efficiency for the ferulic acid. Between 41,155 ± 940 mg/kg ferulic acid was obtained after 6 h reflux when ChCl-AA with 30 wt% water was used for the extraction compared to 30,940 ± 621 mg/kg when neat ChCl-AA was used. Although viscosity of the DES could be improved with the addition of water, there is a threshold where the DES could tolerate the presence of water without changing its solvent behavior. The optimum condition for extraction of ferulic acid from palm pressed fiber was heating for 6 h with DES containing 30 wt% water.

Keywords: deep eutectic solvent, extraction, ferulic acid, palm fibre

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Authors: Prateek Singh, Dilshad Ahmad

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Growing demand for high-quality steel products has inspired researchers to investigate the unit operations involved in the manufacturing of these products (slabs, rods, sheets, etc.). One such operation is tundish operation, in which a vessel (tundish) acts as a buffer of molten steel for the solidification operation in mold. It is observed that tundish also plays a crucial role in the quality and cleanliness of the steel produced, besides merely acting as a reservoir for the mold. It facilitates removal of dissolved oxygen (inclusions) from the molten steel thus improving its cleanliness. Inclusion removal can be enhanced by increasing the residence time of molten steel in the tundish by incorporation of flow modifiers like dams, weirs, turbo-pad, etc. These flow modifiers also help in reducing the dead or short circuit zones within the tundish which is significant for maintaining thermal and chemical homogeneity of molten steel. Thus, it becomes important to analyze the flow of molten steel in the tundish for different configuration of flow modifiers. In the present work, effect of varying positions and heights/depths of dam and weir on the dead volume in tundish is studied. Steady state thermal and flow profiles of molten steel within the tundish are obtained using OpenFOAM. Subsequently, Residence Time Distribution analysis is performed to obtain the percentage of dead volume in the tundish. Design of Experiment method is then used to configure different tundish geometries for varying positions and heights/depths of dam and weir, and dead volume for each tundish design is obtained. A second-degree polynomial with two-term interactions of independent variables to predict the dead volume in the tundish with positions and heights/depths of dam and weir as variables are computed using Multiple Linear Regression model. This polynomial is then used in an optimization framework to obtain the optimal tundish geometry for minimizing dead volume using Sequential Quadratic Programming optimization.

Keywords: design of experiments, multiple linear regression, OpenFOAM, residence time distribution, sequential quadratic programming optimization, steel, tundish

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Authors: Feng-Tsai Weng, Rick Wang, Yan-Cong Liao

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Passivation is a kind of surface treatment for material to reinforce the corrosion resistance specially the stainless alloy. Passive film, is to getting more potential compared to their status before passivation. An oxidation film can be formed on the surface of stainless steel, which has a strong corrosion resistance ability after passivation treatment. In this research, a new passivation technology is proposed for a special stainless alloy which contains a 12-14% Chromium. This method includes the A-A-A (alkaline-acid-alkaline) process basically, which was developed by Carpenter that can neutralize trapped acid. Besides, a corrosion resistant coating layer was obtained by immersing the parts in a water bath of mineral oil at high temperature. Salt spray test ASTM B368 was conducted to investigated performance of corrosion resistant of the passivated stainless steel alloy parts. Results show much better corrosion resistant that followed a coating process after A-A-A Passivation process, than only using A-A-A process. The passivation time is with more than 380 hours of salt spray test ASTM B368, which is equal to 3000 hours of Salt spray test ASTM B117. Proposed passivation method of stainless steel can be completed in about 3 hours.

Keywords: passivation, alkaline-acid-alkaline, stainless steel, salt spray test

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Authors: Salah E. El-Metwally, Marwan Abdo, Basem Abdel Wahed

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Fiber-reinforced polymer (FRP) bars have been proposed as an alternative to conventional steel bars; hence, the use of these non-corrosive and nonmetallic reinforcing bars has increased in various concrete projects. This concrete material is lightweight, has a long lifespan, and needs minor maintenance; however, its non-ductile nature and weak bond with the surrounding concrete create a significant challenge. The behavior of concrete elements reinforced with FRP bars has been the subject of several experimental investigations, even with their high cost. This study aims to numerically assess the viability of using FRP bars, as longitudinal reinforcement, in comparison with traditional steel bars, and also as prestressing tendons instead of the traditional prestressing steel. The nonlinear finite element analysis has been utilized to carry out the current study. Numerical models have been developed to examine the behavior of concrete beams reinforced with FRP bars or tendons against similar models reinforced with either conventional steel or prestressing steel. These numerical models were verified by experimental test results available in the literature. The obtained results revealed that concrete beams reinforced with FRP bars, as passive reinforcement, exhibited less ductility and less stiffness than similar beams reinforced with steel bars. On the other hand, when FRP tendons are employed in prestressing concrete beams, the results show that the performance of these beams is similar to those beams prestressed by conventional active reinforcement but with a difference caused by the two tendon materials’ moduli of elasticity.

Keywords: reinforced concrete, prestressed concrete, nonlinear finite element analysis, fiber-reinforced polymer, ductility

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Authors: A. Talaei, M. Ahiduzzaman, A. Kumar

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In Canada, an increase in the production of iron and steel is anticipated for satisfying the increasing demand of iron and steel in the oil sands and automobile industries. It is predicted that GHG emissions from iron and steel sector will show a continuous increase till 2030 and, with emissions of 20 million tonnes of carbon dioxide equivalent, the sector will account for more than 2% of total national GHG emissions, or 12% of industrial emissions (i.e. 25% increase from 2010 levels). Therefore, there is an urgent need to improve the energy intensity and to implement energy efficiency measures in the industry to reduce the GHG footprint. This paper analyzes the current energy consumption in the Canadian iron and steel industries and identifies energy efficiency opportunities to improve the energy intensity and mitigate greenhouse gas emissions from this industry. In order to do this, a demand tree is developed representing different iron and steel production routs and the technologies within each rout. The main energy consumer within the industry is found to be flared heaters accounting for 81% of overall energy consumption followed by motor system and steam generation each accounting for 7% of total energy consumption. Eighteen different energy efficiency measures are identified which will help the efficiency improvement in various subsector of the industry. In the sintering process, heat recovery from coolers provides a high potential for energy saving and can be integrated in both new and existing plants. Coke dry quenching (CDQ) has the same advantages. Within the blast furnace iron-making process, injection of large amounts of coal in the furnace appears to be more effective than any other option in this category. In addition, because coal-powered electricity is being phased out in Ontario (where the majority of iron and steel plants are located) there will be surplus coal that could be used in iron and steel plants. In the steel-making processes, the recovery of Basic Oxygen Furnace (BOF) gas and scrap preheating provides considerable potential for energy savings in BOF and Electric Arc Furnace (EAF) steel-making processes, respectively. However, despite the energy savings potential, the BOF gas recovery is not applicable in existing plants using steam recovery processes. Given that the share of EAF in steel production is expected to increase the application potential of the technology will be limited. On the other hand, the long lifetime of the technology and the expected capacity increase of EAF makes scrap preheating a justified energy saving option. This paper would present the results of the assessment of the above mentioned options in terms of the costs and GHG mitigation potential.

Keywords: Iron and Steel Sectors, Energy Efficiency Improvement, Blast Furnace Iron-making Process, GHG Mitigation

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Authors: Ahmed H. El-Masry, Mohamed A. Dabaon, Tarek F. El-Shafiey, Abd El-Hakim A. Khalil

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An experimental study was performed to investigate the behavior and strength of proposed technique to connect reinforced concrete (RC) beam to steel or composite columns. This approach can practically be used in several types of building construction. In this technique, the main beam of the frame consists of a transfer part (part of beam; Tr.P) and a common reinforcement concrete beam. The transfer part of the beam is connected to the column, whereas the rest of the beam is connected to the transfer part from each side. Four full-scale beam-column connections were tested under static loading. The test parameters were the length of the transfer part and the column properties. The test results show that using of the transfer part technique leads to modify the deformation capabilities for the RC beam and hence it increases its resistance against failure. Increase in length of the transfer part did not necessarily indicate an enhanced behavior. The test results contribute to the characterization of the connection behavior between RC beam - steel column and can be used to calibrate numerical models for the simulation of this type of connection.

Keywords: composite column, reinforced concrete beam, steel column, transfer part

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Authors: Aymen H. Khalil, Ashraf M. Heniegal, Bassam A. Abdelsalam

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There are many problems related to cantilever slabs such as the time-dependent deformation, corrosion problems of steel reinforcement, and lack of experimental studies on the strength of strengthened cantilever slabs. This paper presents an investigation to evaluate the behavior of reinforced concrete cantilever slabs after strengthening with different techniques. Six medium scale specimens, divided into three groups, were tested along with a control slab. The first group consists of two specimens which were repaired and strengthened using reinforced concrete jacket above with and without shear connector bars, whereas the second group contained two slabs which were strengthened using two strips of two layers of glass fiber reinforced polymer (GFRP) covering 60% and 90% from the cantilever length. The last group involves two specimens strengthened with two steel plates. In one specimen, the steel plates were glued to the surface using epoxy resin. The second specimen, the steel plates were affixed to the concrete surface using expansion bolts. The loading was conducted in two phases. Firstly, the samples were subjected to 40% of the ultimate load of the control slab. Secondly, the specimens reloaded after being strengthened up to failure. The load-deflection, steel strain, concrete strain, failure mode, toughness, and ductility index are discussed in this paper.

Keywords: repair, strengthened, GFRP layers, reloaded, jacketing, cantilever slabs

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Authors: Bunty Tomar, Shiva S.

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Fabrication of steel and copper-based functionally graded material (FGM) through cold metal transfer-based wire arc additive manufacturing is a novel exploration. Components combining Cu and steel show significant usage in many industrial applications as they combine high corrosion resistance, ductility, thermal conductivity, and wear resistance to excellent mechanical properties. Joining steel and copper is challenging due to the mismatch in their thermo-mechanical properties. In this experiment, a functionally graded material (FGM) structure of pure copper (Cu) and 316L stainless steel (SS) was successfully developed using cold metal transfer-based wire arc additive manufacturing (CMT-WAAM). The interface of the fabricated samples was characterized under optical microscopy, field emission scanning electron microscopy, and X-ray diffraction techniques. Detailed EBSD and TEM analysis was performed to analyze the grain orientation, strain distribution, grain boundary misorientations, and formation of metastable and intermetallic phases. Mechanical characteristics of deposits was also analyzed using tensile and wear testing. This works paves the way to use CMT-WAAM to fabricate steel/copper FGMs.

Keywords: wire arc additive manufacturing (waam), cold metal transfer (cmt), metals and alloys, mechanical properties, characterization

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Authors: G. Culache, M. P. Byfield, N. S. Ferguson, A. Tyas

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Steel joints in building structures represent a weak link in the case of accidental transient loading. This type of loading can occur due to blast effects or impact with moving vehicles and will result in large deformations in the material as well as large rotations. This paper addresses the lack of experimental investigations into the response of moment resisting connections subjected to such loading. The current design philosophy was used to create test specimens with flush and extended end plates. The specimens were tested in a specially designed testing rig capable of delivering the sustained loading even beyond the point of failure. Types of failure that the authors attempted to obtain were bolt fracture, flange crushing and end plate fracture. Experimental data is presented, described and analyzed. The tests show that the strength and ductility can be significantly improved by replacing ordinary mild-steel bolts with their stainless steel equivalents. This minor modification is demonstrated to significantly improve the robustness when subjected to loading that results in high deformations and rotation, where loading is maintained during failure. Conclusions are drawn about the wider implications of this research and recommendations made on the direction of future research in this field.

Keywords: steel moment connections, high strain rates, dynamic loading, experimental testing

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Authors: B. Karthik Vasan, Rachil Maliwal, Somnath Basu

Abstract:

Generation of solid waste is a major problem confronting the iron and steel industry around the world. Disposal of untreated wastes is no longer a viable solution in view of the environmental regulations becoming more and more stringent, as well as an increase in community awareness about the long-term hazards of indiscriminate waste disposal. The current work explores the possibility of converting some of the ‘problematic’ solid wastes generated during steel manufacturing operations, viz. dust from primary steelmaking, iron ore handling, and flux calcination processes, into value-added products instead of environmentally hazardous disposal practices. It was possible to develop a synthetic calcium ferrite, which helped to enhance the dissolution of calcined basic fluxes (e.g. CaO) and reduce the overall energy consumption during steel making. This, in turn, increased process efficiency and reduced greenhouse gas emissions. The preliminary results from laboratory-scale experiments clearly demonstrate the potential of utilizing these ‘waste materials’ that are generated in-house in iron and steel manufacturing plants. The energy required for synthesis of the ferrite may be reduced further by partially utilizing the waste heat from the exhaust gases. In the longer run, it would result in significant financial benefits due to reduced dependence on purchased fluxes. The synthesized ferrite is non-hygroscopic and this provides an additional benefit during its storage and transportation, relative to calcined lime (CaO) that is widely used as a basic flux across the steel making industry.

Keywords: calcium ferrite, flux, slag formation, solid waste

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Authors: Stephen Eyije Abechi, Casimir Emmanuel Gimba, Zaharaddeen Nasiru Garba, Sani Shamsudeen, David Ebuka Authur

Abstract:

Corrosion inhibition of mild steel in acid medium using Acalypha chamaedrifolia leaves extract as potential green inhibitor was investigated. Gravimetric (weight loss) technique was used for the corrosion studies. Mild steel coupons of 2cm × 1cm × 0.27 cm dimensions were exposed for varying durations of between 24 to 120 hours, in 1M HCl medium containing a varying concentrations of the leaves extract (0.25g/L, - 1.25g/L). The results show that corrosion rates dropped from a value of 0.49 mgcm-2hr-1 for the uninhibited medium to a value of 0.15 mgcm-2hr-1 for the inhibited medium of 1M HCl in 0.25 g/l of the extract. Values of corrosion inhibition efficiencies of 70.38-85.11% were observed as the concentration of the inhibitor were increased from 0.25g/L, - 1.25g/L. Corrosion Inhibition was found to increase with increase in immersion time and temperature. The magnitude of the Ea indicates that the interaction between the metal surface and the inhibitor was chemisorptions. The Adsorption process fit into the Langmuir isotherm model with a correlation coefficient of 0.97. Evidence from molecular dynamics model shows that Methyl stearate (Line 5) and (3Z, 13Z)-2-methyloctadeca-3,13-dien-1-ol (line 11) were found to have the highest binding energy of -197.69 ± 3.12 and-194.56 ± 10.04 in kcal/mol respectively. The binding energy of these compounds indicates that they would be a very good corrosion inhibitor for mild steel and other Fe related materials.

Keywords: binding energy, corrosion, inhibitor, langmuir isotherm, mild steel

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Authors: C. Han, H. Kim, S. Park

Abstract:

The purpose of the present study is to analyze the effect of surface roughness on fatigue life of SCM440 steel. Two groups of specimens were made from SCM440 steel with and without surface polished after forging process and resulted in different values of surface roughness. The difference of the surface roughness between two groups was clearly distinguished even to the naked eye. Surface roughness of both groups of the specimens was quantitatively measured by a roughness measuring device, Talysurf series2 (Taylor-Hobson Co., USA). Average roughness (Ra) and maximum roughness depth (Rmax) values were obtained by scanning 45 mm with a speed of 0.25 mm/s. Fatigue tests were conducted using a three-point bending method with a cyclic sinusoidal profile of 5 Hz, stress ratio of R = 0.1 and reference life for fatigue limit of 1 × 106 cycles. Ra and Rmax without surface polished were 10.497 ± 1.721 μm and 87.936 ± 16.210 μm, respectively while those values with surface polished were much smaller (ongoing measurements). Fatigue lives of the surface-polished specimens achieved approximately 1 × 106 cycles under the maximum stress of 900 MPa, which was 10 times longer than those of the surface-untreated specimens with an average roughness of 10.082 μm. The results showed that an increase in surface roughness values led to a decrease in fatigue lives.

Keywords: surface roughness, fatigue test, fatigue life, SCM440 steel

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Authors: Emmanuel Ogundimu, Esther Akinlabi, Mutiu Erinosho

Abstract:

Welding is described as the process of joining metals so that bonding can be created as a result of inter-atomic penetration. This study investigated the influence of heat input on the efficiency of the welded joints of 304 stainless steel. Three welds joint were made from two similar 304 stainless steel plates of thickness 6 mm. The tensile results obtained showed that the maximum average tensile strength of 672 MPa is possessed by the sample A1 with low heat input. It was discovered that the tensile strength, % elongation and weld joint efficiency decreased with the increase in heat input into the weld. The average % elongation for the entire samples ranged from 28.4% to 36.5%. Sample A1 had the highest joint efficiency of 94.5%. However, the optimum welding current of 190 for TIG- MIG hybrid welding of type-304 austenite stainless steel can be recommended for advanced technological applications such as aircraft manufacturing, nuclear industry, automobile industry, and processing industry.

Keywords: microhardness, microstructure, tensile, MIG welding, process, tensile, shear stress TIG welding, TIG-MIG welding

Procedia PDF Downloads 199