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University of Utah Metallurgical Engineering
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University of Utah Metallurgical Engineering
2
Prof. Peng Fan, University of Utah
Research interests
Powder metallurgy,
Hard materials
Functionally graded materials
Extractive metallurgy
Thermal energy storage materials
Renewable and sustainable energy
University of Utah Metallurgical Engineering
3
Functionally graded WC-Co
WC-Co, cemented tungsten carbide, is
the most widely used industrial tool
materials
It is extensively used in metal machining,
oil and gas drilling, mining, and
construction.
Prof. Fan and his colleagues invented a
novel process to produce functionally
graded WC-Co with significantly
improved life time of WC-Co tools.
University of Utah Metallurgical Engineering
4
Co, %
Concept of functionally graded WC-Co
distance from surface
Property
Hardness
Toughness
Unlike conventional WC-Co
with uniform Co distribution,
FG WC-Co has lower Co
content at surface region and
thus a hard-surface tough-core
structure, which leads to
superior combinations of
mechanical properties, e.g.,
increased wear resistance
without sacrificing fracture
toughness.
University of Utah Metallurgical Engineering
distance from surface
5
Novel process to make FG WC-Co
University of Utah Metallurgical Engineering
6
Key process parameter: temperature
14
Processing
temperature
needs to be in
the three phase
region of 1275 to
1325 C.
12
Co, wt%
10
8
1300C
6
1400C
4
1250C
2
as-sintered
0
0
20
40
60
80
100
120
140
Depth from surface, mm
Co content profiles in sintered WC-10%Co specimens before and
after carburizing heat treatment at different temperatures.
University of Utah Metallurgical Engineering
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Mechanism of process
stoichiometry
1400
liquid Co
+ WC
liquidus
solidus
1300
solid Co
+ Co3W3C
+ WC
solid Co
+ WC
solid Co + graphite
+ WC
1250
5.2
5.3
liquid Co
+
graphite
+ WC
solid Co
+ liquid Co
+ WC
T, o C
1350
liquid Co
+ Co3W3C
+ WC
5.4
5.5
5.6
5.7
5.8
C, wt%
A vertical section of the ternary phase diagram of WUniversity of Utah Metallurgical Engineering
Co-C at constant 10wt% Co.
8
Mechanism of process
Surface carburization =>
Solid Co in surface region partially or totally
transforms to liquid =>
Liquid Co in surface region increase =>
Balance of liquid Co distribution between
surface and core regions breaks =>
Liquid Co migrates from surface region to core
region =>
Co gradient forms.
University of Utah Metallurgical Engineering
9
Successful scale up of process
Tube furnace:
Pilot production furnace:
<1 kg WC-Co per run
>50 kg WC-Co per run
University of Utah Metallurgical Engineering
10
Direct reduction of Ti slag to make Ti
Carbothermal
Chemical extractive
reduction –WC
Ti-slag
phase metallurgy process
Ilmenite –
Natural Ti ore
Ti slag
(~80% TiO )
2
Mg (Kroll) or Na
(Hunter) reduction
High temperature carbo
chlorination – TiCl
4
Upgraded TiO –
Titanium
chloride (TiCl )
2
Synthetic rutile
4
Armstrong/ITP,
continuous Na reduction
The FFC Process /
electrolysis of TiO2
Proposed Process
Direct reduction
of Ti slag
Chemical extractive
metallurgy
University of Utah Metallurgical Engineering
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Mechanism of process
University of Utah Metallurgical Engineering
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Thermodynamic feasibility analysis
Equilibium amount, log(mole)
1
0.5
H2(g)
MgO
0
TiH2
Mg
MgH2
-0.5
-1
Fe2Ti
Fe
TiAl
Fe3Si
-1.5
FeSi
-2
TiAl3
-2.5
Ti5Si3
V
CaAl2
Mn
Al
-3
FeTi
Cr
V5Si3
CaO
Mg(g)
Cr3Si
ZrH2
CaH2
-3.5
MnSi
-4
100
Mn3Si
200
300
TiSi
Mg2Si
400
Temperature, °C
500
600
700
University of Utah Metallurgical Engineering
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Process flow chart
Ti slag
MgH2 & Salts
Milling/Blending
Direct Reduction
NH4Cl
solution
NaOH
solution
HCl
solution
H2
NH4Cl
Leach&wash
CaO
MgO
NaOH
Leach&wash
Al2O3
SiO2
HCl
Leach&Wash
Fe
Mn
Cr
Drying
TiH2 Powder
Dehydriding
Ti powder
University of Utah Metallurgical Engineering
14
Removing nitrogen in molten steel
Nitrogen in steel needs to minimized in
view of its adverse effects on steel’s
properties.
Two methods were attempted to remove
nitrogen from molten steel – vacuum
degassing and flux treatment.
Prof. Fan and his colleagues invented a
novel process to more effectively remove
nitrogen from molten steel using titanium
monoxide slag.
University of Utah Metallurgical Engineering
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Experimental data using various slags
Table I
Initial slag compositions, experimental methods, final metal and slag compositions
final metal, %
(Al)
(Nb)
initial slag compositions
50%CaO-50%Al2O3
method
SA
time, h
4
(Ti)
0
0.035
0
0.0093
final slag
(N), %
0.035
40%CaO-40%Al2O3-20%TiO2
A
4
0.053
0.008
0
0.0023
0.028
12.2
40%CaO-40%Al2O3-20%TiO2
LS *
18
0.145
0.021
0.62
0.0059
0.09
15.3
40%CaO-40%Al2O3-20%Ti2O3
SA
4
0.153
0.017
0
0.0069
0.2
29.0
40%CaO-40%Al2O3-20%Ti2O3
LS
18
0.256
0.024
0
0.0058
0.28
48.3
40%CaO-40%Al2O3-20%TiO
LS
18
0.51
0.04
0
0.0003
0.26
866.7
40%CaO-40%Al2O3-20%TiO
35%CaO-35%Al2O3-30%TiO
LS *
18
0.88
0.073
0.2
0.0006
0.25
416.7
SA
4
0.42
0.035
0
0.0005
0.26
520.0
1.4
0.0012
0.66
* : NbN added below steel
550.0
35%CaO-35%Al2O3-30%TiO
LS *
18
0.44
0.034
LS: liquid sealing; SA: static atmosphere; A: flowing Ar;
(N)
LN = (N)/(N)
3.8
University of Utah Metallurgical Engineering
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Effective N removal using TiO slag
4
4h
18h
log( (N)/[N] )
3
18h, NbN added in metal
High values of
nitrogen distribution
ratio using titanium
monoxide slag
indicated more
effective removal of
nitrogen from
molten steel.
2
1
0
CaO-Al2O3
20%TiO2
20%Ti2O3
20%TiO
30%TiO
Nitrogen distribution ratio between slagUniversity
and of Utah Metallurgical Engineering
molten steel using various slags at 1673K
17
N removal limit using various slags
50
Tif = 0.05%
40
Nf , ppm
20% TiO2 ( LN = 8.6 )
30
20% Ti2O3 ( LN = 12 )
20
20% TiO ( LN = 99 )
10
0
0
5
10
15
20
25
30
35
40
Ws , kg/t
Nitrogen removal limit vs slagUniversity
amount
of Utah Metallurgical Engineering
using various slags
18
Thermal energy battery
Application: provide heating and cooling for electric vehicles
Valve
Cold air
H2 flow
Air flow
Warm air
Low-temperature
hydride bed
High-temperature
hydride bed
M1H + heat => M1 + H2
M2 + H2 => M2H + heat
University of Utah Metallurgical Engineering
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Thermal energy battery
Operating principles of thermal energy battery
Thermal chemical energy storage
Charging by plugging into the wall
Discharging – converting stored energy
into heat / cold
Heating (or cooling) of cabin through
heat exchanger
University of Utah Metallurgical Engineering
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HVAC system based on thermal battery
Cooling in Warm Weather
Heat
M1H + Heat -> M1 + H2
Warm Air
Heat
LT-HB
De-hydriding
(Endothermic
reaction)
Hydriding
(Exothermic
reaction)
Cool Air
H2
HT-HB
M2 + H2 -> M2 + Heat
Warm Environment Air
Heat
University of Utah Metallurgical Engineering
Hot Air into Environment
21
HVAC system based on thermal battery
Warming in Cool Weather
Heat
M2 + H2 -> M2 + Heat
Cool Air
Hydriding
(Exothermic
reaction)
HT-HB
Warm Air
H2
De-hydriding
(Endothermic
reaction)
LT-HB
Heat
Cold Air into Environment
M1H + Heat -> M1 + H2
Cool Environment Air
University of Utah Metallurgical Engineering
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HVAC system based on thermal battery
Recharge
M2 + H2 -> M2 + Heat
Hydriding
(Exothermic
reaction)
HT-HB
H2
De-hydriding
(Endothermic
reaction)
Cool Air from Cabin or
Outside Environment
Warm Air to Cabin,
Electrical Batteries, or
Outside Environment
LT-HB
M1H + Heat -> M1 + H2
Heat
University of Utah Metallurgical Engineering
Powder Metallurgy & Mining Related
Journals
Journal of Chemical Engineering & Process
Technology
Journal of Material Sciences & Engineering
Journal of Nanomaterials & Molecular
Nanotechnology
University of Utah Metallurgical Engineering
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Powder Metallurgy & Mining Related Conferences
3rd International Conference and Exhibition on
Material Science and Engineering 2014, San Antonio,
USA
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