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University of Utah  Metallurgical Engineering 
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University of Utah  Metallurgical Engineering 
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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 
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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 
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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 
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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.
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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 
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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 
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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 
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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
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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
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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
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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 
24
Powder Metallurgy & Mining Related Conferences
 3rd International Conference and Exhibition on
Material Science and Engineering 2014, San Antonio,
USA
University of Utah  Metallurgical Engineering 
25
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