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Advances in Sintering of Ores, Metallic Powders, and Ceramics
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Advances in Sintering of Ores, Metallic Powders, and Ceramics

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 January 2023) | Viewed by 18526

Special Issue Editors

Prof. Dr. Luis Felipe Verdeja

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Guest Editor
Department of Materials Science and Metallurgical Engineering, University of Oviedo, 33004 Oviedo, Asturias, Spain
Interests: ceramics; refractories; metallurgy; materials
Special Issues, Collections and Topics in MDPI journals
Dr. Daniel Fernández González

E-Mail Website1 Website2
Guest Editor
Departamento de Ciencia de los Materiales e Ingeniería Metalúrgica, Universidad de Oviedo, Oviedo, Asturias, Spain
Interests: iron ore sintering; sintering in ceramics; solar energy in materials; manganese; metallurgical byproducts
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue on “Advances in Sintering of Ores, Metallic Powders, and Ceramics” aims to provide a place where researchers could share the recent advances in sintering of ores, metallic powders, and ceramics. Sintering is a process of agglomerating, compacting, and forming powders of different materials using heat and/or pressure. This technology is widely used in metallurgy and in ceramics, from the sintering of ores to obtain an agglomerated product with the suitable characteristics to be used in the furnace to the sintering of metallic (alloys or high melting point materials) or nonmetallic (ceramics) powders to obtain the part with the almost final shape. The purpose of this Special Issue is to collect research papers presenting the current state of knowledge on sintering process, from modern sintering technologies (for instance, spark plasma sintering or microwave sintering) to improvements in the sintered product passing through the environmental aspects of the process. Contributions presenting different approaches to sintering process, including metallic and nonmetallic materials, are warmly welcomed.

Prof. Luis Felipe Verdeja
Dr. Daniel Fernández González
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Iron ore sintering
  • Sintering in ceramics
  • Sintering of metallic powders
  • Powder metallurgy
  • Ore mineral
  • Spark plasma sintering
  • Microwave sintering
  • Ceramics

Published Papers (7 papers)

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Research

16 pages, 37674 KiB  
Article
Characteristics of Conventional and Microwave Sintered Iron Ore Preform
by Azhar Equbal, Mohammad Ali, Md. Asif Equbal, S. C. Srivastava, Zahid A. Khan, Md. Israr Equbal, Irfan Anjum Badruddin, Khalid Mohamed El-Hady and Sarfaraz Kamangar
Materials 2022, 15(7), 2655; https://doi.org/10.3390/ma15072655 - 4 Apr 2022
Cited by 3 | Viewed by 1905
Abstract
In this study, compacted hematite (Fe2O3) preforms were made and sintered at various temperatures, such as 1250 °C and 1300 °C, using both conventional and microwave sintering methods. The density, porosity, microhardness, cold crushing strength, microphotographs, and X-ray diffraction [...] Read more.
In this study, compacted hematite (Fe2O3) preforms were made and sintered at various temperatures, such as 1250 °C and 1300 °C, using both conventional and microwave sintering methods. The density, porosity, microhardness, cold crushing strength, microphotographs, and X-ray diffraction (XRD) analysis of the sintered preforms were used to evaluate the performance of the two sintering methods. It was found that microwave sintered preforms possessed lesser porosity and higher density than conventionally sintered preforms owing to uniform heating of the powdered ore in microwave sintering method. Furthermore, it was also observed that microwave sintered preforms exhibited relatively higher cold crushing strength and hardness than conventionally sintered preforms. Thus, the overall results revealed that microwave sintering yielded better properties considered in the present study. Full article
(This article belongs to the Special Issue Advances in Sintering of Ores, Metallic Powders, and Ceramics)
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16 pages, 5207 KiB  
Article
Influence of Fuel Level on Properties, Productivity, and Mineralogy of Russian Vanadiferous Titanomagnetite Sinter
by Jiahao Li, Jingwei Men, Songtao Yang and Mi Zhou
Materials 2021, 14(21), 6258; https://doi.org/10.3390/ma14216258 - 21 Oct 2021
Cited by 1 | Viewed by 1136
Abstract
The influence of fuel level on Russian vanadiferous titanomagnetite sinter properties, productivity, and mineralogy are researched by sintering pot testing, metallographic microscopy, scanning electron microscopy analysis, and energy dispersive spectrometer (SEM-EDS) analysis. A comprehensive index is evaluated in conjunction with the same indexes [...] Read more.
The influence of fuel level on Russian vanadiferous titanomagnetite sinter properties, productivity, and mineralogy are researched by sintering pot testing, metallographic microscopy, scanning electron microscopy analysis, and energy dispersive spectrometer (SEM-EDS) analysis. A comprehensive index is evaluated in conjunction with the same indexes and significance coefficient as that in the Panzhihua Iron and Steel Group. Results show that with the increasing fuel level from 3.5% to 6.0%, flame front speed, yield, tumbling test index (TI), and productivity, all first increase and then decrease. The low temperature reduction degradation index (RDI+3.15) and softening zone (ΔT) gradually increase while the RI and starting temperature of softening (T10), and ending temperature of softening (T40) decrease with increasing fuel levels from 3.5% to 6.0%. With the increase of fuel level from 3.5% to 6.0%, the content of FeO, SiO2, and MgO increase, while TiO2 shows a decrease. For the same increase in fuel level, the number of pores and calcium ferrite and hematite decrease but the silicate increases. In addition, in the fuel level range of 3.5% to 5.5%, magnetite correspondingly increases but then shows a drop after 5.5%. Moreover, when the fuel level increases to greater than 5.0%, FeOx and fayalite quickly increase and a small amount of metallic iron appears under the fuel level of 6.0%. Overall, the optimal fuel level under current production conditions and indicator selection is 4.0%. Full article
(This article belongs to the Special Issue Advances in Sintering of Ores, Metallic Powders, and Ceramics)
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13 pages, 3146 KiB  
Communication
Research and Development of Novel Refractory of MgO Doped with ZrO2 Nanoparticles for Copper Slag Resistance
by Cristian Gómez-Rodríguez, Yanet Antonio-Zárate, Josept Revuelta-Acosta, Luis Felipe Verdeja, Daniel Fernández-González, Jesús Fernando López-Perales, Edén Amaral Rodríguez-Castellanos, Linda Viviana García-Quiñonez and Guadalupe Alan Castillo-Rodríguez
Materials 2021, 14(9), 2277; https://doi.org/10.3390/ma14092277 - 28 Apr 2021
Cited by 14 | Viewed by 2492
Abstract
This study investigates the corrosion mechanism on 100 wt.% MgO and 95 wt.% MgO with 5 wt.% nano-ZrO2 ceramic composites. First, MgO powder and powder mixtures (MgO + nano ZrO2) were uniaxially and isostatically pressed; then, they were sintered at [...] Read more.
This study investigates the corrosion mechanism on 100 wt.% MgO and 95 wt.% MgO with 5 wt.% nano-ZrO2 ceramic composites. First, MgO powder and powder mixtures (MgO + nano ZrO2) were uniaxially and isostatically pressed; then, they were sintered at 1650 °C. Corrosion by copper slag was studied in sintered samples. Physical properties, microstructure, and penetration of the slag in the refractory were studied. Results reveal that ZrO2 nanoparticles enhanced the samples’ densification, promoting grain growth due to diffusion of vacancies during the sintering process. Additionally, magnesia bricks were severely corroded, if compared with those doped with nano-ZrO2, mainly due to the dissolution of MgO grains during the chemical attack by copper slag. Full article
(This article belongs to the Special Issue Advances in Sintering of Ores, Metallic Powders, and Ceramics)
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12 pages, 6805 KiB  
Article
Effect of Short Attritor-Milling of Magnesium Alloy Powder Prior to Spark Plasma Sintering
by Peter Minárik, Mária Zemková, Michal Knapek, Stanislav Šašek, Jan Dittrich, František Lukáč, Jiří Kozlík and Robert Král
Materials 2020, 13(18), 3973; https://doi.org/10.3390/ma13183973 - 8 Sep 2020
Cited by 5 | Viewed by 1678
Abstract
The spark plasma sintering (SPS) technique was employed to prepare compacts from (i) gas-atomized and (ii) attritor-milled AE42 magnesium powder. Short attritor-milling was used mainly to disrupt the MgO shell covering the powder particles and, in turn, to enhance consolidation during sintering. Compacts [...] Read more.
The spark plasma sintering (SPS) technique was employed to prepare compacts from (i) gas-atomized and (ii) attritor-milled AE42 magnesium powder. Short attritor-milling was used mainly to disrupt the MgO shell covering the powder particles and, in turn, to enhance consolidation during sintering. Compacts prepared by SPS from the milled powder featured finer microstructures than compacts consolidated from gas-atomized powder (i.e., without milling), regardless of the sintering temperatures in the range of 400–550 °C. Furthermore, the grain growth associated with the increase in the sintering temperature in these samples was less pronounced than in the samples prepared from gas-atomized particles. Consequently, the mechanical properties were significantly enhanced in the material made of milled powder. Apart from grain refinement, the improvements in mechanical performance were attributed to the synergic effect of the irregular shape of the milled particles and better consolidation due to effectively disrupted MgO shells, thus suppressing the crack formation and propagation during loading. These results suggest that relatively short milling of magnesium alloy powder can be effectively used to achieve superior mechanical properties during consolidation by SPS even at relatively low temperatures. Full article
(This article belongs to the Special Issue Advances in Sintering of Ores, Metallic Powders, and Ceramics)
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23 pages, 7370 KiB  
Article
Field-Assisted Sintering/Spark Plasma Sintering of Gadolinium-Doped Ceria with Controlled Re-Oxidation for Crack Prevention
by Tarini Prasad Mishra, Alexander M. Laptev, Mirko Ziegner, Sree Koundinya Sistla, Anke Kaletsch, Christoph Broeckmann, Olivier Guillon and Martin Bram
Materials 2020, 13(14), 3184; https://doi.org/10.3390/ma13143184 - 16 Jul 2020
Cited by 14 | Viewed by 3978
Abstract
Gadolinium-Doped Ceria (GDC) is a prospective material for application in electrochemical devices. Free sintering in air of GDC powder usually requires temperatures in the range of 1400 to 1600 °C and dwell time of several hours. Recently, it was demonstrated that sintering temperature [...] Read more.
Gadolinium-Doped Ceria (GDC) is a prospective material for application in electrochemical devices. Free sintering in air of GDC powder usually requires temperatures in the range of 1400 to 1600 °C and dwell time of several hours. Recently, it was demonstrated that sintering temperature can be significantly decreased, when sintering was performed in reducing atmosphere. Following re-oxidation at elevated temperatures was found to be a helpful measure to avoid sample failure. Sintering temperature and dwell time can be also decreased by use of Spark Plasma Sintering, also known as Field-Assisted Sintering Technique (FAST/SPS). In the present work, we combined for the first time the advantages of FAST/SPS technology and re-oxidation for sintering of GDC parts. However, GDC samples sintered by FAST/SPS were highly sensitive to fragmentation. Therefore, we investigated the factors responsible for this effect. Based on understanding of these factors, a special tool was designed enabling pressureless FAST/SPS sintering in controlled atmosphere. For proof of concept, a commercial GDC powder was sintered in this tool in reducing atmosphere (Ar-2.9%H2), followed by re-oxidation. The fragmentation of GDC samples was avoided and the number of micro-cracks was reduced to a minimum. Prospects of GDC sintering by FAST/SPS were discussed. Full article
(This article belongs to the Special Issue Advances in Sintering of Ores, Metallic Powders, and Ceramics)
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19 pages, 2302 KiB  
Article
Effect of Mineral Aggregates and Chemical Admixtures as Internal Curing Agents on the Mechanical Properties and Durability of High-Performance Concrete
by Francisco Javier Vázquez-Rodríguez, Nora Elizondo-Villareal, Luz Hypatia Verástegui, Ana Maria Arato Tovar, Jesus Fernando López-Perales, José Eulalio Contreras de León, Cristian Gómez-Rodríguez, Daniel Fernández-González, Luis Felipe Verdeja, Linda Viviana García-Quiñonez and Edén Amaral Rodríguez Castellanos
Materials 2020, 13(9), 2090; https://doi.org/10.3390/ma13092090 - 1 May 2020
Cited by 13 | Viewed by 2728
Abstract
In the present work, the effect of mineral aggregates (pumice stone and expanded clay aggregates) and chemical admixtures (superplasticizers and shrinkage reducing additives) as an alternative internal curing technique was investigated, to improve the properties of high-performance concrete. In the fresh and hardened [...] Read more.
In the present work, the effect of mineral aggregates (pumice stone and expanded clay aggregates) and chemical admixtures (superplasticizers and shrinkage reducing additives) as an alternative internal curing technique was investigated, to improve the properties of high-performance concrete. In the fresh and hardened state, concretes with partial replacements of Portland cement (CPC30R and OPC40C) by pulverized fly ash in combination with the addition of mineral aggregates and chemical admixtures were studied. The physical, mechanical, and durability properties in terms of slump, density, porosity, compressive strength, and permeability to chloride ions were respectively determined. The microstructural analysis was carried out by scanning electronic microscopy. The results highlight the effect of the addition of expanded clay aggregate on the internal curing of the concrete, which allowed developing the maximum compressive strength at 28 days (61 MPa). Meanwhile, the replacement of fine aggregate by 20% of pumice stone allowed developing the maximum compressive strength (52 MPa) in an OPC-based concrete at 180 days. The effectiveness of internal curing to develop higher strength is attributed to control in the porosity and a high water release at a later age. Finally, the lowest permeability value at 90 days (945 C) was found by the substitutions of fine aggregate by 20% of pumice stone saturated with shrinkage reducing admixture into pores and OPC40C by 15% of pulverized fly ash. It might be due to impeded diffusion of chloride ions into cement paste in the vicinity of pulverized fly ash, where the pozzolanic reaction has occurred. The proposed internal curing technology can be considered a real alternative to achieve the expected performance of a high-performance concrete since a concrete with a compressive strength range from 45 to 67 MPa, density range from 2130 to 2310 kg/m3, and exceptional durability (< 2000 C) was effectively developed. Full article
(This article belongs to the Special Issue Advances in Sintering of Ores, Metallic Powders, and Ceramics)
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22 pages, 6645 KiB  
Article
Development of an Ultra-Low Carbon MgO Refractory Doped with α-Al2O3 Nanoparticles for the Steelmaking Industry: A Microstructural and Thermo-Mechanical Study
by C. Gómez-Rodríguez, G. A. Castillo-Rodríguez, E. A. Rodríguez-Castellanos, F. J. Vázquez-Rodríguez, J. F. López-Perales, J. A. Aguilar-Martínez, D. Fernández-González, L. V. García-Quiñonez, T. K. Das-Roy and L. F. Verdeja
Materials 2020, 13(3), 715; https://doi.org/10.3390/ma13030715 - 5 Feb 2020
Cited by 14 | Viewed by 3791
Abstract
The effect of α-Al2O3 nanoparticles (up to 5 wt.%) on the physical, mechanical, and thermal properties, as well as on the microstructural evolution of a dense magnesia refractory is studied. Sintering temperatures at 1300, 1500, and 1600 °C are used. [...] Read more.
The effect of α-Al2O3 nanoparticles (up to 5 wt.%) on the physical, mechanical, and thermal properties, as well as on the microstructural evolution of a dense magnesia refractory is studied. Sintering temperatures at 1300, 1500, and 1600 °C are used. The physical properties of interest were bulk density and apparent porosity, which were evaluated by the Archimedes method. Thermal properties were examined by differential scanning calorimetry. The mechanical behavior was studied by cold crushing strength and microhardness tests. Finally, the microstructure and mineralogical qualitative characteristics were studied by scanning electron microscopy and X-ray diffraction, respectively. Increasing the sintering temperature resulted in improved density and reduced apparent porosity. However, as the α-Al2O3 nanoparticle content increased, the density and microhardness decreased. Microstructural observations showed that the presence of α-Al2O3 nanoparticles in the magnesia matrix induced the magnesium-aluminate spinel formation (MgAl2O4), which improved the mechanical resistance most significantly at 1500 °C. Full article
(This article belongs to the Special Issue Advances in Sintering of Ores, Metallic Powders, and Ceramics)
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