Late News Poster Session: Materials Processing
Program Organizers: TMS Administration
Tuesday 5:30 PM
March 21, 2023
Room: Exhibit Hall G
Location: SDCC
N-33: A Closed-loop Recycling Process for Recovery of Critical Metals from Spent Lithium-ion Batteries through Organic Acid Leaching: Jaeyeon Kim1; Jaeheon Lee1; Jiajia Wu2; Jaiwon Byeon3; Yoojin Kim3; 1Colorado School of Mines; 2University of Arizona; 3Seoul National University of Science and Technology
Growing demand for valuable metals for battery materials and environmental issues from battery disposal make the recycling of spent lithium-ion batteries (LIBs) essential. Specifically, the green approaches have garnered attention for battery recycling. In this study, a novel hydrometallurgical process using mixed organic acids as an eco-friendly alternative to a process using conventional inorganic acids was applied to extract valuable metals from LiCoO2. Methanesulfonic acid (MSA) of strong organic acid and citric acid (CA) with good chelating ability were adopted as main lixiviants with H2O2 as a reducing agent. Co and Li extractions were around 95% in the optimized condition; 2.4M MSA, 1.6M CA, 1.5vol% H2O2. The Co and Li were selectively recovered as Co3O4 and LiPO4, respectively, through the precipitation processes and calcination. In addition, to develop a closed-loop recycling process, LiCoO2 and LiFePO4 cathode materials were re-synthesized using the recovered Co3O4 and LiPO4.
A Comparison of Microstructure and Mechanical Properties of TIG and MIG Welded Dissimilar AA7075 / AA6061 Aluminium Alloys Subjected to Friction Stir Processing: Rajeev Rana1; Dagarapu Karunakar1; Anish Karmakar1; 1Indian Institute of Technology Roorkee
The present work investigates the microstructure and mechanical characteristics of TIG and MIG welded dissimilar AA7075 / AA6061 aluminum alloys subjected to Friction Stir Processing (FSP). Initially, aluminum plates were welded using TIG and MIG processes along the rolling direction. Next, FSP was performed on the TIG and MIG welded plates using a rotating tool with a welding speed of 40 mm/min. The microstructures of the welded joints have been quantified using optical microscopy, Field Emission–Scanning Electron Microscopy, and Electron Back Scattered Diffraction. Vickers hardness and tensile tests were carryout out to assess the mechanical properties. The findings revealed that the application of FSP on TIG-welded joints resulted in smaller grain sizes. TIG+FSP joint possessed the highest yield strength, ultimate tensile strength, and stir zone hardness compared to the MIG+FSP joint. Lower hardness was found on the heat-affected zone of the AA6061 side for the MIG+FSP joint.
N-19: An S-STEM Program to Expand Career Opportunities in Engineering Materials: Dwayne Arola1; Eleftheria Roumeli1; Lilo Pozzo1; Junlan Wang1; 1University of Washington
Due to a decline in declared majors in materials engineering at the University of Washington (UW), a team of faculty from the UW and regional 2-year colleges have established an S-STEM program supported by the National Science Foundation. The team represents Chemical, Mechanical and Materials Science and Engineering, which spans from materials synthesis, to processing and applications. The objectives are to: i) increase the number of talented students that transfer into the materials-intensive engineering departments at the UW, ii) to increase the level of diversity in the materials-intensive departments, and to iii) help the Scholars achieve professional success through various mechanisms of support. The program has provided over 70 scholarships to a cadre of qualified undergraduate and graduate students. Through complimentary support mechanisms including faculty advising, professional development workshops, and engagement, the program is impacting engineering education at the UW. This presentation will detail the mechanisms and their impact.
N-20: Analysis of the Phase Stability in the Directionally Solidified Ni-based Superalloy MAR-M247: Rafal Cygan1; Dorota Wyrobek1; Łukasz Rakoczy2; 1Consolidated Precision Products Poland; 2AGH University of Science and Technology
Ni-based superalloys are characterized high strength and corrosion resistance at temperatures. This makes them a key group of materials used in the aviation industry. This work aimed to determine the influence of temperature on the precipitate's stability in the cast MAR-M247 produced via directional solidification. The microstructure, chemical composition, phase constitution, phase transformation temperatures, and microhardness of the castings produced with various withdrawal rates and shell mold temperatures were investigated by X-ray diffraction, scanning and transmission electron microscopy, energy-dispersive X-ray spectroscopy, thermodynamic simulation, and differential scanning calorimetry. Solution heat treatment led to the dissolution of the γ' precipitates and the complete dissolution of the (Cr, W, Mo)5B3 borides and the Ni7(Hf, Zr)2 phases. Secondary γ' precipitates in dendritic regions possess cube-like morphology and finer size than the as-cast state. In the interdendritic spaces, the secondary γ' precipitates have a much more complex morphology originating from the coagulation of finer precipitates.
N-21: Dephosphorization of Iron Ore Containing Phosphorus: Hirokazu Konishi1; Shuna Kushibe1; Yuichiro Koizumi1; Osamu Ishiyama2; Kenichi Higuchi2; 1Osaka University; 2Nippon Steel Corporation
Iron ore grade becomes lower year by year. Especially, phosphorus as an impurity in Australian iron ore are increasing. In the steelmaking process, several methods of dephosphorization have been in practical use, such as distribution to the slag phase and vacuum degassing. However, the dissolved phosphorus cannot be completely removed, and it is finally dispersed uniformly in the solid phase. Trace amounts of phosphorus segregate in steel and induce crack. So, we investigated the dephosphorization of iron ore containing phosphorus. As the first step, partial pressure of P2 is estimated from equilibrium reaction of H2 and CO reduction of Ca3(PO4)2, FePO4, P4O10 under 1273 K. Secondly, dephosphorization was conducted at 973-1373 K under H2-CO2-N2 gases atmosphere. As a result, dephosphorization could be achieved. The ratio of dephosphorization at 1173 K for 6 h became 76%.
N-22: Development and Characterization of a Two-phase Cerium Yttrium Alloy: Effect of Heat Treatment and Composition on Microstructure in Ce-Y Alloys: Casey Shoemaker1; 1Los Alamos National Laboratory
A two-phase cerium yttrium alloy was developed to understand the effect of varying phase fraction on quasi-static and dynamic properties in comparison to unalloyed cerium. The goal of the current work is to discuss the processing pathway as related to the resulting microstructure and phase fraction and eventually to material properties. Test samples are characterized using a combination of metallography, X-ray diffraction, and inductively coupled plasma atomic emission spectroscopy (ICP AES) to identify the influence of the two process variables, heat treatment and starting composition, on microstructure and final phase composition. Through the study, the team developed a process to reproducibly fabricate a two-phase cerium-yttrium alloy with a composition of 5.75 and 6.5 weight percent yttrium heat treated to 450 ⁰C to be mechanically and dynamically tested in future work.
Effect of Multi-axial Forging on Mechanical Properties and Microstructure of AA7075/TaC Composites: John Khalkho1; Dagarapu Karunakar1; 1Indian Institute of Technology Roorkee
In the present study, high-strength AA7075 matrix composites reinforced with tantalum carbide (1, 3, 5, and 7 wt%) were developed through stir casting, followed by multi-axial forging (MAF). MAF was carried out at room temperature with 20% thickness reduction on 10mm thickness composite jobs. The evolution of microstructures during casting and the MAF process were examined by scanning electron microscopy with electron back-scattered diffraction. The microstructure reveals that with the addition of TaC, grain refinement occurs due to the pinning effect. The microstructure of the deformed specimen shows the suppression of dynamic recovery and dislocation density due to strain energy induced at room temperature. The Vickers hardness and tensile strength were found to be the highest for the 5 wt % TaC reinforced specimen. MAF specimen shows an improvement in mechanical properties and percentage elongation. The enhancement in mechanical properties of the MAF specimen is due to higher dislocation density.
N-23: Effects of Advanced Peening Techniques on Corrosion Behavior of Stainless Steel: Dmytro Lesyk1; Hossam Hassan2; Hitoshi Soyama3; Bohdan Mordyuk4; Krishnan Raja2; Bartosz Powalka5; Indrajit Charit2; 1National Technical University of Ukraine "Igor Sikorsky Kyiv Polytechnic Institute"; 2University of Idaho; 3Tohoku University; 4G.V. Kurdyumov Institute for Metal Physics of the NAS of Ukraine; 5West Pomeranian University of Technology
In this study, the water jet caviation peening (wjCP), merged laser shock peening (mLSP), shot peening (SP), water jet shot peening (wjSP), and multi-pin ultrasonic impact peening (UIP) are applied for surface modification to enhance the surface properties of AISI 304 austenitic stainless steel. The plane specimens were processed by the optimized peening parameters. The effect of these advanced mechanical surface treatments on the surface texture, roughness, hardness, grain size, and hardening depth are compared and discussed. The electrochemical corrosion behavior of peened stainless steel parts is also addressed. The corrosion tests were performed in 3.5% NaCl solution at room temperature using an open circuit potential, linear polarization resistance, cyclic polarization, and potentiostatic/potentiodynamic polarization measurements. Results showed that the applied peening techniques led to an increase in the surface hardness due to grain refinement. The most significant increase in the corrosion resistance was observed after the ultrasonic peening.
Evaluation of Microstructure and Mechanical Properties of Al-Mg-Si Alloy Deposited via Submerged Additive Friction Stir Deposition: Ryan Kinser1; Malcom Williams1; James Jordon1; Paul Allison1; 1Baylor University
Many precipitation-strengthened aluminum alloys exhibit a reduction in mechanical properties when subjected to sustained elevated temperatures and slow cooling rates during additive manufacturing. This research investigates a practical and deployable method for improving the as-deposited mechanical properties of aluminum alloys processed via additive friction stir deposition (AFSD) through a submerged cooling approach. Two multilayer depositions were manufactured via AFSD using wrought 6061-T6 (Al-Mg-Si) feedstock and substrate, one conducted in ambient air and the other submerged in water. Tensile characteristics of the as-deposited material in both depositions indicate a reduction in strength relative to the wrought feedstock but suggest a less severe thermal history in the submerged deposition. Process temperatures recorded during the depositions corroborate this trend, revealing a lower peak temperature and increased cooling rate associated with the submerged deposition. The present study illustrates the viability of submerged cooling for improving the as-deposited properties of AFSD aluminum components.
N-25: Machine Learning for Joint Quality Performance-A Comparative Study of the Relationship between Process Parameters and Joint Performance of Al/Steel Resistance Spot Welds: Moses Obiri1; Alejandro Ojeda1; Deb Fagan1; 1Pacific Northwest National Laboratories
10% vehicle weight loss improves fuel economy by 6-8%. Aluminum's strength-to-weight ratio reduces vehicle mass, but it binds poorly with other metals. Spot welding uses electric current and pressure to connect aluminum and low carbon steel. Spot weld quality depends on joint performance and processing parameters. Traditional statistical methodologies don't provide a thorough understanding of welding process evolution due to data structure and variable number. To overcome this gap, supervised and unsupervised machine learning algorithms were used to identify the main elements that determine aluminum and steel joint features and performance and to predict the process parameters required to make joints with preset performance. The results and comparisons between two aluminum types are utilized to create uniform designs to examine the parametric space of the best performing joints and give exploratory recommendations.
N-26: Machine Learning to Model the Relationship between Heat Affected Zone and Weld Join Quality Performance of Aluminum-Steel Resistance Spot Welds: Narmadha Mohankumar1; Moses Obiri1; Deb Fagan1; Alejandro Ojeda1; Luke Durell1; Shoieb Chowdhury1; Hassan Ghassemi-Armaki2; Keerti Kappagantula1; 1Pacific Northwest National Laboratory; 2General Motors
Resistance spot welding (RSW) of Aluminum-steel dissimilar materials is a prominent line of development in the automotive industry to reduce vehicle weight and improve fuel economy. However, properties of Aluminum such as the low melting point, low electrical resistivity, and high thermal conductivity pose unique challenges for the RSW process affecting the Aluminum-steel joint performance. The properties of the heat-affected zone (HAZ) are assumed to influence the Aluminum-steel joint properties and performance but have not been studied extensively. In our work, we use principal component analysis to reduce the dimension of weld performance variables (e.g., peak load, total energy, extension at the break, etc.) and apply machine learning techniques to identify the relationship between the weld performance and properties of HAZ. Moreover, we investigate and account for the uncertainty in the measurements of HAZ properties to improve model accuracy.
N-27: Mechanical Properties of AA5083/Coal Composites Fabricated via Friction Stir Processing Technique: Velaphi Msomi1; Sipokazi Mabuwa1; Oritonda Muribwathoho1; 1Cape Peninsula University of Technology
The fabrication of metal matrix composites is always associated with the response to a weight reduction of structures. The primarily targeted structures are used for transportation because they contribute to global warming through air pollution. The construction of these structures is dominated by heavy metals like steel and steel is the best choice for such applications due to its mechanical properties. There are different types of materials being proposed to replace steel as a way of reducing structural weight, however, most of those materials do not match the mechanical properties of steel. This then suggests that there must be a mechanism used to enhance the mechanical properties of such materials without increasing weight. This work reports on the influence of coal on the mechanical properties of AA5083. The microstructural analysis of the coal reinforced specimens has been studied comparatively with the mechanical behaviour of the said specimen.
N-28: Microstructure Evaluation of the Turbine High Pressure HPT Aircraft Engine Rotor Blades with Internal Channels Reproduced by Monolithic Cores: Dorota Wyrobek1; Rafał Cygan1; 1Consolidated Precision Products Poland
Precision castings of the HPT turbine rotor blades with internal cooling channels are designed to operate under extreme operating conditions. Internal channels were mapped using ceramic cores. The core material was characterized by high mechanical strength while maintaining low shrinkage of firing, high apparent porosity and also showed a low coefficient of thermal expansion. Experiments were performed using various technological parameters. Observations of the microstructure were made on samples cross-sections of blades placed in the central part of the casting. Metallographic specimens were made using standard methods according to ASTM E3. Observations were carried out in the state unetched and etched with Marble reagent, using a scanning electron microscope, detector of backscattered electrons. The analysis of the chemical composition was performed by X-ray energy dispersion spectroscopy (EDS). In order to determine the core effect on liquid alloy C101, microstructure studies were performed in near-surface areas of the blade cooling channel.
N-29: Processing of LIB for Metal Recovery: Amalie Olsen1; 1Norwegian University of Science and Technology
Numerous Li-Ion Batteries are being introduced into society, primarily due to the electric vehicle market’s exponential growth. In view of this, end-of-life treatment technologies must be established to avoid adverse impacts on the material supply of specific elements. Even the environmental impacts of material mining, accumulation of spent LIBs, and associated risks regarding hazardous materials are essential issues that must be addressed. Through leaching experiments, mechanical processing, thermal treatment, characterization, and thermodynamic/kinetic modeling, the present project aspires to find effective, environmentally friendly, and sustainable methods for LIB recycling. A combination of pyrometallurgical and hydrometallurgical unit processes will be used, i.e., untreated and thermally treated Black Mass samples, and mechanically processed spent battery cells will be leached. Different conditions (laboratory/ industrial) will be tested during the experiments to investigate the system’s response. The results will be used as input to thermodynamic and kinetic models to optimize the various process steps.
N-30: Synthesis and Characterization of Next-generation Multiphase Silicon Nitride-based Ceramics: Katherine Brizzolara1; Curtis Martin2; Kevin Hemker1; 1Johns Hopkins University; 2Naval Surface Warfare Center, Carderock Division
Structural ceramics for use in extreme environments must meet stringent requirements. The current study was undertaken to show that multi-phase Si2ON2/Si3N4/BN can be created using a novel two-step processing technique. Nitridation in a tube furnace turns Si, SiO2 and BN powders into α-Si3N4 and then β-Si3N4, while maintaining BN in the matrix. We will contrast nitridation of Si3N4 from silicon powder versus silica powders. Calcining the product in a graphite furnace can lead to Si2ON2, which has improved mechanical properties due to elongated grains. The details of Si2ON2 nucleation and growth are being studied and optimized. The plate-like BN grains further improve the toughness of the overall material. Moreover, processing the multi-phase ceramic in this manner facilitates net-near shape processing, eliminating the need for hot pressing.
N-34: The Beneficiation Process Development for the Ashram REE and Fluorine Project: Maziar Sauber1; Tony Di Feo1; Darren Smith2; 1CanmetMINING; 2Commerce Resources Corp.
Ever-growing global demand for rare earth elements (REE) motivated the development of several flowsheets for Canadian REE deposits to reduce the uncertainties in the global REE supply chain. In the present work, the ore characteristics of the Ashram deposit located in Canada are investigated and the results of processing techniques such as ore sorting, dense media separation, magnetic separation, and flotation are discussed. Some of the latest laboratory findings and industrial applications are presented.
N-31: The Effect of Sampling Direction and Mechanical Characterization of the Friction Stir Processed TIG Welded Joints: Sipokazi Mabuwa1; Velaphi Msomi1; 1Cape Peninsula University of Technology
The TIG-welded dissimilar joints were subjected to the friction stir processing (FSP) technique at room temperature. The specimens for the mentioned tests were extracted longitudinally and transverse to the welding direction. The results obtained from both TIG friction stir processed TIG + FSP joints, and the FSP longitudinally were compared to transverse joints. Regardless of the sampling direction the TIG + FSP joints exhibited greater results compared to TIG welded joints. The FSP longitudinal joints posed a minimal difference in grain size of the stir zone compared to the FSP transverse joints. The hardness of the joints showed a similar reaction. Comparing the mechanical tests of the said sampled joints, the tensile strength of the FSP longitudinal joints was 1.53 times the transverse joint one. The results obtained corresponded with the microstructural grain sizes of the joints. Regardless of the type of joint, the fracture surfaces showed a ductile phenomenon.