Iranian Journal of Materials science and Engineering
Volume:5 Issue: 2, Jun 2008

In this study an algorithm for mold-filling simulation with consideration of surface tension has been developed based on a SOLA VOF scheme. As the governing equations, the Navier-Stokes equations for incompressible and laminar flows were used. We proposed a way of considering surface tension in mold-filling simulation. The proposed scheme for surface tension was based on the continuum surface force (CSF) model; we could confirm the remarkable effectiveness of the surface tension by experiment which concluded in very positive outcome.

Production of titanium aluminides in TiO2-Al-Ca system has been investigated. For this purpose, different compositions of raw materials were studied in a special reaction vessel. In a special case, the non-completed reaction of TiO2 with Al and Ca resulted in the production of granulates of titanium aluminides especially Ti3Al and other Ti – Al phases as the metallic product and Ca12Al14O33 as the non-metallic product. Remelting of metallic granulates led to production of TiAl ingot.

Lead-containing glass borosilicate was synthesized by Sol-gel technique using metalalkoxids such as tetraethyleorthosilicate (TEOS), Al-sec-butoxide and trimethyl borate. The sol containing TEOS converts to gel during drop wise addition of Al-alkoxide while inorganic lead salt was added in the last stage of gelation to prepare the alcogels. The specimens were dried at room temperature to set then heated at 600°C quickly to avoid crystallization preparing a glass containing 63 wt% lead oxide. The influence of pH on absorption behavior of the sols studied by UV visible technique so the characteristic of the gel, alcogel and xerogel were studied in the different acidic concentrations. The UV spectrums show that the higher the acidity of the hydrolysis stages, the higher the absorbance. The results showed the sample with 63 wt% lead was found fully amorphous. Microstructure and phase analysis of the glass powders were investigated by X-ray diffraction (XRD), X-ray fluorescence (XRF) and scanning electron microscopy (SEM) equipped with EDS analysis.

To ensure the rail transportations safety, evaluation of fatigue behavior of the rail steel is necessary. High cycle fatigue behaviour of a rail steel was the subject of investigation in this research using fracture mechanics. Finite element method (FEM) was used for analyzing the distribution of the stresses on the rail, exerted by the external load. FEM analysis showed that the maximum longitudinal stresses occurred on the railhead. To find out about the relation of crack growth with its critical size, and to estimate its lifetime, the behaviour of transverse cracks to rail direction was studied using damage tolerance concept. It revealed that transverse crack growth initially occurred slowly, but it accelerated once the crack size became larger. Residual service life was calculated for defective segments of the rails. In addition, allowable crack size for different non-destructive testing intervals was determined; the allowable crack size decreased as the NDT intervals increased.

The use of alkali-activated cementitious materials especially over the past decades has significantly been increased. The goal of this research is to investigate the effects of silica modulus and alkali concentration on alkali-activation of blast-furnace slag. In this research, the most important physical characteristics of cementitious systems, i.e. the 28-day compressive strength and final setting time, were studied by changing influencing parameters such as silica modulus, i.e. SiO2/Na2O, (0.44, 0.52, 0.60, and 0.68) and Na2O concentration (4, 6, 8 and 10% by weight of dry binder) at a constant water-to-dry binder ratio of 0.25. Final setting time of the studied systems varies in the range between 55-386 minutes. The obtained results show that systems cured at an atmosphere of more than 95% relative humidity at room temperature exhibit relatively high 28-day compressive strengths up to 107 MPa.

Auto-ignited gel combustion process has been used for producing a red hematite-zircon based pigment. The combustible mixtures contained the metal nitrates and citric acid as oxidizers and fuel, respectively. Sodium silicate (water glass) was used as silica source for producing zircon phase. X-Ray Diffractometery, Electron Microscopy and Simultaneous Thermal Analysis were used for characterization of reactions happened in the resulted dried gel during its heat-treatment. L* a* b* color parameters were measured by the CIE (Commission International de I''Eclairage) colorimetric method. This research has showed that solution combustion was unable to produce coral pigment as the end product of combustion without the need for any further heat treatment process.

gasification (BBLG). One particularly harsh application is linings for gasifiers used in the treatment of black liquor (BL). Black liquor is a water solution of the non-cellulose portion of the wood (mainly lignin) and the spent pulping chemicals (Na2CO3, K2CO3, and Na2S). Development of new refractory materials for the black liquor gasification (BLG) application is a critical issue for implementation of this technology. FactSage® thermodynamic software was used to analyze the phases present in BL smelt and to predict the interaction of BL smelt with different refractory compounds. The modeling included prediction of the phases formed under the operating conditions of high temperature black liquor gasification (BLG) process. At the operating temperature of the BLG, FactSage® predicted that the water would evaporate from the BL and that the organic portion of BL would combust, leaving a black liquor smelt composed of sodium carbonate (70-75%), potassium carbonate (2-5%), and sodium sulfide (20-25%). Exposure of aluminosilicates to this smelt leads to significant corrosion due to formation of expansive phases with subsequent cracking and spalling. Oxides (ZrO2, CeO2, La2O3, Y2O3, Li2O, MgO and CaO) were determined to be resistant to black liquor smelt but non-oxides (SiC and Si3N4) would oxidize and dissolve in the smelt. The other candidates such as MgAl2O4 and BaAl2O4 were resistant to sodium carbonate but not to potassium carbonate. LiAlO2 was stable with both sodium carbonate and potassium carbonate. Candidate materials selected on the basis of the thermodynamic calculations are being tested by sessile drop test for corrosion resistance to molten black liquor smelt. Sessile drop testing has confirmed the thermodynamic predictions for Al2O3, CeO2, MgO and CaO. Sessile drop testing showed that the thermodynamic predictions were incorrect for ZrO2.