Reduction and densification characteristics of iron oxide metallic waste during solid state recycling

Rane, Kedarnath; Date, Prashant P.

doi:10.1016/j.apt.2014.08.015

Cited by 13 publications

(6 citation statements)

References 10 publications

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“…The total change in weight from 750 to 1100°C is a measure of the degree of reduction. The degree of reduction 1 (%) is calculated to be 68.58% The calculated degree of reduction for GSGR75 feedstock is much less than that observed in the reduction of compacted powder pellet (powder metallurgy samples) due to limited physical contact between iron oxide and graphite [21].…”

Section: Thermogravimetric and Dsc Analysismentioning

confidence: 82%

Evolution of properties of parts during MIM and sintering of recycled oxide particles

Rane

Date

2019

Powder Metallurgy

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Metal injection moulding (MIM) is an established process for high volume production of complex shaped metallic parts using commercially available feedstocks. The characteristics of parts after moulding, debinding, and sintering cannot be simply predictable from raw materials because the properties get altered with the process parameters and the corresponding levels of porosity during processing steps. In this study, physical properties, microstructure, and mechanical properties of the MIM parts have been characterised to understand the evolution of strength during various steps in MIM processing. Feedstocks with different binder loading show a considerable difference in physical as well as mechanical characteristics. During sintering of parts which have solid loading of grinding sludge, simultaneous in situ reduction and densification takes place, whereas only densification occurs in carbonyl iron parts. It is, therefore, possible to make complex shaped parts of different levels of porosity from downgraded shop floor metallic waste.

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Section: Thermogravimetric and Dsc Analysismentioning

confidence: 82%

Evolution of properties of parts during MIM and sintering of recycled oxide particles

Rane

Date

2019

Powder Metallurgy

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“…An optimized material and process parameter settings for Powder Metallurgy based recycling were selected based on process characteristics (DOR and DOD), and properties of compacted and sintered PM parts as illustrated in [10] and [15] are considered. The latter part of this section demonstrates the suitability and prospective applications of established recycling technique.…”

Section: Resultsmentioning

confidence: 99%

“…As carbon is the limiting reactant (controls carbothermic reduction reaction) and stoichiometric proportion of carbon may not produce the desired degree of reduction [13]. Carbon is mixed with powdered scrap in 25% excess than that theoretically calculated based on above reactions [14,15]. For comparative assessment of properties, commercial pure iron powder commonly used in powder metallurgical applications and carbonyl iron powder (as detailed in Table 2) were processed likewise for PM and MIM purpose respectively.…”

Section: Introductionmentioning

confidence: 99%

Recycling-Cum-Manufacturing Process for Utilization of Finely Divided Ferrous Metallic Scrap

Rane¹,

Date²

2018

Preprint

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The issues of metallic scrap management and its utilization in manufacturing plants are nowadays intensely considered to address essential sustainability guidelines. Efficient recycling procedure for shop floor metallic scrap is not yet available because of abundance and contamination of nonmetallic constituents. Other ferrous metallic scrap are melted and purified during secondary steelmaking to get products in the form of blooms and billets are obtained. This study illustrates the potential of powder technology (powder metallurgy (PM) and metal injection molding (MIM)) based process for solid-state recycling and attainment of usable products. Industrially downgraded grinding sludge is pulverized and used as a raw material. Results showed properties of sintered parts are significantly improved due to in-situ reduction and densification during sintering. Recyclability Index (RI) was created to compare the effect of process variables on obtained products. Based on RI, recycled ferrous parts have about 70% comparable properties with equivalent pure iron parts. Complex reduction and sintering behavior in MIM, particularly, diffusion and pore volume kinetics limits applicability of MIM with this recycling approach. However, few industrial parts were developed and manufactured by PM based approach to validate the applicability of this novel recycling-cum-manufacturing process for the production of porous parts.

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“…may be calculated as: As carbon is the limiting reactant (controls carbothermic reduction reaction) and stoichiometric proportion of carbon may not produce the desired degree of reduction [14]. Carbon is mixed with powdered scrap in 25% excess than the stoichiometric quantity [13,15]. Commercial pure iron powder and carbonyl iron powder (as detailed in Table 2) were used as benchmarks in PM and MIM, respectively, to facilitate normalization.…”

Section: Methodsmentioning

confidence: 99%

“…Following sections discuss the correlation between Degree of Reduction (DOR) and sintered properties along with a novel quantitative evaluation of recyclability using the Powder Technology based recycling approach. Optimized material and process parameter settings for Powder Metallurgy based recycling were selected based on process characteristics (DOR and DOD), and properties of compacted and sintered PM parts, as illustrated in References [10,15]. The latter part of this section demonstrates the suitability and prospective applications of the proposed recycling technique.…”

Section: Degree Of Reduction (Dor) =mentioning

confidence: 99%

Recycling Potential for Finely Divided Ferrous Metallic Scrap Using Powder Technology

Rane

Date

2018

Recycling

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Enormous amount of scrap is generated on the shopfloor during manufacturing. Energy needed to melt increasing quantities of scrap will be ever increasing, and so will be the loss of metal during melting. Hence, conversion of scrap directly into marketable products by solid state processing methods is economical due to a lower energy requirement and a greater yield compared to the melting route. This makes the process more environmentally friendly. However, not all materials can be recycled in a solid state, with equal ease. One therefore needs to quantitatively assess the recyclability of a given kind of scrap. In the present work, a procedure to assess the recyclability of finely divided ferrous metallic scrap generated on the shopfloor is demonstrated. Recyclability includes material and the process used for recycling. For instance, a given material might be more recyclable using one process compared to the other. In the present study, the potential of powder technology (powder metallurgy (PM) and metal injection molding (MIM) based processes are compared for solid-state conversion of scrap directly into usable products. Grinding sludge collected in the shopfloor was pulverized and used as raw material. Properties of sintered parts were found to be significantly better due to in-situ reduction and densification during sintering. A quantitative measure of recyclability, namely, the Recyclability Index (RI) was defined to compare the manufacturability of different products. Recycled ferrous parts manufactured by PM route are found to have a greater RI (superior recyclability) than those manufactured by the MIM route. Complex reduction and sintering mechanisms in MIM parts, particularly, the kinetics of diffusion and volumetric shrinkage, limit suitability of MIM for recycling. In contrast, few industrial parts were developed and manufactured by conventional PM based approach to demonstrate the suitability of this novel recycling process especially for manufacture of porous parts.

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Reduction and densification characteristics of iron oxide metallic waste during solid state recycling

Cited by 13 publications

References 10 publications

Evolution of properties of parts during MIM and sintering of recycled oxide particles

Evolution of properties of parts during MIM and sintering of recycled oxide particles

Recycling-Cum-Manufacturing Process for Utilization of Finely Divided Ferrous Metallic Scrap

Recycling Potential for Finely Divided Ferrous Metallic Scrap Using Powder Technology

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