Proceedings of the International Conference on Metallurgical Engineering and Centenary Celebration : METCENT-2023, 26-28 October, Varanasi, India

This book presents peer reviewed articles from The International Conference on Metallurgical Engineering and Centenary Celebration (METCENT 2023), held at Indian Institute of Technology (BHU) Varanasi, India from the 26-28th of October 2023. It covers wide areas of metallurgical and materials science, highlighting recent advancements in these areas, including but not limited to Advanced Steels, Computational Material Science, Recent Ferrous/Non-Ferrous Metallurgy Processes, Green Iron and Steel Making Technologies and others. METCENT 2023 provides a unique opportunity to all the Metallurgists, Materials Scientists, Academicians and Industry experts to share their experiences on this special occasion. Preface Organization Contents Ferrous Process Metallurgy Development of a Low Silica Calcium Aluminate Based Mould Flux for Casting High Al/Mn Steels 1 Introduction 2 Experimental Methodology 2.1 Preparation of Mold Fluxes 2.2 Measurements Using DSC 2.3 Raman Spectroscopy 3 Results and Discussion 3.1 Sequence of Crystal Precipitation 3.2 Raman Spectroscopy 4 Conclusion References Some Aspects of the Chemistry of Slags Containing Cr and V 1 Introduction References Solid State Reduction of Hematite Ore Using Hydrogen at Moderate Temperatures 1 Introduction 2 Experimental Methods 2.1 Kinetics Analysis 3 Results and Discussion 3.1 Characterization of Hematite Concentrates 3.2 Effect of Flow Rate on the Reduction Rate 3.3 Effect of Temperature 3.4 Kinetics Analysis 3.5 Characterization of reduced hematite 4 Conclusion References Influence of Silicon Source on the Steel Cleanness 1 Introduction 2 Materials and Methods 3 Results and Discussion 4 Conclusions References Utilization of Biomass Pellets in the Iron Ore Sintering Process 1 Introduction 2 Materials and Methods 2.1 Material Selection for Sintering Process 2.2 Sintering Conditions 3 Results and Discussions 3.1 Impact of Biopellet on Sintering Temperature Profiles 3.2 Impact of Biopellet on Sinter Strength 3.3 Impact of Biopellet on Sinter Product Yield (+5 mm) and Fine Generation (−5 mm) 3.4 Impact of Biopellet on Sintering Time, Flame Front Speed (FFS) and Productivity 3.5 Impact of Biopellet on Exhaust Flue Gases 4 Conclusions References Carbothermic Reduction and Kinetics of a Lean Grade Multimetallic Magnetite Ore 1 Introduction 2 Materials and Methods 3 Results and Discussion 4 Conclusion References Reduction Kinetics of Composite Steel Slag-Coke Pellets 1 Introduction 2 Experiment Procedure and Result Discussion 3 Conclusion References Investigating the Suitability of Local Riverbed Sand as a Mold Material for Foundry Industry: A Comparative Study 1 Introduction 2 Experimental Process 2.1 Material Collection 2.2 Chemical Composition 2.3 Grain Size and shape Analysis 2.4 Density 2.5 pH Value 2.6 Fusion Point 2.7 Preparation of Standard Mold Specimens 3 Result and Discussion 3.1 Permeability 3.2 Hardness 3.3 Compressive Strength 3.4 Shear Strength 3.5 Constituent of Mold Composition 3.6 Aluminum (A356) Alloy Casting 3.7 As Cast Properties 4 Conclusions References Computational Material Science Effect of External Magnetic Field on Grain Boundary Migration in Non-magnetic Systems: A Phase-Field Study 1 Introduction 2 Formulation 3 Results and Discussions 4 Conclusion References Deformation in Metals: Insights from ab-initio Calculations 1 Introduction 2 Computational Methods 3 Stacking Fault Energy Estimation 3.1 Stable SFEs Using ANNNI Model 3.2 GSFE Using Periodic Supercell 4 PN Stress Using SVPN Model 4.1 1D PN Model 4.2 2D PN Model 5 Conclusion References A Comparative Heat Transfer Study of Gadolinium and (MnNiSi)1-x(Fe2Ge)x Alloy for Thermomagnetic Energy Generator 1 Introduction 1.1 Thermal Energy Harvesting Devices 1.2 The Thermomagnetic Cycle 1.3 Thermomagnetic Generator Design 2 Thermomagnetic Material 3 Heat Transfer Modelling 3.1 Thermal Conductance 3.2 Discretization 3.3 Solution Methodology 3.4 Convergence Study 4 Results 4.1 Temperature Variation Over Multiple Cycles 4.2 Temperature Variation Over One Full Cycle 4.3 Heat Transfer 4.4 Heat Source and Sink Temperature for TMM with x = 0.3 4.5 Heat Source and Sink Temperature for TMM with x = 0.32 4.6 Comparison Between Gadolinium (Gd) and (MnNiSi)1-x(Fe2Ge)x 5 Verification and Validation 6 Conclusion References Theoretical Comparison and Machine Learning Based Predictions on Li-Ion Battery’s Health Using NASA-Battery Dataset 1 Introduction 1.1 About Dataset 2 Electrochemistry Measurements 3 Models and Discussions 3.1 ML Models 4 Conclusion References Prediction of Mechanical Properties of Cr-Mn-N Austenitic Stainless Steel Using Machine Learning Approach 1 Introduction 2 Methodology 2.1 Details of the Data and Data Preprocessing 2.2 Machine Learning Models 3 Results and Discussion 3.1 External Validation 3.2 Feature Analysis using SHapley Additive Explanation (SHAP) 4 Conclusion References On the Deformation Mechanism and Dislocation Density Evolution in A Polycrystalline Nano Copper at 10 K–700 K/108 s−1–109 s−1 Employing Molecular Dynamics Simulations 1 Introduction 2 Methodology 2.1 Description of Microstructure 2.2 Simulation Details 3 Results and Discussion 3.1 Microstructural Evolution at 300 K and Strain Rate of 1 × 109 s−1 3.2 Effect of the Temperature and Strain Rate 4 Conclusions Appendix A References Thermodynamic Assessment of Tin Based Molten Binary Indium-Tin Solder Alloys 1 Introduction 2 Experimental Details 2.1 Materials 2.2 Procedure 3 Results and Discussion 4 Summary and Conclusions References Advanced Material Nanosized Hybrid Polymer Modifiers (HPM) for Improved Mechanical and Thermal Behavior of Carbon Fiber Reinforced Composites 1 Introduction 1.1 Polymer Matrix Composites 1.2 Polyhedral Oligomeric Silsesquioxanes (POSS) 1.3 Graphene Oxide and Graphene 1.4 Hybrid Polymer Modifiers 2 Materials and Methods 2.1 Materials for Hybrid Polymer Modifiers and Composites 2.2 Preparation of Hybrid Polymer Modifiers 2.3 Preparation of Composites with Hybrid Polymer Modifiers 2.4 Characterization of Composites with Hybrid Polymer Modifiers 3 Results and Discussion 3.1 XRD Results 3.2 Flexural Test Results 3.3 Mode I Interlaminar Fracture Toughness Test Results 3.4 SEM of MEGO Toughened CFRP Composites 4 Conclusions References Efficient Degradation of Pendimethalin via Photo-Catalytic Ozonation Over Ni/Mg@TiO2 Nanocomposites 1 Introduction 2 Materials and Method 2.1 Photocatalytic Ozonalysis Experiment 2.2 Synthesis of Ni/Mg@TiO2 Nanoparticles 2.3 Instrumentation 3 Results and Discussion 3.1 BET Surface and Elemental Analysis 3.2 UV-DRS 3.3 Photoluminescence Spectra (PL) 3.4 SEM and TEM 3.5 XRD Analysis 3.6 Effect of Ni/Mg Doping Concentrations 3.7 Effect of Catalyst Concentration 3.8 Effect of pH 3.9 Catalyst Testing and Product Identification 3.10 Reaction Mechanism 4 Conclusions References Effect of A-Site Pr-Doping on Dielectric and Thermoelectric Properties of Lanthanum Based La2FeNbO6 Double Perovskite Oxide Materials 1 Introduction 2 Experimental Procedure 3 Results and Discussion 3.1 Analyses of the Morphology and Phase Identification 3.2 Frequency Dependence Dielectric Study at Different Temperature 3.3 Temperature Dependent Dielectric Study 3.4 Impedance Study 3.5 Thermoelectric Behavior of La2-xPrxFeCrO6 Double Perovskite 4 Conclusion References Investigation of Solidification Behavior and Processing Defects in the Continuous Cast Al-Based Composite Sheet 1 Introduction 2 Methodology 2.1 Numerical Methodology 2.2 Experimental Study 3 Result and Discussion 3.1 Effect of Superheat Temperature and Melt Pool Height on Solidification 3.2 Experimental Study Appendix References Influence of Sodium on the Microstructure of Laser Rapid Manufactured NiCrSiBC Hardface Alloy Coatings 1 Introduction 2 Experimental 3 Results and Discussion 3.1 Effect of Thermal Aging on Microstructure 3.2 Effect of Long Term Static Sodium Exposure on Microstructure 4 Conclusion References Study of Geometry Modulated Magnetoelectric Composite Structure 1 Introduction 2 Working Principle and Modelling 2.1 Working Principle 2.2 Modelling 3 Finite Element Simulation Procedure 4 Results and Discussion 4.1 Distribution of Magnetization of Tri-Layer ME Composite Under Varying Magnetic Field 4.2 Variation of Magnetoelectric Coefficient 5 Conclusions Appendix References Development and Characterization of Advanced Steels Development of Third Generation Advanced High Strength Steel 1 Introduction 2 Experimental 3 Results and Discussion 3.1 Microstructure and Phases 3.2 Mechanical Properties 4 Conclusions References Cracking Problem During Room Temperature Cold Rolling of Three High Al Low C Ferritic Low Density-Steels 1 Introduction 2 Experimental Details 3 Results and Discussion 3.1 Density Measurement 3.2 Phase Diagram and XRD 3.3 Microstructural Features 3.4 Hardness 3.5 Solid Solution Hardening Effect Due to Al 3.6 Effects of Al on Cracking Behaviour During Cold Rolling 4 Tensile Curve 5 Summary References Effect of Cu on the Microstructure and Properties of Hot Rolled Low Carbon Steels 1 Introduction 2 Experimental Procedure 3 Result 3.1 Microstructural Characterization 3.2 Evaluation of Mechanical Properties 4 Discussion 5 Conclusions References Role of Cerium on High-Temperature Oxidation Behaviour of Low-Carbon Steel 1 Introduction 2 Experimental Methods 3 Results and Discussion 4 Conclusions References High Temperature Oxidation of T91 Alloy 1 Introduction 2 Experimental 2.1 Materials 2.2 Experimental Procedure 3 Results and Discussion 3.1 Characterization of T91 Alloy 3.2 Oxidation of T91 Alloy 3.3 Non Isothermal Kinetics by Using Isoconversional Method 3.4 Isothermal Kinetics 3.5 Effect of Partial Pressure of Oxygen pO2 on the Oxidation of T91 3.6 Conclusions References Development of High Quality SWRH82A Grade Tyre Cord Steel Wire Rods 1 Introduction 2 Grain Boundary Cementite 3 Large Non-deformable Inclusions References Processing and Structure-Property Correlation Rotary Friction Welding of Cast Nickel Base Superalloy with Martensitic Stainless Steel for Aero Engine Application 1 Introduction 1.1 Material Property Requirement and Parameters of Friction Welding 2 Experimental 2.1 About Blisk Assembly 2.2 Material 2.3 Friction welding method 2.4 Mechanical Properties 2.5 Microstructure Characterization 3 Results and Discussion 3.1 Tensile Test 3.2 Microstructure Analysis 3.3 Energy Dispersive Spectroscopy Analysis 3.4 Thermo Mechanically Affected Zone 3.5 Microhardness Study 4 Conclusions References Brittle Fracture Failure Analysis under Mixed-Mode Condition Using Asymmetric Edge Cracked Semicircular (AECS) Configuration 1 Introduction 2 Mixed-Mode Fracture Toughness Testing 3 Stress Intensity Factor (SIF) Evaluation 4 Results and Discussion 5 Conclusions References Analyzing the Effect of Dynamic Impact in 6061 Al Alloy Using MATLAB as a Post Processing Tool 1 Introduction 2 Experimental 2.1 Model and Procedure 3 Results and Discussion 4 Conclusion References Ratcheting Fatigue Behaviour of Advanced Structural Materials 1 Introduction 2 Materials and Methods 3 Theory and Calculation 3.1 Calculation of Homologous Temperature 3.2 Normalizing of Mean Stress and Amplitude of Stress 4 Results 4.1 Microstructure 4.2 Tensile Properties 4.3 Uniaxial Ratcheting Behaviour of the Alloys at Ambient and Homologous (0.42Tm) Temperatures 4.4 Fracture Behaviour of the Alloys at Room and Homologous (0.42Tm) Temperatures 5 Discussion 6 Conclusions References Study of Microstructure and Mechanical Properties of Similar and Dissimilar FSW of Al 7075 and Mg AZ31 Alloys Without and With Zn Interlayer 1 Introduction 2 Experimental Details 3 Results and Discussion 3.1 Similar FSW of Al7075 Alloys (FSW-7075) 3.2 Similar FSW of AZ31 Alloys (FSW-AZ31) 3.3 Dissimilar FSW of Al 7075 and Mg AZ31 Alloys Without Interlayer (FSW-7075-AZ31) 3.4 Dissimilar FSW of Al 7075 and Mg AZ31 Alloys With Zn Interlayer (FSW-7075-AZ31-Zn) 3.5 Hardness and Tensile Behaviour 4 Conclusion References Mechanical and Corrosion Study of Dissimilar Friction Stir Welding of AZ31Mg Alloy and Cu-8Zn Alloy 1 Introduction 2 Materials and Methodology 2.1 Parent Materials (PM) 2.2 FSW Process 2.3 Characterization 3 Findings and Analysis 3.1 Optical Characterization 3.2 SEM and Phase Characterization 3.3 Corrosion Analysis 3.4 Hardness Variation 3.5 Tensile and Fractography 4 Conclusions References Review Papers Enhancing Technologies to Improve Metallurgical Processes 1 Introduction 2 Microwave Treatment 2.1 Interaction of Microwave with the Material 3 Ultrasonic Processing 3.1 Ultrasonics in Metal Solidification 4 Electrostatic Separation 5 Biological Treatment of Effluents 6 Future Outlook References Smelting Reduction Technology – Current Status and Future Outlook 1 Introduction 2 Smelting Reduction Processes 2.1 Corex Process [1] 2.2 Romelt [2] 2.3 HIsmelt [3] 2.4 Finex [4] 3 Commercial capture and utilization of CO2 [5] 4 Foaming of Slag [6] 5 Kinetic Study of Iron Oxide Reduction in Molten Slag [7] 6 Conclusion References Green Steel Technology: A Viable Approach for Sustainable World 1 Introduction 2 Understanding Green Steel Technology 3 Renewable Energy Sources in Steel Production 4 Advanced Manufacturing Techniques 5 Circular Economy Principles in Steel Production 6 Recycling and Reusing Materials 7 Product Design for Durability and Recyclability 8 Waste Reduction and Resource Optimization 9 Collaboration and Value Chain Integration 10 Potential Benefits of Green Steel Technology 11 Challenges and Limitations: 12 Case Studies 12.1 HYBRIT 12.2 ArcelorMittal 12.3 Nippon Steel 12.4 POSCO Steel 12.5 Tata Steel 12.6 SAIL 12.7 JSW 12.8 JSPL 13 Conclusion References A Review on Use of Biomass as An Alternative to Coal for Sustainable Ironmaking 1 Introduction 2 Fossil Fuel Consumption and CO2 Emission by Steel Industry 2.1 Global Initiatives at Controlling the Environmental Damage 3 Use of Hydrogen 4 Use of Biomass 4.1 Blast Furnace – Basic Oxygen Furnace (BF-BOF) Route 4.2 Alternative Routes 5 Conclusions References Basics of Iron Ore Sintering 1 Introduction 2 The Sintering Process 3 Sinter Quality Evaluation 3.1 Shatter Test 3.2 Tumbler Test 3.3 Relative Reducibility 3.4 Reduction Disintegration Index 4 Results and Discussion 5 Design of a Batch Type Pan Sintering Plant 6 Conclusions References Author Index