Metallurgy Commons^™

A Review Of Gallium And Germanium Recovery From Industrial Solid Residues, Ernest V. Oteng, Marthias Silwamba, Lana Alagha, Alex Luyima

Mining Engineering Faculty Research & Creative Works

The global demand for critical elements such as gallium (Ga) and germanium (Ge), and the shift toward circular mining has accelerated the development of new extraction and recovery processing these metals from industrial solid residues. This transition is driven by a substantial surge in demand for advanced technologies and the depletion of primary ore. Consequently, industrial solid residues, particularly zinc processing residues, smelter slags, flue dusts, and coal fly ash, are emerging as viable alternative sources. These residues incorporate Ga and Ge through isomorphic substitution in phases such as ferrites, silicates, and glassy aluminosilicates, and are enriched by industrial processes, …

Thermo-Mechanical Behaviour Of Metal-Coated Optical Fibers For Distributed High-Temperature Sensing: From Laboratory Characterization To Industrial Case Validation, Koustav Dey, Rony Kumer Saha, Bohong Zhang, Laura Bartlett, Jeffrey D. Smith, Ronald J. O'Malley, Jie Huang

Electrical and Computer Engineering Faculty Research & Creative Works

Reliable distributed temperature sensing in high-temperature environments remains a significant challenge due to the thermal and mechanical limitations of conventional optical fibers. In particular, polymer-coated fibers degrade above ∼300 °C due to coating failure, mechanical fragility and hydrogen ingress. Metal-coated optical fibers offer a robust alternative for harsh environments such as Electric Arc Furnaces (EAFs), aerospace engines, nuclear systems, and oil and gas wells, owing to their superior mechanical strength and hermetic sealing. In this work, a first comprehensive experimental investigation of the thermo-mechanical behavior of metal-coated optical fibers for distributed high temperature sensing is presented over a wide temperature …

Analysis Of Tower Stringset Replacement From 33 Kv To 66 Kv Considering Sagging Clearance, Muhammad Lazuardi Azzura, Anne Zulfia Syahrial, Julius Purnama Eka Kartika

Journal of Materials Exploration and Findings

Efforts to increase the capacity of transmission networks are often undertaken by uprating the operating voltage of existing lines rather than building entirely new infrastructure. Such uprating typically involves the replacement of tower insulator stringsets to withstand higher voltages, while also ensuring that mechanical performance remains adequate. This paper presents an analysis of uprating the Parakan–Sunyaragi transmission line from 33 kV to 66 kV, with particular emphasis on conductor sagging and the resulting clearance from the ground. The methodology employed includes calculations based on catenary equations, analysis of conductor tensile forces, and a comparative evaluation of two widely used insulator …

A Basic Review Of Design And Material Selection For Shovel’S Body, Anggi Buana, Winarto Winarto

Journal of Materials Exploration and Findings

Manual shovels still play an important role in construction and agricultural work, selecting the right material is crucial to obtain a shovel body that has structural reliability, ergonomic efficiency, and sustainability. In this study, a method for selecting the most suitable material will be discussed by combining functional analysis (Ashby's material performance index, and the Multi-Criteria Decision Making approach). From the figure of load, material index is formulated as a reference for performance property requirements. Using data from analysis software and qualitative data, eight performance criteria such as durability, corrosion resistance, cost, and environmental impact are then weighted using the …

Additive Manufacturing Of Metals: Mechanical Properties And Their Implications, Sean Chih

Discovery Day - Daytona Beach

Additive manufacturing of metals is a relatively new and groundbreaking approach to manufacturing high-performance components. However, variability in mechanical properties from the process creates a barrier before this manufacturing technique can be widely applied. Understanding when and where to use this manufacturing is also important to create components with efficiency and without harmful defects. The objective of this research is to evaluate the effects of build orientation, printing parameters, internal defects, thermal history, and residual stresses, post-processing heat treatments, and fatigue behavior on additively manufactured components. Literature-based research is conducted on commonly used metals for additive manufacturing, such as stainless …

Comparative Lca Of Germanium Production From Coal Fly Ash Using Chlorinated Distillation And Solvent Extraction, Dennis Dadzie, Kwame Awuah-Offei, Michael Moats, Nasib Al Habib, Weston Hartzell

Mining Engineering Faculty Research & Creative Works

Germanium is increasingly important for high-tech applications, yet its supply chain is vulnerable, with production limited to a few countries. Although prior research has explored alternative techniques for extracting and recovering germanium, the literature lacks comparative life-cycle evidence that quantifies their environmental burdens and translates findings into actionable (policy) recommendations. This paper presents a cradle-to-gate life-cycle assessment that compares the environmental burdens of producing 1 kg of single-crystal germanium from coal fly ash via chlorinated distillation (CD) and solvent extraction (SX). Under the study's assumptions, CD has lower potential impacts in 15 of 19 impact categories, while both routes show …

Magnetic Field-Induced Transformation In Polycrystalline Ni2mnal Heusler Type Magnetic Shape Memory Alloy, Choji J. Daches, Joseph W. Newkirk, Mario Buchely, Laura N. Bartlett

Materials Science and Engineering Faculty Research & Creative Works

The martensitic and magnetic transformations, as well as the mechanical properties, of Ni₂MnAl alloys in as-cast (AC) and heat-treated (HT) conditions were investigated. Magnetic-field-induced strain was evaluated via magnetostriction, with reversible strains of 0.14% and 0.2% achieved in the martensitic phase at 2 K for the AC and HT alloys, respectively. Transformation temperatures and Curie temperatures were determined under constant applied magnetic field, revealing that γ-phase inclusions in the AC microstructure suppress antiferromagnetic domain response, yielding a lower magnetization (∼8.4 emu g⁻¹) compared to the HT alloy (∼13.4 emu g⁻¹). Both alloys exhibited hysteretic behavior in the martensitic state and …

Lafe0.925ti0.075o3 Perovskite Coated With Ethyl Cellulose: A High-Stability, Low-Hysteresis Platform For Advanced Humidity Sensing, Akhmad Futukhillah Fataba Alaih, Djoko Triyono, Rifqi Almusawi Rafsanjani

Makara Journal of Science

Humidity sensors are pivotal in numerous sectors, such as environmental monitoring, industrial automation, and health-care. This study presents the fabrication and detailed evaluation of an advanced humidity sensor using ethyl cellulose (EC)-coated LaFe_0.925Ti_0.075O₃ (LFTO) perovskite nanoparticles synthesized via the sol-gel method. The LFTO nanopar-ticles exhibited a mesoporous structure with an enhanced surface area, which significantly improved their moisture adsorption capabilities. The innovative application of EC coating addresses critical substrate adhesion issues, enhancing mechanical stability without compromising sensor sensitivity. Comprehensive performance evaluations revealed minimal hysteresis (

The Effect Of Mwcnt-Oil Impregnation Of Sintered Components On Their Wear And Corrosion Resistance, Maha Khaled Abdelfadeel

Theses and Dissertations

Powder Metallurgy (PM) offers an advantageous route for manufacturing complex and near net-shape components. Their inherent interconnected porosity that promotes the action of self lubrication compromises their structural integrity by creating pathways for corrosion and excessive wear. This research investigates the efficacy of Multi-Walled Carbon Nanotubes (MWCNTs) as a nano additive within the impregnating base oil (SN-150 base oil). An experimental matrix was designed to evaluate the influence of MWCNTs with different concentrations of 0.05, 0.1, and 0.2 wt.% and ultrasonic dispersion with varying sonication times of 30 and 60 minutes on the tribological and electrochemical performance of sintered steel …

Effect Of Allocation And Allocation Avoidance Methods On Life-Cycle Impact Results For Tellurium Production From Copper Anode Slimes, Ioanna Paschalidou, Kwame Awuah-Offei, Michael Moats

Mining Engineering Faculty Research & Creative Works

The global transition toward green energy has increased demand for metals and intensified the need for sustainable supply sources. Tellurium (Te), an essential metal for photovoltaics technology, is produced primarily as a by-product of copper refinery slimes treatment. This study conducts a life-cycle assessment (LCA) study of Te production to investigate the effect of environmental impact allocation choices on LCA results in multi-product metal systems. A cradle-to-gate LCA model of the Te product system was developed in SimaPro v9.5.0.1 software by combining industrial data, Ecoinvent v3.7.1 datasets, and literature information. Environmental impacts were quantified using the ReCiPe v1.04 Midpoint method …

Eliminating Barriers For The Implementation Of Automation In The Mining Industry, Sefiu O. Adewuyi, Kray Luxbacher, Kanagy David, Miller Ben, Miller Hugh, Michael Moats, Savit Mark

Materials Science and Engineering Faculty Research & Creative Works

The integration of new technologies into U.S. mining operations is necessary for achieving continuous improvement in worker health and safety, as well as improving operational efficiency, but many have questioned why uptake of autonomy in the U.S. mining industry has been slow compared to other nations. Despite extensive research on mining automation, there remains a critical gap in understanding and systematically identifying the barriers to its adoption within the U.S. mining industry and globally. To quantify these barriers, a workshop model of data collection was employed. A total of 708 invitations were extended to professionals to participate in nine different …

Electropulse Annealing: Phase Composition Of Tial6v4, Vaughn Eckhardt, Ethan Croke, Ian Baker, Russ Taylor

Wetterhahn Science Symposium Posters

Titanium alloy TiAl6V4 is the most ubiquitous titanium alloy used for dental care, aerospace manufacturing, and for high performance vehicles. The material typically undergoes a thermal heat  treatment, but electropulse annealing is another process that involves sending current through the material to heat it up at a quicker rate. The rate of post-annealing cooling is high, and around the material's critical point, its two components, alpha and beta phase, change in relative concentration. After testing multiple current densities and temperatures, in general, as the current density that the sample received during electropulse annealing decreased, both the alpha and beta phases …

Recovering Sn From Ultrafine Tails At Mina San Rafael, Peru, Angelica Plenge

Honors Theses

San Rafael is currently the only mine producing tin (Sn) in Peru, operating two concentrators. In the first, called the San Rafael plant, tin concentrate is produced through gravity separation circuits consisting of jigs, spirals, and Mozley tables, followed by reverse flotation, where sulfides are floated while cassiterite (78.77% theoretical tin content) is depressed. Material containing tin values is then directed to a desliming circuit, where the pulp density is adjusted prior to sulfide reverse flotation. The tailings from this stage are subsequently processed through another flotation circuit but, in this case, the Sn is floated. Cycloning is applied throughout …

Temperature And Environmental Implications On Ti3c2cl2 Mxene Degradation Process, Yang Yang

McKelvey School of Engineering Graduate Student Theses & Dissertations

MXenes, a rapidly emerging class of two-dimensional transition metal carbides and nitrides, have attracted considerable attention owing to their exceptional electrical, mechanical, and chemical properties. However, the inherent thinness of their atomic structure and the reactivity of their functional groups render MXenes susceptible to environmental degradation, whereby the lattice integrity is compromised and desirable material functionalities are dimin- ished. In this work, ex situ electron microscopy characterisation is performed on Ti₃C₂Cl₂ MXene specimens subjected to controlled gas environments — nitrogen gas (N₂) and air — at annealing temperatures of 200°C and 600°C, with …

Collector Blends For The Flotation Of Rare Earth Silicates, Padmore Fosu Amankwah

Honors Theses

Rare earth elements (REEs) are critical for modern technologies, but their extraction from minerals remains challenging due to various factors, and their impact on mineral bonding and resulting crystal structure. Fundamental studies have shown that the concentration of rare earth minerals (REMs), such as rare earth silicates (RES), depends on factors such as Lanthanide contraction (LC), Coordination Number (NC), and silicate polymerization (SP). These influence flotation responses pending silicate type (e.g., sorosilicates, phylosilicates, nesosilicates, inosilicates, orthosilicates, etc.). To better understand this behavior and optimize REE recovery, samples from Halleck Creek, an American Rare Earth property in Wyoming, were obtained. Characterization …

Engineering Silicone Magnetic Fluids For Localized Radiation Attenuation During Ocular Melanoma Brachytherapy, Zachary L. Caprow

All Dissertations

Ocular melanoma is commonly treated using plaque brachytherapy; however, radiation-induced damage to healthy ocular tissues frequently results in partial or complete vision loss. This work investigates the development of an injectable, magnetically responsive silicone magnetic fluid designed to localize adjacent to the tumor and attenuate low-energy gamma radiation during treatment.

The material system consists of iron oxide nanoparticles surface-functionalized with a siloxane polymer, in which the nanoparticles provide magnetic responsiveness and radiation attenuation, while the polymer coating ensures colloidal stability, injectability, and biocompatibility. A one-pot synthetic approach was developed wherein a functionalized siloxane polymer containing iron-affinitive groups was reacted with …

A Comparative Study Of Tin Electrorefining In Molten Licl–Kcl–Cacl₂: Experimental Two-Electrode Current Control And Theoretical Three-Electrode Potential Control, Bryant Johnson, George Ankrah, Ander Fuller, Devin Rappleye

Reviews, Analyses, and Instructional Studies in Electrochemistry (RAISE)

Molten salt electrorefining is a mature technology for metal recovery, yet conventional current‑controlled, two‑electrode operation provides limited electrochemical selectivity and restricted insight into electrode‑specific behavior. In this work, a simplified model is developed to compare current‑controlled two‑electrode electrorefining data with a potential‑controlled three‑electrode electrorefining simulation using tin in molten LiCl–KCl–CaCl₂ as a surrogate for plutonium processing. The model examines anodic and cathodic limitations under fixed‑potential operation and evaluates implications for selectivity, efficiency, and runtime relative to experimentally demonstrated two‑electrode performance. Results indicate that independent potential control enables operation closer to thermodynamic selectivity limits, with the potential to suppress impurity oxidation …

Cast In Steel: Horseman's Axe, Sam A. Morris

Create@State

Cast in Steel is a competition between universities across North America started by the Steel Founders Society of America. The competition is centered around giving students the opportunity to learn about casting and the steel industry in general. A prompt of a weapon or tool with some level of historical significance is given to all the teams. The prompt for the 2026 Arkansas State University team, was a Horseman’s Axe. The team designed their rendition of a horseman’s axe, worked with Southern Cast Products as their local industry parter, and fabricated a finished axe to represent Arkansas State University as …

A Sustainable Approach To Tensile Property Enhancement In Sand Casting Via Metal Chip–Sand Composite Molds, Maaruf Isyaku, Danjuma Saleh Yawas, Mathew Olatunde Afolayan, Terva Ause

Journal of Materials Exploration and Findings

The present work focuses on the study of the effect of adding different weight percentages and particle sizes of various metal chips to foundry sand on the tensile strength of aluminum alloy castings, utilizing Taguchi's optimization methodology and regression analysis. Characterization techniques such as X-ray fluorescence (XRF), thermogravimetry, and SEM were also used. The XRF analysis identified aluminum (76.61%), silicon (17.49%), and magnesium (1.28%) as the major elements in the aluminum alloy engine block. For the foundry sand, silicon (89.51%), phosphorus (7.41%), and potassium (1.7%) were found. In contrast, the major constituents in cast iron included iron (88.3%), carbon (3.7%), …

Wasting The Risk, Or Risking The Waste? Understanding The Trends Of Critical Raw Material Loss Into Waste Streams During Copper And Aluminium Processing, Ella Lausberg, Joël Brugger, Rahul Ram, John R. Owen, Deanna Kemp, Micheal S. Moats, Jonathan Hamisi, Vanessa N.L. Wong

Materials Science and Engineering Faculty Research & Creative Works

Many critical raw materials (CRM) necessary in the transition to carbon-neutral energy reside in the waste streams of mining projects, as they are by-products and often not recovered alongside the primary metal. This work aims to document (i) the loss and potential recovery of by-product metals during the host commodity processing and (ii) the consequences of non-recovery, via a multi-scale risk–reward analysis. The information on the deportment of by-product metals through processing circuits is crucial for treating them as a resource, without which they risk near-permanent loss when treated as 'waste'. We review the deportment of tellurium and selenium as …

Inclusion Engineering Through Deoxidation Practice Optimization For Enhanced Mechanical Properties Of Cast Cr-Ni-Mo Steel, Kingsley T. Amatanweze, Viraj A. Athavale, Simon Lekakh, Ronald J. O'Malley, Laura N. Bartlett

Materials Science and Engineering Faculty Research & Creative Works

Deoxidation is an integral part of steelmaking, as it determines steel castability, cleanliness, and porosity levels of the final product. Steel quality is critical to its performance and can be sabotaged by impurities such as non-metallic inclusions and porosity. This study investigates the effects of four distinct deoxidation practices, using Al, Al-Ca, Zr-Ca, and Mn-Si respectively, on tensile strength, tensile ductility and impact toughness of a Cr-Ni-Mo steel. These deoxidation reactions were modeled on a commercially available thermodynamic software and possible inclusion product phases were predicted. The casting samples were studied on a scanning electron microscope (SEM) utilizing energy dispersive …

Post-Calcium Treatment Evolution Of Alumina (Al2o3) Inclusions Morphology, Naziru I. Fuseini, Ronald J. O'Malley, Todd P. Sander, Jeffrey D. Smith, Haiming Wen, Laura N. Bartlett

Materials Science and Engineering Faculty Research & Creative Works

The post-calcium morphological evolution of Al₂O₃ inclusions formed under high-oxygen supersaturation (~1000 ppm) was investigated through time-resolved sampling and quenching of aluminum-killed, calcium-treated steel. SEM-EDS analysis revealed the formation of angular two-phase CaO·Al₂O₃–CaS inclusions within 1 minute, gradually transforming into spherical liquid 12CaO·7Al₂O₃ and CaO·Al₂O₃ with a thin CaS layer around it. The 3D morphology of the CaS phase of the complex CaO·Al₂O₃–CaS inclusions observed at 1 minute appeared as a cone-cap attached to the partially modified CaO·Al₂O₃. This …

Critical Parameters Controlling Oxide Scale Formation And Hydro-Descaling Efficiency During Steelmaking, Tochukwu Princewill Ojiako

Doctoral Dissertations

In modern steelmaking, cast slabs are exposed to high-temperature oxidizing environments during secondary cooling, reheating, and hot rolling, resulting in the formation of multilayer oxide scales on the steel surface. These scales interact with mold-flux residues originating from the casting process (CC). The morphology, chemistry, and adhesion of oxide scale strongly influence its removability during high-pressure hydraulic descaling and ultimately determine the surface quality of hot-rolled products. However, the mechanistic relationship between oxide scale evolution, scale-steel interfacial structure, and hydraulic descaling performance remains poorly understood.

This dissertation investigates oxide scale formation, modification, and removal in low-carbon thin-slab steels produced by …

Effect Of Elemental Additions On The Microstructure, Macrostructure, And Mechanical Properties Of Gray Iron, August E. Rautmann

College of Graduate Studies: Theses & Dissertations

Gray iron is composed primarily of an iron matrix and flake graphite, with the higher percentage of volume taken up by the iron matrix. The iron matrix is the transformation product of austenite, and this prior austenite structure is understood to affect the final grain structure. Grain structure affects the properties of a metal, with a finer structure recognized as beneficial for most properties. Thus, the refinement of austenite structure has potential in improving the material properties of gray iron. This study aims to advance the limited knowledge about the control of austenite grain size via elemental additions. Building off …

Effect Of Wall Movement On Porosity Formation In Ductile Iron Castings Under Varying Processing Parameters, Shamsul Alam

College of Graduate Studies: Theses & Dissertations

Shrinkage porosity is a major defect that significantly impairs the mechanical properties and overall performance of ductile iron castings. Although graphite formation during solidification induces volumetric expansion, this expansion alone is insufficient to fully compensate for the shrinkage occurring throughout solidification. During the solidification and cooling of ductile iron, multiple phase transformations occur, resulting in dynamic volume changes that exert pressure on mold walls and internal cavities. These pressures can deform mold walls and casting surfaces, leading to defects such as swell and porosity, while also influencing shrinkage formation. This study aims to analyze the mechanisms of porosity formation and …

Effects Of Composition, Nodularity, Pouring Temperature, Inoculation, And Mold Strength On Wall-Movement In Sgi Castings During Solidification And Cooling, Noah Brack

College of Graduate Studies: Theses & Dissertations

The iron-carbon casting alloy known as spheroidal graphite iron (SGI), nodular graphite iron, or ductile iron (DI) experiences complex volume changes during its solidification and cooling as graphite nodules and austenite form. These volume changes result in forces on the mold cavity walls and can deform the mold walls in cases when mold walls lack the strength to resist the deformation. This wall movement can cause the formation of casting defects such as swell, warped part geometry, and shrinkage porosity. Though this phenomenon has been studied in the past, it remains difficult to predict casting wall movement with existing data. …

The Effects Of Mold Flux Contamination On Oxide Scale Formation And Hydro-Descaling Efficiency During Steel Processing, Tochukwu Princewill Ojiako, Richard Osei, Mario Buchely, Haiming Wen, Simon Lekakh, Ronald O'Malley

Materials Science and Engineering Faculty Research & Creative Works

Oxide scale formation during thin-slab continuous casting has a complex structure, which is influenced by mold flux contamination, that modifies interfacial reactions during solidification, subsequent reheating, and descaling. While individual aspects of the oxidation behavior of carbon steel have been previously examined, the synergetic effects of mold flux contamination during continuous casting and subsequent reheating on scale modification and the efficiency of hydraulic descaling remain inadequately studied. This study quantitatively examines the effect of flux composition on oxide scale evolution, adhesion, and hydraulic removal in low-carbon steel under simulated industrial conditions. Slab samples with as-cast, cleaned, and flux-coated surfaces were …

A Combined Stochastic And Physical Framework For Alloys And Metal Casting Processes Modeling, Simon N. Lekakh, Oleg Neroslavsky

Materials Science and Engineering Faculty Research & Creative Works

High temperature metal casting processes have dualistic nature and conceptually consist of two parts of distinct processes: the first type is deterministic, strictly obeying the physical law, while the second type is stochastic. Therefore, the metal casting processes are not precisely predictable, and deterministic considerations cannot provide exact outcomes. To solve this problem, the combined stochastic and deterministic framework was suggested. The local processes were described using deterministic models for several parameter arrangements, while the distribution of these arrangements on macro level was calculated using stochastic approaches. The approach was used for cast alloy design, investment casting process optimization, and …

Thermal Transformations And Mechanical Properties Of All-D-Metal Mn2fecu Heusler-Type Shape Memory Alloy, Choji J. Daches, Joseph W. Newkirk, Mario Buchely

Materials Science and Engineering Faculty Research & Creative Works

All-d-metal Heusler alloys are emerging functional materials in which magnetic ordering, lattice distortion, and mechanical behavior are strongly coupled through d–d electronic interactions. This study systematically investigates the structural, thermal, magnetic, and mechanical properties of Mn₂FeCu synthesized within a Heusler-type compositional framework. SEM/EDS revealed a dual-phase FCC-based microstructure consisting of Mn–Fe–rich and Mn–Cu–rich domains, while XRD confirmed FCC symmetry with compositional partitioning rather than full L2₁ ordering. Differential scanning calorimetry identified partial melting of the Cu-rich phase near ~ 900 °C. Dilatometry showed a thermoelastic FCC → FCT transformation at ~ 770–780 °C with a recoverable strain of ~ 0.067%. …

Comparative Evaluation Of Gating Systems In Femnal Castings, K. Balasubramanian, Laura Bartlett, M. Xu

Materials Science and Engineering Faculty Research & Creative Works

To understand the efficiency of gating systems, four systems, namely AFS styled pressurized system, AFS styled non-pressurized system, naturally pressurized system with a side riser and a naturally pressurized system with a top riser, were studied. The naturally pressurized systems were provided with overflows which collected the incoming metal swirl while the pressurized and non-pressurized systems had runner wells. Parameters like velocity of metal flow, air entrapment, microporosity and Niyama criterion were considered, and a design was developed with a common pouring basin using solidification software. Two molds were 3D printed using carbonitride sand, and steel of composition Fe-29Mn-8.2Al-0.91C-0.88Si-0.49Mo was …