Quantifying the influences of coal fly ash on rheological and compaction behaviour of iron powder and mild steel machining chips

Singh, A and Singh, J and Dhami, HS and Sinha, MK and Viswanathan, K and Kumar, R (2022) Quantifying the influences of coal fly ash on rheological and compaction behaviour of iron powder and mild steel machining chips. In: Advanced Powder Technology, 33 (11).

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Abstract

The solid wastes produced by the industries are becoming an ever-alarming issue for the environment, health and economy. The metal cutting industries and the coal-fired thermal power plants produce metal chips and coal fly ash (CFA) in abundance. In contrast to traditional utilization and recycling, a new approach is conceived to fabricate metal matrix composites (MMCs) through the powder metallurgy (P/M) technique. For comparison, the commercial iron powder, CFA mixture with mild steel machining chips (MSMCs) were studied for their rheological and compaction properties. The morphology and elemental characteristics of the starting materials were explored by scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS). The influence of CFA on the flowability behaviour was exhibited through the Hausner ratio and the angle of repose. At the same time, the compressibility behaviour was evaluated by Carr's index and linear compaction equations. During analysis, it was observed that the addition of CFA to the iron powder and MSMCs enhanced their rheological behaviour significantly. It has been concluded that the CFA spherical particles with a high surface finish have acted as a lubricating medium among the irregular and non-spherical iron particles and MSMCs. Further, the inclusion of CFA (0–15wt.%) reduced the green density up to significant levels, which might be helpful to improve the specific mechanical properties of the MMCs synthesized thereof. Also, the addition of CFA to the iron powder and MSMCs reduced their ability to plastic deformation, which eventually improved the strengthening of the MMCs through the load transfer mechanism.

Item Type:	Journal Article
Publication:	Advanced Powder Technology
Publisher:	Elsevier B.V.
Additional Information:	The copyright for this article belongs to Elsevier B.V.
Keywords:	Coal; Coal ash; Compaction; Density (specific gravity); Energy dispersive spectroscopy; Fly ash; Iron powder; Low carbon steel; Metal recovery; Metallic matrix composites; Metals; Morphology; Powder metallurgy; Scanning electron microscopy, Coal fired thermal power plants; Coal fly ash; Compaction behavior; Machining chips; Matrix composite; Metal chips; Metal matrix; Mild steel machining chip; New approaches; Rheological behaviour, Compressibility
Department/Centre:	Division of Mechanical Sciences > Mechanical Engineering
Date Deposited:	29 Nov 2022 09:02
Last Modified:	29 Nov 2022 09:02
URI:	https://eprints.iisc.ac.in/id/eprint/77885

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