In this study, highly calcareous and siliceous fly ash particles were utilized for the fabrication of Al-and Al-alloy-based Metal-Matrix Composites (MMCs) by means of powder metallurgy. After compacting and sintering Al and Al/Si powders containing 10, 15, and 20wt. % ash particles, the homogenous (and with minimal amount of voids) microstructure of the produced composites was verified by means of Scanning Electron Microscopy (SEM). The composites were tested for their dry sliding wear behavior using a pin-on-disc machine against spheres of alumina. The worn surfaces of composites were then examined by using SEM and Energy Dispersive X-Ray Spectroscopy (EDS). It was shown that the addition of both types of FA enhanced the tribo-performance of Al, with the optimum metal powder replacement determined to the point of 15% wt., in the case of high-Si and 10% wt., in the case of high-Ca ash particles. Regarding alloy-matrix composites, although they generally presented worse tribological performance than pure Al/Si products, the additions of ashes up to 15% wt. resulted in only slight deterioration of the wear performance of composites.
The development of value-added ceramic materials deriving only from industrial by-products is particularly interesting from technological, economic, and environmental point of views. In this work, the synergistic sintering of ternary and binary mixtures of fly ash, steelmaking electric arc furnace dust, and ladle furnace slag for the synthesis of compacted ceramics is reported. The sintered specimens' microstructure and mineralogical composition were characterized by SEM-EDS and XRD, respectively. Moreover, the shrinkage, apparent density, water absorption, and Vickers microhardness (HV) were investigated at different sintering temperatures and raw material compositions. The characterization of the sintered compacts revealed the successful consolidation of the ceramic microstructures. According to the experimental findings, the ceramics obtained from fly ash/steel dust mixtures exhibited enhanced properties compared to the other mixtures tested. Moreover, the processing temperature affected the final properties of the produced ceramics. Specifically, a 407% HV increase for EAFD and a 2221% increase for the FA-EAFD mixture were recorded, by increasing the sintering temperature from 1050 to 1150 ∘ C. Likewise, a 972% shrinkage increase for EAFD and a 577% shrinkage increase for the FA-EAFD mixture were recorded, by increasing the sintering temperature from 1050 to 1150 ∘ C. The research results aim at shedding more light on the development of sustainable sintered ceramics from secondary industrial resources towards circular economy.
The transformation of both calcareous and siliceous Greek power station by-products (lignite ashes) into novel composite materials with photocatalytic properties for environmental application was investigated. Particularly, a comparison between the development of coated ceramic substrates and the modification of ash surfaces is attempted. Specifically, a) the sintering process (1000 °C, 2 h) of both fly and bottom ash (either calcareous or siliceous) for their conversion into compacted ceramic substrates coated with TiO2 slurry and then further thermally treated (500 °C, 1 h) to acquire TiO2 film consistency onto the ceramic substrate and b) the process of TiO2 precipitation on lignite ash surfaces in acidic solution after neutralization, and estimation of the TiO2 percentage, are compared. The microstructures obtained were examined by XRD and SEM-EDX analysis. Vickers microhardness was also determined for the ceramic microstructures, with satisfactory results (up to 356HV). The energy gap measurements of the coatings were found to be between 3.02eV and 3.17eV, which is located between the energy gap of anatase (3.23eV) and rutile (3.02eV). The coating mass was about 0.059 g/cm2. The photocatalytic activity under visible and UV irradiation was investigated in aqueous solutions of methylene blue and methyl orange organic dyes, with encouraging results. A main advantage of the processes proposed is the immobilization of TiO2 onto largely available secondary resources, which can lead to production of value-added ‘green’ photocatalysts for the treatment of industrial effluents in the framework of circular economy.
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