Saeed Ghali

Followers

Following

Co-authors

Public Views

Interests

Uploads

Papers by Saeed Ghali

Processing of low grade manganese ore in submerged arc furnace

Canadian Metallurgical Quarterly

Effect of Substituting Ni by N on Corrosion Behavior of Stainless Steel

International Journal of Materials Technology and Innovation

This article aims at investigating the influence of partial and total replacement of Ni by N in t... more This article aims at investigating the influence of partial and total replacement of Ni by N in the chemical composition of t he exhausted valve steel grade X45CrNiW18-9 on its corrosion behavior. Five experiments were designed. Melting was carried out in an induction furnace with a capacity of 10 Kg under nitrogen pressure. The chemical compositions of produced stainless steels were determined. The produced stainless-steel grades were forged by using free forging. The nitrogen content of each steel grade was determined. Samples of forged stainless-steel grades were subjected to heat treatment at 1050 °C for one hour and then water quenched. Microstructures of heat-treated stainless-steel grades were investigated. The influence of substituting Ni by N on the corrosion behavior of five grades of steel was studied using different concentrations of NaCl-FeCl3 solutions. SEM was used to examine the morphology of the corroded surfaces after the potentiodynamic polarization experiments.

format_quoteStudy utilized various chloride solutions to assess the corrosion resistance of stainless-steel grades with different Ni/N ratios.format_quote

Download

Ferrosilicon magnesium production

Scandinavian Journal of Metallurgy, 2003

The production of ferrosilicon magnesium by using carbon as a reducing agent in an electric arc f... more

Mathematical Analysis of the Effect of Iron and Silica on the Reduction Performance of Manganese Ores

Journal of Metallurgy, 2015

In the current study, a factorial design is used to investigate the effect of total iron and sili... more In the current study, a factorial design is used to investigate the effect of total iron and silica on the metallurgical performance of different grades of manganese ores. The derived mathematical formulations are applied to estimate the reduction disintegration index (RDI+6.3, RDI+3.15, and RDI−0.5), reduction index (total reduction index (RIT), manganese reduction index (RIM), and iron reduction index (RIF)), and softening-melting property (start of softening (TS1), end of softening (TS2), start of melting (Tm1), and end of melting (Tm2)) of manganese ores. The RDI+6.3 and RDI+3.15 are increased with the individual effect of SiO2 and the interaction effect of iron with silica, while they are decreased as the total iron increased. The high-Fe high-SiO2 manganese ore showed the highest RIT and RIF. The RIM was almost identical in all manganese ores. The presence of high content of SiO2 resulted in a narrow softening range (62–83°C), while the high-Fe high-SiO2 manganese ore exhibite...

format_quoteLow iron-high silica manganese ores demonstrate low melting temperatures, making them suitable for manganese-rich slag production.format_quote

Download

Activation Energy of Nitriding 0.23%C Ferromanganese

This article aims at studying the kinetics of the reaction between nitrogen and 0.23%C ferromanga... more This article aims at studying the kinetics of the reaction between nitrogen and 0.23%C ferromanganese through gas – solid reaction. The nitriding process of fine ferromanganese was carried out at temperature range of 1073 K – 1223 K, under nitrogen and hydrogen gas pressure of 16-18 bar and at time range up to 360 min. Sample weight was 150 gm nitrided in cylindrical chamber with inner diameter of 56 mm and length of 2000 mm. The change in nitrogen pressure was taken as an indication for nitrogen pickup. The weight gain i.e. nitrogen pickup in kilograms per surface area (m 2 ) was determined with time at different temperatures. Nitriding rate constants were calculated and the activation energy of nitriding process was derived from Arrhenius equation. The nitriding rate constant was found to be increase by increasing temperature of the reaction. The activation energies of nitriding process of fine ferromanganese at time range from 0 sec. to 2700 Sec. and from 5400 sec. to 21600 sec. ...

Download

Influence of Sintering Temperature, Glass and Starch Powder on Compression Properties of Carbon Steel Foam Containing 10% Mill Scale

The International Conference on Applied Mechanics and Mechanical Engineering

Influence of sintering temperature, addition of glass powder or starch to carbon steel powder on ... more Influence of sintering temperature, addition of glass powder or starch to carbon steel powder on compressive properties of foam steel was investigated. Two groups of foam steels were produced, both groups were including carbon steel powder and mill scale (10%), the first one was including from 3%-12% glass powder while the second group was including starch (3%-12%). All powder components were good mixed and then 6% phosphoric acid was added. The green specimens were sintered at 1100 o C, 1150 o C and 1200 °C for 60 min in carburizing atmosphere. The apparent density of sintered specimens were measured, it was found in the range of 0.60-1.38 gm/cm 3. The compressive strengths of sintered specimens contain starch and glass powder were 31-52.7 MPa, 27-39.5 MPa respectively. The measured compression strengths were compared with the predicted publishing work. It was found that the measured results were in a good agreement with the predicted ones.

format_quoteApparent density measurements utilized Archimedes' method, providing an established technique for density assessment in foam materials.format_quote

Download

Influence of different parameters on compression strength of foam steel produced by slip reaction foam sintering

Ironmaking & Steelmaking

In this study, a 24 factorial design was used to investigate the magnitude effects of sintering t... more In this study, a 24 factorial design was used to investigate the magnitude effects of sintering temperature, mill scale, carbon content and starch additions on compression strength of produced foam steel. The design was based on experimental results of compression test of steel foam with additions of mill scale up to 20%, carbon up to 0.5%, sintering temperatures from 1000 to 1200°C with starch (from 3 to 12%). MatLab was used to carry out the required calculations. Regression models were used to deduce a mathematical formulation to predict the influence of different parameters on compression strength of foam steel. The results showed that mill scale addition has the highest positive effect while the interaction combination between starch with carbon has the highest negative effect on compression strength. The results of the driven model were found to be in good agreement with the experiments and publishing work.

Mathematical analysis of the effect of iron and silica on the reduction performance of manganese ores

In the current study, a factorial design is used to investigate the effect of total iron and sili... more In the current study, a factorial design is used to investigate the effect of total iron and silica on the metallurgical performance of different grades of manganese ores. The derived mathematical formulations are applied to estimate the reduction disintegration index (RDI +6.3 , RDI +3.15 , and RDI −0.5), reduction index (total reduction index (RIT), manganese reduction index (RIM), and iron reduction index (RIF)), and softening-melting property (start of softening (1), end of softening (2), start of melting (1), and end of melting (2)) of manganese ores. The RDI +6.3 and RDI +3.15 are increased with the individual effect of SiO 2 and the interaction effect of iron with silica, while they are decreased as the total iron increased. The high-Fe high-SiO 2 manganese ore showed the highest RIT and RIF. The RIM was almost identical in all manganese ores. The presence of high content of SiO 2 resulted in a narrow softening range (62-83 ∘ C), while the high-Fe high-SiO 2 manganese ore exhibited a wider softening range (135-140 ∘ C). The melting range was very small in high-Fe low-SiO 2 (3-16 ∘ C) and high-Fe high-SiO 2 (6-8 ∘ C) manganese ores, while the low-Fe low-SiO 2 manganese ore showed wider melting range (72-74 ∘ C). The derived mathematical models are in a good agreement with the experimental results. The calculations are carried out using Matlab program.

Download

Mathematical Analysis of the Parameters Affecting the Direct Reduction of Iron Ore Pellets

by Elsayed Mousa and Saeed Ghali

The H2/CO ratio in the reducing gas of iron ore pellets is one of the most important factors that... more The H2/CO ratio in the reducing gas of iron ore pellets is one of the most important factors that affect the efficiency of the direct reduction processes. The magnitude effect of this ratio on the reduction is still not clear compared with the reduction time and temperature. In the current study, a 2 3 factorial design was used to elucidate the reduction potential of different ratios of H2/CO in the reduction process at different temperatures and time. A regression model has been developed based on the experimental data of iron ore pellets that reduced with simulated Midrex, Hyl, and Syngas at 850 o C and 1050 o C. The reduction time was selected at 1.0 and 15 minutes in all trails. The H2/CO ratios in the applied reducing gas were equal to 0.4, 1.0, 1.6, and 2.6. The results showed that the reduction time has the highest positive effect followed by the applied temperature and then H2/CO ratio. The mutual interaction combination between time and temperature was higher than that between H2/CO ratio with either time or temperature. The lowest positive effect on the reduction processes was exhibited by the mutual interaction between all of operational parameters which are represented in H2/CO ratio, temperature, and time. The developed mathematical model was tested against various experimental data to estimate its efficiency in the prediction of the reduction degree. The predicted values of the reduction process by the current mathematical model were found in a good agreement with experimental results in many cases. The Matlab program was used to carry out the required calculations.

Download

Mathematical Model of Prediction of Nitrogen Pickup in Nitriding Process of Low Carbon Ferromanganese

Journal of Metallurgy, 2014

Low carbon ferromanganese was nitrided through gas-solid reaction. The nitriding process has been... more Low carbon ferromanganese was nitrided through gas-solid reaction. The nitriding process has been carried out on lab scale at temperature range 800 ∘ C-950 ∘ C at different nitrogen pressures. Temperature, time, and partial nitrogen pressure of nitriding process of fine low carbon ferromanganese were investigated. Nitrogen content, in weight percent, was more than 9%. MATLAB software was used to derive mathematical model to predict nitrogen content as a function of temperature and nitrogen pressure. According to derived model, nitrogen content can be calculated by the following equation: N content, wt.% = (−30.8882 + 0.0326 * )/(1+ −(( +0.0038 * −8.4155)/(3.6374−0.0018 * )) ), where, T is nitriding temperature in K and P is nitrogen pressure in bar. The experimental results are in good agreement with the predicted results. The results showed that nitrogen content, at steady state, is mainly depending on temperature and pressure of nitriding process. MATLAB is a good tool to make precision mathematical model.

Download

Influence of Vanadium and Cast Temperature on Nitrogen Solubility of Stainless Steel

Journal of Metallurgy, 2014

Three stainless steel grades with different vanadium content were produced in open induction furn... more Three stainless steel grades with different vanadium content were produced in open induction furnace. The base chemical composition of investigated stainless steel has contained 18.48-18.75% Cr, 5.17-5.62% Mn, 2.47-2.58% Mo, and 6.39-6.64% Ni. The vanadium contents of the three stainless steel grades were 0.009%, 0.112%, and 0.189%. The proposed stainless steels were casted at temperatures 1753 K and 1833 K. The nitrogen contents were determined for the produced steel grades at every cast temperature. The determined nitrogen contents were compared with those calculated from the developed equation of Grigorenko and Pomarin. The influence of cast temperature and vanadium content on nitrogen solubility was investigated. Interpretation between experimental and calculated nitrogen content was carried out. Increasing vanadium content and decreasing cast temperature were found to have positive significant effect on the nitrogen solubility. There were great deviations between experimental results and those calculated by Grigorenko and Pomarin equation.

Download

Nitriding of Medium Carbon Ferromanganese Alloy in Gas Solid Reaction

Journal of Minerals and Materials Characterization and Engineering, 2011

Nitriding process of medium carbon ferromanganese was carried out in the solid state, on lab and ... more Nitriding process of medium carbon ferromanganese was carried out in the solid state, on lab and bench scale at temperature range 1023-1323 K using different nitrogen and hydrogen pressures. The influence of H 2 /N 2 gas ratio, temperature and time on nitriding process of fine (-2 mm) medium carbon ferromanganese were investigated. Nitrogen content, in weight percent ranging from 2.1 to 9.7 could be obtained. The optimum temperature and time of nitriding process was found to be 1223 K and 21.6 ks respectively. The results showed that nitrogen content is mainly depending on time and temperature of nitriding process. The comparison between results of lab and bench scale, at optimum conditions, showed good coincidence. At optimum conditions; 1223 K, 21.6 ks and at 2/8 of H 2 /N 2 , nitrogen content of fine medium carbon ferromanganese was 9.5%.

Download

Enhancing the Strain-Hardening Behavior of Hadfield Steel Using Ladle Treatment Technique

by Saeed Ghali and Ahmed Farahat

Key Engineering Materials, 2016

A Model for FeSiMg Alloy Production by Reduction Technique

Journal of Minerals and Materials Characterization and Engineering, 2011

Ferrosilicon magnesium is basic foundry alloys used for the production of ductile cast iron. Magn... more Ferrosilicon magnesium is basic foundry alloys used for the production of ductile cast iron. Magnesium content plays an important role in the produced alloy grades from dolomite ore. The focus of the present work is to simulate mathematical model to predict magnesium content in the ferrosilicon magnesium, which produced by silicothermic reduction of calcined dolomite. The basic assumptions of this model are: constant low viscosity of molten charge, the reaction is irreversible of second order and the reaction is isothermal. The reaction is based on the following equation: 2 2 2 2 SiO Si Mg Si MgO + → + The results of previous work was found to be in a good coincidence with the predicted values by the model ] [ ] )[ (

Download

Simulation of austenitic stainless steel oxidation containing nitrogen at temperature range 500 oC – 800 oC

International Journal of Applied Mathematics and Statistics, Aug 1, 2014

Download

Production and Application of Advanced High Nitrogen steel

Nitrogen was considered for long period to be in the same category as certain undesirable residua... more

format_quoteWider application of nitrogen steels is limited by complex processing versus higher risk of porous ingots during solidification.format_quote

Download

Silico-manganese production utilizing local manganese ores and manganese-rich slag

Ironmaking & Steelmaking

Silicomanganese (SiMn) is widely used in Egypt as a complex reducer and alloying addition in the ... more Silicomanganese (SiMn) is widely used in Egypt as a complex reducer and alloying addition in the production of various grades of steel due to its economic and metallurgical advantages. This work investigated the possibility of using local Egyptian manganese ores mixed with ferromanganese slag to produce SiMn alloy in a submerged arc furnace at a relatively low temperature. This paper discusses the optimal choice of raw materials mix and optimum conditions controlling the production process, such as smelting time, basicity, coke ratio, Mn/Fe and Mn/Si ratios of the blend to obtain standard SiMn. At the optimum conditions, a standard SiMn alloy containing 65.9-69.0% Mn, 15.6-17.6% Si, 1.8-2.35% C, 0.1-0.2% P and 0.015-0.025% S has been successfully produced.

Simulation of austenitic stainless steel oxidation containing nitrogen at temperature range 500 oC – 800 oC

International Journal of Applied Mathematics and Statistics

This article aims at estimation the contribution effect of nickel, nitrogen, time and temperature... more This article aims at estimation the contribution effect of nickel, nitrogen, time and temperature on the oxidation behavior of austenitic stainless steels. Therefore, 24 factorial design and MatLab program were used to driven regression model. According to the model the weight gain (mg/cm2) can be calculated by equation: weight gain=-0.03234+0.016216[N%]+0.006195[Ni%]+0.000959*t+0.000113T-0.01704[N%][Ni%]-0.05566[N%]*t+5.76*〖10〗^(-5) [N%]T-0.00429[Ni%]*t-1.1*〖10〗^(-5) [Ni%]T+3.26*〖10〗^(-6) T*t+0.012523[N%][Ni%]*t+8.26*〖10〗^(-6) [N%][Ni%]T+0.000113[N%]T*t+8.51*〖10〗^(-6) [Ni%]T*t-2.6*〖10〗^(-5) [N%][Ni%]T*t Where, [N%] & [Ni%] are nitrogen and nickel concentration in weight percent, T is temperature in Celsius, and t is time in hour. The factorial design was based and applied for previous published work. The model showed that nickel has highest positive effect in retardation weight gain, while time and temperature enhance weight gain. Nitrogen has a little positive effect in increasing...

Download

Simulation of cooling process effect on mechanical properties of 65Mn strip

A New grade of steel shots for casting cleaning and surface preparation

Saeed Ghali

Uploads

Papers by Saeed Ghali

Log In