Even though a lot of new advanced materials have been developed nowadays, steel remains a major material in construction, automobiles, appliances, industrial machinery as well as in the nuclear industry. Due to steel easily corroded, a proper surface protection is required to avoid any failures and extended the life cycle of the components. Surface coating is an efficient and economical method to obtain desirable material surfaces properties. Hot dip aluminizing technique was utilized in this study. Experiments have been conducted on the mild steel substrates with 12mm diameter. Prior to hot dipping process, observation on grain growth at three different temperatures had also been conducted to understand the behaviour of steel under application of heat. The substrates were heated at 700ºC, 800ºC and 900ºC for 1 hour and the microstructure was analyzed. The temperature of 800C was chosen for hot dipping. The substrates were dipped into the molten aluminum maintained at temperature 800ºC for 2,4,6,8,10,15 and 20 minutes. Optical microscopy and energy dispersive X-ray spectroscopy were used in this investigation. From the microstructure observation, it showed the appearance of intermetallic layer covered by the top layer of Al on the mild steel substrate increased with the increase in dipping time ranging from 36 to 282μm. The result of EDX analysis revealed the existence of Fe and Al in form of Fe2Al5 phase for all the dipping time.
Aluminum foams were fabricated by sintering dissolution process (SDP) using sodium chloride (NaCl) as space holder. The compositions of space holder, used in this study were 40 and 60 wt. % with different dissolution times; 1, 2 and 3 h. The effect of different dissolution times on compressive behavior and energy absorption of foams were evaluated. The result showed that by increasing space holder and dissolution times, energy absorption capability increases. For aluminum foam contains 60 wt. % NaCl, longer dissolution times resulted in thinner cell wall and cell structure become more unstable which lead to lower plateau region.
Recently, various solid wastes from industry such as glass waste, fly ash, sewage sludge and slag have been recycled into various value-added products such as ceramic tile. The conventional solutions of dumping the wastes in landfills or incineration, including in Malaysia are getting obsolete as the annual huge amount of the solid wastes would boost-up disposal cost and may cause permanent damage to the flora and fauna. This recent waste recycling approach is much better and greener as it can resolve problems associated with over-limit storage of industrial wastes and reduce exploration of natural resources for ceramic tile to continuously sustain the nature. Therefore, in this project, an attempt was made to recycle electric arc furnace (EAF) slag waste, obtained from Malaysia's steel making industry, into ceramic tile via conventional powder compaction method. The research work was divided into two stages. The first stage was to evaluate the suitability of EAF slag in ceramic tile by varying weight percentage of EAF slag (40 wt.%, 50 wt.% and 60 wt.%) and ball clay (40 wt.%, 50 wt.% and 60 wt.%), with no addition of silica and potash feldspar. In the second stage, the weight percentage of EAF slag was fixed at 40 wt.% and the percentage of ball clay (30 wt.% and 40 wt.%), feldspar (10 wt.% and 20 wt.%) and silica (10 wt.% and 20 wt.%) added was varied accordingly. Results obtained show that as weight percentage of EAF slag increased up to 60 wt.%, the percentage of apparent porosity and water absorption also rose, with a reduction in tile flexural strength and increased porosity. On the other hand, limiting the weight percentage of EAF slag to 40 wt.% while increasing the weight percentage of ball clay led to a higher total percentage of anorthite and wollastonite minerals, resulting in higher flexural strength. It was found that introduction of silica and feldspar further improved the flexural strength due to optimization of densification process. The highest flexural strength, lowest apparent porosity and water absorption of EAF slag based tile was attained at the composition of 40 wt.% EAF slag--30 wt.% ball clay--10 wt.% feldspar--20 wt.% silica. The properties of ceramic tile made with EAF slag waste (up to 40 wt.%), especially flexural strength are comparable to those of commercial ceramic tile and are, therefore, suitable as high flexural strength and heavy-duty green ceramic floor tile. Continuous development is currently underway to improve the properties of tile so that this recycling approach could be one of the potential effective, efficient and sustainable solutions in sustaining our nature.