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Wei LK, Abd Rahim SZ, Al Bakri Abdullah MM, Yin ATM, Ghazali MF, Omar MF, Nemeș O, Sandu AV, Vizureanu P, Abdellah AEH. Producing Metal Powder from Machining Chips Using Ball Milling Process: A Review. MATERIALS (BASEL, SWITZERLAND) 2023; 16:4635. [PMID: 37444950 DOI: 10.3390/ma16134635] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/26/2023] [Revised: 06/20/2023] [Accepted: 06/23/2023] [Indexed: 07/15/2023]
Abstract
In the pursuit of achieving zero emissions, exploring the concept of recycling metal waste from industries and workshops (i.e., waste-free) is essential. This is because metal recycling not only helps conserve natural resources but also requires less energy as compared to the production of new products from virgin raw materials. The use of metal scrap in rapid tooling (RT) for injection molding is an interesting and viable approach. Recycling methods enable the recovery of valuable metal powders from various sources, such as electronic, industrial, and automobile scrap. Mechanical alloying is a potential opportunity for sustainable powder production as it has the capability to convert various starting materials with different initial sizes into powder particles through the ball milling process. Nevertheless, parameter factors, such as the type of ball milling, ball-to-powder ratio (BPR), rotation speed, grinding period, size and shape of the milling media, and process control agent (PCA), can influence the quality and characteristics of the metal powders produced. Despite potential drawbacks and environmental impacts, this process can still be a valuable method for recycling metals into powders. Further research is required to optimize the process. Furthermore, ball milling has been widely used in various industries, including recycling and metal mold production, to improve product properties in an environmentally friendly way. This review found that ball milling is the best tool for reducing the particle size of recycled metal chips and creating new metal powders to enhance mechanical properties and novelty for mold additive manufacturing (MAM) applications. Therefore, it is necessary to conduct further research on various parameters associated with ball milling to optimize the process of converting recycled copper chips into powder. This research will assist in attaining the highest level of efficiency and effectiveness in particle size reduction and powder quality. Lastly, this review also presents potential avenues for future research by exploring the application of RT in the ball milling technique.
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Affiliation(s)
- Leong Kean Wei
- Faculty of Mechanical Engineering & Technology, Universiti Malaysia Perlis, Arau 02600, Malaysia
| | - Shayfull Zamree Abd Rahim
- Faculty of Mechanical Engineering & Technology, Universiti Malaysia Perlis, Arau 02600, Malaysia
- Center of Excellence Geopolymer and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, Kangar 01000, Malaysia
| | - Mohd Mustafa Al Bakri Abdullah
- Center of Excellence Geopolymer and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, Kangar 01000, Malaysia
- Faculty of Chemical Engineering & Technology, Universiti Malaysia Perlis, Kangar 01000, Malaysia
| | - Allice Tan Mun Yin
- Faculty of Mechanical Engineering & Technology, Universiti Malaysia Perlis, Arau 02600, Malaysia
| | - Mohd Fathullah Ghazali
- Faculty of Mechanical Engineering & Technology, Universiti Malaysia Perlis, Arau 02600, Malaysia
- Center of Excellence Geopolymer and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, Kangar 01000, Malaysia
| | - Mohd Firdaus Omar
- Center of Excellence Geopolymer and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, Kangar 01000, Malaysia
- Faculty of Chemical Engineering & Technology, Universiti Malaysia Perlis, Kangar 01000, Malaysia
| | - Ovidiu Nemeș
- Department of Environmental Engineering and Sustainable Development Entrepreneurship, Faculty of Materials and Environmental Engineering, Technical University of Cluj-Napoca, B-dul Muncii 103-105, 400641 Cluj-Napoca, Romania
| | - Andrei Victor Sandu
- Faculty of Materials Science and Engineering, Gheorghe Asachi Technical University of Iasi, Blvd. D. Mangeron 71, 700050 Iasi, Romania
- Romanian Inventors Forum, Str. Sf. P. Movila 3, 700089 Iasi, Romania
| | - Petrica Vizureanu
- Faculty of Materials Science and Engineering, Gheorghe Asachi Technical University of Iasi, Blvd. D. Mangeron 71, 700050 Iasi, Romania
- Technical Sciences Academy of Romania, Dacia Blvd 26, 030167 Bucharest, Romania
| | - Abdellah El-Hadj Abdellah
- Laboratory of Mechanics, Physics and Mathematical Modelling (LMP2M), University of Medea, Medea 26000, Algeria
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Ahmadian H, Sadoun A, Fathy A, Zhou T. Utilizing a unified conceptual dynamic model for prediction of particle size of duel-matrix nanocomposites during mechanical alloying. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118291] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/29/2023]
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Sojithamporn P, Sawangrat C, Leksakul K, Sharma B, Ameyama K. Fabrication of Copper of Harmonic Structure: Mechanical Property-Based Optimization of the Milling Parameters and Fracture Mechanism. MATERIALS (BASEL, SWITZERLAND) 2022; 15:8628. [PMID: 36500124 PMCID: PMC9739911 DOI: 10.3390/ma15238628] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/10/2022] [Revised: 12/01/2022] [Accepted: 12/01/2022] [Indexed: 06/17/2023]
Abstract
A severe plastic deformation process for the achievement of favorable mechanical properties for metallic powder is mechanical milling. However, to obtain the highest productivity while maintaining reasonable manufacturing costs, the process parameters must be optimized to achieve the best mechanical properties. This study involved the use of response surface methodology to optimize the mechanical milling process parameters of harmonic-structure pure Cu. Certain critical parameters that affect the properties and fracture mechanisms of harmonic-structure pure Cu were investigated and are discussed in detail. The Box-Behnken design was used to design the experiments to determine the correlation between the process parameters and mechanical properties. The results show that the parameters (rotation speed, mechanical milling time, and powder-to-ball ratio) affect the microstructure characteristics and influence the mechanical performance, including the fracture mechanisms of harmonic-structure pure Cu specimens. The best combination values of the ultimate tensile strength (UTS) and elongation were found to be 272 MPa and 46.85%, respectively. This combination of properties can be achieved by applying an optimum set of process parameters: a rotation speed of 200 rpm; mechanical milling time of 17.78 h; and powder-to-ball ratio of 0.065. The superior UTS and elongation of the harmonic-structure pure Cu were found to be related to the delay of void and crack initiation in the core and shell interface regions, which in turn were controlled by the degree of strength variation between these regions.
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Affiliation(s)
- Phanumas Sojithamporn
- Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
| | - Choncharoen Sawangrat
- Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
- Advanced Manufacturing and Management Technology Research Center (AM2Tech), Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
| | - Komgrit Leksakul
- Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
| | - Bhupendra Sharma
- Department of Mechanical Engineering, Faculty of Engineering, Kyushu University, Fukuoka 819-0395, Japan
| | - Kei Ameyama
- Department of Mechanical Engineering, College of Science and Engineering, Ritsumeikan University, Kyoto 525-8577, Japan
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Hamey RG, El-Midany AA, El-Shall HE. How reliable the light scattering in sizing the deformable particles by milling? PARTICULATE SCIENCE AND TECHNOLOGY 2022. [DOI: 10.1080/02726351.2022.2136588] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
Affiliation(s)
- R. G. Hamey
- Department of Materials Science and Engineering, University of Florida, Gainesville, FL, USA
| | - A. A. El-Midany
- Mining, Petroleum, and Metallurgical Engineering Department, Faculty of Engineering, Cairo University, Cairo, Egypt
| | - H. E. El-Shall
- Department of Materials Science and Engineering, University of Florida, Gainesville, FL, USA
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Najjar I, Sadoun A, Alsoruji GS, Elaziz MA, Wagih A. Predicting the mechanical properties of Cu–Al2O3 nanocomposites using machine learning and finite element simulation of indentation experiments. CERAMICS INTERNATIONAL 2022; 48:7748-7758. [DOI: 10.1016/j.ceramint.2021.11.322] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 09/02/2023]
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Bor A, Jargalsaikhan B, Uranchimeg K, Lee J, Choi H. Particle morphology control of metal powder with various experimental conditions using ball milling. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.08.053] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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Abd-Elwahed M, Wagih A, Najjar I. Correlation between micro/nano-structure, mechanical and tribological properties of copper-zirconia nanocomposites. CERAMICS INTERNATIONAL 2020; 46:56-65. [DOI: 10.1016/j.ceramint.2019.08.230] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 09/02/2023]
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Michalchuk AAL, Tumanov IA, Boldyreva EV. Ball size or ball mass – what matters in organic mechanochemical synthesis? CrystEngComm 2019. [DOI: 10.1039/c8ce02109k] [Citation(s) in RCA: 41] [Impact Index Per Article: 8.2] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
The effects of milling ball mass, size and material are isolated for a model mechanochemical co-crystallisation.
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Affiliation(s)
- Adam A. L. Michalchuk
- Novosibirsk State University
- Novosibirsk
- Russian Federation
- EaStCHEM School of Chemistry
- University of Edinburgh
| | - Ivan A. Tumanov
- Novosibirsk State University
- Novosibirsk
- Russian Federation
- Boreskov Institute of Catalysis
- Siberian Branch of the Russian Academy of Sciences
| | - Elena V. Boldyreva
- Novosibirsk State University
- Novosibirsk
- Russian Federation
- Boreskov Institute of Catalysis
- Siberian Branch of the Russian Academy of Sciences
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