Effect of Ultrafine Fly Ash and Water Glass Content on the Performance of Phosphorus Slag-Based Geopolymer

Phosphorus slag (PS), an industrial waste slag, has been used in geopolymers because it is rich in silicon and calcium. The poor performance of phosphorus slag-based geopolymer is due to its aluminum deficiency. In this work, low-calcium fly ash, treated by a wet-grinding process, named wet-grinding ultrafine fly ash (WUFA) was used as an Al supplement to replace some of the phosphorus slag, and the wet-grinding, ultrafine fly ash-phosphorus slag (WUFA-PS)-based geopolymer was prepared. The effects of the substitution amount of WUFA and the activator dosage on the hydration properties, mechanical properties, pore structure and SEM of the WUFA-PS geopolymer were discussed in detail. The results indicate that WUFA and more activators contribute to the Al and high alkalinity environment, which positively induces the production of more geopolymer gels, thus releasing more heat and optimizing the pore structure of the matrix. The compressive strength increased by up to 28.1%. The enhanced performance of the WUFA-PS-based geopolymer may also arise from the filling effect and activity improvement of WUFA. This study has proved the feasibility of preparing a geopolymer by blending wet-grinding ultrafine fly ash and phosphorus slag and has provided references for the ratio and performance evaluation of WUFA-PS-based geopolymer concrete.     

Fabrication of Low-Temperature Sintering Building Bricks Using Drilling Cutting and Geopolymeric Technology

This study explores the practicability of using drill cutting (DC) as raw material to fabricate building bricks through the high-temperature sintering method and low-temperature geopolymeric setting (LTGS) process. Drilling mud can be recycled and reutilized after certain treatment procedures and is considered as a non-hazardous waste. However, the treatment process is time-consuming and not cost-effective. For the sintering method, low porosity and high mechanical strength bricks can be sintered at temperatures above 800 °C and meet CNS standards. For the low-temperature geopolymeric setting process, sodium silicate was selected as an activating agent for geopolymerization of drill cutting. Several process parameters, such as Si₂O/Na₂O modulus of alkali solution and low-temperature geopolymeric setting temperature, were investigated. The physical and mechanical properties of the fabricated brick were evaluated. According to the test results, 72.4 MPa compressive strength building bricks with low porosity (13.9%) and water absorption (6.0%) can be fabricated with 2.0 Si₂O/Na₂O alkali solution at 500 °C. The drill cutting brick fabricated not only meets the CNS 382.R2002 common brick standard, but also solve its disposal problem.     

Relationship between Moisture Transportation,Efflorescence and Structure Degradation in Fly Ash/Slag Geopolymer

The relationship between moisture transportation and efflorescence in sodium hydroxide- or sodium silicate-activated fly ash/slag geopolymers was investigated. The results show that the efflorescence products are sodium carbonate hydrates, mainly composed of natron, heptahydrate, trona and sodium carbonate. The efflorescence induces compressive strength loss, water absorption increases and pore structure degradation in the geopolymer. When the curved surface of a geopolymer cylinder is covered with plastic film, the moisture transportation drives the free alkalis to the top surface to initiate efflorescence. In comparison, the efflorescence occurring on the curved surface of an uncovered geopolymer cylinder results in a more intensive alkalinity loss. For the uncovered geopolymers prepared with sodium hydroxide activator, efflorescence deposits are formed on the lower half of cylinder. A low capillary absorption capacity developed in the pore structure can only drive the moisture to the middle of cylinder, which is confronted with the drying front. More efflorescence products are formed on the upper half of the uncovered geopolymer cylinder prepared with sodium silicate activator. A relatively higher capillary absorption capacity, developed in the more compact pore structure, transports the moisture from the bottom to the top of cylinder, so no drying line is observed in the cylinder.     

Strength and Microstructure of Geopolymer Based on Fly Ash and Metakaolin

The production of Portland cement is widely regarded as a major source of greenhouse gas emissions. This contributes to 6–7% of total CO₂ emissions, according to the International Energy Agency. As a result, several efforts have been made in recent decades to limit or eliminate the usage of Portland cement in concrete. Geopolymer has garnered a lot of attention among the numerous alternatives due to its early compressive strength, low permeability, high chemical resistance, and great fire-resistant behaviour. This study looks at the strength and microstructure of geopolymer based on fly ash and a combination of metakaolin and fly ash. Compressive strengths were measured at 7, 14, and 28 days, and microstructure was examined using SEM and XRD.     

Characteristics of Waste Iron Powder as a Fine Filler in a High-Calcium Fly Ash Geopolymer

Geopolymer (GP) has been applied as an environmentally-friendly construction material in recent years. Many pozzolanic wastes, such as fly ash (FA) and bottom ash, are commonly used as source materials for synthesizing geopolymer. Nonetheless, many non-pozzolanic wastes are often applied in the field of civil engineering, including waste iron powder (WIP). WIPs are massively produced as by-products from iron and steel industries, and the production rate increases every year. As an iron-based material, WIP has properties of heat induction and restoration, which can enhance the heat curing process of GP. Therefore, this study aimed to utilize WIP in high-calcium FA geopolymer to develop a new type of geopolymer and examine its properties compared to the conventional geopolymer. Scanning electron microscopy and X-ray diffraction were performed on the geopolymers. Mechanical properties, including compressive strength and flexural strength, were also determined. In addition, setting time and temperature monitoring during the heat curing process were carried out. The results indicated that the addition of WIP in FA geopolymer decreased the compressive strength, owing to the formation of tetrahydroxoferrate (II) sodium or Na₂[Fe(OH)₄]. However, a significant increase in the flexural strength of GP with WIP addition was detected. A flexural strength of 8.5 MPa was achieved by a 28-day sample with 20% of WIP addition, nearly three times higher than that of control.     

Improvements of Flexural Properties and Thermal Performance in Thin Geopolymer Based on Fly Ash and Ladle Furnace Slag Using Borax Decahydrates

This paper elucidates the influence of borax decahydrate addition on the flexural and thermal properties of 10 mm thin fly ash/ladle furnace slag (FAS) geopolymers. The borax decahydrate (2, 4, 6, and 8 wt.%) was incorporated to produce FAB geopolymers. Heat treatment was applied with temperature ranges of 300 °C, 600 °C, 900 °C, 1000 °C and 1100 °C. Unexposed FAB geopolymers experienced a drop in strength due to a looser matrix with higher porosity. However, borax decahydrate inclusion significantly enhanced the flexural performance of thin geopolymers after heating. FAB2 and FAB8 geopolymers reported higher flexural strength of 26.5 MPa and 47.8 MPa, respectively, at 1000 °C as compared to FAS geopolymers (24.1 MPa at 1100 °C). The molten B₂O₃ provided an adhesive medium to assemble the aluminosilicates, improving the interparticle connectivity which led to a drastic strength increment. Moreover, the borax addition reduced the glass transition temperature, forming more refractory crystalline phases at lower temperatures. This induced a significant strength increment in FAB geopolymers with a factor of 3.6 for FAB8 at 900 °C, and 4.0 factor for FAB2 at 1000 °C, respectively. Comparatively, FAS geopolymers only achieved 3.1 factor in strength increment at 1100 °C. This proved that borax decahydrate could be utilized in the high strength development of thin geopolymers.     

Cutting Forces and Tool Wear Investigation during Turning of Sintered Nickel-Cobalt Alloy with CBN Tools

This article describes issues related to the machining of parts made of sintered nickel-cobalt alloy. Longitudinal turning with a CBN (cubic boron nitride) tool was analyzed. The results of experiments showed the influence of cutting parameters in the field of finishing machining on the values of cutting forces and specific cutting force, taking into account the wear of the cutting edge. Measurements and analysis of the topography and roughness parameters of the machined surface, as well as the cutting tool wear, were presented. The microscopic examination showed that the average grain size of the sintered nickel-cobalt alloy was 3.22 ± 0.1 (μm). The presence of the hardening state variability of the material during machining, as well as the value of the cutting force fluctuation as a function of the tool wear VB, were stated. The specific cutting force values increased to a small degree for the tool wear in the range of VB = 0–0.2 mm, and reached similar values in the range k_c = 5500–7500 N/mm². The specific cutting force values increased significantly for wear VB > 0.2 mm and were characterized by a large variability. The occurring phenomena were analyzed and several explanations were proposed. A recommendation was developed for the machining of parts made of sintered nickel-cobalt alloy. The Taguchi method was used in the experiment methodology.     

Life Cycle Assessment and Impact Correlation Analysis of Fly Ash Geopolymer Concrete

Geopolymer concrete (GPC) has drawn widespread attention as a universally accepted ideal green material to improve environmental conditions in recent years. The present study systematically quantifies and compares the environmental impact of fly ash GPC and ordinary Portland cement (OPC) concrete under different strength grades by conducting life cycle assessment (LCA). The alkali activator solution to fly ash ratio (S/F), sodium hydroxide concentration (C_NaOH), and sodium silicate to sodium hydroxide ratio (SS/SH) were further used as three key parameters to consider their sensitivity to strength and CO₂ emissions. The correlation and influence rules were analyzed by Multivariate Analysis of Variance (MANOVA) and Gray Relational Analysis (GRA). The results indicated that the CO₂ emission of GPC can be reduced by 62.73%, and the correlation between CO₂ emission and compressive strength is not significant for GPC. The degree of influence of the three factors on the compressive strength is C_NaOH (66.5%) > SS/SH (20.7%) > S/F (9%) and on CO₂ emissions is S/F (87.2%) > SS/SH (10.3%) > C_NaOH (2.4%). Fly ash GPC effectively controls the environmental deterioration without compromising its compressive strength; in fact, it even in favor.     

Mechanical and Durability Analysis of Fly Ash Based Geopolymer with Various Compositions for Rigid Pavement Applications

Ordinary Portland cement (OPC) is a conventional material used to construct rigid pavement that emits large amounts of carbon dioxide (CO₂) during its manufacturing process, which is bad for the environment. It is also claimed that OPC is susceptible to acid attack, which increases the maintenance cost of rigid pavement. Therefore, a fly ash based geopolymer is proposed as a material for rigid pavement application as it releases lesser amounts of CO₂ during the synthesis process and has higher acid resistance compared to OPC. This current study optimizes the formulation to produce fly ash based geopolymer with the highest compressive strength. In addition, the durability of fly ash based geopolymer concrete and OPC concrete in an acidic environment is also determined and compared. The results show that the optimum value of sodium hydroxide concentration, the ratio of sodium silicate to sodium hydroxide, and the ratio of solid-to-liquid for fly ash based geopolymer are 10 M, 2.0, and 2.5, respectively, with a maximum compressive strength of 47 MPa. The results also highlight that the durability of fly ash based geopolymer is higher than that of OPC concrete, indicating that fly ash based geopolymer is a better material for rigid pavement applications, with a percentage of compressive strength loss of 7.38% to 21.94% for OPC concrete. This current study contributes to the field of knowledge by providing a reference for future development of fly ash based geopolymer for rigid pavement applications.     

Evaluation of Wear Behaviour in Metallic Binders Employed in Diamond Tools for Cutting Stone

A type of disc-on-plate test methodology was used to determine the wear behavior of metallic binders employed in the manufacturing of diamond impregnated tools. The disc consists of a special circular wheel that allows the binder materials alone (i.e., without diamond, but sintered under conditions identical to those of the complete tool) to be tested against a plate of stone material under pre-determined testing conditions. The testing conditions are intended to be equivalent to those used in the industrial processes. Using plates of five types of granite and one type of marble, this work comprises wear tests of 15 different types of metallic binders and two sintering modes conducted under, at least, three different values of contact-force. The analysis of the results demonstrated that the wear of the binders can be related to their mechanical properties through an empirical expression. The larger the difference between the characteristics of the tribological pair (binder versus stone), the higher is the correlation between the experimental wear data and the values given by the empirical expression. The relationships presented in this work allow predicting the wear behavior of the binder, and therefore may help in the design process of diamond tools. There was a clear difference between the wear behavior of metallic binders when they were employed against the two main classes of stone under analysis (marble and granite).     

Evaluation on the Mechanical Properties of Ground Granulated Blast Slag (GGBS) and Fly Ash Stabilized Soil via Geopolymer Process

This study intended to address the problem of damaged (collapsed, cracked and decreased soil strength) road pavement structure built on clay soil due to clay soil properties such as low shear strength, high soil compressibility, low soil permeability, low soil strength, and high soil plasticity. Previous research reported that ground granulated blast slag (GGBS) and fly ash can be used for clay soil stabilizations, but the results of past research indicate that the road pavement construction standards remained unfulfilled, especially in terms of clay’s subgrade soil. Due to this reason, this study is carried out to further investigate soil stabilization using GGBS and fly ash-based geopolymer processes. This study investigates the effects of GGBS and ratios of fly ash (solid) to alkaline activator (liquid) of 1:1, 1.5:1, 2:1, 2.5:1, and 3:1, cured for 1 and 7 days. The molarity of sodium hydroxide (NaOH) and the ratio of sodium silicate (Na₂SiO₃) to sodium hydroxide (NaOH) was fixed at 10 molar and 2.0 weight ratio. The mechanical properties of the soil stabilization based geopolymer process were tested using an unconfined compression test, while the characterization of soil stabilization was investigated using the plastic limit test, liquid limit test, scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier transform infrared spectroscopy (FTIR). The results showed that the highest strength obtained was 3.15 MPA with a GGBS to alkaline activator ratio of 1.5 and Na₂SiO₃ to NaOH ratio of 2.0 at 7 days curing time. These findings are useful in enhancing knowledge in the field of soil stabilization-based geopolymer, especially for applications in pavement construction. In addition, it can be used as a reference for academicians, civil engineers, and geotechnical engineers.     

Resistance of Soda Residue–Fly Ash Based Geopolymer Mortar to Acid and Sulfate Environments

The early mechanical performances of low-calcium fly ash (FFA)-based geopolymer (FFA–GEO) mortar can be enhanced by soda residue (SR). However, the resistance of SR–FFA–GEO mortar to acid or sulfate environments is unclear, owing to the various inorganic calcium salts in SR. The aim of this study was to investigate the long-term mechanical strengths of up to 360 d and evaluate the resistance of SR–FFA–GEO mortar to 5% HCl and 5% Na₂SO₄ environments through the losses in compressive strength and mass. Scanning Electron Microscopy (SEM), Energy-Dispersive Spectroscopy (EDS) and Fourier Transform Infrared Spectrometer (FTIR) experiments were conducted for the SR–FFA–GEO mortars, both before and after chemical attack, to clarify the attack mechanism. The results show that the resistances of the SR–FFA–GEO mortar with 20% SR (namely M10) to 5% HCl and 5% Na₂SO₄ environments are superior to those of cement mortar. The environmental HCl reacts with the calcites in SR to produce CaCl₂, CO₂ and H₂O to form more pores under HCl attack, and the environmental Na⁺ cations from Na₂SO₄ go into Si-O-Al network structure, to further enhance the strength of mortar under Na₂SO₄ attack. These results provide the experimental basis for the durability optimization of SR–FFA–GEO mortars.     

Different Fiber Reinforcement Effects on Fly Ash-Based Geopolymer Long-Term Deflection in Three-Point Bending and Microstructure

This study investigated the effect of a low amount of polyvinyl alcohol (PVA) and steel fiber reinforcement on fly ash-based geopolymer composite long-term deflection and its microstructure. For testing purposes, specimens with different amounts and types of fiber reinforcement as well as plain (reference) were prepared. The long-term deflection test was performed by loading specimens with 40% of the ultimate flexural strength. A microstructure analysis was performed using polished section specimens, and images were acquired at 25-times magnification on a scanning electron microscope. The results of the flexural strength test show that all geopolymer composites with fiber reinforcement have lower flexural strength than plain geopolymer composites. The long-term deflection tests show that the highest deflections exhibit 1% PVA fiber-reinforced specimens. The lowest amount of deflection is for 1% steel fiber-reinforced specimens. Specific creep shows similar results to plain, and 1% steel fiber-reinforced specimens, while 1% PVA and 0.5% PVA/0.5% steel fiber-reinforced specimen exhibits the same properties. The quantitative microanalysis of the polished section further confirms the deflection results. Specimens with 1% PVA fiber reinforcement have significantly higher porosity than all other specimens. They are followed by plain specimens and 1% steel fiber, and 0.5% PVA/0.5 steel fiber-reinforced specimens have almost the same porosity level.     

Setting Time,Microstructure, and Durability Properties of Low Calcium Fly Ash/Slag Geopolymer: A Review

Ordinary Portland cement (OPC) is known for its significant contribution to carbon dioxide emissions. Geopolymer has a lower footprint in terms of CO₂ emissions and has been considered as an alternative for OPC. A well-developed understanding of the use of fly-ash-based and slag-based geopolymers as separate systems has been reached in the literature, specifically regarding their mechanical properties. However, the microstructural and durability of the combined system after slag addition introduces more interactive gels and complex microstructural formations. The microstructural changes of complex blended systems contribute to significant advances in the durability of fly ash/slag geopolymers. In the present review, the setting time, microstructural properties (gel phase development, permeability properties, shrinkage behavior), and durability (chloride resistance, sulfate attack, and carbonatation), as discussed literature, are studied and summarized to simplify and draw conclusions.     

Recycling of Pre-Washed Municipal Solid Waste Incinerator Fly Ash in the Manufacturing of Low Temperature Setting Geopolymer Materials

In this work, three samples of municipal solid waste incinerators fly ash (MSWI-FA) have been stabilized in systems containing coal fly ash to create geopolymers through a polycondensation reaction. Monolithic products have been obtained with both MSWI fly ash as received and after the partial removal of chloride and sulfate by water washing. The polycondensation products have been characterized qualitatively by means of Fourier transform infrared spectroscopy, X-ray diffraction and scanning electron microscopy and quantitatively, through the determination of the volume of reacted water and silicate. Furthermore, the heavy metals and chloride releases together with the physico-mechanical properties have been evaluated on the hardened products. In conclusion, considering the technological and environmental performances of the obtained geopolymers, they could be suitable for many non-structural applications, such as backfilling of abandoned quarries, decorative materials or brick fireplaces, hearths, patios, etc.     

Strength and Microstructure Characteristics of Blended Fly Ash and Ground Granulated Blast Furnace Slag Geopolymer Mortars with Na and K Silicate Solution

Mineral geopolymer binders can be an attractive and more sustainable alternative to traditional Portland cement materials for special applications. In geopolymer technology the precursor is a source of silicon and aluminium oxides, the second component is an alkaline solution. In the synthesis of geopolymer binders the most commonly used alkaline solution is a mixture of sodium or potassium water glass with sodium or potassium hydroxide or silicate solution with a low molar ratio, which is more convenient and much safer in use. In this paper, we present the influence of sodium or potassium silicate solution on the physical and mechanical properties of fly ash and ground granulated blast furnace slag-based geopolymer mortars. Mercury intrusion porosimetry and microstructural observation allowed for comparing the structure of materials with a different type of alkaline solution. The evolution of compressive and flexural tensile strength with time determined for composites using 10%, 30% and 50% slag contents (referring to fly ash mass) was analysed. The tests were performed after 3, 7, 14 and 28 days. It was observed that, as the amount of slag used increases in the precursor, the strength of the material grows. Mortars with the sodium alkaline solution were characterised by a higher strength at a young age. However, the values of strength 28 days were higher for geopolymers with potassium alkaline solution reaching 75 MPa in compression. Geopolymer mortar microstructure observation indicates a high matrix heterogeneity with numerous microcracks. Matrix defects may be caused by the rapid kinetics of the material binding reaction or shrinkage associated with the drying of the material.     

Characterisation at the Bonding Zone between Fly Ash Based Geopolymer Repair Materials (GRM) and Ordinary Portland Cement Concrete (OPCC)

In recent years, research and development of geopolymers has gained significant interest in the fields of repairs and restoration. This paper investigates the application of a geopolymer as a repair material by implementation of high-calcium fly ash (FA) as a main precursor, activated by a sodium hydroxide and sodium silicate solution. Three methods of concrete substrate surface preparation were cast and patched: as-cast against ordinary Portland cement concrete (OPCC), with drilled holes, wire-brushed, and left as-cast against the OPCC grade 30. This study indicated that FA-based geopolymer repair materials (GRMs) possessed very high bonding strength at early stages and that the behavior was not affected significantly by high surface treatment roughness. In addition, the investigations using scanning electron microscopy (SEM) and energy-dispersive X-ray (EDX) spectroscopy have revealed that the geopolymer repair material became chemically bonded to the OPC concrete substrate, due to the formation of a C–A–S–H gel. Fundamentally, the geopolymer network is composed of tetrahedral anions (SiO₄)⁴⁻ and (AlO₄)⁵⁻ sharing the oxygen, which requires positive ions such as Na⁺, K⁺, Li⁺, Ca²⁺, Na⁺, Ba²⁺, NH⁴⁺, and H₃O⁺. The availability of calcium hydroxide (Ca(OH)₂) at the surface of the OPCC substrate, which was rich in calcium ions (Ca²⁺), reacted with the geopolymer; this compensated the electron vacancies of the framework cavities at the bonding zone between the GRM and the OPCC substrate.     

Influence of Bentonite on Mechanical and Durability Properties of High-Calcium Fly Ash Geopolymer Concrete with Natural and Recycled Aggregates

In this study, bentonite (a naturally occurring pozzolana) was incorporated as a partial replacement (up to 20%) for high-calcium fly ash (HCFA)-based geopolymeric natural aggregate concrete (GNAC) and geopolymeric recycled aggregate concrete (GRAC). The mechanical (compressive strength and splitting tensile strength), durability (chloride migration coefficient, water absorption, and acid attack resistance), and rheological properties (slump test, fresh density, and workability) were investigated. The results revealed that incorporation of bentonite (10 wt % with ordinary Portland cement) showed appreciable improvement in the strength and durability of both the GNAC and GRAC, though its effect is more significant for GRAC than the GNAC.     

Use of Gypsum as a Preventive Measure for Strength Deterioration during Curing in Class F Fly Ash Geopolymer System

This study discusses strength deterioration during the curing process of fly ash geopolymer and the use of CaSO₄·2H₂O (gypsum) as a deterioration remedy when the ash was synthesized using a 10M NaOH and Na-silicate solution. The strength decline was mainly due to the widespread formation of nanometer-sized cracks that were related to excessive Na and Si concentrations at an early age. Use of 2 wt% CaSO₄·2H₂O resulted in the best measured strength by temporarily reducing Na and Si concentrations; Na was absorbed by SO₄²⁻, up to 11% in the matrix within one day, and formed Na₂SO₄ (thenardite), which gradually dissolved over time, slowly releasing Na ions. However, more than 4% gypsum suppressed overall strength development because too many Na ions were locked into Na₂SO₄ and could not participate in geopolymerization. The addition of gypsum impeded glass dissolution and even halted the process when more than 4% gypsum was used.     

The Oxidation Behaviour and Notch Wear Formation of TiAlN Coated Tools Using Different Oxidation Techniques

This paper proposes a novel approach to assessing oxidation behavior of TiAlN coatings with defined stoichiometry on the rake and flank surfaces. This is based on the multi-parametric comparison of the oxidation effects detected on the coatings’ surfaces resulting from static diffusion couple tests. In this experimental study the diffusion couples consisting of Ti-based and Ni-based alloys and coated TiAlN cutting inserts are tested, respectively. The optimum oxidation temperature was determined by annealing the selected TiAlN coating in a high temperature chamber at temperatures: 700 °C, 800 °C, 900 °C and 1000 °C in air. Concurrently, the mass change and corresponding thickness of the Al₂O₃ oxidized layer were measured and computed. The comparison of oxides produced covers the surface morphologies, chemical elements and phases which were analyzed by means of SEM (scanning electron microscope), EDS (energy dispersive spectroscopy) and XRD (X-ray diffraction techniques). Additionally, scratch tests were performed to assess the penetration depth down to the substrate and coating failure mechanism after oxidation in diffusion couples. An acceptable similarity of Al₂O₃ films formed on the TiAlN coating surfaces in diffusion couples and machining processes was established.