Isnaldi R. Souza Filho

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• Dr.
• Junior Professor (Chair of Sustainable Metallurgy) at French National Centre for Scientific Research

Strain partitioning and localization were investigated in a high-Mn steel (17.1 wt.% Mn) during tensile testing by a correlative probing approach including in-situ synchrotron X-ray diffraction, micro- digital image correlation (μ-DIC) and electron microscopy. By combining Warren's theory with the μ-DIC analysis, we monitored the formation of plana...

Iron- and steelmaking is the largest single industrial CO2 emitter, accounting for 6.5% of all CO2 emissions on the planet. This fact challenges the current technologies to achieve carbon-lean steel production and to align with the requirement of a drastic reduction of 80% in all CO2 emissions by around 2050. Thus, alternative reduction technologie...

Iron- and steelmaking cause ∼7% of the global CO2 emissions, due to the use of carbon for the reduction of iron ores. Replacing carbon by hydrogen as the reductant offers a pathway to massively reduce these emissions. However, the production of hydrogen using renewable energy will remain as one of the bottlenecks at least during the next two decade...

Red mud is the waste of bauxite refinement into alumina, the feedstock for aluminium production1. With about 180 million tonnes produced per year1, red mud has amassed to one of the largest environmentally hazardous waste products, with the staggering amount of 4 billion tonnes accumulated on a global scale1. Here we present how this red mud can be...

A circular steel economy based on recycling scrap is severely hampered by the increasing accumulation of Cu returning from more and more electrified products, which severely limits processing, application, and safety of steels. As of yet, no viable strategies for its removal have been developed, and the increasing Cu contamination can only be dilut...

Hydrogen plasma smelting reduction (HPSR) is an energy efficient, electrified, and fast process route to reduce not only iron ores but also thermally stable oxide materials, such as steelmaking sidestreams, waste, lean metallic ores, and metals with strong oxygen bonds. Both basic research of the underlying redox reaction mechanisms and upscaling a...

Nickel is a critical element in the shift to sustainable energy systems, with the demand for nickel projected to exceed 6 million tons annually by 20401, 2, 3–4, largely driven by the electrification of the transport sector. Primary nickel production uses acids and carbon-based reductants, emitting about 20 tons of carbon dioxide per ton of nickel...

Comparative analysis of red mud reduction techniques was performed using both carbothermal and hydrogen-based reduction methods, combining thermochemical modeling and experimental validation. The reduction process is mostly important because of the high contamination risk assessment of soil with disposed red mud. Therefore, the minimization of red...

Hydrogen plasma smelting reduction (HPSR) has been envisaged as a potential $$\text{CO}_2$$ CO 2 -lean process for ore-based steelmaking, combining the reduction, melting and refining steps into a single unit process. However, scaling the process to industrial use still requires some work. In previous studies, optical emission spectroscopy (OES) ha...

Aluminum is the forefront metal for lightweight design of transport vehicles and civil engineering structures. For its primary production, bauxite ore needs to be refined through the Bayer process to produce alumina, during which waste, called bauxite residue or red mud, is formed. Due to the large scale of alumina production, red mud production is...

Citation: Stopic, S.; Schneider, R.; Kostić, D.; Filho, I.R.S.; Perušić, M.; Emil-Kaya, E.; Friedrich, B. Combined Decarbonizing Technologies for Treatment of Bauxite Residues. Waste 2025, 3, 11. https://doi. Abstract: This study explores both pyrometallurgical and hydrometallurgical methods for decarbonizing and recovering valuable metals from bau...

Aluminum is the fastest growing mass-produced material group, a prerequisite for lightweight design of cars, airplanes as well as civil engineering structures. For its primary production through the Hall-Héroult process, alumina is used as the primary feedstock that is extracted through refinement of bauxite ore. During this process, the by-product...

Circular Steel for Fast Decarbonization: Thermodynamics, Kinetics, and Microstructure Behind Upcycling Scrap into High-Performance Sheet Steel: Steel production stands accounts for approximatelybout 8% of all global CO2 emissions, with the primary steelmaking route from using iron ores accounting for about 80% of those emissions, mainly due to the...

Due to the ever‐increasing demand for high‐quality steel and the need to reduce CO2 emissions, research and development of sustainable steelmaking processes have gained a lot of interest in the past decade. One of these processes is the hydrogen plasma smelting reduction (HPSR), which has proven to be a promising solution for iron ore reduction whe...

Steel production accounts for approximately 8% of all global CO 2 emissions, with the primary steelmaking route using iron ores accounting for about 80% of those emissions, mainly due to the use of fossil-based reductants and fuel. Hydrogen-based reduction of iron oxide is an alternative for primary synthesis. However, to counteract global warming,...

https://lt.org/publication/can-we-extract-iron-red-mud-using-hydrogen-plasma https://www.youtube.com/watch?v=HRkltMAAgCE

Fast growth of sustainable energy production requires massive electrification of transport, industry and households, with electrical motors as key components. These need soft magnets with high saturation magnetization, mechanical strength, and thermal stability to operate efficiently and safely. Reconciling these properties in one material is chall...

Because of their high mixing entropies, multi-component alloys can exhibit enhanced catalytic activity compared to traditional catalysts in various chemical reactions, including hydrogenation, oxidation, and reduction processes. In this work, new AgCoCuFeNi high entropy alloy nanoparticles were synthesized by the hydrogen reduction-assisted ultraso...

In this work we investigate the feasibility and optimisation pathways for using oxide-filled consumable electrodes as both ore feeding system and reducing/melting arc carrier in the hydrogen plasma smelting reduction process. Similar in nature to Söderberg-type electrodes, but free of C-containing substances, this approach has the potential advanta...

We present a novel pathway by conjoining hydrogen-based direct reduction and hydrogen plasma reduction that allows significant improvement of the iron oxide reduction with faster processing and effectiveness. With the presented hybrid approach, we deliver a way to exploit the specific characteristics, kinetics and efficiencies of both technologies...

Understanding the effect of gangue elements is of critical importance to optimize the efficiency of hydrogen-based direct reduction (HyDR) of iron ore, as one of the key steps towards climate-neutral steel production. Here, we demonstrate on the example of Si-doped Fe2O3 , how thin films can be effectively utilized as a model system to facilitate s...

Hydrogen plasma smelting reduction (HPSR) has the potential to be a viable solution for both reducing metal-bearing oxides and treatment of metallurgical sidestreams for metal recovery. However, thermal plasmas are known for their erratic and sometimes unpredictable behavior. Plasmas are highly dynamic entities, as their properties change rapidly d...

Unlabelled: Out of the multitude of researched processing routes for sustainable ironmaking, hydrogen-based direct reduction and hydrogen plasma smelting reduction (HyPSR) are currently the most promising candidates for a successful industrial application. Both processes operate under gaseous atmospheres, which turn the partial and absolute pressu...

To counteract the rising greenhouse gas emissions, mainly CO2, the European steel industry needs to restructure the current process route for steel production. Globally, the blast furnace and the subsequent basic oxygen furnace are used in 73% of crude steel production, with a CO2 footprint of roughly 1.8 t CO2 per ton of produced steel. Hydrogen P...

Soft magnetic materials (SMMs) serve in electrical applications and sustainable energy supply, allowing magnetic flux variation in response to changes in applied magnetic field, at low energy loss 1. The electrification of transport, households and manufacturing leads to an increase in energy consumption due to hysteresis losses 2. Therefore, minim...

Fe- and steelmaking is the largest single industrial CO2 emitter, accounting for 6.5% of all CO2 emissions on the planet. This fact challenges the current technologies to achieve carbon-lean steel production and to align with the requirement of a drastic reduction of 80% in all CO2 emissions by around 2050. Thus, alternative reduction technologies...

To successfully transition from fossil-fuel to sustainable carbon-free energy carriers, a safe, stable and high-density energy storage technology is required. The combustion of iron powders seems very promising in this regard. Yet, little is known about their in-process morphological and microstructural evolution, which are critical features for th...

Soft magnetic materials (SMMs) serve in electrical applications and sustainable energy supply, allowing magnetic flux variation in response to changes in applied magnetic field, at low energy loss1. The electrification of transport, households and manufacturing leads to an increase in energy consumption due to hysteresis losses2. Therefore, minimiz...

Alloys processed by laser powder-bed fusion show distinct microstructures composed of dislocation cells, dispersed nanoparticles, and columnar grains. Upon post-build annealing, such alloys show sluggish recrystallization kinetics compared to the conventionally processed counterpart. To understand this behavior, AISI 316L stainless steel samples we...

The enormous magnitude of 2 billion tons of alloys produced per year demands a change in design philosophy to make materials environmentally, economically, and socially more sustainable. This disqualifies the use of critical elements that are rare or have questionable origin. Amongst the major alloy strengthening mechanisms, a high-dispersion of se...

Mining tailings are becoming more and more abundant and consequently it has been shown to be a material of great concern, especially after the dam failures in Brazil, Bento Rodrigues, 2015 and Brumadinho, 2019. In this work, iron ore tailings (IOT) were used as an aggregate in the production of geopolymers based on metakaolin used as a precursor an...

Steel production causes a third of all industrial CO2 emissions due to the use of carbon-based substances as reductants for iron ores, making it a key driver of global warming. Therefore, research efforts aim at replacing these reductants with sustainably produced hydrogen. Hydrogen-based direct reduction (HyDR) is an attractive processing technolo...

Fossil-free ironmaking is indispensable for reducing massive anthropogenic CO2 emissions in the steel industry. Hydrogen-based direct reduction (HyDR) is among the most attractive solutions for green ironmaking, with high technology readiness. The underlying mechanisms governing this process are characterized by a complex interaction of several che...

The ultimate goal for structural materials is achieving both high strength and ductility. However, increasing one of these properties can usually decrease the other, resulting in the so-called strength-ductility trade-off. According to the Considère criterion, increased strain hardening rates are demanded at higher strains to prevent necking and st...

Iron- and steelmaking cause ~7% of the global CO2 emissions, due to the use of carbon for the reduction of iron ores. Replacing carbon by hydrogen as the reductant offers a pathway to reduce emissions. However, production of hydrogen using renewable energy will remain a bottlenecks, because making the annual crude steel production of 1.8 billion to...

Fossil-free ironmaking is indispensable for reducing massive anthropogenic CO2 emissions in the steel industry. Hydrogen-based direct reduction (HyDR) is among the most attractive solutions for green ironmaking, with high technology readiness. The underlying mechanisms governing this process are characterized by a complex interaction of several che...

Soft magnetic materials (SMMs) are indispensable components in electrified applications and sustainable energy supply, allowing permanent magnetic flux variations in response to high frequency changes of the applied magnetic field, at lowest possible energy loss1. The global trend towards electrification of transport, households and manufacturing l...

The lack of strength and damage tolerance can limit the applications of conventional soft magnetic materials (SMMs), particularly in mechanically loaded functional devices. Therefore, strengthening and toughening of SMMs is critically important. However, conventional strengthening concepts usually significantly deteriorate soft magnetic properties,...

Steel is the most important material class in terms of volume and environmental impact. While it is a sustainability enabler, for instance through lightweight design, magnetic devices, and efficient turbines, its primary production is not. Iron is reduced from ores by carbon, causing 30% of the global CO 2 emissions in manufacturing , qualifying it...

Steel is the most important material class in terms of volume and environmental impact. While it is a sustainability enabler, for instance through lightweight design, magnetic devices, and efficient turbines, its primary production is not. Iron is reduced from ores by carbon, causing 30% of the global CO2 emissions in manufacturing, qualifying it a...

With 1.85 billion tons produced per year, steel is the most important material class in terms of volume and environmental impact. While steel is a sustainability enabler, for instance through lightweight design, magnetic devices, and efficient turbines, its primary production is not. For 3000 years, iron has been reduced from ores using carbon. Tod...

A R T I C L E I N F O Keywords: Lean duplex steel Strain-induced martensite Austenite reversion Magnetic properties Microstructural evolution A B S T R A C T Strain-induced α′-martensite and austenite reversion in a cold rolled UNS S32304 lean duplex steel were tracked by means of magnetic measurements, with emphasis on both M s (saturation magneti...

open access links: https://link.springer.com/article/10.1007%2Fs11661-020-05947-2 https://rdcu.be/b6P8O https://doi.org/10.1007/s11661-020-05947-2 This is a viewpoint paper on recent progress in the understanding of the microstructure–property relations of advanced high-strength steels (AHSS). These alloys constitute a class of high-strength, for...

The presence of δ-ferrite in 316L stainless steel powder reused several times contributes to structural defect formation in selective laser melted parts built using the pin support structure. The virgin 316L stainless steel powder is fully austenitic. After several powder reuse cycles, reused powder has a finer particle size and about 6 vol. % of δ...

In situ synchrotron X-ray diffraction was used to track real-time austenite reversion in AISI 201 austenitic stainless steel deformed to a true strain of 0.34 under tensile testing. The deformed material was continuously annealed from 100 °C up to 800 °C at a heating rate of 0.05 °C s −1. Phase changes and microstrain partitioning were evaluated by...

The formation of submicron structural defects within austenite (γ), ε-and α′-martensite during cold rolling was followed in a 17.6 wt.% Mn steel. Several probes, including XRD, EBSD, and ECCI-imaging, were used to reveal the complex superposition of the strain hardening mechanisms of these phases. The maximum amount of ε-martensite is observed at a...

Austenite (g) reversion in a cold-rolled 17.6 wt.% Mn steel was tracked by means of dilatometry and in-situ magnetic measurements during slow continuous annealing. A splitting of the g-reversion into two stages was observed to be a result of strong elemental partitioning between g and a 0-martensite during the low temperature stage between 390 and...

Austenite (g) reversion in a cold-rolled 17.6 wt.% Mn steel was tracked by means of dilatometry and in-situ magnetic measurements during slow continuous annealing. A splitting of the g-reversion into two stages was observed to be a result of strong elemental partitioning between g and a 0-martensite during the low temperature stage between 390 and...

Strain-induced martensite (SIM) formation was evaluated upon cold-rolling of a 17.6 wt.%Mn-TRIP steel by means of magnetic measurements, X-ray diffraction, and high-resolution electron backscatter diffraction (EBSD). α′-martensite formation was observed to be dependent on the presence of prior ε-martensite. Upon deformation, the coercivity of the f...

A systematic study of the superconducting properties in a series of arc-melted Nb-B samples close to the 1:1 composition was carried out. Powder X-ray diffraction (XRD) shows that all samples are both non-stoichiometric, and comprising of two crystal phases: a majority orthorhombic NbB-type phase, and traces of a minor body-centered cubic Nb-rich p...

Strain partitioning and texture evolution of AISI 201 austenitic stainless steel were investigated upon cold rolling up to a true strain of ε = 0.92. ε-martensite formation is the main work hardening mechanism at low strains (ε = 0.11). With increasing strain, the volume fraction of α’-martensite increases with a sigmoidal-like behavior. Remaining...

The AISI 317L stainless steel is an austenitic grade with at least 3%Mo. Recently, this steel has replaced AISI 316L in many applications in chemical and petrochemical industries, due to its higher pitting corrosion resistance. The microstructure of the hot rolled and annealed material studied in this work consists of austenitic grains and 4.0% of...

Oxide-dispersion strengthened (ODS) Eurofer steel is targeted for structural applications in future fusion nuclear reactors. Samples were cold rolled down to 80% reduction in thickness and annealed at 1350 C up to 8 h. The microstructural characterization was performed using Vickers microhardness testing, electron backscatter diffraction, scanning...

In this work the recrystallization of the ABNT 1015 steel deformed by equal channel angular extrusion (ECAP) was reported. The corresponding von Mises equivalent strain (?vM) of the material, after one unique ECAP pass was 0.67. After deformation the material was annealed (under vacuum) at several temperatures up to 800°C. The microstructural chara...