The erosion/corrosion of small superalloy turbine rotors operating in the effluent of a PFB coal combustor

Superalloy turbine rotors in a single stage turbine with 6 percent partial admittance were operated in the effluent of a pressurized fluidized bed coal combustor for up to 164 hours. Total mass flow was 300 kg/hr and average particulate loadings ranged from 600 to 2800 ppm for several coal/sorbent combinations. A 5.5 atm turbine inlet gas pressure and inlet gas temperatures from 700 to 800 C yielded absolute gas velocities at the stator exit of about 500 m/s. The angular rotation speed (40,000 rpm) of the six inch diameter rotors was equivalent to a tip speed of about 300 m/s, and average gas velocities relative to the rotating surface ranged from 260 to 330 m/s at mean radius. The rotor erosion pattern reflects heavy particle separation with severe (5 to 500 cm/yr) erosion at the leading edge, pressure side center, and suction side trailing edge at the tip. The erosion distribution pattern provides a spectrum of erosion/oxidation/deposition as a function of blade position. This spectrum includes enhanced oxidation (10 to 100 x air), mixed oxides in exposed depletion zones, sulfur rich oxides in deposition zones, and rugged areas of erosive oxide removal

Corrosion and Degradation of Materials

Studies on the corrosion and degradation of materials play a decisive role in the novel design and development of corrosion-resistant materials, the selection of materials used in harsh environments in designed lifespans, the invention of corrosion control methods and procedures (e.g., coatings, inhibitors), and the safety assessment and prediction of materials (i.e., modelling). These studies cover a wide range of research fields, including the calculation of thermodynamics, the characterization of microstructures, the investigation of mechanical and corrosion properties, the creation of corrosion coatings or inhibitors, and the establishment of corrosion modelling. This Special Issue is devoted to these types of studies, which facilitate the understanding of the corrosion fundamentals of materials in service, the development of corrosion coatings or methods, improving their durability, and eventually decreasing corrosion loss

Introducing New Coating Material Alloy with Potential Elements for High Corrosion Resistance for Oil and Gas Application

In petroleum and petrochemical industries, offshore and onshore systems have to function in an aggressive environment that exposes the production equipment components to thermal cycling and wear and corrosion. Although maintenance of material degradation in oil and gas is costly, internal and external parts of the equipment and pipelines must be well inspected and continually maintained. For this reason, highly advanced corrosion and wear–monitoring systems must be installed in the critical areas of the plant to protect pipes and equipment from seawater and crude oil. Therefore, researchers are in search of advanced materials and methods that could be applied in oil and gas pipelines and accessories for increasing their working time. The common manufacturing processing method for improving the surface of piping and accessories is overlay welding or cladding. This method has some limitations, such as its limitation for choosing materials. In addition, the high temperature of welding causes some defects on the final surface, such as thermal residual stress, cracking, and distortion in the substrate. The method is also time consuming and costly. However, the coating method provides a blend of unique properties with low cost. Thermal spray methods are cold spraying techniques that have a considerably less thermal stress, residual stress, and other defects. Among different thermal spray coating techniques, high-velocity oxygen fuel (HVOF) and plasma are the most commonly used thermal spraying coating processes to produce anti-wear and corrosion coatings with different types of materials such as metal, alloys, and ceramic composite . Furthermore, HVOF and plasma thermally sprayed coating processes induce microstructure heterogeneities, which increase the corrosion and wear resistance. In this research, one type of alloy with chemical composition NiCrCoAlY was chosen for increasing corrosion resistivity of carbon steel piping. A corrosion behavior of coated samples in seawater was investigated for 30 days. Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) results indicated that these types of alloys protected the surface of carbon steel piping from harsh environments. However, the corrosion protection of NiCoCrAlY deposited by HVOF technique is higher than a plasma coating technique

Corrosion of cast aluminum alloys: a review

Research on corrosion resistance of cast aluminum alloys is reviewed in this article. The effect of the main microstructural features of cast aluminum alloys such as secondary dendrite arm spacing (SDAS), eutectic silicon morphology, grain size, macrosegregation, microsegregation, and intermetallic compounds is discussed. Moreover, the corrosion resistance of cast aluminum alloys obtained by modern manufacturing processes such as semi-solid and additive manufacturing are analyzed. Finally, the protective effects provided by different coatings on the aluminum cast alloys?such as anodized, plasma electrolytic oxidation (PEO), and laser?is reviewed. Some conclusions and future guidelines for future works are proposed

NASA-UVA light aerospace alloy and structures technology program (LA2ST)

The NASA-UVa Light Aerospace Alloy and Structures Technology (LA2ST) Program was initiated in 1986 and continues with a high level of activity. Projects are being conducted by graduate students and faculty advisors in the Department of Materials Science and Engineering, as well as in the Department of Civil Engineering and Applied Mechanics, at the University of Virginia. Here, we report on progress achieved between July 1 and December 31, 1994. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites and thermal gradient structures in collaboration with NASA-Langley researchers. Specific technical objectives are presented for each research project. We generally aim to produce relevant data and basic understanding of material mechanical response, environmental/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement and modeling advances; and a pool of educated graduate students for aerospace technologies

Evaluation of cavitation erosion resistance of Al-Si casting alloys: effect of eutectic and intermetallic phases

In the present paper, the influence of eutectic and intermetallic phases on cavitation resistance of Al-Si alloys was studied. In fact, Al-Si alloys are commonly used for the production of components, such as cylinders, pistons, pumps, valves and combustion chambers, which in service may incur in cavitation phenomenon. Samples of AlSi3, AlSi9 and AlSi9CuFe were characterized from the microstructural point of view. Hardness measurements were also performed. Subsequently, cavitation tests were carried out according to ASTM G32 standard and the erosion mechanism was examined by scanning electron microscope. It was found the both eutectic and intermetallic phases enhance cavitation resistance, expressed in terms of mass loss. Particularly, intermetallic particles with complex morphologies provide a positive contribution, exceeding that of other microstructural features, as grain size. The effect of T6 heat treatment was also evaluated. It was confirmed that the precipitation of fine strengthening particles in the Al matrix successfully hinders the movement of dislocations, resulting in a longer incubation stage and a lower mass loss for heat-treated samples in comparison with as-cast ones. Finally, the relationship between cavitation resistance and material hardness was investigated

Nanostructured Coating for Aluminum Alloys Used in Aerospace Applications

The authors would like to acknowledge the Estonian Ministry of Education and Research by granting the projects IUT2–24, TLTFY14054T, PSG448, PRG4, SLTFY16134T and by the EU through the European Regional Development Fund under project TK141 (2014-2020.4.01.15-00). The atomic oxygen testing was performed in the framework of the “Announcement of opportunity for atomic oxygen in the ESTEC Materials and Electrical Components Laboratory/ESA-TECQE-AO-013375),” through a collaboration with Picosun Oy. The authors also thank Dr. Elo Kibena-Põldsepp for the electrodeposition of Ag onto the anodized substrates.A thin industrial corrosion-protection nanostructured coating for the Al alloy AA2024-T3 is demonstrated. The coating is prepared in a two-step process utilizing hard anodizing as a pre-treatment, followed by sealing and coating by atomic layer deposition (ALD). In the first step, anodizing in sulfuric acid at a low temperature converts the alloy surface into a low-porosity anodic oxide. In the second step, the pores are sealed and coated by low-temperature ALD using different metal oxides. The resulting nanostructured ceramic coatings are thoroughly characterized by cross-sectioning using a focused ion beam, followed by scanning electron microscopy, transmission electron microscopy, X-ray microanalysis, and nanoindentation and are tested via linear sweep voltammetry, electrochemical impedance spectroscopy, salt spray, and energetic atomic oxygen flow. The best thin corrosion protection coating, made by anodizing at 20 V, 1 °C and sealing and coating with amorphous Al2O3/TiO2 nanolaminate, exhibits no signs of corrosion after a 1000 h ISO 9227 salt spray test and demonstrates a maximum surface hardness of 5.5 GPa. The same coating also suffers negligible damage in an atomic oxygen test, which is comparable to 1 year of exposure to space in low Earth orbit. © 2022 The Author(s). Published on behalf of The Electrochemical Society by IOP Publishing Limited.Estonian Ministry of Education and Research by granting the projects IUT2–24, TLTFY14054T, PSG448, PRG4, SLTFY16134T; ERDF TK141 (2014-2020.4.01.15-00); Institute of Solid State Physics, University of Latvia as the Center of Excellence acknowledges funding from the European Union’s Horizon 2020 Framework Programme H2020- WIDESPREAD-01-2016-2017-TeamingPhase2 under grant agreement No. 739508, project CAMART2

Investigation on Fatigue Behavior of Alloys by Various Approaches

abstract: Fatigue is a degradation process of materials that would lead to failure when materials are subjected to cyclic loadings. During past centuries, various of approaches have been proposed and utilized to help researchers understand the underlying theories of fatigue behavior of materials, as well as design engineering structures so that catastrophic disasters that arise from fatigue failure could be avoided. The stress-life approach is the most classical way that academia applies to analyze fatigue data, which correlates the fatigue lifetime with stress amplitudes during cyclic loadings. Fracture mechanics approach is another well-established way, by which people regard the cyclic stress intensity factor as the driving force during fatigue crack nucleation and propagation, and numerous models (such as the well-known Paris’ law) are developed by researchers. The significant drawback of currently widely-used fatigue analysis approaches, nevertheless, is that they are all cycle-based, limiting researchers from digging into sub-cycle regime and acquiring real-time fatigue behavior data. The missing of such data further impedes academia from validating hypotheses that are related to real-time observations of fatigue crack nucleation and growth, thus the existence of various phenomena, such as crack closure, remains controversial. In this thesis, both classical stress-life approach and fracture-mechanics-based approach are utilized to study the fatigue behavior of alloys. Distinctive material characterization instruments are harnessed to help collect and interpret key data during fatigue crack growth. Specifically, an investigation on the sub-cycle fatigue crack growth behavior is enabled by in-situ SEM mechanical testing, and a non-uniform growth mechanism within one loading cycle is confirmed by direct observation as well as image interpretation. Predictions based on proposed experimental procedure and observations show good match with cycle-based data from references, which indicates the credibility of proposed methodology and model, as well as their capability of being applied to a wide range of materials.Dissertation/ThesisMasters Thesis Materials Science and Engineering 201

Fatigue and Fracture of Traditional and Advanced Structural Alloys

The fatigue behavior of traditional and advanced materials is a very relevant topic in different strategic applications impacting and affecting our daily lives. The present Special Issue invites papers to update readers on the state of the art on this important topic. Both review and original manuscripts are welcome. Special attention will be dedicated to innovative materials and innovative manufacturing processes or post-treatments able to improve the fatigue life and reliability of a structural component. Scale effect will be also fully treated focusing on different applications and multiscale approaches aimed at understanding structural integrity under cyclic loadings. This state of the art perspective will help engineers, designers and people from the academy gain an updated view on this very challenging topic which is nowadays very important due to the advances in manufacturing technologies that allow complex new materials to be fabricated

Modelling Polycrystalline Materials: An Overview of Three-Dimensional Grain-Scale Mechanical Models

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