Search Results (57)

The fatigue performance of a recently developed nickel superalloy disc was investigated at 700 °C in two environments: air and sulphur dioxide (SO₂). Prior to testing, specimens were coated with various amounts of sodium sulphate (Na₂SO₄) and sodium chloride (NaCl) mixed salt (98% Na₂SO₄ + 2% NaCl), and the influence of both environment and salt loading on corrosion fatigue were assessed. Preliminary results showed that salt exposure in air reduced fatigue strength, with greater damage at higher salt levels. In the SO₂ environment, fatigue strength dropped even more due to low-temperature hot corrosion (LTHC). The details of the corrosion morphology formed in both air and SO₂ environments are discussed. Full article

Graphene is considered one of the most promising flexible transparent electrode materials as it has high charge carrier mobility, high electrical conductivity, low optical absorption, excellent mechanical strength, and good bendability. However, graphene-based flexible transparent electrodes face a critical challenge in balancing electrical conductivity and optical transmittance. Here, we present a green and scalable direct ink writing (DIW) strategy to fabricate graphene grid patterns by optimizing ink formulation with sodium dodecyl sulfate (SDS) and ethanol. SDS eliminates the coffee ring effect via Marangoni flow, while ethanol enhances graphene flake alignment during hot-pressing, achieving a high conductivity of 5.22 × 10⁵ S m⁻¹. The grid-patterned graphene-based flexible transparent electrodes exhibit a low sheet resistance of 21.3 Ω/sq with 68.5% transmittance as well as a high stability in high-temperature and corrosive environments, surpassing most metal/graphene composites. This method avoids toxic solvents and high-temperature treatments, demonstrating excellent stability in harsh environments. Full article

High-entropy alloys are known for their promising mechanical properties, wear and corrosion resistance, which are maintained across a wide range of temperatures. In this study, a CoCrFeNiCu-based high-entropy alloy, distinguished from conventional CoCrFeNi systems by the addition of Cu, which is known to enhance toughness and wear resistance, was investigated to better understand the effects of compositional modification on processability and performance. The influence of key process parameters, specifically laser power and scan speed, on the processability of CoCrFeNiCu-based high-entropy alloys produced by laser powder bed fusion additive manufacturing was investigated, with a focus of low laser power, which is critical for minimizing defects and improving the resulting microstructure and mechanical performance. The printed sample density gradually increases with higher volumetric energy density, achieving densities exceeding 99.0%. However, at higher energy densities, the samples exhibit susceptibility to hot cracking, an issue that cannot be mitigated by adjusting the process parameters. Mechanical properties under optimized parameters were further evaluated using Charpy impact and (in situ) tensile tests. These evaluations were supplemented by in situ tensile experiments conducted within a scanning electron microscope to gain insights into the behavior of defects, such as hot cracks, during tensile testing. Despite the sensitivity to hot cracking, the samples exhibited a respectable ultimate tensile strength of 662 MPa, comparable to fine-grained steels like S500MC (070XLK). These findings underscore the potential of CoCrFeNiCu-based high-entropy alloys for advanced applications. However, they also highlight the necessity for developing strategies to ensure stable and reliable processing methods that can mitigate the susceptibility to hot cracking. Full article

316L stainless steel is widely employed in various industrial sectors, including shipbuilding, offshore plants, high-temperature/high-pressure (HTHP) piping systems, and hydrogen infrastructure, due to its excellent mechanical stability, superior corrosion resistance, and robust resistance to hydrogen embrittlement. This study presents 316L stainless steel alloys fabricated via hot isostatic pressing (HIP), conducted at 1300 °C and 100 MPa for 2 h, incorporating Cr₂N powder and an optimized Ni/Mn ratio based on the nickel equivalent (Ni_eq). During HIP, Cr₂N decomposition yielded a uniformly refined, dense austenitic microstructure, with enhanced corrosion resistance and mechanical performance. Corrosion resistance was evaluated by potentiodynamic polarization in 3.5 wt.% NaCl after 1 h of OCP stabilization, using a scan range of −0.25 V to +1.5 V (Ag/AgCl) at 1 mV/s. Optimization of the Ni/Mn ratio effectively improved the pitting corrosion resistance and mechanical strength. It is cost-effective to partially substitute Ni with Mn. Of the various alloys, C13Ni-N exhibited significantly enhanced hardness (~30% increase from 158.3 to 206.2 HV) attributable to nitrogen-induced solid solution strengthening. E11Ni-HM exhibited the highest pitting corrosion resistance given the superior PREN value (31.36). In summary, the incorporation of Cr₂N and adjustment of the Ni/Mn ratio effectively improved the performance of 316L stainless steel alloys. Notably, alloy E11Ni-HM demonstrated a low corrosion current density of 0.131 μA/cm², indicating superior corrosion resistance. These findings offer valuable insights for developing cost-efficient, mechanically robust corrosion-resistant materials for hydrogen-related applications. Further research will evaluate alloy resistance to hydrogen embrittlement and investigate long-term material stability. Full article

The combustion behavior and thermal performance of industrial-scale borax pentahydrate (Na₂B₄O₇·5H₂O) melting furnaces remain underexplored despite their critical role in boric oxide (B₂O₃) production, a key input for high-performance manufacturing. This study addressed this gap by employing three-dimensional computational fluid dynamics (CFD) simulations to model two operational natural gas-fired furnaces with distinct burner configurations (four-burner and six-burner systems). The analysis focused on optimizing burner placement, specifically, the axial distance and inclination angle, to enhance thermal uniformity and reduce refractory wall damage caused by aggressive high-temperature borate corrosion. A comprehensive parametric study of twelve burner configurations revealed that tilting the burners at 5–10° significantly improved temperature uniformity while reducing peak wall temperatures and mitigating localized hot spots. The optimal design, incorporating a 10° burner angle and a staggered burner arrangement (Case 11), attained a melt pool temperature of 1831.3 K and a charging average wall temperature of 1812.0 K. These values represent essential benchmarks for maximizing furnace efficiency and operational stability. The modified designs for the four- and six-burner systems led to improved temperature distributions and a notable reduction in maximum wall temperatures, directly contributing to longer maintenance intervals and improved refractory durability. The findings of this study confirm that minor geometrical and angular adjustments in burner placement can yield significant performance gains. The validated CFD approach and proposed design modifications offer a scalable, low-cost strategy for improving combustion efficiency and furnace lifespan in borax processing facilities. Full article

Ni-based superalloys with enhanced environmental resistance at high temperatures are crucial for advanced gas turbine engines. The new polycrystalline nickel-based superalloy has excellent mechanical properties, but as a low-Cr, high-alloying superalloy, its environmental resistance has never been investigated. The hot corrosion behavior of the nickel-based superalloy under molten salt conditions and its effect on its tensile properties were investigated in this paper. The results showed the following: The diffusion of the Cr, Al, and Ni elements governs the majority of the corrosion process, resulting in the production of an environmentally damaged organization with internal sulfidation and surface oxidation. The Wagner model predicts the inability to form a dense Al oxide scale on the surface because the crucial generation condition of external Al oxides is not met. In addition, the growth stress in the damage scales is the main cause of cracking and spalling in the isothermal corrosion process. Due to the increased local stress concentration brought on by this environmental degradation, the sulfide scale acts as a fracture source, guiding the matrix cracking and influencing the tensile properties of the alloy. Full article

Rare-earth tantalates (RETaO₄) are considered as a type of emerging thermal barrier coating materials applied to the hot components of gas turbines and aerospace engines due to their excellent thermal stability, high-temperature fracture toughness, corrosion resistance and extremely low thermal conductivity. However, the relatively low hardness and thermal expansion coefficients may limit their service lifetime in a harsh engine environment. To address the current limitation of rare-earth tantalates and further optimize the mechanical and thermal properties, the defective fluorite-structured Y₂Zr₂O₇ (YZ) was introduced as a second phase into the YTaO₄ (YT) matrix to form YT_1−x–YZ_x (x = 0, 0.25, 0.5, 0.75, 1) composite ceramics in this work. The mechanical and thermal properties of YT_1−x–YZ_x composite ceramics are significantly improved compared to pure-phase YTaO₄ ceramics. The Vickers hardness of YT_1−x–YZ_x (x = 0.25, 0.5, 0.75) composite ceramics is 9.1~11.3 GPa, which are 2~2.5 times higher than that of YTaO₄ (4.5 GPa). Among them, YT_0.75–YZ_0.25 exhibits a maximum fracture toughness (3.7 ± 0.5 MPa·m^1/2), achieving a 23% improvement compared to YTaO₄ (3.0 ± 0.23 MPa·m^1/2) and a 118% improvement compared to Y₂Zr₂O₇ (1.73 ± 0.28 MPa·m^1/2). The enhancement is attributed to the combined effect of the intrinsic strengthening of the second phase, as well as the residual stress and grain refinement caused by the introduction of a second phase. Additionally, the thermal expansion coefficients of YT_1−x–YZ_x composite ceramics at 1673 K range from 10.3 × 10⁻⁶ K⁻¹ to 11.0 × 10⁻⁶ K⁻¹, which is also higher than that of YTaO₄ (10.0 × 10⁻⁶ K⁻¹). Consequently, the superior mechanical and thermal properties indicate that YT–YZ composite ceramics possess promising application prospects for thermal barrier coatings. Full article

In the Czochralski single-crystal silicon manufacturing industry, single-crystal furnaces often experience corrosion from silicon vapor, which reduces their operational lifespan. However, the preparation of metal coatings on the surface of C/C composites is challenging due to their low coefficient of thermal expansion and the intricate structure of carbon fibers. To address this issue and achieve high-quality alloy coatings, Ni-Al and Ni-Al/Si composite coatings are successfully prepared on the surface of C/C composites through a combination of electroplating and hot-dip plating, and their oxidation behavior at elevated temperatures is thoroughly investigated. The experimental results indicate that the Ni-Al composite coatings exhibit superior antioxidant properties compared to Ni coatings following thermal shock experiments, thereby significantly enhancing the antioxidant performance of C/C composites. This improvement is attributed to the preferential oxidation of surface aluminum, which forms a dense Al₂O₃ layer in aerobic and high-temperature environments, effectively preventing oxygen from reaching the underlying matrix. During the oxidation process, coating elements migrate outward along the concentration gradient, while oxygen molecules diffuse inward. Simultaneously, aluminum atoms diffuse inward, and Ni atoms diffuse outward, where they partially dissolve with oxygen. The inner coating’s Ni enhances the bonding of the coating by connecting the substrate to the outer layer. Meanwhile, the added Si in the Ni-Al/Si composite coating further improves the antioxidant properties of the coating. Full article

The effect of hot rolling on the microstructure, mechanical, and corrosion properties of the magnesium alloy 96 wt% Mg–2.3 wt% Zn–0.7 wt% Ca–1 wt% Mn was studied. After heat treatment, the original plates of an as-cast alloy were rolled from a 7 mm thickness to a 0.2 mm thickness at two temperatures—300 or 400 °C. It has been established that increasing the rolling temperature from 300 to 400 °C increases the fraction of recrystallized grains in the microstructure and after rolling at 400 °C, the microstructure is fully recrystallized. The best strength–ductility balance of the alloy was obtained after rolling at 300 °C, with a high total percentage reduction of 93–97%: the yield stress, the ultimate tensile strength, and the elongation averaged at 285 MPa, 310 MPa, and 5%, respectively. The alloy after rolling, annealed at 400 °C, shows improved ductility but lower strength: the yield stress, the ultimate tensile strength, and the elongation were 200 MPa, 260 MPa, and 17%, respectively. The strong dependence of corrosion resistance on respect to rolling direction is observed, which can be reduced after heat treatment. The as-rolled alloy and the heat-treated alloy had low corrosion rates in Hanks’ solution of 0.54 and 0.19 mm/year, respectively. Full article

In this study, low Mn content Fe-Mn-Si-based shape memory alloys [Fe-(17-2x) Mn-6Si-xNi-yCr-0.3C (x = 0, 1, 2, 3, 4; y = 0, 1, 3, 5)] were prepared via vacuum arc remelting. The alloys were hot-rolled and solid-solution-treated at 1150 °C for 1 h followed by aging at elevated temperatures. The effects of Cr and Ni addition on the shape memory performance and corrosion resistance of the alloys in 3.5 wt% NaCl solutions were investigated using bending test and potentiodynamic polarization, respectively. It was revealed that the recoverable strain of the alloys remains larger than 2% when 1Ni is replaced with 2Mn and Cr is added. However, it becomes less than 2% in 11Mn and 9Mn alloys because of the easy formation of the α’ martensite. The shape memory effect of alloys is highly improved due to the precipitation of fine carbides in the grains by the addition of Cr and after aging treatment at elevated temperatures (≧700 °C). The highest shape recovery ratios of 88.3% for 17Mn0Ni3Cr, 94.0% for 15Mn1Ni3Cr, 94.4% for 13Mn2Ni5Cr, 88.1% for 11Mn3Ni5Cr, and 86.8% for 9Mn4Ni7Cr, respectively, were achieved after 800 °C aging treatment. The strip-like second phase (carbides) forms at the grain boundaries in the Cr-free alloys after 600 °C aging treatment. There are lots of fine carbides (M23C6 and M7C3) precipitated in the interior of the grains at the aging treatments ≧ 700 °C. However, M7C3 is eliminated at 900 °C aging treatment. The corrosion resistance results showed that the corrosion resistance of the alloys is improved by adding Cr. The maximum corrosion potentials (−0.474 V) have been observed for 13Mn2Ni5Cr, and similar mechanisms have been analyzed in all series of alloys. Full article

In this investigation, the effects of different annealing temperatures (180, 200, 220, 240, 260, and 280 °C) on the microstructure evolution and properties of an extruded Mg–2.0Zn–1.0Y–0.5Zr (wt%) magnesium alloys were determined. Optical microscopy (OM), scanning electron microscopy (SEM), immersion corrosion, electrochemical corrosion experiments, and tensile testing were performed. Research has found that combining hot extrusion with subsequent low-temperature annealing significantly improves the strength, plasticity, and corrosion resistance of alloys due to grain refinement and a reduced dislocation density. The alloy was completely recrystallized at an annealing temperature of 240 °C for 4 h after solid solution extrusion, and the grains were fine and uniform, demonstrating the best comprehensive properties. Its corrosion rate, ultimate tensile strength, yield strength, and elongation were 0.454 ± 0.023 mm/y, 346.7 ± 8.9 MPa, 292.4 ± 6.9 MPa, and 19.0 ± 0.4%, respectively. The corrosion mechanism of the specimens under extruded and annealed conditions was analyzed. After annealing at 240 °C for 4 h, the dislocation and bimodal grain structure of the samples were almost eliminated, resulting in uniform and fine grains, which were conducive to the formation of a more uniform and denser oxide film, thus improving the corrosion resistance of the alloy. Full article

Bamboo is a fast-growing plant with properties such as low cost, abundant resources, and good carbon sequestration effect. However, the swift growth of bamboo resources generates an immense quantity of processing waste, which is necessary to effectively utilize bamboo processing waste. The leftovers from bamboo processing can be reutilized by fast pyrolysis to prepare renewable bio-oil. In this study, bamboo bio-oil was partially substituted for phenol to synthesize phenolic resin with different substitution rates under the action of an alkaline catalyst, and then to serve as the adhesive to produce bamboo scrimber. Bamboo bundles were impregnated with synthetic bio-oil phenolic resin to create bamboo scrimber, which was subsequently hot-pressed. The research shows that modified phenolic resins with a bio-oil substitution rate of under 30% have good physical and chemical properties, while the free aldehyde content of phenolic resin with 40% bio-oil substitution exceeds the limit value (0.3%) specified in the Chinese National Standard. The thermal stability of phenolic resins was also increased after bio-oil modification, indicated by the movement of the TG curve to higher temperature ranges. It was found that the bamboo scrimber prepared with 20% BPF resin adhesive had the best comprehensive properties of a good mechanical strength, hydrophobicity, and mildew resistance, particularly with an elastic modulus of 9269 MPa and a static bending strength of 143 MPa. The microscopic morphology showed that the BPF resin was well impregnated into the interior of the bamboo bundle and had a compact bonding structure within the bamboo scrimber. The anti-mold performance experiment found that the bio-oil-modified resin increased the anti-mold level of the bamboo scrimber from slightly corrosion-resistant to strong corrosion-resistant. The conclusions obtained from this study have a good reference value for achieving the comprehensive utilization of bamboo, helping to promote the use of all components, reduce the production cost of bamboo scrimber, and improve its mildew resistance performance. This provides new ideas for the development of low-cost mildew resistant bamboo scrimber novel materials. Full article

This study aims to address the aforementioned challenges, solutions and implementation perspectives with regard to sustainable manufacturing. In this research, the conventional and hot turning of AISI630 hardened stainless steel have been investigated using PVD-(Ti,Al)N/(Al,Cr)₂O₃ coated carbide cutting tools at various feed rates and cutting speeds. The high hardness of AISI630, along with the low thermal conductivity, has made it one of the most difficult-to-cut materials, and consequently, its machining is associated with high tool wear and poor workpiece surface quality. AISI630 stainless steel is used in the manufacture of pressure vessels and components exposed to high-stress and corrosive environments in the oil and gas industries. In the present research work, tool flank wear and crater wear mechanisms have been studied in different cutting conditions as well as different preheating temperatures using SEM microscopy. Experimental results showed that hot turning operation at temperatures up to 300 °C reduces flank wear by 33% and improves machined surface roughness by 23%. In addition, FEM simulation has been developed to predict tool tip temperature and cutting forces during turning processes. Experimental and FEM analysis shows that cutting force reduction at a preheating temperature of 300 °C is one of the reasons that reduces tool wear compared to conventional turning. Moreover, it has been shown that by increasing preheating temperature in hot turning, the hardness of the carbides in the workpiece decreases more than the hardness of the tool substrate and reduces coating materials, consequently reducing cutting tool abrasion wear phenomenon. Full article

The stress corrosion cracking during the operation of the internal combustion hot blast stove was analysed. The computational fluid dynamics and finite element analysis models were established to analyse the temperature, stress and other variables related to the condensation of the water and acids. The corrosion characteristics of condensation of acid and the stress corrosion cracking of the metallic shell of the hot blast stove during the operation were predicted by applying the fluid temperature and mapping it to the solid temperature. The stress corrosion cracking surface mobility mechanism was adopted and modified with a weight concept to consider the effect of the acid condensation and its concentration. The regions that have higher crack propagation rates were analysed. The influence of the increase in the blast temperature on the crack propagation rate was studied with the increase in the blast temperature by 45 K and 90 K from the reference blast temperature. The maximum temperature of the refractory linings was 1847 K in the on-gas period, and the maximum change in the shell temperature was 5.2 K when the blast temperature was increased by 90 K. The maximum crack propagation rate for the reference blast temperature was evaluated as $7.61\times {10}^{-7}$ m/s. The maximum value of the crack propagation rate was increased by 16.7% when the blast temperature increased by 90 K. The conical region was found to have higher crack propagation rates, which means that the conical region should be the region of interest for managing the internal combustion hot blast stoves. Full article

Regenerated magnesia-calcium brick samples with different aluminium oxide (Al₂O₃) contents were prepared using spent magnesia-calcium bricks and fused magnesia as the main raw materials and Al₂O₃ powders as the additive. The phase compositions, microstructures, room temperature, hot flexural strength, and kiln coating adherence of the regenerated samples were investigated. This indicates that the Al₂O₃ content increased, mainly resulting in the content of tetracalcium aluminoferrite (C₄AF) and tricalcium aluminate (C₃A) increasing in the regenerated samples. The bulk density, room temperature flexural strength, and kiln coating adherence all increased, whereas the hot flexural strength and corrosion resistance to cement clinker both deteriorated with an increase in the Al₂O₃ content. This was because, on the one hand, the low melting point phases of C₄AF and C₃A improved the sinterability of the regenerated samples during the burning stage, and on the other hand, they melted or existed in the liquid phase at the experimental temperature, which degraded the hot flexural strength and corrosion resistance but enhanced the kiln coating adherence as the wettability of the liquid phase. The content of Al₂O₃ in the regenerated magnesia-calcium brick should not be higher than 1.1 wt.%, considering its comprehensive performance for cement rotary kiln. Full article