Search Results (44)

Steel structures exposed to estuarine regions near the sea are susceptible to high-velocity and sediment-laden flows induced by runoff and tides, as well as storm surges, leading to significant erosion. This erosion causes defects in the protective coatings on steel surfaces, resulting in the accelerated corrosion of their components. However, damage to the protective coating of steel components is a relatively long process and is not easy to monitor in real time. This paper conducts an accelerated deterioration test of protective coatings under water and sediment erosion to explore the damage laws of the protective coatings of steel components under different test conditions. This study reveals that the adhesion of the protective coating decreased rapidly initially and then slowly with prolonged erosion time. In the early stage of erosion, scratches and pits are easily formed on the coating surface, while the damage tends to be uniform in the later stage. The damage characteristic values and damage rate of the protective coating were obtained based on the image recognition method. The characteristic value of scratch lengths ranged from 5 to 25 mm, and for pit diameters, they ranged from 1 to 4 mm. The maximum damage rate was 9.8%, and the damage rate showed a trend that approximately followed a logarithmic function with erosion time. It was also found that the sediment concentration had the greatest influence on the damage rate, followed by the erosion velocity, and the erosion angle had the least influence. Additionally, the relationships between adhesion and damage rate, as well as the relationship between adhesion and erosion depth, were established. It was found that the mean erosion depth exhibits a linear functional relationship with the damage rate, while adhesion exhibits a logarithmic functional relationship with both the damage rate and the erosion depth. The empirical formula proposed can provide a theoretical basis for quantitatively describing the surface defect conditions of the coating. Full article

Enhancing the strength and toughness of aluminum alloys using microstructure optimization remains a key challenge. In this study, an AA2024 aluminum alloy with a double-layer multi-gradient structure was fabricated using 50% constrained deformation and single-stage peak aging at 150 °C. Microstructural and compositional analysis was performed using SEM, XRD, and TEM to investigate grain structures, dislocation density, and the distribution of precipitated phases. The results revealed a heterogeneous microstructure with variations in grain size, dislocation gradient, and precipitation phases between the constrained and deformation layers. Mechanical testing demonstrated a 30.9% increase in yield strength, a 16.4% increase in tensile strength, and a 13.9% improvement in uniform elongation compared to the T6 temper. Corrosion tests showed enhanced resistance, with a shallower intergranular corrosion depth and higher self-corrosion potential. The improved mechanical properties were attributed to the dislocation gradient and heterogeneous precipitation phases, while the enhanced corrosion resistance resulted from the transformation of the S phase from a continuous grain boundary distribution to a discontinuous distribution along dislocations. This study provides a novel approach for optimizing the mechanical and corrosion properties of AA2024 aluminum alloy using microstructure design and precise thermal–mechanical treatment. Full article

The grain boundary diffusion process employing a mixed diffusion source, comprising heavy rare-earth elements and low-melting metals, significantly enhances the coercivity (H_cj) of sintered Nd-Fe-B magnets. In the present study, Tb and Ga were deposited onto the surface of Nd-Fe-B magnets to serve as a diffusion source for improving hard magnetic properties. The effects of varying deposition sequences of Tb and Ga on the magnetic properties and microstructure of the magnets were analyzed. The findings demonstrate that TbF₃ grain boundary diffusion facilitated by Ga effectively increases the efficiency of Tb substitution, leading to enhanced coercivity. When Tb and Ga are deposited simultaneously, coercivity shows a notable improvement of 53.15% compared to the untreated magnet, with no reduction in remanence. Additionally, thermal stability is enhanced, resulting in superior overall magnetic properties. Microstructural analysis reveals that Ga promotes the diffusion of Tb into the magnet. In the magnet where Tb and Ga are co-deposited, the formation of a thinner and more uniform (Nd,Tb)₂Fe₁₄B shell–core structure, along with the greater infiltration depth of Tb, leads to a broader distribution of core–shell structures within the magnet. This effectively increases the anisotropy fields (H_A) of the main phase grains, preventing the nucleation of antiferromagnetic domains at the edges of main-phase grains, thereby enhancing coercivity. Furthermore, the corrosion resistance of the magnet subjected to mixed diffusion is improved. This study provides a foundation for producing highly efficient magnets with a lower content of heavy rare-earth elements. The simplicity and flexibility of the process make it highly suitable for industrial applications. Full article

Aluminum and its alloys are widely used in the busbar structures of electrolytic aluminum production. However, they are prone to corrosion and wear damage during use, leading to a decline in current-transmission efficiency and potentially causing safety issues. To repair damaged aluminum busbars, this paper explores the feasibility of using cold spraying technology for surface restoration. Using 6063 aluminum alloy as the substrate, AlZn/nickel-plated graphite composite coatings were applied through cold spraying. The effects of different nickel-plated graphite contents on the microstructure, mechanical properties, and corrosion resistance of the coatings were studied. Annealing treatments (200 °C, 300 °C, 400 °C) were further used to improve the coating’s density and performance. The results show that with an increase in the nickel-plated graphite content, the porosity of the coating gradually increases, while the coating’s density and bond strength improve. Additionally, the annealing treatment significantly enhanced the uniformity and hardness of the coating. Moreover, the cold-sprayed coatings exhibited excellent corrosion resistance, especially in the annealed coatings, which showed superior microstructural stability and lower corrosion current density. This study provides a new technological approach for the repair of aluminum busbars and offers an in-depth discussion on the application of cold spraying technology in the surface restoration of aluminum-based composite materials. Full article

CO₂ injection composite fracturing is an effective method for shale oil and gas well development. The downhole casing is prone to uniform corrosion, pitting, perforation, and even corrosion fracture in the CO₂ environment. Therefore, it is particularly important to reveal the physical characteristics of CO₂ under actual geological conditions and the impact of CO₂ corrosion on the performance of casing. A mathematical model for the temperature and pressure field of CO₂ in the wellbore under fracturing conditions is established in this paper, and the temperature and pressure distribution along the depth of the well is calculated. By optimizing the CO₂ state equation and using the S-W equation, Lee model, and RK model to calculate the CO₂ density, viscosity and compression factor, respectively, the phase distribution pattern of CO₂ along the actual wellbore is obtained. Through CO₂ corrosion tests on the casing, the influence of temperature and CO₂ concentration on the corrosion rate of the casing is clarified. The peak corrosion rate of Q125 steel corresponds to 80 °C, and the corrosion rate increases with the increase in CO₂ concentration. Finally, a prediction model for the uniform corrosion rate of casing under different temperatures and CO₂ concentration conditions is obtained, which can provide technical support for the design of CO₂-enhanced fracturing technology. Full article

Difficult-to-cut titanium matrix composites (TiB+TiC)/Ti6Al4V have extensive application prospects in the fields of biomedical and aerospace metal microcomponents due to their excellent mechanical properties. Jet electrochemical micromilling (JEMM) technology is an ideal method for machining microstructures that leverages the principle of electrochemical anodic dissolution. However, the matrix Ti6Al4V is susceptible to passivation during electrochemical milling, and the inclusion of high-strength TiB whiskers and TiC particles as reinforcing phases further increases the machining difficulty of (TiB+TiC)/Ti6Al4V. In this study, a novel approach using NaCl+NaNO₃ mixed electrolyte for the JEMM of (TiB+TiC)/Ti6Al4V was adopted. Electrochemical behaviors were measured in NaCl and NaCl+NaNO₃ electrolytes. In the mixed electrolyte, a higher transpassive potential was required to break down the passive film, which led to better corrosion resistance of (TiB+TiC)/Ti6Al4V, and the exposed reinforcing phases on the dissolved surface were significantly reduced. The results of the JEMM machining indicate that, compared to NaCl electrolyte, using mixed electrolyte effectively mitigates stray corrosion at the edges of micro-grooves and markedly improves the uniformity of both groove depth and width dimensions. Additionally, the surface quality was noticeably improved, with a reduction in Ra from 2.84 μm to 1.03 μm and in Rq from 3.41 μm to 1.40 μm. Full article

This study investigates the influence of pre-corrosion damage on the fatigue behavior of AlSi10MgMn high-pressure die-cast specimens, using the statistical distribution of corrosion depths. The analysis is conducted on two different surface conditions: an unmachined rough surface ($R_a=5.05$$\mathsf{\mu }\mathrm{m}$) and a machined, polished surface ($R_a=0.25$$\mathsf{\mu }\mathrm{m}$). For the unmachined specimens, the corrosive damage manifests as homogeneously spread localized corrosion, whereas the polished specimens exhibit less uniform but deeper corrosion. The average corrosion depth of the polished specimens is found to be slightly higher (313 $\mathsf{\mu }\mathrm{m}$ compared to 267 $\mathsf{\mu }\mathrm{m}$) with a broader depth distribution. Specimens are tested under a constant bending load amplitude in laboratory conditions at a stress ratio of $R=0$ until fracture. A fracture mechanics-based methodology is developed to assess the remaining fatigue life of corroded specimens, utilizing short and long crack fracture mechanical parameters derived from SENB specimens. This model incorporates a thickness reduction of the critical specimen cross-section based on the corrosion depth distribution and combines it with a small initial crack of the intrinsic defect size ($a_{eff}=14$$\mathsf{\mu }\mathrm{m}$). Regardless of the surface condition, using the most frequent corrosion depth for thickness reduction provides a good estimate of the long-life fatigue strength, while using the 90th percentile depth allows for a conservative assessment. Full article

Titanium and titanium alloys with a medium thickness of 5 to 12 mm are widely used for ocean platforms, military equipment and in other fields because of their light weight, appropriate strength and corrosion resistance. In this study, autogenous laser welding and narrow-gap laser welding processes were researched and compared, and the welding characteristics, weld microstructure and joint strength were analyzed. The results showed that autogenous laser welding had higher efficiency, narrower weld width and higher microstructure uniformity. Autogenous laser welding can achieve the single pass weld penetration at laser keyhole mode. The weld width of narrow-gap laser welded joint was 12.5 mm, which was nearly three times than that of autogenous laser welding. The grain size of autogenous laser welding was obviously smaller and more uniform in depth than that of narrow-gap laser welding. In the weld zone, the coarse columnar α grains grew from the fusion line, while in the heat-affected zone, equiaxed α grains with needle and sawtooth α morphologies were presented. The microhardness of the heat-affected zone was higher than in the weld zone and the base metal due to the denser needle microstructure. The tensile samples all fractured at the base metal, indicating the welded joint strength efficiency was greater than 1. Full article

To cope with harsh working conditions, new corrosion-resistant coated steel wires with higher tensile strength have been developed. This study investigates the corrosion characteristics of a new zinc–aluminum alloy-coated steel wire under stress conditions. The particulate corrosion products generated by the oxidation of the coating in the initial stage of corrosion are converted into layer-structured corrosion products at the early stage of corrosion. Moreover, high-stress conditions have a significant influence on the critical conversion time from the coating corrosion stage to the iron matrix corrosion stage. Thus, the uniform corrosion depth (i.e., the mass loss rate) could be fitted with a continuous power function model rather than the previously used two-stage model owing to an ambiguous moment of conversion under stress conditions. The pitting corrosion depth could be fitted with a lognormal distribution in this study. The probability distributions for the aspect ratios of corrosion pits under different stress conditions tended to be consistent. Finally, the block’s maximum pitting factor followed a Gumbel distribution with a scale parameter that changed linearly with the stress level and a location parameter related to the square of the stress level. Full article

This paper address the performance optimization of the battery heat sink module by analyzing the lattice structure of the battery heat sink module through in-depth modeling and simulation, and combining the laser powder bed fusion (LPBF)-forming technology with mechanical and corrosion resistance experiments for a comprehensive study. It is found that the introduction of the lattice skeleton significantly improves the thermal conductivity of the phase change material (PCM), realizing the efficient distribution and fast transfer of heat in the system. At the same time, the lattice skeleton makes the heat distribution in the heat exchanger more uniform, improves the utilization rate of the PCM, and helps to maintain the stability of the cell temperature. In addition, the melting of PCM in the lattice heat exchanger is more uniform, thus maximizing its latent heat capacity. In summary, by optimizing the lattice structure and introducing the lattice skeleton, this study successfully improves the performance of the battery heat dissipation system, which provides a strong guarantee for the high efficiency and stable operation of the battery, and provides new ideas and references for the development of the battery heat dissipation technology. Full article

The study aims to investigate the impact of uniform, grooving and non-uniform corrosion degradation on the hot-spot stresses of a T-shaped tubular joint using the finite element method. The through-thickness linearization method is employed to estimate the hot-spot stresses, allowing a more reasonable consideration of the effect of grooving corrosion and non-unform corrosion. The grooving corrosion degradation is modelled assuming that the corrosion rate of the weld metal is 1.4 times that of the base metal. The non-uniform corrosion is modelled by moving the nodes around the weld by a random distance along the direction perpendicular to the surface. The random distances are generated based on the surface roughness parameter Ra. The results indicate that the stress concentration factor (SCF) increases with the uniform corrosion depth. The grooving corroded tubular joint results in a higher SCF than those of the corresponding uniformly corroded tubular joint. The non-uniform corrosion can lead to SCF deviations from the SCF of the uniformly corroded tubular joint. The SCF deviation at the critical region follows the normal distribution, and its standard deviation increases with Ra. Full article

Titanium has a low density and high corrosion resistance. In order to achieve the goal of a lightweight material, and to extend the normal working hour of proton-exchange membrane fuel cells (PEMFCs), ultra-thin titanium plates were chosen to manufacture the key components—bipolar plates (BPs). For the purpose of overcoming the challenges of manufacturing with a large depth to width ratio, a multi-stage formation process was established with characteristics such as high efficiency and a lower price. In this study, the process parameters were examined through an experimental approach. The outcomes show that the channel formed by multistage forming is deeper than that formed by single-stage forming under the same displacement conditions. To achieve greater flow depths, it is recommended to increase the displacements as much as possible during both the first- and second-stage forming processes. The implementation of three-stage forming can effectively reduce the maximum thinning rates within flow channels while improving the overall deformation uniformity. This method deviates from traditional one-stage loading processes by adopting multi-stage loading instead. By employing appropriate mold designs, material deformation and flow can be enhanced throughout gradual loading processes, thereby preventing strain concentration and enhancing the ultimate formation height accuracy within micro-flow channels. Consequently, the proposed three-stage forming process proves highly appropriate for the mass production of BPs utilizing titanium plates. Full article

316 L stainless steel is an ideal bipolar plate material for a proton exchange membrane fuel cell (PEMFC). However, the thickening of the passivation film on the stainless steel surface and the dissolution of corrosive ions during operation will affect the durability of the PEMFC. Herein, a heterogeneous layer is prepared on the surface of 316 L stainless steel through dual ion implantation of molybdenum ion and carbon ion combined with heat treatment to promote the corrosion resistance and conductivity of the bipolar plate. The ion implantation technique resulted in a uniform distribution of Mo and C elements on the surface of 316 L stainless steel, with a modified layer depth of about 70–80 nm. The electrical conductivity of the ion implanted samples was significantly improved, and the interfacial contact resistance was reduced from 464.25 mΩ × cm² to 42.49 mΩ × cm². Heat treatment enhances the surface homogenization, repairs the defects of irradiation damage, and improves the corrosion resistance of stainless steel. The corrosion current density of (Mo+C)-600 samples decreased from 1.21 × 10⁻⁸ A/cm² to 2.95 × 10⁻⁹ A/cm² under the long-term corrosion condition of 4 h. These results can provide guidance for the modification of stainless steel bipolar plates. Full article

3003 aluminum alloy exhibits commendable corrosion resistance, ease of processing, and good formability, rendering it extensively utilized across many industrial sectors. In this study, the corrosion behavior of 3003 aluminum alloy in a homogenized state and after hot extrusion deformation in an acidic salt spray environment for different times was studied. The microstructure of the 3003 aluminum alloy in the homogenized state and after hot extrusion was characterized using scanning electron microscopy (SEM), optical microscope (OM), laser scanning confocal microscope (LSCM) etc., while electrochemical methods were employed to study the difference in corrosion resistance between these two states. The results show that corrosion pits on the surface of the homogenized 3003 aluminum alloy increase with time, and corrosion extends along the second phase arrangement, while the hot extruded 3003 aluminum alloy mainly exhibits corrosion pit extension. The grain size of the homogenized 3003 aluminum alloy is larger than that of the hot extruded state, and the second phase is distributed in a reticular pattern. Hot extrusion deformation ensures not only a uniform distribution of the second phase in the 3003 aluminum alloy but also a reduced grain size, an increased grain boundary density, a heightened electrochemical activity in acidic environments, and an augmented pitting density. Compared with the homogenized 3003 aluminum alloy, the pitting density, maximum pitting depth, and weight loss of the hot extruded state are increased. Full article

Titanium alloys are widely used in aerospace and biomedicine because of their excellent mechanical characteristics, but these properties also make such alloys difficult to cut. Jet electrochemical micromilling (JEMM) is based on the principle of electrochemical anodic dissolution; it has some inherent advantages for the machining of titanium alloy microstructures. However, titanium oxidizes readily, forming an oxide film that impedes a uniform dissolution during electrochemical machining. Therefore, a high voltage and an aqueous NaCl electrolyte are usually used to break the oxide film, which can lead to severe stray corrosion. To overcome this problem, the present study investigated the JEMM of Ti-6Al-4V using a NaCl–ethylene glycol (NaCl-EG) electrolyte. Electrochemical testing showed that Ti-6Al-4V exhibits a better corrosion resistance in the NaCl-EG electrolyte compared to the aqueous NaCl electrolyte, thereby reducing stray corrosion. The localization and surface quality of the grooves were enhanced significantly when using JEMM with a NaCl-EG electrolyte. A multiple-pass strategy was adopted during JEMM to improve the aspect ratio, and the effects of the feed depth and number of passes on the multiple-pass machining performance were investigated. Ultimately, a square annular microstructure with a high geometric dimensional consistency and a smooth surface was obtained via JEMM with multiple passes using the optimal parameters. Full article