Advanced Materials for Harsh Environments: Session IV
Sponsored by: ACerS Electronics Division
Program Organizers: Navin Manjooran, Solve; Gary Pickrell, Virginia Tech

Wednesday 2:00 PM
October 20, 2021
Room: A223
Location: Greater Columbus Convention Center

Session Chair: Agnieszka Wusatowska-Sarnek, Commonwealth Fusion Systems; Navin Manjooran, Chairman, Solve

2:00 PM
Now On-Demand Only - Passive Wireless Sensors for Real Time Temperature and Corrosion Monitoring of Coal Boiler Components Under Flexible Operation: Brian Jordan¹; Kavin Idhaiam¹; Zachary Lynch¹; Daryl Reynolds¹; Edward Sabolsky¹; ¹WVU
    The work focussed upon the development of wireless high temperature sensors for monitoring the temperature and corrosion of metal components commonly used in coal-fired boilers. The sensor architecture was based on a passive and chipless radio frequency identification (RFID) design in order to eliminate issues with sensor interconnection in the harsh environment. The RFID sensors design included thick film refractory metal and/or electrically conductive components pattered over a base ceramic dielectric layer. These sensors are either directly deposited onto to, or transferred over, common boiler metals, such as stainless steel 347H. Various wireless sensor interrogation methods and signal processing methods were investigated. The high-temperature corrosion behaviour of the stainless steel was characterized up to 1200慢 in high steam conditions, and the corrosion kinetics were correlated to the wireless sensor response over time. Post-mortem microstructural analysis after corrosion testing was completed on the coupons to investigate sensor stability and failure mechanisms.

2:20 PM
Development of High Performance H2 Permeation Barrier Coating with Good Thermal Cycling Resistance: Sumit Bhattacharya¹; Yinbin Miao¹; Nicholas Stauff¹; Taek Kim¹; Abdellatif Yacout¹; ¹Argonne National Laboratory
    We are reporting development of a class of metal/ceramic based multilayer coatings which have successfully demonstrated a significant hydrogen impermeability at high operating temperature (up to 500 oC). These coatings have been manufactured using atomic layer deposition (ALD) and physical vapor deposition (PVD) techniques. This presentation will be highlighting two aspects of the developed barrier coating: (a) thermal cycling stability; and (b) reduction of hydrogen permeation rate. To understand the overall effect from thermal cycling on H2 permeation –five repetitive cycles of heating from 25 蚓 to 500 蚓 – were conducted. Our study focused upon features such as: (a) structural properties of coating materials that included grain structure (columnar or equiaxed) and crystalline or amorphous phases; (b) coating interface (e.g., amorphous/crystalline, amorphous/amorphous, crystalline/crystalline; and metal/ceramic and (c) coating material chemistry (e.g., metal, metal oxides). Additionally, potential application of this coating in high temperature micro nuclear reactors will be discussed.

2:40 PM
Influence of Alkaline Earth Metals on Structure Formation, Mechanical and Special Properties of Aircraft Casting from Magnesium Alloys: Vadim Shalomeev¹; Sergei Sheyko¹; Ievgeniia Chetvertak¹; ¹National University "Zaporizhska Politecnics"
    In this research were studied possibilities and were received the patterns of structure and properties of magnesium alloy improvement through its modifying by alkaline earth metals. The article scrutinizes separate and shared calcium and barium influence on macro and micro structure of system Mg-Al-Zn alloy. It is demonstrated, that alkaline earth metals were part of the complex intermetallic phases located in the grain center and served as additional centers of crystallization. The research provides patterns of separate and shared influence of alkaline earth metals on the casting properties complex from magnesium alloy. It is demonstrated that complex modifying (0,1 % Са + 0,1 % Ва) of magnesium alloy decreased the number of its structural components by a factor of 1,5, while increasing alloy durability by 20 %, plasticity by a factor of 2 and prolonged heat-resistence - 1,5.

3:00 PM
Microstructural Stability at Elevated Temperature of the Ni-based Electron Beam Welded Superalloys Dissimilar Joint: Oskar Dziuba¹; Grzegorz Cempura¹; Agnieszka Wusatowska-Sarnek²; Adam Kruk¹; ¹AGH University of Science and Technology; ²Pratt & Whitney
    ATI 718Plus^® and Inconel 718 are precipitation-strengthened Ni-based superalloys exhibiting high strength and great corrosion resistance. Electron beam welding is the optimal joining process for Ni-based superalloys because of the narrow heat-affected zone and low level of introduced strains. The effect of annealing at 649 °C for up to 500 h on the microstructure of the dissimilar ATI 718Plus^®/Inconel 718 fusion zone is not well known. Here we used various electron microscopy techniques to identify and characterize phases formed by the Laves phase transformation. Moreover, microhardness measurements were performed to assess the effect of microstructure evolution on mechanical properties. We found that Laves phase partially transformed into a complex cluster of precipitates contained δ/η and α-Cr phases. Moreover, main strengthening phases precipitated within the γ-matrix of the fusion zone. Our results show the instability of the Laves phase at elevated temperature and the effect of microstructural changes on mechanical properties.