Advanced Materials for Harsh Environments: On-Demand Oral Presentations
Sponsored by: ACerS Electronics Division
Program Organizers: Navin Manjooran, Solve; Gary Pickrell, Virginia Tech
Friday 8:00 AM
October 22, 2021
Room: On-Demand Room 9
Location: MS&T On Demand
Investigation of Automotive Materials Compatibility for Regenerative Fuels – Oxymethylene Dimethyl Ether (OME): Ruediger Reitz1; 1Technische Universität Darmstadt
Regenerative oxygenated fuels that have a nearly neutral greenhouse gas life cycle, are promising for implementation with respect to socio-climapolitical efforts for environmental protection. However, there are challenges with regard to their compatibility with fuel-bearing components. Present study systematically investigates the material compatibilities of aluminum and iron alloys as well as selected coatings with automotive relevance. Depending on the composition and ageing state of the fuel, different material degradation behaviors are observed and may occur in some cases to a considerable extend. The degradation degree and morphological attack structure is strongly influenced by the blend proportion and composition of corrosion-stimulating impurities such as water or organic ions. Within the framework of a DoE-based experimental approach, the respective influencing factors are characterized phenomenologically and the underlying degradation mechanisms are investigated by means of electrochemical methods. An evaluation matrix can thus be used to identify critical scenarios and classify appropriate materials.
Structural Response of Si (111) and Diamond/Si (111) to 193 nm and 5 ns Laser Pulses: Chaoya Han1; 1University of Delaware
This study explores the structural behavior of Si(111) and polycrystalline diamond film on Si(111) in response to high-energy laser (HEL) irradiation. Following an ISO protocol, experiments were designed to measure the laser-induced damage threshold (LIDT) using ArF 193 nm and 5 ns pulses. The LIDT values are found to be 0.34 mJ/cm2 and 1.18 mJ/cm2 for Si and diamond/Si, respectively. For Si, when the laser fluence is in a range of less than 1.18 mJ/cm2, typical wave-ripple irradiation pattern appears along a direction seemly irrelevant to the crystal orientation. A turbulent pattern followed by burst structure occurs at high fluence of above 2.25 mJ/cm2. The surface undulation largely consists of amorphous Si. On diamond/Si, no obvious wave-ripple pattern forms after the irradiation. Instead, diamond cracks and breaks from the substrate as the fluence increases. Structural details of the irradiation area are further analyzed by TEM using FIB-prepared specimens.
Influence of the Gas Composition on the Metal Dusting Attack of Oxide Forming Alloys: Clara Schlereth1; Anke Ulrich1; Mathias Galetz1; 1DECHEMA-Forschungsinstitut
In industries handling carbonaceous gases, the high temperature corrosion mechanism called “metal dusting” can cause unforeseen plant shutdowns and high additional costs. One of the major challenges is the prediction of the corrosion process onset. A high risk of metal dusting is indicated by a high carbon activity aC of the gas. However, gases with similar aC do not always cause similar metal dusting attack. To develop a better understanding of the influence of the gas components, commercial Ni-base alloys (e.g. Alloy 601, 602 CA) were exposed to five different gas mixtures containing CO, CO2, H2, and H2O with constant aC. Tests were performed at 620°C and 18 bar. While protective oxide scales formed in some gases, severe metal dusting attack was observed in others. The outlet gas composition was determined using mass spectroscopy. Based on oxide scale formation and metal dusting attack, reactions defining the corrosion mechanism are proposed.
Microstructure and Mechanical Properties of Friction Stir Welded Haynes 282: Mageshwari Komarasamy1; Christopher Smith1; Jens Darsell1; Woongjo Choi1; Saumyadeep Jana1; Anand Kulkarni2; Kyle Stoodt2; Glenn Grant1; 1Pacific Northwest National Laboratory; 2Siemens Corporation
Advanced ultrasupercritical (A-USC) steam plants are designed to operate at high temperatures and pressures due to the necessity for higher operational efficiency. The extreme operating conditions of A-USC requires the deployment of precipitation strengthened Ni-base alloys that exhibit elevated temperature strength and good fabricability. In the current study, friction stir welding, a solid state joining technique was implemented on a precipitation strengthened nickel-based superalloy, Haynes 282. Detailed microstructural and mechanical properties characterization was carried out. The processed region exhibited wrought, fine-grained microstructure, absence of weld defects and elemental segregation. Both hardness and cross-weld tensile tests demonstrated that the weld region was stronger than the base material. And the cross-weld tensile samples failed in the base material. Based on weld strength reduction factor analysis, friction stir welded Haynes 282 outperformed fusion welds. Furthermore, creep performance of the cross-welded samples was comparable to the base material.
Enhancing the Hardness and Corrosion Resistance of Ni-based Alloys with Thermomechanical Processing: Haruka Shima1; Manami Mori2; Kenta Yamanaka1; Kazuo Yoshida1; Akihiko Chiba1; 1Tohoku University; 2National Institute of Technology, Sendai College
In this study, we examined the effect of heat treatment on the microstructure, mechanical properties, and corrosion behavior of cold-swaged Ni-30Co-16Cr-15Mo-6Fe-2Cu (mass%) alloy. An alloy rod was processed by cold swaging, with reduction in area of 50-90 %, and then annealed at 473-1273 K for various periods. The hardness of the alloy increased by cold swaging significantly. Notably, aging at 473-873 K further enhanced the Vickers hardness of the cold-swaged specimens through the nanostructural elemental evolution in the heavily deformed FCC matrix. The Cu precipitation was also observed. Although the precipitation of the Mo-rich μ-phase occurred at higher annealing temperature, the alloy was softened due to the recrystallization. Potentiodynamic polarization testing in a sulfuric acid solution revealed that such nanoscale structural evolution does not degrade the corrosion resistance of the alloy. Consequently, an excellent combination of high hardness and corrosion resistance, which exceeds that of existing corrosion-resistant superalloys, was achieved.
Robust Heat Resistant Superhydrophobic Coatings Fabricated by Functionalized Nanoparticles: Anna Schmidt-Verma1; Thomas Fischer1; Sanjay Mathur1; 1Universität zu Köln
The technology of superhydrophobic ceramic coatings with self-cleaning properties gained strong attention during recent years. Impurities on treated materials are easier removed which leads to reduced maintenance costs and offers a green alternative to aggressive cleaning agents. The potential of commercial products is immense, but the wide range of possible applications is limited by the low temperature and mechanical stability. A route for the preparation of a superhydrophobic coating with mechanical and thermal stability was fabricated on glass substrates. The coating was formed in a solution containing various nanoparticles such as SiO2, TiO2 and ZrO2 and silicic acid, in which the ratio of silicic acid was varied. For receiving superhydrophobicity, subsequent and in-situ functionalization with low surface energy material has been performed. Robust thermally stable films with contact angle close to 180° were preserved even after temperature treatments up to 350 °C and mechanical tests.
Finite Element Corrosion Model and Experimental Characterization of Austenitic Stainless-Steel Engine Valves Oxidized in CO2 at 700 °C: Iman Abdallah1; Louis Bailly-Salins1; Xueyang Wu2; Robert Ullberg2; Taeho Kim1; Mohamed ElBakhshwan1; Mark Carroll3; John Perepezko1; Wen Jiang4; Simon Phillpot2; Michael Tonks2; Adrien Couet1; 1UW-Madison; 2University of Florida; 3Tenneco; 4Idaho National Laboraotry (INL)
Current stainless-steel (SS) alloys used in engine cylinder exhaust valves are operated in harsh environment such as carbon dioxide, water vapor and gasoline. To reduce carbon gas emission, engines are being downsized and tend to operate at elevated temperatures (700 °C - 800 °C) for better performance and efficiency. At higher temperatures, SS used in the exhaust valves will undergo material degradation, corrosion and failure. In this work, corrosion modeling and experiments of high manganese SS alloys used in engine valves are being carried out to predict materials lifetime. Corrosion tests in pure CO2 and CO2+ 50% water vapor at temperatures of 700 °C were performed followed up to 1000 hours. Multiscale characterizations of the oxide layers are performed at selected times, using Glow Discharge Optical Emission and X-ray Photoelectron Spectroscopy, Scanning and Transmission Electron Microscopy. Corrosion kinetics is modeled in MOOSE using 3D geometry of valves.
Corrosion Behaviors of Carbon Steels and Cr-bearing Steels in Supercritical CO2: Kaiyang Li1; Yimin Zeng1; 1CanmetMATERIALS, Natural Resources Canada
Carbon capture and storage (CCS) is a promising technology that can retain the core value of fossil fuel power plants while significantly reduce CO2 emissions. As an essential part of CCS, CO2 transportation is achieved by pipeline network since it could transport large amounts of CO2 in a relatively cost-effective and safe fashion. However, the unavoidable impurities in the transported s-CO2 stream may cause severe corrosion and threaten the pipeline integrity. Cr-bearing steels are believed to improve corrosion resistance, yet little work has been carried out. In this paper, corrosion studies of carbon steels and Cr-containing steels in supercritical CO2 streams with impurities are conducted at 10 MPa and 45 oC. The morphology and chemical composition of the formed surface corrosion products are characterized by optical images, X-ray diffraction and SEM. Besides, the effect of Cr addition on corrosion behavior of steel is discussed.
Electrical, Microstructural and Thermomechanical Properties of Doped-LaCrO3 Ceramics for High Temperature Electronics and Sensing Applications: Javier Mena1; Edward Sabolsky1; Katarzyna Sabolsky1; Konstantinos Sierros1; Kavin Sivaneri Varadharajan Idhaiam1; 1West Virginia University
Important electrical and sensor applications require stable conductors under temperatures up to 1500°C in various redox environments. High temperature conductors such as nitrides and carbides are not stable under oxidizing atmospheres. Therefore, low redox materials can be a more attractive alternative. In this work, careful dopant studies of the LaCrO3 system were performed in order to control the electronic and ionic conductivity, as well as the relative chemical and microstructural stability. Neodymium and Niobium dopants were initially studied to control p-type, and potentially n-type conductive mechanisms, respectively, while other dopants were also investigated. The electrical conductivity and Seebeck coefficient were characterized up to 1500°C under varying oxygen partial pressures. The phase and microstructural evolution were also investigated by XRD and SEM. The materials exhibiting acceptable electrical and thermomechanical performance were printed within thick films sensors. Results may hold the key for developing new generation of high temperature sensing materials.
Evaluation of High Temperature Planar Passive Wireless Sensor Fabricated by Stereolithography Process: Kavin Sivaneri Varadharajan Id1; Matthew Barre1; Zachary Lynch1; Engin Ciftyurek1; Katarzyna Sabolsky1; Edward Sabolsky1; Konstantinos Sierros1; Daryl Reynolds1; 1West Virginia University
In this work, an all-ceramic passive wireless sensor capable of operating at high temperatures in harsh environmental conditions was fabricated by directly depositing ceramic-forming polysilizane on an alumina dielectric substrate using a stereolithography process. Different active and inactive filler materials were loaded into the pre-ceramic polymer and their effect on the cross-linking, microstructural stability and electrical properties were studied. The photoactive preceramic polymer was cast directly onto the alumina substrate and the LC pattern was realized using a 365 nm UV source mounted onto a commercial 3D printer by fiber optics. The substrate was developed to realize the desired RLC sensor and sintered at 1200 – 1400oC. The microstructural and electrical properties were evaluated by scanning electron microscopy, 4-point conductivity, impedance spectroscopy, and X-ray diffractometer. The wireless response of the RLC sensor was characterized by a multimode user-defined software radio which acts as a signal transmitter and receiver.