Advanced Materials for Harsh Environments: Session I
Sponsored by: ACerS Electronics Division
Program Organizers: Navin Manjooran, Solve; Gary Pickrell, Virginia Tech
Monday 8:00 AM
October 10, 2022
Room: 333
Location: David L. Lawrence Convention Center
Session Chair: Shen Dillon, University of California, Irvine; Navin Manjooran, Chairman, Solve; Gary Pickrell, Virginia Tech
8:00 AM Invited
A Case Study on the Value of Legacy Data for the Discovery and Design of Creep-resistant 9 – 12 wt% Cr Martensitic Steels: Jennifer Carter1; Amit Verma2; 1Case Western Reserve University; 2Carnegie Mellon University
Corrosion in light metal alloys is complex due to the simultaneous interaction of variables such as chemical composition, microstructure, corrosive environment (composition, pH), and temperature. It is also vital to understand how each of these factors contribute towards corrosion at multiple length scales. In this talk, we will discuss about the combination of multimodal corrosion with multiscale imaging to probe the corrosion behavior of light metal alloys. Using examples of joining of Al alloys and coatings for corrosion protection of Magnesium alloys, we will elaborate on the application of bulk and local electrochemical methods with ex situ and in situ imaging. This approach has yielded several interesting insights into the role of metallurgical phases and microstructural defects that contribute to local and global corrosion damage. Finally, the role of these multimodal electrochemical analyses in guiding corrosion mitigation will be discussed.
8:40 AM
Grain Boundary Engineering to Improve Austenitic Stainless Steels Stress Corrosion Cracking Behavior in Boiling Saturated Magnesium Chloride Solutions: Osama Alyousif1; 1Kuwait University
Grain Boundary Engineering (GBE) through various thermomechanical processes on Type 304 Austenitic Stainless Steel was used to enhance the performance of the steel in boiling saturated magnesium chloride solutions. The microstructure development showed increased fractions of beneficial grain boundaries such as ∑3 and ∑9 in addition to changes in grain sizes compared to solution annealed typical microstructure. The stress corrosion cracking tests in the corrosive environments have showed improved failure times for the different thermomechanical processes used compared to the solution annealed sample tested at same conditions. The microstructure analysis used by metallographic imaging and electron backscatter diffraction helped in understanding the materials behavior and showed a correlation between special boundaries development and materials ability to resist harsh environments.
9:00 AM
Characterization of Nb-Si Alloys for High-temperature Applications: Kaiser Aguirre1; Scott Oppenheimer2; Akane Suzuki2; Bernard Bewlay2; John Lewandowski1; 1Case Western Reserve University; 2GE Research
After decades of rigorous development, the high-temperature performance of Ni-based superalloys is beginning to plateau and is ultimately limited by their melting temperature of ~1400C. Multiple material systems that would enable a step-wise change in high-temperature performance with operating temperatures of >1300C are being explored and developed. This research focuses on the characterization of Nb-Si alloys by microindentation and compression testing at room temperature. Test data are correlated to indentation and fracture surface images to elucidate fracture mechanisms of the constituent phases. High temperature microindentation and compression data are also presented.
9:20 AM
Corrosion Detection in Oil and Gas Pipeline Using 3-D Bluetooth Printed Microsensor: Stephen Appiah1; Holly Martin1; Pedro Cortes1; Frank Li1; Vamsi Bora1; Brendan Kuzior1; 1Youngstown State University
Corrosion is a huge economic and environmental concern for metal applications. Detecting and monitoring corrosion are imperative to prolong material life span, decrease the life-cycle cost, and reduce environmental impact. There are various methodologies for corrosion detection and monitoring which include, but are not limited to, ultrasonic, fiber optics, acoustics, and thermal imaging. These corrosion detection techniques exploit changes in structural, chemical, mechanical, thermal, electrical, and magnetic properties of metals to detect corrosion and calculate corrosion rate. This project focuses on developing 3-D printed Bluetooth microsensor to detect corrosion in steels used for oil and gas pipeline. The microsensor will detect the changes in magnetic and electric properties of the metal caused by corrosion, including resistance, impedance, conductance, magnetic permeability and magnetorestriction. Through the use of the microsensor, both uniform and localized corrosion can be detected, allowing for the understanding of the life-span and prevention of environmental damages.
9:40 AM
Corrosion Phenomena in Powder-Processed Aluminum Alloys Containing Quasicrystalline Dispersoids: Sarshad Rommel1; Hannah Leonard1; Mingxuan Li1; Thomas Watson2; Tod Policandriotes3; Mark Aindow1; 1University of Connecticut; 2Pratt & Whitney; 3Collins Aerospace
The aperiodic structures of quasicrystals (QCs) give rise to an unusual combination of mechanical properties including high hardness, strength, elastic modulus and wear resistance. These properties have generated raised significant interest in the use of QCs for next generation structural materials in aerospace applications. Recently, we have developed a series of Al-Cr-Mn-Co-Zr alloys that exhibits a nano-composite FCC Al matrix plus QC dispersoid microstructure in gas-atomized powders. These alloys have excellent mechanical properties but also exhibit remarkable pitting corrosion resistance in salt fog exposures. A combination of scanning and transmission electron microscopy, X-ray diffraction, and electrochemical techniques have been used to investigate the corrosion behavior of these alloys upon exposure to Cl- rich environments. The impact of alloy composition and upset forging on the corrosion phenomena occurring on these alloys is discussed, with an emphasis on the role of microstructure and the QC phase.
10:00 AM Break
10:20 AM
Electrochemical Characterization of Joints Inconel 600 to TiC-Composites, Immersed in Seawater: Mariano Braulio-Sánchez1; Pedro Durán-Reséndiz1; Rogelio Orozco-Martinez1; 1Instituto Tecnologico Superior del Sur de Guanajuato
This work shows the electrochemical study of dissimilar joint of inconel 600 to TiC/Ni immersed in synthetic seawater. The composite-inconel 600 assemblies were brazed with BNi3 alloy by brazing technique. The corrosion rate (CR) was evaluated from the technique of electrochemical noise (EN). In addition, the corrosion potential measures as a function of the time were carried out to get the stabilization time of the anodic and cathodic reactions. Electrochemical measurements were carried out under static conditions, ambient temperature and atmospheric pressure, the electrochemical results show that the susceptibility of localized corrosion of composite sample was higher than the joints. The corrosion process is of mixed type, that us to say a process of transfer of load influenced by a mechanism of mass. Analysis by scanning electron microscopy (SEM) revealed that mechanism corrosion was cells differential aeration (difference of concentration of oxygen).
10:40 AM
Exfoliated-graphite-based Flexible Graphite as a Multifunctional Material for Harsh Environments: Deborah Chung1; 1State University of New York Buffalo
Flexible graphite sheets made by compacting exfoliated graphite (made from intercalated graphite) without a binder are high-temperature resistant and chemically resistant, as they are all graphite. Thus, they are suitable for harsh environments. Due to the cellular structure stemming from the exfoliated graphite and the preferred in-plane orientation of the carbon layers, the sheet is resilient under normal compression. The resiliency enables the application as a gasket (e.g., for replacing asbestos). The resiliency and piezoresistivity enable the application as a resistance-based compressive strain/stress sensor. The thermal conductivity enables applications as heat spreaders and thermal gap-filling materials. The electrical conductivity enables applications as heating elements, sliding electrical contacts and electrodes (including electrochemical electrodes). The ability to absorb and reflect electromagnetic (microwave) radiation enables applications in electromagnetic interference (EMI) shielding (including EMI gasketing) and electromagnetic pulse (EMP) protection. The electret (permanent electric dipole) behavior enables the application as a low-voltage power source.
11:00 AM Concluding Comments