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New Alloys, Materials and Processes for Components Working in Energy Equipment

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Materials Characterization".

Deadline for manuscript submissions: closed (15 October 2021) | Viewed by 14652

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Special Issue Editors

Dr. Amaia Calleja-Ochoa

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Department of Mechanical Engineering, University of the Basque Country (UPV/EHU), Nieves Cano 12, 01006 Vitoria-Gasteiz, Spain
Interests: mechanical engineering; coatings; machining; manufacturing of aeroengine components
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Luis Norberto López De Lacalle

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The Aeronautics Advanced Manufacturing Center-CFAA, 48170 Zamudio, Biscay, Spain
Interests: manufacturing process
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Anselmo Eduardo Diniz

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Universidade Estadual de Campinas Fac Mech Engn CAMPINAS, SP, BRAZIL
Interests: mechanical engineering; with emphasis on manufacturing / machining

Special Issue Information

Dear Colleagues,

Nowadays, energy equipment represents a challenge both for design, materials and manufacturing. The critical aspects of these types of equipment and high added value imply daily research efforts. Turbines, combustion engines, compressors, cogeneration equipment, oil and gas facilities are critical systems.

On one hand, new materials and alloys with improved characteristics (structure, properties and applications) are of great interest in this field. In fact, the evolution of the energy sector is constant, so, efficient machining of difficult-to-cut materials and complex geometries is key to perform the final operations to achieve the precision required. Industry is all time making big efforts in daily continuous improvements. In many cases the evolution is lineal, only from time to time breakthrough advances are expected. In the latter the additive manufacturing is introducing new possibilities.

Machining technology is rich in aspects, aiming at quality and productivity. In fact, cutting tool substrate grades and new coatings to improve quality and productivity are launched to the market in a daily basis. In the same line, new superalloys and composites bring extra challenges to manufacturing industry, Additionally, sustainability is also a concern, and green approaches are proposed, such as reduction of coolant, energy consumption reduction, and recycling of chips and even recycling of cutting tool substrates. Tungsten for instance is a critical raw material, and alternatives based on ceramics or extra-hard materials are defined.

The special issue is open to new findings and approaches, taking into account the following points:

New superalloys and materials used in energy equipment
Surface integrity and damage by manufacturing methods
Intermetallic alloys (structure, properties and applications)
Benchmarking of machining processes
Solutions for difficult-to-cut alloys
Machine tools for high performance machining
Coatings and new grades for tool materials
Tool wear and tool life
New lubricoolant approaches
Sustainability in machining: green machining
Additive manufacturing in energy equipment

New design and reliability methods for the full system life cycle

Dr. Amaia Calleja-Ochoa
Prof. Norberto López de Lacalle Marcaide
Prof. Anselmo Eduardo Diniz
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

alloys
composites
manufacturing
machining
intermetallic
turbines
oil and gas

Published Papers (5 papers)

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Research

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12 pages, 4873 KiB

Open AccessArticle

A New Approach in the Design of Microstructured Ultralight Components to Achieve Maximum Functional Performance

by Amaia Calleja-Ochoa, Haizea Gonzalez-Barrio, Norberto López de Lacalle, Silvia Martínez, Joseba Albizuri and Aitzol Lamikiz

Materials 2021, 14(7), 1588; https://doi.org/10.3390/ma14071588 - 24 Mar 2021

Cited by 30 | Viewed by 2691

Abstract

In the energy and aeronautics industry, some components need to be very light but with high strength. For instance, turbine blades and structural components under rotational centrifugal forces, or internal supports, ask for low weight, and in general, all pieces in energy turbine devices will benefit from weight reductions. In space applications, a high ratio strength/weight is even more important. Light components imply new optimal design concepts, but to be able to be manufactured is the real key enable technology. Additive manufacturing can be an alternative, applying radical new approaches regarding part design and components’ internal structure. Here, a new approach is proposed using the replica of a small structure (cell) in two or three orders of magnitude. Laser Powder Bed Fusion (L-PBF) is one of the most well-known additive manufacturing methods of functional parts (and prototypes as well), for instance, starting from metal powders of heat-resistant alloys. The working conditions for such components demand high mechanical properties at high temperatures, Ni-Co superalloys are a choice. The work here presented proposes the use of “replicative” structures in different sizes and orders of magnitude, to manufacture parts with the minimum weight but achieving the required mechanical properties. Printing process parameters and mechanical performance are analyzed, along with several examples. Full article

(This article belongs to the Special Issue New Alloys, Materials and Processes for Components Working in Energy Equipment)

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16 pages, 6015 KiB

Open AccessFeature PaperArticle

Delamination Fracture Behavior of Unidirectional Carbon Reinforced Composites Applied to Wind Turbine Blades

by Ana Boyano, Jose Manuel Lopez-Guede, Leyre Torre-Tojal, Unai Fernandez-Gamiz, Ekaitz Zulueta and Faustino Mujika

Materials 2021, 14(3), 593; https://doi.org/10.3390/ma14030593 - 27 Jan 2021

Cited by 9 | Viewed by 3352

Abstract

One of the materials that is used widely for wind turbine blade manufacturing are fiber-reinforced composites. Although glass fiber reinforcement is the most used in wind turbine blades, the use of carbon fiber allows larger blades to be manufactured due to their better mechanical characteristics. Some turbine manufacturers are using carbon fiber in the most critical parts of the blade design. The larger rotors are exposed to complex loading conditions in service. One of the most relevant structures on a wind turbine blade is the spar cap. It is usually manufactured by means of unidirectional laminates, and one of its major failures is the delamination. The determination of material features that influence delamination initiation and advance by appropriate testing is a fundamental topic for the study of composite delamination. The fracture behavior is studied across coupons of carbon fiber reinforcement epoxy laminates. Fifteen different test conditions have been analyzed. Fracture surfaces for different mode ratios have been explored using optical microscope and scanning electron microscope. Experimental results shown in the paper for critical fracture parameters agree with the theoretically expected values. Therefore, this experimental procedure is suitable for wind turbine blade material characterizing at the initial coupon-scale research level. Full article

(This article belongs to the Special Issue New Alloys, Materials and Processes for Components Working in Energy Equipment)

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9 pages, 4960 KiB

Open AccessArticle

Analysis of the Part Distortions for Inconel 718 SLM: A Case Study on the NIST Test Artifact

by Silvia Martínez, Naiara Ortega, Diego Celentano, Antonio J. Sánchez Egea, Eneko Ukar and A. Lamikiz

Materials 2020, 13(22), 5087; https://doi.org/10.3390/ma13225087 - 11 Nov 2020

Cited by 17 | Viewed by 1895

Abstract

The present paper evaluates the misalignment and geometry distortion of the standard National Institute of Standards and Technology (NIST) test artifact in Inconel 718 alloy, when several layers with and without supports are employed to manufacture it by the Selective Laser Melting (SLM) process. To this end, a coordinate-measuring machine (CMM) is used to measure the geometrical distortion in each manufacturing configuration, following the same measurement protocol. The results show that the laser path strategy favors a thermal gradient which, consequently, induces geometrical distortions in the part. To prove this hypothesis, a numerical simulation is performed to determine the thermal gradient and the pattern of the residual stresses. It was found that the geometrical distortion certainly depends on the position of the feature position and laser strategy, where thermal cycles and residual thermal stresses had an impact in the end-part geometry, especially if a high strength-to-weight ratio commonly used in aeronautics is present. Full article

(This article belongs to the Special Issue New Alloys, Materials and Processes for Components Working in Energy Equipment)

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Review

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18 pages, 3640 KiB

Open AccessFeature PaperReview

Cohesive Strength and Structural Stability of the Ni-Based Superalloys

by Igor Razumovskii, Boris Bokstein, Alla Logacheva, Ivan Logachev and Mikhail Razumovsky

Materials 2022, 15(1), 200; https://doi.org/10.3390/ma15010200 - 28 Dec 2021

Cited by 2 | Viewed by 1541

Abstract

The influence of alloying elements on the cohesive strength of metal heat-resistant alloys (HRAs) is analyzed. Special parameters are introduced to characterize the individual contribution of each alloying element. These are the partial molar cohesion energy of the matrix (χ) and the cohesive strength of the grain boundaries (η) and can be calculated by computer modeling based on the density functional theory. The calculating results of the parameters χ and η in nickel HRAs with mono– and polycrystalline structures alloyed with refractory metals are presented. The calculated data are used to select the chemical composition and develop new nickel (Ni) HRAs with superior creep-rupture properties. It is assumed that a similar approach can be used to search for alloying elements that will contribute to increasing the cohesive strength of additive objects. The resistance of coherent γ-γ′ and lamellar (raft) structures in nickel HRAs to the process of diffusion coarsening during operation is analyzed. Full article

(This article belongs to the Special Issue New Alloys, Materials and Processes for Components Working in Energy Equipment)

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30 pages, 35875 KiB

Open AccessFeature PaperReview

Strive to Reduce Slurry Erosion and Cavitation in Pumps through Flow Modifications, Design Optimization and Some Other Techniques: Long Term Impact on Process Industry

by Adnan Aslam Noon, Absaar Ul Jabbar, Hasan Koten, Man-Hoe Kim, Hafiz Waqar Ahmed, Umair Mueed, Ahmad Adnan Shoukat and Bilal Anwar

Materials 2021, 14(3), 521; https://doi.org/10.3390/ma14030521 - 21 Jan 2021

Cited by 16 | Viewed by 3601

Abstract

Centrifugal pumps are being widely used in various industries for moving fluids that carry solids through pipelines where the need of head and flow rate is not high. Slurry erosion and cavitation are an extremely complex and not yet fully understood phenomenon that occur in centrifugal pumps; however, these undesirable phenomena can be reduced to a certain extent. Appropriate design and development of experiments is required to reasonably predict slurry erosion and cavitation. However, CFD methodology complements analytical solutions and experiments whenever testing of equipment has limitations. The current paper highlights the various slurry erosion and cavitation reduction techniques utilized by different researchers. Economic analysis conducted for a case study relevant to centrifugal pump (CP) usage in Pakistan shows that an 8% enhancement in pump efficiency can reduce the life cycle cost to about 17.6%, which could save up to USD 4281 for a single pump annually in Pakistan. Full article

(This article belongs to the Special Issue New Alloys, Materials and Processes for Components Working in Energy Equipment)

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