Search Results (78)

Nickel-based superalloy Hastelloy C276 is widely used in high-performance industries due to its strength, corrosion resistance, and thermal stability. However, these same properties pose substantial challenges in machining, resulting in high tool wear, surface defects, and dimensional inaccuracies. This study investigates methods to enhance machining performance and surface quality by evaluating the tribological behavior of TiSiN/TiAlN-coated carbide inserts under six cooling and lubrication conditions: dry, MQL with coconut oil, Cryo-LN₂, Cryo-LCO₂, MQL–Cryo-LN₂, and MQL–Cryo-LCO₂. Open-slot finishing was performed at constant cutting parameters, and key indicators such as cutting zone temperature, tool wear, surface roughness, chip morphology, and microhardness were analyzed. The hybrid MQL–Cryo-LN₂ approach significantly outperformed other methods, reducing cutting zone temperature, tool wear, and surface roughness by 116.4%, 94.34%, and 76.11%, respectively, compared to dry machining. SEM and EDS analyses confirmed abrasive, oxidative, and adhesive wear as the dominant mechanisms. The MQL–Cryo-LN₂ strategy also lowered microhardness, in contrast to a 39.7% increase observed under dry conditions. These findings highlight the superior performance of hybrid MQL–Cryo-LN₂ in improving machinability, offering a promising solution for precision-driven applications. Full article

This study investigates the effects of aluminum (Al) and titanium (Ti) additions on the porosity, microstructure, and corrosion performance of Hastelloy C276-based coatings fabricated via laser cladding on nodular cast iron substrates. Nickel-based alloy powders blended with varying Ti (1–10 wt.%) and Al (0.5–2.5 wt.%) contents were deposited under optimized laser parameters. Microstructural characterization revealed that Ti addition refined the grain structure and promoted the formation of TiC phases, while Al addition dispersed eutectic networks into isolated island-like structures. Both elements effectively suppressed porosity by reducing gas entrapment during solidification. However, excessive Ti (10 wt.%) induced brittle fracture due to TiC agglomeration, and Al addition caused interfacial cracks owing to Al₂O₃ formation. Electrochemical tests in a 3.5 wt.% NaCl solution indicated that Al/Ti additions enhanced initial passivation but reduced corrosion resistance due to weakened oxide film stability. XPS analysis revealed that Al-enriched coatings formed Al₂O₃ and Al(OH)₃, whereas Ti-modified coatings developed TiO₂ and TiC, both influencing the passivation behavior. These findings provide critical insights into tailoring laser-clad coatings for marine applications by balancing porosity suppression and corrosion resistance. Full article

The short-term mechanical properties of commercial corrosion-resistant nickel alloys based on Ni-Cr (Hastelloy^® G-35^® or UNS N06035), Ni-Mo (Hastelloy^® B-3^® or UNS N10675), and Ni-Cr-Mo (VDM^® Alloy C-4 or UNS N06455, VDM^® Alloy 59 or UNS N06059, and KhN62M-VI) systems were analyzed in the as-received state and after long-term (up to 5000 h) aging at 500–700 °C. All alloys exhibited moderate strength and high ductility in the as-received state. Under the influence of high temperatures, these alloys showed a tendency toward the decomposition of Ni-based FCC solid solutions and a change in mechanical properties. It was shown that the difference in chromium and molybdenum content in Ni-Cr-Mo alloys leads to the formation of secondary phases of various composition and morphology, which had varied influence on the short-term mechanical properties of the materials. Grain boundary precipitates had a negligible effect on the strength properties of the investigated alloys, while intragranular precipitates embrittled nickel-based alloys, reducing their possible application at high temperatures. Full article

Hastelloy is widely used in the manufacturing of high-temperature components in the aerospace industry because of its high strength and corrosion-resistant physical properties, as well as its ability to maintain excellent mechanical properties at high temperatures. However, with developments in science and technology, the amount of available components for use in high-temperature and corrosive environments is increasing, their structures are becoming more complex and varied, and requirements with regard to the surface quality of the components has also become more stringent. The integration of cold plasma (CP) and nano-lubricant minimum quantity lubrication (NMQL), within a multi-physics coupling-assisted micro-grinding process (CPNMQL), presents a promising strategy to overcome this bottleneck. In this paper, micro-grinding of Hastelloy C-276 was performed under dry, CP, NMQL, and CPNMQL conditions, respectively. Contact angle testing, X-ray photoelectron spectroscopy (XPS) analysis, and nano-scratch experiments were used to investigate the mechanism of CPNMQL and to compare the micro-milling performance under different cooling and lubrication conditions employing various characteristics such as grinding temperature, surface roughness, and 3D surface profile. The results showed that at different micro-grinding depths, the micro-grinding temperature and surface roughness were significantly reduced under CP, NMQL, and CPNMQL conditions compared to dry friction. Among them, CPNMQL showed the best performance, with 53.4% and 54.7% reductions in temperature and surface roughness, respectively, compared to the dry condition. Full article

Corrosion of nickel alloys in molten salts is a complex process dependent on many factors. The paper describes the influence of microstructural changes in several nickel-based alloys (Hastelloy^® G-35^®, VDM^® Alloy 59, KhN62M-VI, Hastelloy^® B-3^®) on the mechanism of their corrosion in molten fluoride salts. The corrosion experiments were performed in LiF–NaF–KF and (LiF–NaF–KF) + UF₄ melts at 550–750 °C. Formation of excess secondary phases along the grain boundaries of the alloys led to heterogeneity of the alloy microstructure. As a result of these changes, microgalvanic couples formed on the surface of the alloys, leading to the development of intergranular corrosion upon contact with molten electrolytes. Secondary phases acted as microanodes or microcathodes depending on a number of factors. Formation and composition of the secondary phases affected the depth and extent of the corrosion damage to nickel alloys. Full article

The purpose of this study is to investigate the effects of process parameters on the microstructure and mechanical properties of the Hastelloy X (HX) alloy using a laser powder bed fusion (L-PBF) process. A combined experimental and numerical approach was used to evaluate the influence of the energy density distribution and temperature evolution on the microstructure, defects, and mechanical properties. After the specimens were built on SUS304 substrate by the L-PBF, the microstructure and defects in the specimens were analyzed by SEM and EBSD analysis methods, and then the hardness and the tensile tests were performed. The cooling rate under different laser conditions was obtained by the finite element method (FEM). The results show that a low volume energy density (VED) was applied to the unmelted powder particles, and a high energy density resulted in spherical defects. In addition, the microstructures were found to coarsen with increasing the energy density along with a tendency to strengthen the (001) texture orientation in both x–y and x–z planes. Compared to the parts with the thermal history from numerical results, the low cooling rate with high energy density had larger crystal grains elongated along the building direction, coarser sub-grains, resulting in a reduction in microhardness and yield strength together with an increase in elongation for the L-PBF HX alloy. The presented results provide new insights into the effects of parameters and the cooling rates. It can play an important role in optimizing the L-PBF processing parameters, identifying the cause of defects, and controlling the cooling rates for the crystallographic texture in such a way as to guide the development of better metrics for designing processing parameters with the desired mechanical properties. Full article

SAE 5160 steel, classified as high-strength, low-alloy steel, is widely used in the automotive sector due to its excellent mechanical strength and ductility. However, its inherently low corrosion resistance limits its broader application. This study explores the application of the cathodic cage plasma deposition (CCPD) technique to enhance the corrosion resistance of SAE 5160 steel. The treatment was performed using a Hastelloy cathodic cage under two atmospheric conditions: hydrogen-rich (75%H₂/25%N₂) and nitrogen-rich (25%H₂/75%N₂). Comprehensive analyses revealed significant improvements in surface properties and corrosion resistance. The hydrogen-rich condition (H25N) facilitated the formation of Cr_0.4Ni_0.6 and CrN phases, associated with a nanocrystalline structure (37.6 nm) and a thicker coating (45.5 μm), resulting in polarization resistance over 290 times greater than that of untreated steel. Conversely, nitrogen-rich treatment (H75N) promoted the formation of Fe₃N and Fe₄N phases, achieving a dense but thinner layer (19.6 μm) with polarization resistance approximately 20 times higher than that of untreated steel. These findings underscore the effectiveness of CCPD as a versatile and scalable surface engineering technique capable of tailoring the properties of SAE 5160 steel for use in highly corrosive environments. This study highlights the critical role of optimizing gas compositions and treatment parameters, offering a foundation for advancing plasma-assisted technologies and alloying strategies. The results provide a valuable framework for developing next-generation corrosion-resistant materials, promoting the longevity and reliability of high-strength steels in demanding industrial applications. Full article

This study addresses the crack formation problem when laser cladding CoCrFeNiAl high-entropy alloy onto H13 hot-work die steel, aiming to identify suitable transition layer materials. Five nickel-based alloys—Inconel 718, Inconel 625, Hastelloy X, FGH4096, and FGH4169—are selected as alternatives. Three-point bending and hot tensile tests are conducted to assess performance under different stress directions. Test results show that the FGH4096 and FGH4169 coatings fail due to insufficient element diffusion and weak interfacial bonding. Cracks appear at the coating–substrate interface of Inconel 625 and Hastelloy X. In contrast, Inconel 718 performs best, with excellent thermal expansion matching and strong stress resistance. In the three-point bending test, the specimens with Inconel 718 transition layers did not show cracks during the loading process, while specimens with some other alloy transition layers cracked or fractured, which proves that Inconel 718 can effectively enhance the bonding force between the coating and the substrate and improve the material’s performance under bending stress. In the hot tensile test, the stress–strain curve of Inconel 718 is at a high position with a high yield strength, showing excellent resistance to plastic deformation and significantly improving the performance of the nickel-based layer under hot tensile conditions. Therefore, Inconel 718 is identified as the optimal transition layer material. Full article

Molten salt reactors (MSRs) offer advantages such as enhanced safety, reduced nuclear waste, and cost effectiveness. However, the corrosive nature of fluoride-based molten salts challenges the longevity of structural materials. Ni-based alloys, like Hastelloy N, have shown resistance to fluoride salt corrosion but suffer from issues like helium embrittlement caused by neutron irradiation. To address these concerns, the incorporation of graphene (Gr) into Ni-based alloys is being explored. Gr’s superior mechanical properties and irradiation tolerance make it a promising reinforcement material. In this study, a Ni-17Mo alloy, a simplified model of Hastelloy N, was combined with reduced graphene oxide (RGO) using powder metallurgy. The effects of milling time and sintering temperature on the microstructure and mechanical properties were systematically studied. The results indicated that optimal sintering at 1100 °C enhanced tensile strength and ductility. Additionally, RGO incorporation improved the alloy’s strength but reduced its elongation. This research highlights the potential of Gr-reinforced Ni-based alloys for advanced MSR applications, offering insights into fabrication techniques and their impact on material properties. Full article

Hybrid layered reinforced materials are able to increase the reliability, durability, and expand the functionality of high-temperature components in supercritical and ultra-supercritical power plants and in oil, gas, and petrochemical equipment operating under conditions with multifactorial influences (temperature, force, deformation). As a result of this research, surface reinforced ceramic composite materials with a gradient distribution of properties have been developed. These materials include thermal barrier layers (Gd₂O₃-Yb₂O₃-Y₂O₃-ZrO₂) and Ni-based layers reinforced with ceramic carbide and oxide particles. They are strong, have a high heat and wear resistance, and provide the specified functional and mechanical properties. The formation technology for the hybrid composites has also been developed. This technology includes the mechanical alloying of powder compositions, which is followed by vacuum plasma spraying. The structure of the powder compositions and composite layers, the density of the obtained composite materials, and the heat and wear resistance of the composites have also been investigated. The microhardness of the alloy layers of the hybrid composite materials Hastelloy X–GYYZO–material 1 and Hastelloy X–GYYZO–material 2 was as follows: super alloy Hastelloy X, HV_0.2 = 3.8–3.95 GPa; layer GYYZO, HV_0.3 = 16.1–16.7 GPa; layer material 1, HV_0.3 =18.3–18.8 GPa; layer material 2, HV_0.3 =19.1–19.6 GPa. The influence of the refractory phase of HfC and TaC on the strength of the composites was studied. It was found that the maximum strength (710–715 MPa) in the composites Hastelloy X—GYYZO—material 1 and Hastelloy X–GYYZO–material 2 is achieved with a content of HfC and TaC–27–28%. Full article

Composite coatings reinforced with varying mass fractions of SiC particles were successfully fabricated on 316 stainless steel substrates via laser cladding. The phase compositions, elemental distribution, microstructural characteristics, hardness, wear resistance and corrosion resistance of the composite coatings were analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), Vickers hardness testing, friction-wear testing and electrochemical methods. The coatings have no obvious pores, cracks or other defects. The phase compositions of the Hastelloy C276 coating includes γ-(Ni, Fe), Ni₂C, M₆C, M₂(C, N) and M₂₃C₆. SiC addition resulted in the formation of high-hardness phases, such as Cr₃Si and S₅C₃, with their peak intensity increasing with SiC content. The dendrites extend from the bonding zone towards the top of the coatings, and the crystal direction diffuses from the bottom to each area. Compared with the dendritic crystals formed at the bottom, the microstructure at the top is mostly equiaxed crystals and cellular crystals with smaller volume. When SiC powder particles are present around the crystals, the microstructure of the cladding layer grows acicular crystals containing Si and C. These acicular crystals tend to extend away from the residual SiC powder particles, and the grain size in this region is smaller and more densely distributed. This indicates that both melted and unmelted SiC powder particles can contribute to refining the grain structure of the cladding layer. The optimal SiC addition was determined to be 9 wt%, yielding an average microhardness of 670.1 HV_0.5, which is 3.05 times that of the substrate and 1.19 times that of the 0 wt% SiC coating. The wear resistance was significantly enhanced, reflected by a friction coefficient of 0.17 (43.59% of the substrate, 68% of 0 wt%) and a wear rate of 14.32 × 10⁻⁶ mm³N⁻¹·m⁻¹ (27.35% of the substrate, 40.74% of 0 wt%). The self-corrosion potential measured at 315 mV, with a self-corrosion current density of 6.884 × 10⁻⁶ A/cm², and the electrochemical charge-transfer resistance was approximately 25 times that of the substrate and 1.26 times that of the 0 wt%. In this work, SiC-reinforced Hastelloy-SiC composite coating was studied, which provides a new solution to improve the hardness, wear resistance and corrosion resistance of 316L stainless steel. Full article

Additive manufacturing (AM) methods like powder bed fusion–laser beam (PBF-LB) enable complex geometry production. However, understanding and predicting the microstructural properties of AM parts remain challenging due to the inherent non-homogeneity introduced during the manufacturing process. This study demonstrates a novel approach for 3D microstructure representation and virtual testing of non-homogeneous AM materials using 2d electron backscatter diffraction (EBSD) data. By employing the representative volume element (RVE) method, we reconstruct the 3D microstructure from 2D EBSD datasets, effectively capturing the grain morphological characteristics of PBF-LB-produced Hastelloy X. Using validated RVE data, we artificially generate combinations of two grain textures to gain deeper insight into locally affected areas, particularly the stress distribution within the interfaces, as well as global material behavior, exploring non-homogeneity. Computational homogenization (CH) utilizing a crystal elasticity finite element (CEFE) method is used to virtually test and predict directional elastic properties, offering insights into relationships between microstructure evolution and property correlation. The experimentally validated results show a strong correlation, with only 0.5–3.5% correlation error for the selected grain tessellation method. This consistency and reliability of the methodology provide high confidence for additional virtual tests predicting the properties of non-homogeneous, artificially generated combined-grain structures. Full article

The results of experimental and numerical studies of plastic forming of sheets made of the difficult-to-deform Hastelloy X, a nickel-based alloy with a thickness of 1 mm, using layered elastomeric punches and steel dies, are presented in this publication. The elastomeric punches were characterized by hardness in the range of 50–90 Shore A, while the dies were made of 90MnCrV8 steel with a hardness of over 60 HRC. The principle of operating the stamping die was based on the Guerin method. The finite-element-based numerical modeling of the forming process for various configurations of polyurethane inserts was also carried out. The results obtained from numerical modeling were confirmed by the results of experimental tests. The drawpieces obtained through sheet forming were subjected to geometry tests using optical 3D scanning. The results confirmed that in the case of forming difficult-to-deform Hastelloy X, Ni-based alloy sheets, the hardness of the polyurethane inserts significantly affected the geometric quality of the obtained drawpieces. Significant nonuniform sheet metal deformations were also found, which may pose a problem in the process of designing forming tools and the technology of the plastic forming of Hastelloy X, Ni-based alloy sheets. Full article

A molten salt reactor is one of the fourth-generation reactors and is considered to be a feasible replacement for current reactors due to their many advantages. However, there are a number of issues that remain; one of which is the corrosion of the materials. Corrosion problems in molten salt reactors have been reported since The Molten Salt Reactor Experiment at Oak Ridge National Laboratory in the 1960s. There have been many attempts to mitigate the corrosion problem, but a fundamental solution has not yet been achived. In this study, surface reaction-diffusion-coupled simulations were performed to simulate the corrosion of a Ni–Cr–Fe material, a prototype of Hastelloy N, which is being promoted as a structural material for molten salt reactors in F–Li–Na–K eutectic salts. This surface reaction-diffusion-coupled simulation framework was developed to study which corrosion reactions are dominant in molten salt environment corrosion where a large number of oxidation–reduction reactions exist, the correlation between composition of alloy and corrosion rate, and the effect of Cr depletion on corrosion. Full article

This review sets out to investigate the detrimental impacts of hydrogen gas (H₂) on critical boiler components and provide appropriate state-of-the-art mitigation measures and future research directions to advance its use in industrial boiler operations. Specifically, the study focused on hydrogen embrittlement (HE) and high-temperature hydrogen attack (HTHA) and their effects on boiler components. The study provided a fundamental understanding of the evolution of these damage mechanisms in materials and their potential impact on critical boiler components in different operational contexts. Subsequently, the review highlighted general and specific mitigation measures, hydrogen-compatible materials (such as single-crystal PWA 1480E, Inconel 625, and Hastelloy X), and hydrogen barrier coatings (such as TiAlN) for mitigating potential hydrogen-induced damages in critical boiler components. This study also identified strategic material selection approaches and advanced approaches based on computational modeling (such as phase-field modeling) and data-driven machine learning models that could be leveraged to mitigate potential equipment failures due to HE and HTHA under elevated H₂ conditions. Finally, future research directions were outlined to facilitate future implementation of mitigation measures, material selection studies, and advanced approaches to promote the extensive and sustainable use of H₂ in industrial boiler operations. Full article