Search Results (25)

The peak load boiler (PLB) is a heat production facility that uses SA178 Gr. A and SA516 Gr. 70 low-carbon steels as tube and plate materials, respectively. Recently, failures were frequently observed near plugged tubes due to water leakage, raising concerns about corrosion mechanisms and their impact on tube durability. This work investigates the corrosion failure mechanisms using a combination of endoscopy, ultrasound inspection, oxide scale analysis (X-ray diffraction), chemical analysis (ion chromatography and inductively coupled plasma mass spectrometry), and computational fluid dynamics simulations. The undamaged tube near the leaked tube exhibited oxide scale levels comparable to those directly affected. Surface examinations revealed gas-side pits indicative of localized corrosion, while oxide scales were predominantly composed of iron oxides formed under humid conditions and sodium compounds derived from boiler water. Analysis of the leaked water revealed its mixture with combustion gases, forming an acidic, chloride-rich environment that significantly accelerates corrosion. Computational fluid dynamics simulations demonstrated that leaked water vapor facilitated the condensation of acidic ions near affected tubes, promoting dew point corrosion. These phenomena, driven by localized condensation and chemical concentration at the dew point temperature, exacerbate material degradation, emphasizing the importance of targeted prevention strategies. Full article

This research investigates the application of activated tungsten inert gas (A-TIG) welding on boiler grade SA516 Grade 70 carbon steel using nano titanium dioxide (TiO₂) nano flux to enhance weld penetration depth, microstructure, and mechanical properties. A unique flux application technique was devised and experiments were carried out. Response Surface Methodology (RSM) was utilized to optimize weld parameters, namely arc length, welding current, and travel speed.The selection between A-TIG and TIG welding significantly influences penetration depth, as A-TIG benefits from arc constriction and elevated current density. The welding speed is crucial for controlling heat input, whereas current and arc length enhance penetration by influencing arc force and energy distribution. Optimizing all three parameters guarantees optimal penetration and weld quality. Microstructural research revealed enhanced mechanical properties in A-TIG weldments, distinguished by acicular ferrite in the fusion zone, which augmented toughness and tensile strength (520 MPa) compared to TIG weldments (470 MPa) and the base metal (480 MPa). Although A-TIG welds exhibited reduced impact toughness (68 J) relative to the base metal (128 J), A-TIG joints had superior ductility. The findings of this research clearly demonstrate the A-TIG welding process improved the depth of penetration and mechanical strength of the weld joints. Full article

The purpose of this study was to investigate the composition of oxide films formed on SA106 Gr.B carbon steel in nitrite solutions at 35 °C for 1000 h. The product of the reduction of nitrite during the corrosion inhibition process was also examined. The X-ray photoelectron spectroscopy results revealed that a thin Fe₃O₄ film was formed and ammonium ions were adsorbed on the outermost surface of the oxide film. The presence of ammonium ions was also demonstrated by ion chromatography. These results indicate that nitrites are reduced to ammonium ions, which in turn promotes the formation of the protective Fe₃O₄ film. Full article

Graphitic carbon nitride (g-C₃N₄, CN) has emerged as a promising photocatalytic material due to its inherent stability, antibacterial properties, and eco-friendliness. However, its tendency to aggregate and limited dispersion hinder its efficacy in practical antibacterial applications. To address these limitations, this study focuses on developing a composite hydrogel coating, in which sodium alginate (SA) molecules interact electrostatically and through hydrogen bonding to anchor CN, thereby significantly improving its dispersion. The optimal CN loading of 35% results in a hydrogel with a tensile strength of 120 MPa and an antibacterial rate of 99.87% within 6 h. The enhanced mechanical properties are attributed to hydrogen bonding between the -NH2 groups of CN and the -OH groups of SA, while the -OH groups of SA facilitate the attraction of photogenerated holes from CN, promoting carrier transfer and separation, thereby strengthening the antibacterial action. Moreover, the hydrogel coating exhibits excellent antibacterial and corrosion resistance capabilities against Pseudomonas aeruginosa on 316L stainless steel (316L SS), laying the foundation for advanced antimicrobial and anticorrosion hydrogel systems. Full article

The role of flow velocity on the formation and dissolution of oxides on SA106Gr.B carbon steel was investigated at both microscopic and atomic scales. In static water, a compact oxide layer with highly faceted magnetite particles was formed. Atomic-scale transmission electron microscopy images of such a layer revealed highly ordered and parallel lattice fringes, indicating that the oxide had very high crystallinity and minimal lattice defects. In contrast, turbulent water prompted the creation of a porous oxide layer consisting of amorphous magnetite particles. Here, numerous mismatched lattice fringes were observed, indicating a prevalence of point defects within the oxide structure. These differences in oxide properties are attributed to hydrodynamic shear stress induced by turbulent flow. These findings provide atomic-level insights into how carbon steel corrosion accelerates in fast-flowing water. Full article

Corrosion-related damage incurs significant capital costs in many industries. In this study, an anti-corrosive pigment was synthesized by modifying calcium carbonate with sodium alginate (SA), and smart self-healing coatings were synthesized by reinforcing the anti-corrosive pigments into a polyolefin matrix. Structural changes during the synthesis of the anti-corrosive pigment were examined using scanning electron microscopy (SEM) and X-ray diffraction (XRD) analysis. Moreover, thermal gravimetric analysis confirmed the loading of the corrosion inhibitor, and electrochemical impedance spectroscopic analysis revealed a stable impedance value, confirming the improved corrosion resistance of the modified polyolefin coatings. The incorporation of the anticorrosive pigment into a polyolefin matrix resulted in improved pore resistance properties and capacitive behavior, indicating a good barrier property of the modified coatings. The formation of a protective film on the steel substrate reflected the adsorption of the corrosion inhibitor (SA) on the steel substrate, which further contributed to enhancing the corrosion resistance of the modified coatings. Moreover, the formation of the protective film was also analyzed by profilometry and elemental mapping analysis. Full article

Nuclear power tube plates are made from the high-strength, low-carbon alloy steel SA-5083, which has high values of toughness and plasticity, though it is forged with poor consistency and entails serious work hardening. It requires a large number of deep holes with a high machining accuracy and high surface quality to be processed. However, the quality of the processed holes is often not up to the standard of the Boring and Trepanning Association (BTA) for the deep-hole drilling of tube plates; this has led to deep-hole processing becoming a bottleneck in the manufacture of steam generators for the main equipment of nuclear power islands. The variation laws of the diameter, roundness, perpendicularity, roughness, microhardness, and residual stress in relation to the feed, speed, and drilling depth are explored in the macro- and micro-dimensions; also explored is the wear morphology of BTA drills. The internal influence mechanisms between them are revealed in order to provide a scientific basis for the control of surface quality and machining accuracy as well as the optimization of process parameters. Our research results indicate that the guide block wear is mainly concentrated at the top 1–2 mm and that the drilling depth and feed have a great influence on the machining diameter. The hole wall roughness is between 0.3 and 0.6 μm, the maximum microhardness is about 2.15 times the hardness of the matrix material, and the residual stress is compressive stress. With increases in the feed and drilling depth, the hole diameter and the roughness increase. With an increase in the speed, the roughness decreases and the compressive stress of the BTA deep-hole drilling wall increases. Full article

The ability to predict transformation behaviour during steel processing, such as primary heat treatments or welding, is extremely beneficial for tailoring microstructures and properties to a desired application. In this work, a model for predicting the continuous cooling transformation (CCT) behaviour of low-alloy steels is developed, using semi-empirical expressions for isothermal transformation behaviour. Coupling these expressions with Scheil’s additivity rule for converting isothermal to non-isothermal behaviour, continuous cooling behaviour can be predicted. The proposed model adds novel modifications to the Li model in order to improve CCT predictions through the addition of a carbon-partitioning model, thermodynamic boundary conditions, and a Koistinen–Marburger expression for martensitic behaviour. These modifications expanded predictions to include characteristic CCT behaviour, such as transformation suppression, and an estimation of the final constituent fractions. The proposed model has been shown to improve CCT predictions for EN3B, EN8, and SA-540 B24 steels by better reflecting experimental measurements. The proposed model was also adapted into a more complex simulation that considers the chemical heterogeneity of the examined SA-540 material, showing a further improvement to CCT predictions and demonstrating the versatility of the model. The model is rapid and open source. Full article

All light or heavy water reactors fabricated with carbon steels suffer from flow-accelerated corrosion (FAC). The FAC degradation of SA106B with different flow velocities was investigated in terms of microstructure. As flow velocity increased, the major corrosion type changed from general corrosion to localized corrosion. Severe localized corrosion occurred in the pearlite zone, which can be the prior location for generating pits. After normalizing, the improvement in microstructure homogeneity reduced the oxidation kinetics and lowered cracking sensitivity, causing a decrease in FAC rates of 33.28%, 22.47%, 22.15%, and 17.53% at flow velocity of 0 m/s, 1.63 m/s, 2.99 m/s, and 4.34 m/s, respectively. Additionally, localized corrosion tendency was decreased by reducing the micro-galvanic effect and tensile stresses in oxide film. The maximum localized corrosion rate decreased by 21.7%, 13.5%, 13.8%, and 25.4% at flow velocity of 0 m/s, 1.63 m/s, 2.99 m/s, and 4.34 m/s, respectively. Full article

In this study, a micro–nano TaC ceramic steel matrix reinforced layer was prepared by an in situ reaction between a pure tantalum plate and GCr15 steel. The microstructure and phase structure of the in situ reaction reinforced layer of the sample at 1100 °C and reaction time 1 h were characterized with FIB micro-section, TEM transmission, SAED diffraction pattern, SEM and EBSD. The phase composition, phase distribution, grain size, grain orientation and grain boundary deflection, phase structure and lattice constant of the sample were characterized in detail. The results show that the phase composition of the Ta sample is Ta, TaC, Ta₂C and α-Fe. TaC is formed after Ta and carbon atoms meet, and the orientation changes in the X and Z directions. The grain size of TaC is widely in the range of 0~0.4 μm, and the angular deflection of TaC grain is not obvious. The high-resolution transmission structure, diffraction pattern and interplanar spacing of the phase were characterized, and the crystal planes of different crystal belt axes were determined. The study provides technical and theoretical support for further research on the preparation technology and microstructure of the TaC ceramic steel matrix reinforcement layer. Full article

The corrosion behavior of carbon steel X36 (CSX36) in solutions of soils collected from different areas linked to the main pipe network of a water distribution system in Jeddah City (Obhour Al Shamaliyah, Ob-Sh; Al Shateie, Sh; Al Safa, Sf; Al Samer, Sa; and Al Jameaah, Ja) at an ambient temperature (23 ± 1 °C) was studied. The corrosion behavior was monitored using various techniques, such as weight loss and electrochemical (open circuit potential [OCP]; electrochemical impedance spectroscopy; and potentiodynamic polarization) measurements. Visual and microscopic examinations of the surface morphology of the studied metals were evaluated and discussed. The corrosion rates in all the studied soil solutions decreased with an increase in the immersion period over 80 weeks. The corrosivity of the studied soils based on weight loss measurements followed the order Sh > Ja > Ob-Sh > Sa > Sf. The value of the OCP gradually shifted to more negative values, indicating a higher tendency to corrode. For the soil solutions studied, the E_corr shifted to more negative values, indicating that the corrosion process was under cathodic control. The values of i_corr and 1/R_p tended to increase as the soil resistivity decreased. Moreover, there was good consistency between the corrosivity order of the studied soil solution obtained from electrochemical impedance spectroscopy and PDP measurements in the following order: Ob-Sh > Sh > Ja > Sa > Sf. A comprehensive assessment of the soil corrosivity based on various soil variables revealed that soil solutions of Ob-Sh and Sh are extremely corrosive, while the rest of the soil solutions are noncorrosive. Full article

A free radical polymerization method was used to synthesize the phosphorus-free copolymer hydroxyethyl methacrylate-acrylic acid-sodium allyl sulfonate (HEMA-AA-SAS). The structure of HEMA-AA-SAS was characterized, and the scale inhibition performance of the copolymer was determined. Near 100% of scale inhibition was achieved when the copolymer concentration was 6 mg/L, suggesting that HEMA-AA-SAS had a significant effect on the inhibition efficiency. The corrosion inhibition performance of the copolymer and the effects under different water quality conditions were determined using a rotating sample method. When the copolymer with 7.5 mg/L was implemented, the corrosion inhibition effect on the carbon steel hanging sheet reached 88.12%. The effects of copolymers on calcium carbonate crystals were analyzed using scanning electron microscopy (SEM) and X-ray powder diffraction (XRD), which showed that the copolymers could destroy crystal morphology effectively. Through the calculation of the corrosion activation energy, the results show that the corrosion activation energy increases and the corrosion reaction rate decreases after the copolymer has been added. The copolymer HEMA-AA-SAS has excellent scale and corrosion inhibition performance. Full article

Solar energy presents the greatest potential by which to produce heat energy with reduced carbon emissions for power generation. To increase its harvesting and conversion, it is necessary to understand fundamental concepts and develop new materials. Although many processes can obtain selective absorbing surfaces (SAS) for application in solar energy exploitation, including electroplating methods, those processes have not sufficiently investigated the substrate’s treatment impact. The present work investigates 304 stainless steel (SS304) substrates treatment influence on the film’s (coatings) optical properties of SAS based on CrO₃ electroplating. For this purpose, three main steps featured in the methodology: substrates treatment, coatings deposition, and physical-chemical characterization. The former was performed by detergent cleaning (DC), acid treatment (AT), and electropolishing (EP). Then, coatings were electroplated towards chromium deposition on the substrates with different deposition times. Finally, films were characterized by Profilometry, UV-Vis-NIR, and IR regions Spectroscopy and Scanning Electron Microscopy (SEM). The results indicated that, in terms of surface treatments on the substrate, the electropolished (EP) substrates presented average roughness values of 35 nm, reflectivity of 5.09%, and clear morphological difference (SEM) when compared to other treatments in this study (DC and AT). A SAS was successfully obtained, and the electropolished substrates (EP) presented coatings with better optical performance than other samples (DC and AT), with absorptivity values around 98% and emissivity of approximately 7%. A relationship between substrate treatment, its roughness, and the impacts on the optical selectivity of SASs was observed. Therefore, electropolishing is presented as a promising treatment for the SASs substrates. Full article

The strength and ductility of low-carbon carbide-free bainitic (CFB) automotive steel are not good enough. In this study, a short austenitization (SA) process in conjunction with isothermal bainitic transformation was adopted to refine the bainitic ferrite lath, thus improving the mechanical properties of low-carbon CFB steel. The microstructure evolution was traced by dilatometric measurements and microstructure characterization, which revealed the refined microstructure by SA process. Besides, the deformation behaviors of the studied steels were analyzed, indicating that the improved work hardening capability by refined bainitic ferrite lath and more stable austenite were responsible for the better strength-ductility match. The CFB steel treated by SA process exhibits a high tensile strength of ~1180 MPa, and its elongation of 22.6% is comparable with commercial QP980 steel. Full article

In mold making, the mold surface roughness directly affects the surface roughness of the produced part. To achieve surface roughness below 0.8 μm, the cost of surface finish is high and time-consuming. One alternative to the different grinding and polishing steps is laser polishing (LP). This study investigates and models the LP of tool steel (X38CrMoV5-1-DIN 1.2343), typical for the mold industry, having an initial rough surface obtained by electrical discharge machining. The microstructures of the re-melted layer and heat-affected zone due to the LP process were also studied. Four parameters: the laser spot size, velocity, maximum melt pool temperature and overlapping were investigated via a design of experiments (DoE) approach, specifically a factorial design. The responses were line roughness (Ra), surface roughness (Sa), and waviness (Wa). The surface topography was measured before and after the LP process by white light profilometer or confocal microscopy. DoE results showed that the selected factors interact in a complex manner, including the interactions, and depend on the responses. The DoE analysis of the results revealed that the roughness is mainly affected by the velocity, temperature and overlap. Based on a first DoE model, an optimization of the parameters was performed and allowed to find optimum parameters for the LP of the rough samples. The optimum conditions to minimize the roughness are a spot size of 0.9 mm, a velocity of 50 mm/s, a temperature of 2080 °C and an overlap of 90%. By using these parameters, the roughness could be reduced by a factor of almost 8 from 3.8 µm to approximately 0.5 µm. Observations of the microstructure reveal that the re-melted layer consists of columnar grains of residual austenite. This can be explained by the carbon intake of the electro-machined surface that helps stabilize the austenitic phase. Full article