Search Results (826)

The three-phase region of Mo₃Si-Mo₅Si₃-Mo₅SiB₂(MoSiB) exhibits excellent high-temperature oxidation resistance and is considered a highly promising high-temperature structural material. However, the presence of porous structures significantly increases the surface area exposed to oxidation. Metallic porous materials often suffer from inadequate corrosion resistance and insufficient high-temperature oxidation resistance, whereas ceramic porous materials are plagued by high brittleness. Intermetallic compounds offer a combination of the advantages of both metals and ceramics. Nevertheless, the high-temperature oxidation behavior of porous MoSiB has not yet been systematically elucidated. The study systematically investigates the effect of pore structure on the high-temperature oxidation behavior of porous MoSiB at 1000 °C and 1300 °C, with a focus on oxidation kinetics, phase evolution, surface and cross-sectional morphology and underlying oxidation mechanisms. The effects of porosity and temperature on the oxidation process are also analyzed. The results indicate that at 1000 °C, the material exhibits uniform oxidation, with lower porosity contributing to better oxidation resistance. At 1300 °C, oxidation is limited to the surface layer, where low-viscosity SiO₂(B) rapidly seals the pores to form a dense protective layer. This research reveals the high-temperature oxidation mechanism and phase evolution of porous MoSiB, providing a theoretical foundation for its application in high-temperature structural fields. Full article

Addressing issues such as corrosion and the eccentric wear of metal tubing strings, low heating efficiency, and high operation and maintenance costs of lifting systems in heavy-oil extraction, core equipment comprising carbon-fiber-reinforced PEEK（Polyetheretherketone） multi-layer composite continuous tubing has been developed. This equipment integrates an embedded cable-laying system and an intelligent regulation module, establishing a rodless oil-extraction technology system suitable for heavy-oil reservoirs. This article systematically describes the process structure, preparation principle, core characteristics, and key parameters of this composite continuous tubing. By deriving an equivalent thermal-resistance model for the multi-layer structure and an unsteady-state heat-transfer equation, precise regulation of the wellbore temperature field is achieved. Combined with field tests at Well A in Jinghe Oilfield, the tubing’s effectiveness in reducing viscosity, increasing production, saving energy, and extending the operational cycle in heavy-oil extraction is verified. The results show that the carbon-fiber-reinforced PEEK composite continuous tubing possesses characteristics such as high strength, strong corrosion resistance, low friction, and high thermal insulation. When paired with a viscosity–temperature coupling regulation algorithm, the heating efficiency is improved by 40% compared to traditional electric heating rods. The efficiency ranges from 37% to 43% when the formation thermal conductivity fluctuates by ±20%. Field applications have achieved a 230% increase in daily oil production, a 30% reduction in system energy consumption, and an extension of the hot washing cycle to over 180 days. The development of this tubing breaks through the technical bottleneck of traditional metal tubing, providing a new material solution for the efficient and intelligent development of heavy-oil extraction, and has broad promotional value. Full article

Optical fiber sensors deployed in harsh industrial fields, e.g., high-temperature wet-oxygen, face severe challenges in signal attenuation and mechanical degradation. While amorphous silicon oxycarbide (a-SiOC) coatings offer a promising solution due to their adjustable thermo-mechanical properties, balancing their structural density with environmental stability remains a critical technical bottleneck. In this study, a-SiOC coatings were deposited on optical fibers using hexamethyldisilane (HMDS) and trace oxygen via radio-frequency capacitively coupled plasma-enhanced chemical vapor deposition (PECVD). A systematic investigation was conducted to determine the impact of deposition temperature (70–420 °C) on the precursor dissociation kinetics, microstructural evolution, and corrosion resistance of the coatings. An elevation in temperature promotes the elimination of organic terminal groups (–CH₃, –H) and enhances surface diffusion, driving the coating from a loose, carbon-rich “polymer-like” structure (dominated by Si–C bonds) to a dense, inorganic “silica-like” skeleton (dominated by Si–O–Si bonds). High-temperature corrosion tests in a wet-oxygen environment (500–900 °C) demonstrate that the failure mechanism is highly dependent on deposition temperature. Coatings deposited at low temperatures suffer catastrophic cracking due to pronounced oxidative shrinkage and the release of volatile species, whereas coatings deposited at 420 °C exhibit microcracking caused by severe carbon phase separation and stress concentration within the rigid inorganic network. In the present system, 350 °C is identified as the optimal deposition temperature, as it achieves the best balance of network densification and structural flexibility, while exhibiting the best mechanical performance. Full article

Against the global carbon neutrality backdrop, amine-based CO₂ capture technology is critical for industrial greenhouse gas emission reduction. However, mixed amine absorbents can cause severe corrosion of Q235B carbon steel, restricting the stable operation of carbon capture, utilization, and storage (CCUS) projects. This study systematically investigated the corrosion behavior of Q235B carbon steel in a novel mixed amine system under simulated industrial conditions using weight loss tests, electrochemical measurements (EIS, potentiodynamic polarization), and advanced characterizations (FT-IR, ¹³C NMR, SEM-EDS, XRD). The temperature was the dominant factor: corrosion rate increased significantly with rising temperature. Under CO₂-saturated conditions, 15–30% absorbent concentrations showed no significant effect on corrosion rate owing to similar molar loading and pH. At 60 °C and 30% concentration, the corrosion rate peaked at 30 L/L CO₂ loading. Carbamate accumulation promoted corrosion at low loading, while increased bicarbonate inhibited corrosion at high loading. The main corrosion products (Fe₃O₄, Fe₂O₃) formed loose, porous films with poor protectiveness. This work clarifies the electrochemical corrosion mechanism and provides data support for corrosion prevention in CCUS equipment. Full article

Thermal spray technologies are widely used in aerospace, gas turbine, and automotive industries, where nickel-based superalloys are valued for their mechanical strength and resistance to oxidation and corrosion at elevated temperatures. This study investigates the microstructure and tribological performance of Ni–5Al/Inconel 625 composite coatings deposited on AISI 1025 steel using wire arc spraying, aiming to provide a cost-effective alternative to bulk superalloys and more advanced thermal spray techniques. Microstructural characterization was performed using optical microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy, while surface roughness, microhardness, and dry sliding wear behavior were evaluated using ball-on-disk tests against Al₂O₃ counter-bodies. Confocal microscopy and three-dimensional triboscopic imaging were employed to analyze wear-track morphology and friction behavior. X-ray diffraction (XRD) analysis confirmed the presence of a predominantly intermetallic Ni₃Al (γ′) phase with secondary NiAl in the bond coat, indicating significant interdiffusion between the NiAl bond coat and the Inconel 625 top coat. The top coat exhibited a face-centered cubic (FCC) γ Ni-based solid solution. The coatings exhibited a typical lamellar structure with low porosity (2%–3%) and oxide content of 12%–15%, primarily chromium and niobium oxides located at splat boundaries. Abrasion, combined with interlamellar decohesion, was identified as the dominant wear mechanism. Post-deposition polishing reduced surface roughness from 11.9 µm to 2.12 µm, leading to a 2.5-fold reduction in wear volume and a significant decrease in debris pile-up. The corresponding specific wear rates were approximately 9.3 × 10⁻⁵ mm³/Nm and 3 × 10⁻⁵ mm³/Nm for the as-prepared and polished conditions, respectively, which are within the range reported in the literature for similar coatings. These findings demonstrate that wire arc-sprayed Ni–5Al/Inconel 625 coatings, particularly after polishing, offer improved wear resistance while maintaining cost-effectiveness, making them a promising alternative for tribological applications. Full article

In this work, welan gum (WG) was investigated as a green corrosion inhibitor for metals in acidic petroleum drilling fluids. The side chain of WG was subsequently modified by grafting with 3-chloropropionic acid (WG-CAR), further improving the corrosion inhibition performance. At the same concentration, WG exhibited a better corrosion inhibition efficiency than the commercial β-cyclodextrin. Moreover, the graft-modified WG-CAR achieved 60.35% at a concentration as low as 100 ppm, whereas WG and β-cyclodextrin only reached 28.25% and 25.42%, respectively. These improvements are attributed to their electron-donating hydroxyl and carboxyl functional groups, through which the lone pair electrons in oxygen atoms can fill the unoccupied d-orbitals of iron atoms, forming coordination bonds. This promotes Langmuir chemisorption, thereby forming a protective layer on the steel surface that inhibits anodic and cathodic corrosion reactions. In addition, calculations show that the WG-CAR molecule possesses a larger dipole moment and enhanced electron-donating capacity, resulting in stronger coordination interactions for the protective layer. Even at a high temperature of 323 K, WG-CAR (200 ppm) maintains an inhibition performance of 36.80%, higher than that of WG (10.66%). This work broadens the application of WG and brings new perspectives for the development and design of corrosion inhibitors. Full article

Inconel 625 is widely used in high-temperature structural components because of its excellent strength, toughness, and corrosion resistance. However, long-term exposure to elevated temperatures can induce precipitation of carbides, γ″ phase, and δ phase, leading to microstructural degradation and reduced mechanical reliability. Although precipitation evolution and tensile properties of aged Inconel 625 have been widely studied, the relationship between long-term precipitate evolution and impact fracture behavior remains insufficiently clarified. In this study, solution-treated Inconel 625 alloy was aged at 700 °C and 750 °C for up to 5000 h, with additional stress-assisted aging at 750 °C under 30 MPa and 51 MPa. Impact toughness, microhardness, fracture morphology, and precipitate evolution were systematically investigated. The results show that long-term aging significantly reduces impact toughness at both room and elevated temperatures, with a more pronounced reduction at room temperature. The room-temperature impact energy decreases from 314 J to approximately 10 J and stabilizes after 2000 h. Quantitative analysis shows that γ″ precipitate coarsening follows the Lifshitz–Slyozov–Wagner relationship, indicating diffusion-controlled growth. Stress-assisted aging under the present low stress levels has only a limited influence on precipitate evolution and impact toughness. The toughness degradation is mainly attributed to chain-like grain-boundary carbides and needle-like or plate-like δ phase, which embrittle grain boundaries, segment the austenitic matrix, and limit impact energy absorption. Full article

Extending the service life of nuclear power plant components beyond their originally designed operational period requires a detailed understanding of the microstructural stability of the materials used. This study focuses on low-temperature precipitation in the austenitic stainless steel 08CH18N10T, which is employed in the main circulation piping of pressurized water reactors. During long-term operation in the temperature range of 100–320 °C, secondary phases such as M₂₃C₆ carbides and intermetallic phase sigma (σ) can precipitate, which can lead to local chromium depletion at grain boundaries, subsequent sensitization of the steel, and susceptibility to intergranular corrosion. The research includes the analysis of samples taken from the decommissioned V1 unit of the Jaslovské Bohunice Nuclear Power Plant, which has been in operation for 28 years. The samples were subjected to thermal aging under laboratory conditions, with an emphasis on evaluating microstructural changes and their impact on corrosion resistance. Based on the experimental results, it can be concluded that the thermal stability of all tested materials is suitable for the operation of the main circulation piping, as the service temperatures to which the main circulation piping is exposed during operation remain below the activation of precipitation that would lead to sensitization and, consequently, susceptibility to intergranular corrosion. Activation of low-temperature precipitation was observed only at 450 °C, while at temperatures up to 400 °C, the structural stability of the material was confirmed, demonstrating its suitability for operation within the specified temperature range of the nuclear power plants’ main circulation piping. Full article

Cost-effective β-titanium alloys were developed via the hydrogenation–dehydrogenation (HDH) process using low-cost β-stabilizers Mo and Fe. Ti-5Mo-xFe (x = 2, 4 wt%) alloys were fabricated by powder metallurgy and subjected to six post-heat treatment conditions to reduce porosity and improve properties. The as-sintered alloys exhibited high porosity (15–20%), which adversely affected mechanical and corrosion performance. Heat treatment above the β-transus significantly reduced porosity, with Ti-5Mo-4Fe treated at 900 °C for 2 h showing the greatest reduction. Microstructures evolved from α + β lamellar Widmanstätten to equiaxed β with TiFe precipitates. Increased Fe content and heat-treatment temperature enhanced strength, while TiFe precipitates degraded corrosion resistance. Thus, optimized post-heat treatment improves strength and corrosion performance, although Fe content must be controlled. Full article

Metal–polymer hybrid composites blend the high strength and stiffness of metals with the low weight and corrosion resistance of polymers. This synergy is expected to provide better crashworthiness, energy absorption, and design flexibility compared to traditional single-material structures. The present research intended to examine the crashworthiness features of an aluminium/CFRP structure under various operating conditions by optimizing process parameters through Design Expert software and experimental investigation. The design of the experiment was carried out using Design Expert software version 13 with response surface methodology (RSM) where working temperature, isothermal holding time, and crushing speed are taken as process variables. The test results demonstrate that the peak load, energy absorption (EA), and specific energy absorption (SEA) are significantly higher for the sample with working temperature, isothermal holding time, and crushing speed set at 25 °C, 13 h, and 5 mm/min, respectively. Moreover, EA and SEA are also relatively higher for this sample compared to the other samples. The test results showcased that temperature is a decisive factor for the mechanical properties of the tube, which is clearly reflected in experimental results. The higher peak force and EA indicate greater strength and a more energy-dissipative system. Moreover, a close correlation was observed between the experimentally measured and RSM-based optimization. Hence, RSM was found to be suitable for designing the experiments and for understanding the failure modes of the CFRP/aluminium structure. Full article

Ceramics are widely evaluated for their extreme hardness, high-temperature stability, and corrosion resistance, which enable applications in harsh service environments. However, these same properties, high melting points, brittleness, and low thermal shock resistance, make conventional manufacturing of complex ceramic components difficult and expensive. Traditional processes often require costly diamond tooling or energy-intensive sintering and tend to produce only simple geometries, with significant waste material and risk of defects. Additive manufacturing (AM) has recently emerged as a promising route to fabricate intricate, near-net-shape ceramic parts without these drawbacks. By building components layer by layer, AM reduces the need for extensive machining and enables the fabrication of geometrically complex, near-net-shape ceramic structures with reduced material waste, although challenges such as porosity, interlayer defects, and cracking during post-processing remain. Nonetheless, ceramic AM technologies lag behind their metal and polymer counterparts, and significant challenges remain in achieving fully dense parts with reliable mechanical properties. This review provides an in-depth overview of the state of the art in ceramics and ceramic composite additive manufacturing. We detail the most widely used AM processes (stereolithography, binder jetting, material extrusion, powder bed fusion, inkjet printing, and direct energy deposition) and typical feedstock formulations for each technique. We examine the resulting mechanical properties (strength, toughness, hardness, wear resistance) and functional properties (thermal stability, dielectric behavior, biocompatibility) of additively manufactured ceramics, and discuss their current and potential engineering applications in the aerospace, defense, automotive, biomedical, and energy sectors. Persistent challenges, including porosity, shrinkage and cracking during sintering, achieving uniform microstructures, high process costs, and scalability issues, are analyzed, and we highlight promising future directions such as multi-material grading, integration of machine learning for process optimization, and sustainable manufacturing approaches. Despite significant progress, challenges remain in achieving fully dense structures, improving process reliability, and scaling ceramic AM for industrial applications, highlighting the need for further research in process optimization, material design, and multi-material integration. Full article

The steam generator is a core component of nuclear power plants that facilitates heat exchange between the primary and secondary circuits, directly impacting the overall operation of the plant in terms of safety and reliability. During prolonged operation, the heat transfer tubes of the steam generator are subjected to erosion, corrosion, and cracking due to high-temperature, high-pressure fluid impact and vibration. Existing in-service inspection strategies for heat transfer tubes generally employ fixed intervals and coverage, failing to effectively differentiate the actual risk of tubes in various regions, leading to wasted inspection resources or safety hazards. This paper proposes a dynamic inspection and plugging management strategy based on flow-induced vibration (FIV) analysis, specifically utilizing the flow stability ratio (FSR). By calculating the FSR of heat transfer tubes, the strategy categorizes them into high-risk, medium-risk, and low-risk regions, and dynamically adjusts inspection frequency and coverage based on these risk levels. Theoretical analysis and validation with actual data demonstrate that this strategy can improve inspection efficiency and ensure the safety of the steam generator. Full article

In response to corrosion challenges encountered during the gathering and transportation of wet natural gas, this study systematically investigates the corrosion behavior of L245NCS steel in environments containing O₂, H₂S, CO₂ and simulated oilfield-produced water. The research employs a combined approach involving high-pressure autoclave experiments and transparent flow loop simulations. Autoclave tests reproduce gas phase, liquid phase, and gas–liquid interface conditions under a controlled O₂-H₂S-CO₂ mixture, while a visual flow loop equipped with elbows and undulating sections is used to examine liquid accumulation behavior and flow characteristics under dynamic, real-world operating conditions. Results indicate that corrosion is most severe at the gas–liquid interface. H₂S is identified as the primary corrosive agent, exerting a stronger influence than CO₂ or O₂. Liquid accumulation is the main factor leading to non-uniform corrosion distribution, and its formation is influenced by water content, pressure, temperature difference, and pipeline shutdown and restart operations. Critical areas such as low-lying sections, downhill bottoms, and the beginning of uphill sections exhibit localized corrosion rates up to 61.4% higher than areas without liquid accumulation. This integrated methodology bridges mechanistic understanding with engineering practice, providing a basis for corrosion risk assessment, optimal monitoring point placement, and integrity management of wet gas pipelines. Full article

Atmospheric corrosion of carbon and low-alloy steels causes direct economic losses that are estimated at around 3.4% of the global GDP, and its accurate multi-year prediction is essential for protective coating selection, service-life estimation, and infrastructure maintenance scheduling. In this study, machine learning (ML) algorithms, including gradient boosting regressor (GBR), eXtreme gradient boosting (XGBoost), random forest (RF), support vector regression (SVR), and ridge regression, were trained on a 600-sample physics-grounded dataset to predict the cumulative atmospheric corrosion loss (µm) of low-alloy steels over 1–10 years of exposure. The dataset was constructed using the exact ISO 9223:2012 dose–response function (DRF) for a first-year corrosion rate and the ISO 9224:2012 power-law multi-year kinetic model (C(t) = C₁·t0.5), spanning ISO 9223 corrosivity categories C2–CX across 11 environmental and material input features. All models were evaluated on the original (untransformed) corrosion scale under an 80/20 train/test split and five-fold cross-validation. Gradient boosting achieved the best overall performance with test set R² = 0.968, CV-R² = 0.969, RMSE = 10.58 µm, MAE = 5.99 µm, and MAPE = 12.6%. XGBoost was a close second (R² = 0.958, CV-R² = 0.960). RF achieved an R² of 0.944. SHAP (SHapley Additive exPlanations) analysis identified SO₂ deposition rate, exposure time, relative humidity, Cl⁻ deposition rate, and temperature as the five most influential predictors. The dominance of the SO₂ deposition rate (mean |SHAP| = 26.37 µm) and the high second-place ranking of exposure time (13.67 µm) are fully consistent with the ISO 9223:2012 dose–response function and ISO 9224:2012 power-law kinetics, respectively, while among the material features, Cu and Cr contents showed the strongest negative SHAP contributions, confirming their corrosion-inhibiting roles in weathering steels. These results establish a physics-consistent, interpretable ML benchmark exceeding R² = 0.90 for multi-year cumulative corrosion loss prediction and provide a quantitative tool for alloy screening, coating selection in aggressive atmospheric environments, and service-life planning. Full article

Industrial emissions of large amounts of CO₂ have seriously affected human health, making it imperative to reduce atmospheric CO₂ concentrations. However, carbon capture technologies such as chemical absorption and membrane separation are still limited by high regenerative energy costs, corrosion, and low efficiency in diluting flue gas. Within this technological landscape, physical adsorption separation technology, due to its advantages such as a wide operating temperature range, low equipment corrosivity, and low regeneration energy consumption, has gradually become a research hotspot in carbon capture technology. The core of physical adsorption lies in finding high-quality adsorbents. Metal–organic frameworks (MOFs), with their ultra-high specific surface area, tunable pore structure, and abundant functionalization sites, are considered highly promising next-generation CO₂ adsorbent materials. This review summarizes strategies for modifying MOFs to improve CO₂ adsorption performance, focusing on aperture adjustment, doped metal ions, functional group doping, and computational screening. Performance enhancements are mechanism-dependent rather than simply additive. Moderate aperture adjustment and defect engineering can improve gas selectivity and CO₂ capture capacity, while excessively narrow pores sacrifice available pore volume and gas diffusion. Doped metal ions, particularly in MOF-74 and related materials, can enhance CO₂ capture capacity while controlling framework integrity and dopant composition. Functional group Doping remains an effective method for capturing low-partial-pressure CO₂. Computational screening is shifting from ranking based on single adsorption capacity to a comprehensive consideration that includes humidity tolerance, stability, and regenerability. Overall, under industrial conditions, modified MOFs should be evaluated by balancing affinity, selectivity, capacity, stability, and energy efficiency. This review provides guidance for the rational design of MOF-based carbon capture adsorbents. Full article