Search Results (3,243)

This study presents a novel hybrid intelligent framework integrating fuzzy logic and artificial neural networks (ANN) to model the erosion-corrosion behavior of glass-fiber-reinforced pipes (GRP) under harsh operating conditions. Experimental data encompassing multiple operational parameters—including abrasive sand concentrations (250 g, 400 g, 500 g), flow rates (0.0067 m³/min, 0.01 m³/min, 0.015 m³/min), chlorine content (0–10 wt.%), and exposure times (1–5 h)—were utilized to develop the computational models. The fuzzy logic system effectively captured qualitative expert knowledge and uncertainty in material degradation processes, while ANN models provided quantitative predictions of erosion and corrosion rates. Results demonstrated good prediction accuracy, with R² values of 0.81 for corrosion rate and moderate prediction accuracy 0.56 for erosion rate. The analysis revealed that flow rate (correlation: 0.6) and fuzzy severity (0.6) were the most influential parameters, followed by chlorine content (0.41) and sand concentration (0.32). The hybrid model identified optimal operating conditions to minimize material degradation: low sand concentration (250 g), low flow rate (0.0067 m³/min), absence of chlorine, and shorter exposure times. This intelligent modeling approach provides a powerful tool for predictive maintenance, operational optimization, and service life prediction of GRP systems in aggressive environments, bridging the gap between experimental data and computational intelligence for enhanced material performance assessment. Full article

Platinum coatings produced by magnetron sputtering are highly valued due to their exceptional properties, including excellent electrical conductivity, high catalytic activity, and superior corrosion resistance. The quality of these coatings, however, is strongly dependent on the sputtering parameters. This study performs optimization of platinum thin film deposition on stainless steel substrates by systematically varying magnetron sputtering parameters. Experimental data were obtained under different conditions of discharge current, pressure, and deposition time. The results were analyzed using both classical regression techniques and advanced machine learning approaches to assess the influence of process parameters on deposition rate and coating thickness. Among the tested models, Gaussian Process Regression (GPR) demonstrated the highest accuracy and stability. The findings indicate that deposition time is the dominant factor influencing coating thickness, while discharge current primarily governs the deposition rate. Furthermore, multi-objective optimization and active learning approaches highlighted the potential of combining artificial intelligence methods with experimental design to reduce the number of required trials and improve process efficiency. Full article

Currently, there are several deep drill geothermal projects that aim to discharge superheated or supercritical geothermal fluid for sustainable power production. In geothermal power utilisation, the well casing steel and surface equipment is susceptible to corrosion due to corrosive species in the geothermal fluid. The temperature and the phase state of the fluid greatly affect the extent and the forms of corrosion that can occur. To mitigate corrosion damage in the casing and surface equipment, the recently developed production method Extra High-speed Laser Application (EHLA) cladding is proposed as a solution. To simulate application of carbon steel and EHLA clads in superheated geothermal wells, the materials were tested in a superheated steam containing CO₂ and H₂S at 450 °C temperature and 150 barG pressure. Microstructural and chemical analysis was performed with SEM, EDX and XRD, and corrosion rate was analysed with the weight loss method. The carbon steel was prone to corrosion with a double corrosion layer but the corrosion of the EHLA clads was insignificant. The results show that the EHLA clads tested have good corrosion resistance in the test environment, and the study can aid in the selection of casing and clad materials for future deep geothermal wells. Furthermore, this study shows that the EHLA clads increase the variety of corrosion mitigation solutions for future geothermal projects. Full article

As high-end equipment manufacturing advances, demand for improved surface performance in critical components has increased. Laser cladding is an advanced surface strengthening technique that affords effective surface modification. During the laser cladding process, obtaining a fine grain microstructure usually helps to enhance the microhardness, wear resistance, and corrosion resistance of the cladding layer. However, conventional laser cladding often yields coarse columnar grains that limit further performance improvements, so process optimization to achieve grain refinement is necessary. In this study, oscillating laser cladding was combined with a pulsed-wave (PW) laser mode to deposit a fine-grained Al₂CrFe₂Ni₄Ti_1.5 high-entropy alloy cladding on Q550 steel substrates. Compared with continuous-wave (CW) laser cladding, the PW mode produced markedly refined grains and concomitant improvements in microhardness, wear resistance, and corrosion resistance. Specifically, the microhardness of the PW cladding layer reached approximately 673.34 HV_0.5, the wear volume was approximately 0.06 mm³, the wear rate was approximately 0.21 × 10⁻⁴ mm³/N·m, and the corrosion current density decreased to approximately 1.212 × 10⁻⁵ A·cm⁻². This work presents a novel approach for producing high-performance, wear-resistant, and corrosion-resistant high-entropy alloy cladding layers, and offers both theoretical insight and potential engineering applications. Full article

Fast pyrolysis of vegetable oils and residues generates bio-oil (BO), a renewable hydrocarbon source with high acidity that limits its direct use in refineries. In this study, BOs were produced from refined soybean oil (RSO) and waste cooking oil (WCO) at 525 °C in a continuous bench-scale pyrolysis at 525 °C, with a 390 ± 8 g h⁻¹ feed rate, under steady-state conditions. The resulting bio-oils exhibited high acidity (acid index of 145 and 127 mg KOH g⁻¹, respectively) and elevated olefinic and oxygen contents, making them corrosive and unsuitable for co-refining with petroleum. To reduce acidity, ethyl esterification was performed using lipase B from Candida antarctica (CALB), using a Box–Behnken 3³ factorial design. Variables included temperature (40–60 °C), bio-oil:ethanol mass ratio (1:1–1:5), and catalyst concentration (3–10% w/w). The acid index was reduced by up to 76%, with optimal conditions (62 °C, 1:1 mass ratio, 11% CALB) yielding a final value of 28 mg KOH g⁻¹. Similar reductions were obtained for waste cooking oil bio-oil, confirming robustness across feedstocks. CALB retained over 70% activity after three cycles, demonstrating stability. This enzymatic esterification process shows strong potential for lowering bio-oil acidity, enabling integration into petroleum refineries, diversifying feedstocks, and advancing renewable fuel production. Full article

Carbon fiber reinforced silicon carbide (C/SiC) composite material exhibits exceptional properties, including high strength, high stiffness, low density, outstanding high-temperature performance, and corrosion resistance. Consequently, they are widely used in aerospace, defense, and automotive engineering. However, their anisotropic, high hardness, and brittle characteristics make them a typical difficult-to-machine material. This paper focuses on achieving high-quality micro hole machining of C/SiC composite material via electrical discharge machining. It systematically investigates electrical discharge machining characteristics and innovatively develops a hollow internal flow helical electrode reaming process. Experimental results reveal four typical chip morphologies: spherical, columnar, blocky, and molten. The study uncovers a multi-mechanism cutting process: the EDM ablation of the composite involves material melting and explosive vaporization, the intact extraction and fracture of carbon fibers, and the brittle fracture and spalling of the SiC matrix. Discharge energy correlates closely with surface roughness: higher energy removes more SiC, resulting in greater roughness, while lower energy concentrates on m fibers, yielding higher vaporization rates. C fiber orientation significantly impacts removal rates: processing time is shortest at θ = 90°, longest at θ = 0°, and increases as θ decreases. Typical defects such as delamination were observed between alternating 0° and 90° fiber bundles or at hole entrances. Cracks were also detected at the SiC matrix–C fiber interface. The proposed hole-enlargement process enhances chip removal efficiency through its helical structure and internal flushing, reduces abnormal discharges, mitigates micro hole taper, and thereby improves forming quality. This study provides practical references for the EDM of C/SiC composite material. Full article

In this study, amorphous Fe₆₀Nb₃B₁₇Si₆Cr₆Ni₄Mo₄ coatings were prepared using the high-velocity air fuel method. The microstructure, wear resistance, and corrosion resistance of the Fe₆₀Nb₃B₁₇Si₆Cr₆Ni₄Mo₄ coatings were examined for various levels of nanocrystallization. In contrast to the as-sprayed coating, the samples that were heat-treated formed partial α-Fe and crystalline Cr₂O₃. The generated nanocrystals exerted a dispersion-strengthening effect on the coatings, leading to enhanced hardness and fracture toughness. When the annealing temperature was below the initial crystallization temperature, the wear resistance improved by approximately 1.65 times, the wear rate decreased to half of that in the as-sprayed state, and the depth of the wear scar reduced. However, the resistance of the coatings to corrosion deteriorated as the degree of crystallization increased. X-ray photoelectron spectroscopy analysis revealed that heat treatment modified the composition of the passive film, thereby influencing its corrosion resistance. These results provide crucial insights into the application of Fe-based amorphous coatings in wear- and corrosion-resistant environments. Full article

Al–Zn–Ca alloys are good candidates for industrial electronics and electric vehicles due to their high thermal conductivity, castability, and corrosion resistance, but their strength requires improvement. This study investigates how Sc and Zr additions affect the microstructure, thermal, mechanical, and corrosion properties of an Al–3 wt% Zn–3 wt% Ca base alloy. Microstructural analysis showed that substituting Sc with Zr did not drastically alter the phase composition but changed the elemental distribution: Sc was uniform, while Zr segregated to center of dendritic cell. Zr addition also refined the grain size from 488 to 338 μm. An optimal aging treatment at 300 °C for 3 h was established, which enhanced hardness for all alloys via precipitation of Al₃Sc/Al₃(Sc,Zr) particles. However, this Zr substitution reduced thermal conductivity (from 184.7 to 168.0 W/mK) and ultimate tensile strength (from 269 to 206 MPa), though it improved elongation at fracture (from 4.6 to 7.1%). All aged alloys exhibited high corrosion resistance in 5.7% NaCl + 0.3% H₂O₂ water solution, with Zr-containing variants showing a lower corrosion rate and better pitting resistance. The study confirms the potential of tuning Sc/Zr ratios in Al–Zn–Ca alloys to achieve a favorable balance of strength, ductility, thermal conductivity, and corrosion resistance. Full article

Vertical shafts are the lifelines of coal mines, serving as critical conduits for resources and personnel. However, the long-term exposure of shaft walls to groundwater erosion significantly reduces their service life and increases the risk of structural failures. This issue is particularly pressing in Inner Mongolia and Henan Provinces, two of China’s major coal-producing regions, where the challenge of sulfate attack on shafts in deep stratigraphic environments has become a growing concern. This study focused on the corrosion damage observed in these two typical auxiliary shafts: the net diameters and depths of the auxiliary shafts in Shunhe Coal Mine and Mataihao Coal Mine are 6 m and 768.5 m and 9.2 m and 457 m, respectively. The rock section shaft walls in the study range from 5 to 10 m in thickness and are constructed using C40 to C60 grade concrete. To assess the extent of this damage, we conducted a comprehensive analysis of shaft wall samples using water analysis, XRD (X-ray diffraction) analysis, FT-IR (Fourier transform infrared) spectroscopy, and XRF (X-ray fluorescence) analysis. The findings reveal that the identified secondary sulfate reaction products within the shaft wall concrete include calcium sulfate, gypsum, ettringite, and thaumasite. The CaO loss rates in the auxiliary shaft walls of Shunhe Coal Mine and Mataihao Coal Mine are as high as 66% and 47%, respectively. Additionally, the concentrations of SO₃ and MgO in both mines exceed normal levels by up to 5 and 11 times, and 13 and 3 times, respectively. Despite this, severe corrosion is primarily confined to the inner surface of the auxiliary shaft walls, without significant penetration into the deeper shaft structure. The corrosion damage is predominantly concentrated in the shaft sections where the geological environment is characterized by bedrock. This study provides field evidence and laboratory analyses to inform the mitigation of sulfate attack in auxiliary shafts. Full article

Gas well deliquification is a key technology for mitigating liquid loading and restoring or enhancing production capacity in ultra-deep, high-temperature, and high-pressure gas wells. The abnormal corrosion behavior observed in the gas lift tubing of the Well X-1 oilfield in western China, within the 50–70 °C interval (1000–1500 m), was investigated. By analyzing the asymmetric wall thinning and axial groove morphology on the inner surface of tubing and then establishing a two-dimensional model of the vertical wellbore, the gas–liquid flow behavior and associated corrosion mechanisms were also elucidated. Results indicate that the flow pattern evolves from slug flow at the bottomhole, through a transitional pattern below the gas lift valve, to annular-mist flow at and above the valve. The wall shear stress peaks at the gas lift valve coupled with the significantly higher fluid velocity above the valve, which markedly elevates the corrosion rate. In this regime, the resultant annular-mist flow features a high-velocity gas core carrying entrained droplets, whose impingement synergistically enhances electrochemical corrosion, forming severe groove-like morphology along the inner tubing wall. Therefore, the corrosion in this well is attributed to the synergistic effect of the mechano-electrochemical coupling between multiphase flow and electrochemical processes on the inner surface of the tubing. Full article

This study systematically investigates the influence of laser power (1000 W, 1400 W, 1800 W) on the microstructure and properties of Ni25 alloy coatings prepared by laser cladding to optimize process parameters for enhanced comprehensive performance. Through the analysis of multi-dimensional characterization, it is found that the laser power significantly changes the thermal cycle, thus determining the evolution of microstructure. At 1000 W, a fine dendritic structure with dispersed hard phases (BNi₃, BFe₃Ni₃, CrB₂, Cr₇C₃) yielded the highest hardness (442.52 HV) but poor wear (volume loss: 0.3346 mm³) and corrosion resistance (Icorr: 2.75 × 10⁻⁴ A·cm⁻²) due to microstructural inhomogeneity. The 1400 W coating, featuring a uniform γ-Ni dendrite/eutectic network and increased B solid solubility, achieved an optimal balance with the lowest wear rate (0.0685 mm³), superior corrosion resistance (Icorr: 2.34 × 10⁻⁵; A·cm⁻²), and a stable friction coefficient (0.816), despite lower hardness (342.00 HV). At 1800 W, grain coarseness and Cr₇C₃ decomposition led to blocky hard phases, recovering hardness (415.36 HV) and reducing the friction coefficient (0.757), but resulting in intermediate wear and corrosion resistance. This study demonstrates that the uniformity and continuity of the microstructure are the key determinants governing the comprehensive service properties of the laser cladding layer, with their importance outweighing a single hardness index. 1400 W is identified as the optimal laser power, providing critical insights for fabricating high-performance Ni25 coatings in demanding service environments. Full article

Network microstructure titanium matrix composites (NMTMCs) possess excellent performance and are promising for aerospace applications, yet their microstructural heterogeneity poses substantial challenges to achieving high-quality micro-machined surfaces. The aim of this study is to evaluate electrochemical machining (ECM) as a post-processing method for improving the surface quality of NMTMCs after electrical discharge machining (EDM). This study systematically examines the effects of electrolyte concentration, machining voltage, and pulse frequency on surface roughness. Electrochemical measurements in NaCl and NaNO₃ revealed that standalone electrochemical machining causes severe selective corrosion due to the large dissolution rate mismatch between TiBw reinforcements and the Ti-6Al-4V matrix, making it unsuitable for direct finishing. Accordingly, ECM was applied to EDM-prepared surfaces, and under optimized conditions (10 wt.% NaCl, 4.5 V, 200 kHz), ECM effectively mitigates the protrusions at the edges of discharge pits caused by the EDM process. Surface roughness (Sa) is significantly reduced from 0.90 μm to 0.45 μm, and the surface morphology becomes more uniform. These results demonstrate that ECM is a viable post-EDM finishing strategy for achieving high-quality micro-machining of NMTMCs. Full article

This study investigates the effect of electrolytic-plasma hardening time on the microstructure formation, hardness distribution, and corrosion behavior of grade 45 structural steel. The treatment was performed in a 15% aqueous sodium carbonate (Na₂CO₃) solution at an applied voltage of 300 V for different holding times (8, 10, and 12 s). Scanning electron microscopy and X-ray diffraction analyses revealed that increasing the EPH duration promotes the formation of a more uniform martensitic layer and reduces the amount of residual cementite. Microhardness measurements showed an increase in surface hardness from 190 HV for the untreated steel to 770 HV after the longest treatment. The cross-sectional hardness profile indicated the presence of a thin decarburized sublayer and a zone of maximum hardness corresponding to the martensitic structure. Potentiodynamic polarization tests in a 0.5 M NaCl solution showed a slight increase in corrosion current density after treatment; however, the corrosion rate remained within the range of 0.19–0.45 mm year⁻¹, confirming the satisfactory corrosion resistance of the hardened layer. The results demonstrate that controlling the EPH duration allows for optimizing the balance between enhanced hardness and maintained corrosion resistance of grade 45 steel. Full article

Accurate prediction of the internal corrosion rate is crucial for the safety management and maintenance planning of oil and gas pipelines. However, this task is challenging due to the complex, multi-factor nature of corrosion and the scarcity of available inspection data. To address this, we propose a novel hybrid prediction model, GM-Markov-PSO, which integrates a gray prediction model with a Markov chain and a particle swarm optimization algorithm. A key innovation of our approach is the systematic incorporation of symmetry principles—observed in the spatial distribution of corrosion factors, the temporal evolution of the corrosion process, and the statistical fluctuations of monitoring data—to enhance model stability and accuracy. The proposed model effectively overcomes the limitations of individual components, providing superior handling of small-sample, non-linear datasets and demonstrating strong robustness against stochastic disturbances. In a case study, the GM-Markov-PSO model achieved prediction accuracy improvements ranging from 0.93% to 13.34%, with an average improvement of 4.51% over benchmark models, confirming its practical value for informing pipeline maintenance strategies. This work not only presents a reliable predictive tool but also enriches the application of symmetry theory in engineering forecasting by elucidating the inherent order within complex corrosion systems. Full article

This study aims to evaluate the corrosion inhibition performance of different types of inhibitors for steel reinforcement in cement paste under accelerated carbonation conditions. Electrochemical methods, including electrochemical impedance spectroscopy EIS, linear polarization resistance LPR, and open-circuit potential OCP measurements, were utilized on specimens with various inhibitor formulations during exposure to a high-CO₂ environment. The results indicate that composite inhibitors provide the greatest protection, significantly outperforming single-component anodic or cathodic inhibitors. Among anodic inhibitors, sodium molybdate showed more effective corrosion inhibition than sodium chromate, and among cathodic inhibitors, BTA was more effective than DMEA, as evidenced by higher polarization resistance and more stable passivation. After 120 days of carbonation, the specimen with the optimal composite inhibitor remained passive with a low corrosion rate and a relatively noble steel potential, whereas the uninhibited specimen exhibited active corrosion. Full article