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- монокристалл (1)
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Organisationseinheit der BAM
- 5 Werkstofftechnik (1137)
- 5.1 Mikrostruktur Design und Degradation (338)
- 5.2 Metallische Hochtemperaturwerkstoffe (277)
- 5.4 Multimateriale Fertigungsprozesse (216)
- 5.6 Glas (151)
- 5.3 Polymere Verbundwerkstoffe (131)
- 5.5 Materialmodellierung (115)
- 8 Zerstörungsfreie Prüfung (107)
- 9 Komponentensicherheit (98)
- 7 Bauwerkssicherheit (91)
Paper des Monats
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The use of high niobium alloyed cast iron alloys is a relatively new approach in which the niobium addition intends to improve the properties of the material by the precipitation of hard niobium carbides during solidification. Steels can be replaced by ductile cast iron in some rolling applications, such as gears and cams, in order to reduce material costs. The aim of this work is to evaluate ductile iron alloyed with 1 weight percent (wt.%) niobium for the as cast specimens and with 1.8 wt.% and 2.4 wt.% niobium for the austempered specimens under lubricated slip-rolling tests using mixed/boundary conditions in an Amsler-type machine. Austempered ductile iron (ADI) alloyed with 1 wt.% chromium, or Carbidic ADI, was tested for comparison. For the as cast conditions, the niobium addition resulted in an increase of wear resistance owing to the low contact pressure of these tests. However, for the austempered specimens, the best performance was found for unalloyed ADI. The main factor acting in the initiation and propagation of cracks in ductile iron is the presence of the graphite nodules. The coarse carbides also contributed to the initiation of cracks and spalling of the material.
Die warmfeste austenitische Gusseisenlegierung EN-GJSA-XNiSiCr35-5-2 (häufig auch als Ni-Resist D-5S bezeichnet) wurde hinsichtlich ihres mechanischen Verhal-tens bei hoher Temperatur charakterisiert. Dazu wurden (isotherme) niederzyklische (LCF-) und (nicht-isotherme) thermomechanische Ermüdungsversuche (TMF) zwischen Raumtemperatur und 900 °C durchgeführt. Diese Ergebnisse dienten (zu-sammen mit weiteren Versuchsdaten) der Kalibrierung werkstoffmechanischer Modelle. Bei den höchsten Prüftemperaturen wurde Schädigung in Form von Kriechen beobachtet und metallographisch dokumentiert.
Despite of the significant advances in AM process optimization there is still a lack of experimental results and understanding regarding the mechanical behavior and microstructural evolution of AMparts, especially in loading conditions typical for safety-relevant applications e.g. in the aerospace or power engineering. Within the scope of the presented investigations, a characterization of the fatigue behavior of additively manufactured Ti-6Al-4V in the low cycle fatigue regime was carried out in the range of 0.3 to 1.0 % strain amplitude at room temperature, 250°C and 400°C. The Ti-6Al-4V specimens are machined out of lean cylindrical rods, which were fabricated using powder laser metal deposition (LMD) with an improved build-up strategy. The improved strategy incorporates variable track overlap ratios to achieve a constant growth in the shell and core area. The low-cycle-fatigue behavior is described based on cyclic deformation curves and strain-based fatigue life curves. The lifetimes are fitted based on the Manson-Coffin-Basquin relationship. A characterization of the microstructure and the Lack-of-Fusion (LoF)-defect-structure in the as-built state is performed using optical light microscopy and high-resolution computed tomography (CT) respectively. The failure mechanism under loading is described in terms of LoF-defects-evolution and crack growth mechanism based on an interrupted LCF test with selected test parameters. After failure, scanning electron microscopy, digital and optical light microscopy and CT are used to describe the failure mechanisms both in the longitudinal direction and in the cross section of the specimens. The fatigue lives obtained are comparable with results from previous related studies and are shorter than those of traditionally manufactured (wrought) Ti-6Al-4V. In this study new experimental data and understanding of the mechanical behavior under application-relevant loading conditions (high temperature, cyclic plasticity) is gained. Furthermore, a better understanding of the role of LoFdefects and AM-typical microstructural features on the failure mechanism of LMD Ti-6Al-4V is achieved.
Die Untersuchung und Charakterisierung der Entwicklung/Änderung der Mikrostruktur, der mechanischen Eigenschaften sowie der Lebensdauer additiv gefertigter metallischer Werkstoffe hat bisher, vor allem im Hinblick auf die komplexe Belastungsfälle bei sicherheitsrelevanten Anwendungen, mit der rasanten Entwicklung der Fertigungstechniken nicht Schritt gehalten. Im Rahmen dieser Arbeit wurde eine Charakterisierung des Ermüdungsverhaltens von additiv gefertigten TiAl6V4 im Low-Cycle-Fatigue Bereich (niederzyklische Ermüdung) nach Norm ISO 12206 mit Dehnungsamplituden von 0.3 bis zu 1.0 % und bei Raumtemperatur, 250°C und 400°C durchgeführt. Die TiAl6V4 Proben wurden aus zylindrischen Halbzeugen gefertigt, welche durch Laser-Pulver-Auftragsschweißen mit einer optimierten Aufbaustrategie hergestellt wurden. Die optimierte Aufbaustrategie beinhaltet variierende Spurüberlappungsgraden, die die Fertigung der dünnen zylindrischen Körper ohne weitere Ausgleichslagen ermöglicht. Das Werkstoffverhalten wird anhand von Wechselverformungskurven sowie einer Darstellung der Lebensdauer in einem Wöhler-Diagramm beschrieben. Ein Fitting der Lebensdauer-Daten erfolgt anhand der Manson-Coffin-Basquin Beziehung. Eine Eingangscharakterisierung der mikrostrukturellen Merkmale inklusive Bindefehler aus dem Herstellungsprozess wird durch Lichtmikroskopie und hochauflösende Computertomographie (CT) durchgeführt. Der Versagensmechanismus während der Belastung wird anhand von Zwischenuntersuchungen mit CT und einem unterbrochenen Versuch mit ausgewählten Versuchsparametern beschrieben. Nach dem Versagen wurden die Proben am REM, mit Lichtmikroskopie und mit CT fraktographisch in Längs- und Querrichtung untersucht. Die erfassten Lebensdauern sind ähnlich zu denen aus herkömmlichen Studien und liegen unter derjenigen von dem konventionell hergestellten (geschmiedeten) Werkstoff. In dieser Arbeit wurden für den untersuchten Werkstoff bei anwendungs- und sicherheitsrelevanten Belastungszuständen (hohe Temperaturen, zyklische Plastizität) neue experimentelle Daten und Kennwerte ermittelt und Verständnis über das mechanische Verhalten und die Entwicklung der Mikrostruktur aufgebaut. Darüber hinaus wurde Verständnis über die Rolle von Bindefehlern und anderen typisch für AM auftretenden Gefügemerkmalen auf das Versagensverhalten von DED-L TiAl6V4 gewonnen.
The coefficient of thermal expansion (CTE) and the thermomechanical properties of the polymers used in superconducting magnets need to be known in order to predict their stress state under the different magnet assembly and operating conditions.
We have measured Young’s moduli of typically used polymers during in situ heat cycles with the dynamic resonancemethod. The dynamic test results are compared with Young’s moduli determined from quasi-static stress–strain measurements at room temperature, 77 K and 4.2 K. A moderate elastic anisotropy is found for the fiber reinforced polymers. CTEs are compared based on dilation experiments. TheCTEs of the fiber reinforced polymers studied are similar to those of copper or steel. In contrast, the pure resins exhibit relatively larger CTEs.
Despite of the significant advances in additive manufacturing (AM) process optimization there is still a lack of experimental results and understanding regarding the mechanical behavior and its relationship with the microstructural features of AM-parts, especially in loading conditions typical for safety-relevant applications. Within the scope of the presented ongoing investigations, a basic microstructural characterization, tensile tests at room and elevated temperature (400°C) as well as a characterization of the fatigue behavior of additively manufactured Ti-6Al-4V in the low cycle fatigue regime are carried out in the as-built state. After failure, different techniques are used to describe the failure mechanisms of the specimens. The AM-Specimens are provided by the Fraunhofer institute for production systems and design technology and investigated at the BAM following the philosophy of the TF-Project AGIL.
Die BAM ist nahezu über die gesamte Wertschöpfungskette hinweg wissenschaftlich tätig. Von der sicheren und effizienten Wasserstofferzeugung (POWER-to-GAS), über die (Zwischen-)Speicherung von Wasserstoff in Druckgasspeichern bis hin zum Transport bspw. mittels Trailerfahrzeug zum Endverbraucher.
Komplettiert werden die Aktivitäten der BAM durch die sicherheitstechnische Beurteilung von wasserstoffhaltigen Gasgemischen, die Verträglichkeitsbewertung von Werkstoffen bis hin zur Detektion von Wasserstoffkonzentrationen über geeignete Sensorik, auch mittels ferngesteuerter Messdrohnen (sog. UAV-Drohnen).
Zudem untersucht die BAM proaktiv Schadensrisiken und Unfallszenarien für die Sicherheitsbetrachtung, um mögliche Schwachstellen aufzeigen und potenzielle Gefährdungen erkennen zu können.
During capture and storage technology (CCS) as well as in geothermal energy production Steels need to withstand the corrosive environment such as: heat, pressure, salinity of the aquifer and CO2-partial pressure. 1.4542 shows unusual corrosion phenomena, but is still sufficiently resistant in corrosive environments. To better understand its behaviour differently heat treated coupons of 1.4542 and for comparison X20Cr13 and X46Cr13 were kept in the artificial brine of the Northern German Basin at T=60 °C. Ambient pressure as well as p=100 bar for 700 h - 8000 h in water saturated supercritical CO2 and CO2-saturated synthetic aquifer Environment was applied. Fatigue tests were performed via push-pull tests with a series of 30 specimens from 150 MPa to 500 MPa (sinusoidal dynamic test loads, R=-1; resonant frequency ~ 30 Hz). FeCO3 and FeOOH are corrosion products also after dynamic corrosion tests. Martensitic microstructure offers good corrosion resistance in geothermal environment. The S-N-curve showing no typical fatigue strength and very steep slopes of possible fatigue strength for finite life. Possible influencing artefacts, such as Al-inclusions could not be correlated to early rupture despite specimens containing inclusions at the fracture surface and cross section reached lower number of cycles. Applied potential proofed to enhance fatigue life tremendously.
Friction stir welding (FSW) of high-melting temperature alloys, such as steel and Inconel, requires tooling that can survive under the applied loads at the elevated temperatures. Tungsten-Rhenium (W-Re) alloys are a suitable candidate for this application; however, the costs typically associated with achieving the required densities and grain structure for the tooling are high due to the lengthy traditional processing required. Further costs are incurred in machining the starting bar stock to the final FSW tooling configuration. An alternate processing method is used in this study to shorten the fabrication time using direct current sintering which rapidly consolidates the starting powders at lower temperatures than used in traditional powder metallurgy. Although this process enables retention of the fine grain size, the sintering time is too short to form the desired single, solid phase. Therefore, the specimens were subjected to a post-consolidation heat treatment to fully solutionize the W matrix. Once the desired density and solid solution phase was verified in coupons, the final processing parameters were used to consolidate a net shape tool for FSW.
Corrosion fatigue specimen with different surfaces (technical surfaces after machining and polished surfaces) of high alloyed martensitic stainless steel X46Cr13 (1.4043) and duplex stai nless steel X2CrNiMoN22 3 2 (1.4462) were compared at load amplitudes from 175 MPa to 325 MPa in the geothermal brine of the N orthern German Basin at 98 °C. Surface corrosion layers and pits reveal carbonate corrosion products on the surface such as FeCO 3 and FeOOH as the main precipitation phases with no dependence on the original surface roughness . At high stress amplitudes above 275 MPa technical surfaces (P50% at σa 300 MPa=5 × 10 5 ) resulted in more cycles to failure than polished (P50% at σa 300 MPa=1.5 × 10 5 ). The greater slope coefficient for technical surfaces k = 19.006 compared to polished surfaces k =8.78 demonstrate s earlier failure at given stress amplitude σa .
Geothermal energy is one of the most promising energy resources to replace fossil fuel. To extract this energy, hot fluids of various salts and gases are pumped up from a geothermal well having a certain depth and location. Geothermal wells in volcanic regions often contain highly corrosive CO2 and H2S gases that can be corrosive to the geothermal power-plants, which are commonly constructed of different steels, such as carbon steel. This research focuses on the corrosion behaviour of carbon steel exposed to an artificial geothermal fluid containing CO2 gas, using an artificial acidic-saline geothermal brine as found in Sibayak, Indonesia. This medium has a pH of 4 and a chloride content of 1,500 mg/L. Exposure tests were conducted for seven days at 70 °C and 150 °C to simulate the operating temperatures for low and medium enthalpy geothermal sources. Surface morphology and cross-section of the specimens from the above experiments were analysed using scanning electron microscope (SEM) and energy dispersive X-ray (EDX). Electrochemical tests via open circuit potential (OCP) and electrochemical impedance spectroscopy (EIS) were performed to understand the corrosion processes of carbon steel in CO2-containing solution both at 70 °C and 150 °C. Localized corrosion was observed to a greater extent at 70 °C due to the less protectiveness of corrosion product layer compared to that at 150 °C, where FeCO3 has a high corrosion resistance. However, a longer exposure test for 28 days revealed the occurrence of localized corrosion with deeper pits compared to the seven-day exposed carbon steel. In addition, corrosion product transformation was observed after 28 days, indicating that more Ca2+ cations incorporate into the FeCO3 structure.
Carbon Capture and Storage (CCS) is identified as an excellent technology to reach the target of CO2 reduction. However, the safety issue and cost-effectiveness hinder the future of CCS. For the reliability and safety issues of injection wells, the corrosion resistance of the materials used needs to be determined.
In this study, representative low-cost materials including carbon steel 1.8977 and low alloyed steel 1.7225 were investigated in simulated pore water at 333 K and under CO2 saturation condition to represent the worst-case scenario: CO2 diffusion and aquifer fluid penetration. These simulated pore waters were made from relevant cement powder to mimic the realistic casing-cement interface. Electrochemical studies were carried out using the pore water made of cement powder dissolved in water in comparison with those dissolved in synthetic aquifer fluid, to reveal the effect of cement as well as formation water on the steel performance. Two commercially available types of cement were investigated: Dyckerhoff Variodur® and Wollastonite. Variodur® is a cement containing high performance binder with ultra-fine blast furnace slag which can be used to produce high acid resistance concrete. On the other hand, Wollastonite is an emerging natural material mainly made of CaSiO3 which can be hardened by converting to CaCO3 during CO2 injection.
The results showed the pH-reducing effect of CO2 on the simulated pore water/aquifer (from more than 10 to less than 5) leading to the active corrosion process that happened on both 1.8977 and 1.7225. Electrochemical characterization showed negative free corrosion potential and polarisation curves without passive behaviors. The tested coupons suffered from pitting corrosion, which was confirmed by surface analysis. Interestingly, basing on the pit depth measurements from the tested coupons and the hardness of cement powder, it is suggested that Variodur® performed better than Wollastonite in both aspects. The electrochemical data was compared to that resulted from exposure tests to give a recommendation on material selection for bore-hole construction.
During carbon sequestration the CO2-induced corrosion of injection pipe steels is a relevant safety issue when emission gasses are compressed into deep geological layers. The reliability of the high alloyed steel X35CrMo17 suitable as injection pipe for the geological onshore CCS-site (Carbon Capture and Storage) in the Northern German Basin, is demonstrated in laboratory experiments in equivalent corrosive environment (T = 60 °CC, p = 1–100 bar, aquifer water, CO2-flow rate of 9 L/h, 700–8000 h exposure time). Corrosion kinetics and microstructure were characterized and compared to other potential injection pipe steels (42CrMo4, X46Cr13, X20Cr13 and X5CrNiCuNb16-4).
Coupons of X5CrNiCuNb16-4 that may be used as injection pipe with 16% Chromium and 0.05% Carbon (1.4542, AISI 630) were exposed for 3000 h to CO2-saturated saline aquifer water similar to the conditions in the Northern German Basin at ambient pressure and 60 °C. Surface corrosion layers and pits reveal carbonate corrosion products on the surface such as FeCO3 and FeOOH as the main precipitation phases with no dependence on the original surface roughness. Corrosion rates for polished and technical surfaces were below 0.005 mm/year compared to corrosion rates of 0.035 mm/year after shot peening.
Electrochemical deposition of polyaniline on carbon steel for corrosion study in geothermal solution
(2019)
Polyaniline has been widely developed for many applications, e.g. sensor, supercapacitor components, electrochromic devices, and anticorrosion pigments. Although the addition of polyaniline pigment in organic coatings has been an alternative for corrosion protection in industrial applications, the protection mechanism is still not fully understood. Herein in this study, as a part of the development of polyaniline/silicon dioxide coating for geothermal application, polyaniline has been deposited electrochemically on carbon steel surface in oxalic acid medium and tested in geothermal solution to understand the contribution of polyaniline to the corrosion protection of a polyaniline-based composite in the geothermal system. To observe the surface/interface reaction between the electrolyte and electrode surface during the electrochemical polymerization, electrochemical impedance spectroscopy (EIS) was applied after each cycle. For corrosion study in the geothermal application, an artificial geothermal solution was used with the composition of 1,500 mg/l Cl⁻, 20 mg/l SO₄²⁻, 15 mg/l HCO₃⁻, 200 mg/l Ca²⁺, 250 mg/l K⁺, and 600 mg/l Na⁺, and pH 4 to simulate a geothermal brine found in Sibayak, Indonesia. An electrochemical measurement was performed by monitoring the open circuit potential over seven days, with the interruption by EIS every 22 hours. The experiments were performed at room temperature and 150 °C (1 MPa) in an oxygen-free environment. Impedance spectra showed a reduction of the total impedance value of approximately 10 times for specimens measured at 150 °C compared to the specimens measured at room temperature, suggesting a less stable layer at high temperature.
This contribution provides current findings regarding materials susceptibility for carbon capture, utilization and storage (CCUS) applications. Basing on results gathered in 2 German long-term projects (COORAL and CLUSTER) suitable materials are introduced as well as dominating impurities of the CO2-stream and corrosion mechanisms. Investigations cover the whole CCUS process chain and provide material recommendations for certain parts.
The current competitive situation on electricity markets forces conventional power plants into cyclic operation regimes with frequent load shifts and starts/shutdowns. In the present work, the cyclic mechanical behavior of ferritic-martensitic 9-12 % Cr steels under isothermal and thermomechanical loading was investigated for the example of grade P92 material. A continuous softening was observed under all loading conditions. The introduction of hold periods to the applied cycles reduced material lifetime, with most prominent effects at technologically relevant small strain levels. The microstructural characterization reveals a coarsening of the original “martensitic” lath-type microstructure to a structure with polygonal subgrains and reduced dislocation density. The microstructural data forms the input for a physically-based modelling approach.