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Additive Manufacturing by Selective Laser Melting (SLM) offers ample scope for producing geometrically complex parts as compared to the traditional subtractive manufacturing strategies. However, the residual stresses (RS) developed during the processing can reduce the load bearing capacity as well as induce unwanted distortion, limiting the application of SLM parts. In the present work, residual stresses in additivly manufactured IN718 part were analised by means of neutron diffraction and synchrotron X-ray diffraction.
The work presents the microstructure, chemical composition and mechanical properties of Inconel 686 coatings after high - temperature corrosion in environment of aggressive gases. To produce the Ni - base weld overlays the QS Nd:YAG laser beam was used. The substrates were 13Mo4-5 boilers plate steel. Ni - base alloys characterize the excellent high temperature corrosion resistance, good strength and good ability to work in aggressive environments. Applied overlays had a proper combination of the metal substrate in particular small amount of Fe. This could be achieved by the reduction of the melting of the substrate and its dissolution into the overlays. The microstructure, chemical composition of the obtained overlays were investigated by means of a light microscope, a scanning electron microscope (SEM) equipped with the EDS detector. The overlays had cellular-dendritic structure. The variations of the chemical composition (especially Mo, Ni and W ) in the interdendritic and dendritic regions were observed. The interdendritic regions were enriched during solidifications in Mo and W and had lower content of Ni.
The microstructure of weld overlay Ni - base alloy deposited on carbon steel by laser QS-Nd:YAG
(2017)
Ni- base alloys are used as a one of the most important coating material and can be applied in a different environments and elements of devices having various applications. To protect the surface of the material from aggressive gases at high temperature, there are use different kinds of the Ni- base alloys. One of such alloy is Ni-Cr-Mo-W called commercial Inconel 686. This alloy based on NiCr22Mo9Nb (Inconel 625), in which content of molybdenum increased and niobium was replaced with the addition of tungsten, in order to counteract the strong segregation in the microstructure, which results in homogeneity of the chemical composition of the structure. Inconel 686 is also characterized by greater resistance to high temperature corrosion and heat resistance than Inconel 625. The Inconel 686 alloy was deposited on 13CrMo4-5 steel by laser QS - Nd:YAG. In the poster the microstructure (SEM) and chemical composition (EDS) of obtained weld overlays were investigated.
Up to now, the mechanisms of surface nucleation and surface-induced texture formation are far from being understood. Corresponding phenomena are discussed hypothetically or even controversial, and related studies are restricted to very few glasses. As a main drawback, the vast majority of previous work on oriented growth of surface crystals do not consider the possible effects of glass surface treatments (like polishing defects, adhered particles and cracks, …) or ambient annealing conditions (vacuum or atmospheric pressure) which both can influence crystal nucleation and growth. Moreover, very few observations of crystal orientation related to surface crystallization were focused on separately growing crystals. In conclusion, up to now, no systematic studies on initially oriented crystal growth or nucleation from defined active nucleation sites have been pursued.
Therefore, the main objective of the proposed project is to gain a basic understanding of the mechanisms of surface-induced microstructure formation in glass ceramics. We shall answer the question whether preferred orientation of surface crystals is the result of oriented nucleation or caused by other orientation selection mechanisms acting during early crystal growth. In both cases, crystal orientation may be caused by the orientation of the glass surface itself or the anisotropy and orientation of active surface nucleation defects.
New techniques of experimental characterization of surface-crystallized glasses shall be applied to find answers to the questions posed above. Based on a controlled preparation and annealing of the glass sample surfaces, that includes the defined creation of active nucleation defects, and followed by the microstructural characterization especially during the very early growth stages of separated surface crystals, the orientation relations between defect and initiated surface crystal will be analyzed. In order to gain new insights, a couple of entirely new microstructure diagnostics techniques, including chemically contrasted XRM, laser-based sample preparation for XRM, and 3D electron backscatter diffraction shall be developed or applied.
This way, using X-ray microscopy as a pivotal technique for the non-destructive 3D characterization of relatively large samples at superior spatial resolution (but also complemented by other microstructure diagnostics techniques, e.g. TEM elemental mappings at cross-sectioned samples) unprecedented insights into the microstructure evolution upon surface crystallization of model glasses will be gained.
Absorption edge tomography is a method which exploits the sudden change of the attenuation coefficient, when the photon energy crosses the absorption edge of an element. The beamline BAMline at BESSY II, which is operated by the Federal Institute for Materials Research and Testing, can provide a monochromatized beam in a photon energy range from 5 keV up to 80 keV with a bandwidth of 2%. Together with the microtomography setup, this enables differential tomography sensitive to any element with N >= 24 (Cr) by using an appropriate K- or L-edge in this range. Here, absorption edge tomography at the Yttrium edge is employed to perform a non-destructive 3D characterization of the microstructure of a high strength Mg-Y-Zn alloy. The long period stacking ordered (LPSO) phase which forms fibres in this material was extracted based on the Yttrium content and the fibre length distribution was analysed.
P92 is one of the important steels for super heater tubes used in combustion plants. However, in fossil fuel fired environments the formation of oxides and sulfides are challenging the material. To understand early corrosion mechanisms, which are important for process prediction, high temperature in-situ ageing experiments of Fe-Cr-Mn alloys in SO2 and SO2+H2O atmosphere were performed, applying energy dispersive X-ray diffraction (EDXRD) analysis.
Ferritic alloys containing Cr form Cr5S6 precipitates along grain boundaries in hot SO2 environment. Grain boundary precipitates may influence the steel’s mechanical behavior. Cr5S6 precipitates were reconstructed three-dimensionally using FIB tomography analysis to determine the volume, number, and penetration depth. The volume growth of Cr5S6 precipitates increased only for the initial aging time of 3 h but became constant after 6 h. The number of precipitates increased linearly.
Optimization of laser treatment parameters of Inconel 686 overlay weld on carbon steel 13Mo4-5
(2017)
The work presents the effects of the change of the laser cladding parameters on microstructure, chemical composition and mechanical properties of Inconel 686 overlays (coatings). To obtain the best quality of these coatings the various parameters of laser cladding such as the power density of the laser beam, the laser beam velocity and overlapping ratio of the weld tracks were applied. The substrates were boilers plate made of the 13Mo4-5 steel. Ni - base alloys characterize by the excellent high-temperature corrosion resistance, good strength and good ability to work in aggressive environments. Applied overlays had a proper combination of the metal substrate in particular small amount of Fe. This could be achieved by the reduction of the substrate melting and its dissolution into the overlays. The microstructure, chemical composition of the obtained overlays were investigated by means of a light microscope, a scanning electron microscope (SEM) equipped with the EDS detector. The overlays had cellular-dendritic structure. The variations of the chemical composition (especially Mo, Ni and W ) in the interdendritic and dendritic regions were observed. The interdendritic regions were enriched during solidifications in Mo and W and had lower content of Ni.
An understanding on crystallization behavior and kinetics in glasses is one of the important topics in the glass science and technology. Tsukada et al.1) found an extremely unique and curious phenomenon in the crystallization of multiferroic (ferroelectric and ferroelastic properties) ’-Gd2(MoO4)3 crystals in Gd2O3-MoO3-B2O3 glasses. That is, crystals formed in the crystallization break into small pieces with a triangle prism or pyramidal shape having a length of 50-150 um spontaneously during the crystallization in the inside of an electric furnace, not during the cooling in air after the crystallization. They proposed to call this phenomenon “self-powdering phenomenon”. To the best of our knowledge, such a self-powdering phenomenon has not been observed in the crystallization of any other glasses. To investigate this phenomenon is very important for the glass science and for the preparation of bulk crystallized glasses with ferroelastic crystals. In this work, the preparation of crystallized glasses keeping the original shape is challenged, and the mechanism of self-powdering phenomenon is proposed. Glasses with the compositions of 21Gd2O3-63MoO3-(16-x)B2O3-xTeO2 (mol%) (x=0, 2, 4, 8) such as 21Gd2O3-63MoO3-16B2O3 (GM16B) and 21Gd2O3-63MoO3-8B2O3-8TeO2 (GM8T8B) were prepared using a conventional melt quenching technique. The quenched glasses were heat-treated at some temperatures, and the crystalline phase present in the crystallized samples was identified by X-ray diffraction (XRD) analyses, and the morphology and birefringence of crystals formed were observed using a polarized optical microscope (POM). The densities of GM16B and GM8T8B glasses are 4.76 g/cm3 and 4.91 g/cam3, respectively, and these values are higher than the density of ’-Gd2(MoO4)3 crystal, 4.555 g/cm3. These differences in the density might induce the large stresses in the inside of crystals during the crystal growth. The crystallized glasses of GM16B with ’-Gd2(MoO4)3 crystals do not keep the original glass shape, showing self-powdering phenomenon (breaking into small pieces). However, the crystallized glasses of GM8T8B keep the original glass shape without indicating any self-powdering. It is proposed that the stress at the interface between the glassy phase and ’-Gd2(MoO4)3 crystalline phase might be reduced in GM8T8B glasses containing TeO2 with weak Te-O bonds.
Ferritic-martensitic high temperature alloys are widely used as boiler tube and heat exchanger materials in combustion based power plants. All technologies have in common that the applied materials are exposed to different temperatures, process pressures and reactive atmospheres which lead to a change of the material properties and a further degradation of the material.
To date corrosion analytics mainly proceeds via the use of various microscopic techniques and the analysis of the corrosion products after the reaction is completed. Comprehensive efforts have been made to study high temperature corrosion by the use of environmental SEM’s or in-situ TEM technologies. The here presented work will show a different approach to study high temperature gas corrosion in a multiple gas atmosphere by energy dispersive X-ray diffraction (EDXRD). For this technique high energetic white X-ray radiation (10-100 keV) was used as radiation source instead of conventional monochromatic radiation. It enables us to study crystallization procedures on short and medium time scales (1 min < t < 24 h) and the collection of Bragg-Signals of the phases of interest as a function of process time. Their occurrence can directly be correlated with thermodynamic and kinetic parameters. A special designed corrosion reactor was used to combine high temperature gas corrosion experiments with the collection of diffraction patter. The crystallization and reaction paths for oxide and sulfide formation was followed in-situ on Fe-Cr and Fe-Cr-Mn model alloys in a hot SO2 containing (T=650 °C) atmosphere.
Boehmite nanoparticles (AlOOH) were recently found to improve properties such as crack resistance, shrinkage and compressive strength in epoxy composites. Concentration and surface modification of boehmite nanoparticles are key factors for abovementioned enhancements. To understand the underlying mechanisms, more detailed research of micro- and nanoscopic mechanical properties is required. The presented study aims to investigate the influence of concentration and surface modification of boehmite on the stiffness of the bulk epoxy by means of AFM-based approaches: Force-Distance curves (FDC) on the sub- microscale and Intermodulation AFM and amplitude-dependent force spectroscopy (ADFS) on the nanoscale. For this purpose, stiffness-maps of epoxy filled with boehmite, with and without surface modification (HAc-boehmite) were obtained by FDC. These measurements showed a slight increase in overall stiffness of composite with increasing the nanoparticle content. The stiffening effect was observed to be intensified with HAc-boehmite. Since the lateral resolution of FDC is not high enough to distinguish nanoparticles, this effect was assumed to be due to the inevitable inclusion of nanoparticles in the measurement. By using Intermodulation-AFM, yielding ADFS stiffness maps with the resolution of <10 nm, we were able to calculate the average stiffness of bulk epoxy without the interference of nanoparticles. It was expected that the stiffness of regions faraway from particles would be equal to neat epoxy. In contrast, the results showed a drastic increase in stiffness of epoxy with increasing boehmite concentration (0, 1, 2.5, and 15%) especially in case of introducing 15wt% HAc-boehmite. Another important observation was formation of a spatial structure with non-homogenous stiffness distribution in bulk epoxy with HAc-boehmite. The underlying mechanisms of described observations are not fully understood yet. One hypothesis is the local increase in crosslinking density which we aim to investigate in our further studies by combining Dynamic Mechanical Thermal Analysis (DMTA) and Intermodulation-AFM.
The application of inorganic nanoparticles as reinforcement agent for polymer composites is constantly growing. Improving the performance of the material with desirable properties requires understanding of the interaction between polymer chains and nanoparticles and the properties of the interphase as well. Boehmite, a mineral of aluminum with basic unit of AlO(OH), is a novel and promising nanofiller which leads to enhanced performance of polymer composites. It has been recently reported that boehmite nanoparticles have reinforcing effect on epoxy matrix in carbon-fiber composites. It was primarily assumed that these improvements are due to very high Young’s modulus of boehmite particles. However, in our latest study we presented new values for the Young’s modulus of boehmite much lower than those reported earlier. This brings up the importance of interphase properties, e.g. the crosslink density, which can have the dominant role in the overall material property. Nevertheless, due to resolution limitations of conventional nanoprobing approaches, characterization of the interphase between individual particles and matrix is a challenge.
In this study, the main goal is to investigate the interphase of the epoxy/boehmite nanocomposites using AFM-based methods. We simplify the three-dimensional nanocomposite system to a two-dimensional horizontally layered sample with a large and easy to access interphase area. For this purpose, 1µm coatings of hydrothermally synthesized boehmite are prepared as the substrate on which the epoxy is later molded and cured. AFM surface potential and force maps were obtained on the cross-sectional cut of epoxy/ boehmite sample. The results show unexpectedly a large interphase area (approx. 1 µm) with different electrical and mechanical properties comparing to bulk epoxy. The average force-distance curves from this region showed more elastic behavior compared to bulk. The underlying mechanism of this influence is not fully understood yet. Thus, further investigation on the interphase region using the novel Nano-IR approach provides more information about the chemical characteristics. Numerical simulation will give complementary information to understand the effect of nanoparticles on the crosslinking density of the interphase. This can be different to bulk epoxy due to either different local temperature gradients or due to a surface selectivity of boehmite towards the monomer molecules.
Spray drying based granulation processes aim for flowable granules neither containing voids nor hard shells thus leading to a homogenous microstructure in the green and sinter bodies without strength reducing large pores. The increase of the specific surface area due to the utilization of finer powders as raw materials makes the production of granules of demanded quality more sophisticated. Innovations regarding additives as well as process engineering are therefore required.
While conventional spray granulation processes of ceramic materials are based on rotational, one stream or two stream nozzles for nebulization, the investigations in the ZIM project concentrate on the applicability of an ultra sound atomizer unit. A spray dryer comprised of the aforementioned ultra sound atomization unit implemented in a commercial spray dryer (Niro, Denmark) was used as test system. Potential advantages of the ultra sound nebulization are investigated for model systems of alumina, zirconia and a ZTA composite while focusing on solids content, yield, pressability and granule properties (size, size distribution, flowability, shape and microstructure) as well as the final sinter body properties (density, microstructure and flexural strength).
First ultra sound spray drying experiments yielded granules with excellent processability. Spray drying of identical slurries, as before tested and optimized for a two stream nozzle atomization process, resulted in a more suitable size distribution for dry pressing (less particles below 20 µm) and a higher yield. Furthermore, sinter bodies produced of ultra sound granules seem to have less large pores and a more homogenous microstructure
The results are based on data1. Figure 3 displays temperatures of the tank wall and of the gas phase over testing time. It can be seen that a complete coating strongly delayed the heating of tank wall and gas phase, whereas the partly coated tanks only had a minor influence on temperature development. There was no significant difference between a half coated and a thirdly coated tank measurable. Figure 4 shows the internal pressure of tanks over testing time. Only the fully coated tank enabled a low pressure over 90 min testing time. Hence, a complete coating is necessary to guarantee the fire safety of hazmat tanks and a partly coating is not sufficient.
Fluorescence microscopic and spectroscopic monitoring of degradation processes upon polymer ageing
(2017)
The majority of all routinely used methods to assess polymer aging are based on destructive tests and methods. Early indicators for the deterioration of polymer materials are e.g., physical or mechanical properties like tensile strength, adhesion, brittleness, and color. It is well-known, however, that predominantly chemical changes are the underlying process of the physical changes that occur in organic materials upon aging over time. Typical initial steps during polymer degradation are crosslinking or chain breaking, alteration of autofluorescence, “yellowing” or bleaching caused by the formation of new functional groups. A straightforward strategy towards the sensitive detection and monitoring of chemical changes in the course of polymer aging is based on non-destructive optical measurements. Luminescence techniques, one of the most sensitive spectroscopic methods are the method of choice. Here, we present first results of luminescence-based monitoring of polymer degradation induced by different environmentally relevant weathering factors (e.g. humidity and UV exposure). Our studies include fluorescence spectroscopy as well as spectral scanning confocal fluorescence microscopy and clearly demonstrate the possibility to follow accelerate-aging processes by luminescence detection.
One of today’s major problems in many technical plants as well as fuel tanks is Microbial induced corrosion (MIC), leading to considerable damage and huge financial losses. Successful prevention of MIC requires the localization of first signs of corrosion as well as the identification of factors influencing the corrosion process. Hence, there is a growing need for sensitive and preferably inexpensive tools that enable the early detection of MIC. Of utmost importance are methods, which provide spatially and time-resolved information and allow the determination of corrosion rates at sites of interest for possible prevention of MIC.
Polyurethanes (PU) are formed by polyaddition reaction between diols and diisocyantes. They can be formed utilizing three building blocks, namely a polyol or long-chain diol, a chain extender or short-chain diol, and a diisocyanate. The derived multi-phase block copolymer has thermoplastic properties and is called thermoplastic PU (TPU). This modular approach allows for a variety of alternations yielding a broad range of structural properties and applications. TPUs are based on three main classes of polyols, i.e. polyethers, polyesters, and polycaprolactones. With these different polyols and the ability of changing the ratio of building blocks a variety of material properties can be obtained thus TPUs find numerous applications in e.g. lightweight construction1, insulation, flame retardants, lacquer and glue, as well as medicine.
Linear, isocyanate terminated, polyurethane prepolymers prepared from non-equivalent amounts of diisocyanate such as methylene diphenyl diisocyanate (MDI) attached to a polyol are widely used as precursors of the correspondent polymers. Chain-extending reactions with low molecular weight compounds bearing different amounts of active hydrogens enable both linear and crosslinked polyurethane to be formed.
Due to TPUs being used in a broad range of applications facing a variety of stress (e.g. mechanical, hydrolytic, thermal, radiative/UV, as well as its combinations) the complexity of possible degradation mechanism is high. A functional group derived from degradation of the bulk matrix can be detected utilizing a suited fluorogenic sensor molecule. There are several fluorogenic dyes known for the application as sensor for amine groups e.g. fluorescamine, pyrylium dyes, deriving a fluorescent signal upon reaction.
Experimental study on M23C6 nucleation and growth mechanisms in Ni-base superalloy single crystals
(2017)
The addition of carbon to Ni-base superalloy single crystals has been increasingly carried out to improve low angle grain boundary (LAGB) resistance and castability. Consequently, the precipitation of carbides is highly probable during long-term application of components subjected to higher temperatures (> 1000 °C). While the view on the role of carbides as strengthening or detrimental is polemical, their inevitable increased presence in carbon-doped alloys must be addressed. In the present work, the evolution of M23C6 carbides forming in the commercial grade Ni-base superalloy LEK 94 during high-temperature and low-stress creep exposure is assessed. Although carbon is not intentionally added to the LEK 94 alloy, it admits up to 0.1 at. %, which together with the high content of M23C6-forming transition metals, leads to their precipitation. The precipitation is induced here during creep experiments at 1020 °C and a nominal applied stress of 160 MPa along [001]. The correlation of precipitation and external load is carried out by evaluating the carbides in the gage section of parallel and circularly notched cylindrical samples, as well as in their heads. Characterization is made by transmission electron microscopy (TEM). Although primary MC carbides form mostly in interdendritic regions during casting, high temperature exposure induces M23C6 carbide nucleation especially in the γ phase of dendritic regions, where a stronger partitioning of refractory elements is present. The carbides have a needle shape with their main axis on 〈100〉 and a cube-on-cube orientation relationship. They present incoherent {100} facets along their elongated region and semi-coherent {111} facets at their ends. Their nucleation and growth mechanisms are discussed based on microstructural observation under different experimental conditions.
Mechanochemistry has become a valuable method for the synthesis of new materials, especially for pharmaceutical cocrystals. The Advantages of fast reactions in high purity and yield face a lack of understanding the underlying mechanism. Therefore, in situ setups to study mechanochemical reactions have been established. Herein, we present an in situ investigation of the mechanochemical cocrystal formation of pyrazinamide (PZA) with pimelic acid (PM) using synchrotron XRD. Two new polymorphs of PZA:PM (1:1) were synthesized by milling the starting materials in milling jars of different materials. While Form I is only obtained using a steel jar, Form II can be obtained purely in jars made of Perspex. In situ XRD experiments reveal a direct formation of Form II in Perspex and an intermediate formation of Form II in steel jars converting to Form I upon further grinding. Heating experiments and DFT calculations predict that Form II is the thermodynamically more stable polymorph. Therefore, the reaction progress in the steel jar contradicts Ostwald’s rules of stages as the more stable Form II converts into the metastable Form I. Hence, mechanochemistry offers the possibility to synthesize new materials that cannot be obtained using conventional methods.