Hastelloy C-276 Research Articles

Enhanced cavitation erosion and electrochemical corrosion properties of additively manufactured Hastelloy C276 coating by ultrasonic shot peening

Enhanced cavitation erosion and electrochemical corrosion properties of additively manufactured Hastelloy C276 coating by ultrasonic shot peening

Exploring cryo-MQL medium for hard machining of hastelloy C276: a multi-objective optimization approach

Exploring cryo-MQL medium for hard machining of hastelloy C276: a multi-objective optimization approach

Optimization of process parameters in micro electrochemical machining using TOPSIS technique with Analytical Hierarchy Process (AHP)

Electro-chemical machining (ECM) is one of the extensively used unconventional machining processes employed in industries to machine difficult-to-machine materials such as super alloys, titanium alloys, stainless steel, etc It does not impart any mechanical stresses on the workpiece. The primary requirement of the work material used in this process should be electrically conductive materials. In favour of these characteristics, Hastelloy C276 is used as a work material because it exhibits excellent physical properties over cast iron. Generally, the quality of machining mostly relies on the electrolyte (mmol L−1), feed rate (mm/rev), and duty ratio. These credential parameters are considered in this present work to enhance the machining quality, such as circularity, taper angle, and metal removal rate (MRR). The Taguchi L9 orthogonal array is used to learn machining behaviour under various circumstances. And this time, an Analytic Hierarchy Process (AHP) is used to allocate the weight for each response in the TOPSIS multi-criteria decision-making method. According to the findings, sodium nitrate (NaNo3) has a higher metal removal rate than sodium chloride (NaCl) and sodium bromide (NaBr). It will, however, result in a low-quality hole. The taper angle is inversely proportional to the feed rate.

Meso-level surface modification of Hastelloy C276 by WS2 powder mixed electrical discharge alloying process through micro-EDM setup

The present research provides a rigid, wear-resistant lubricating localized layer on Hastelloy C276 (HC 276) surface at meso level by tungsten disulphide (WS2) powder suspended electrical discharge alloying (EDA) process through micro-electrical discharge machining (μ-EDM) setup. The performance characteristics of the coated surface were evaluated in terms of material deposition rate (MDR), surface morphology, surface roughness (Ra, Rz and Rq), recast layer thickness (RLT), compositional analysis, micro-hardness & indentation depth, wear test and water contact angle analysis. Maximum MDR has been achieved at 15 g/L WS2 concentration and 80 V of gap voltage whereas The RLT varies from 6.87 μm to 18.91 μm and is enhanced with the increase in WS2 concentration. The critical surface characterization confirms higher WS2 concentration reduces the crater dimensions and the presence of micro-cracks and micro-voids on the coated surface. The surface roughness has been increased with the gap voltage and capacitance, whereas higher WS2 concentration provides lower surface roughness. X-Ray diffraction analysis (XRD) confirms the presence of hard and wear resistance phases like WC, WO3, ZnO, and MoO2 on the coated surface. Energy-Dispersive X-Ray Spectroscopy (EDS) analysis along with elemental mapping justifies tool, dielectric materials, and powder particles migration on the coated surface. The micro-hardness of the coated surface (402 HV to 1166 HV) is enhanced by 3–4 times compared to the base material (299 HV) whereas the indentation depth has been reduced with the rise in WS2 concentration and lies within the RLT of the coated surface. The wear rate of the WS2 coated surface is drastically reduced compared to the base material with a lower value of coefficient of friction (COF). The coated surface became hydrophobic in nature with a contact angle of 109.6° compared to the hydrophilic base HC 276.

Prediction of specific cutting energy consumption in eco-benign lubricating environment for biomedical industry applications: Exploring efficacy of GEP, ANN, and RSM models

This study emphasizes the criticality of measuring specific cutting energy in machining Hastelloy C276 for biomedical industry applications, offering valuable insights into machinability and facilitating the optimization of tool selection, cutting parameters, and process efficiency. The research employs artificial intelligence-assisted meta-models for cost-effective and accurate predictions of specific cutting energy consumption. Comparative analyses conducted on Hastelloy C276, utilizing a TiAlN-coated solid carbide insert across various media (dry, MQL, LN2, and MQL+LN2), reveal the superiority of hybrid LN2+MQL in reducing specific cutting energy consumption. Subsequently, the analysis of variance underscores the cutting speed as the most influential parameter as compared to other inputs. Finally, a statistical evaluation compares the Gene Expression Programming (GEP) model against the Artificial Neural Network (ANN), and Response Surface Methodology model, demonstrating the superior predictive performance of the GEP meta-model. The GEP model demonstrates validation results with an error range of 0.25%–1.52%, outperforming the ANN and RSM models, which exhibit an error range of 0.49%–8.33% and 2.68%–10.18%, respectively. This study suggests the potential integration of contemporary intelligent methodologies for sustainable superalloy machining in biomedical industry applications, providing a foundation for enhanced productivity and reduced environmental impact of surgical instrument and biomedical device machining.

Investigation of Microstructure and Mechanical Characteristics of Thin-walled Hastelloy C-276 Manufactured Through Pulsed-Arc Additive Manufacturing Technique

Investigation of Microstructure and Mechanical Characteristics of Thin-walled Hastelloy C-276 Manufactured Through Pulsed-Arc Additive Manufacturing Technique

Combination effects of laser heating and water cooling on the repair performance of Hastelloy C-276 by underwater laser direct metal deposition

The Ni-based Hastelloy C-276 was repaired by in-air and underwater laser direct metal deposition (in-air DMD and UDMD) with four gradient cooling rates (in-air DMD, in-air DMD with interlayer cooling, UDMD and UDMD with each layer re-covered by water). The microstructure and mechanical properties of repaired samples were systematically characterized with respect to the cooling rates. All samples presented good metallurgical bonding and columnar dendrites with epitaxial growth. The underwater environment had a more pronounced acceleration effect on the cooling rate compared to interlayer cooling. The rapid cooling induced intense thermal cycling, resulting in increased dislocation density and grain refinement with primary dendrite arm spacing (PDAS) diminishing from 5.30 to 3.21 μm. Accelerated cooling rate contributed to precipitation of massive M6C carbides. Carbides coarsened (sizes from 257 to 354 nm) and exhibited a reduced content as cooling rate slowed down due to intrinsic heat treatment (IHT). The residual water film in UDMD repair promoted oxide formation. Samples with increased cooling rates exhibited superior mechanical performance. The improved microhardness, tensile and impact properties were primarily attributed to the enhanced fine grain strengthening and Orowan strengthening facilitated via reduced grain size, increased dislocation density and carbide content. Quantities of large-size carbides were detrimental to tensile and impact properties as displayed in the in-air DMD sample with interlayer cooling (carbide size of 341 μm). The study could serve as a reference for in-situ restoration in deep-water environments.

Experiment-based process modelling and analysis in Nd:YAG laser cutting of Hastelloy C-276: RSM-CCD technique

Experiment-based process modelling and analysis in Nd:YAG laser cutting of Hastelloy C-276: RSM-CCD technique

Hastelloy C276/AISI SS304 dissimilar metal welding: A comparative review of the effective application of laser and Micro-GTAW

Hastelloy C276, known for its high temperature strength and corrosion resistance, is essential in the manufacture of medical devices and aerospace components. This study developed a micro-controlled GTA welding technology capable of precisely welding 0.4 mm thick dissimilar metals, Hastelloy C276 and SS304. This technology utilizes advanced digital signal processing (DSP) to control the arc time with precision up to 1/100 of a second and improves the welding quality through spot stitch and cold-welding functions. Moreover, the use of 300A inverter-type GTA welding equipment and 2 kW fiber laser welding equipment in this study improved the precision of the welding process. The effectiveness of this technology has been validated through macro-inspections and heat-affected zone (HAZ) analysis. The new welding technique demonstrates the potential to overcome existing welding limitations on thin Hastelloy C276 plates by integrating digital signal processing and rapid response control mechanisms.

Corrosion characteristics of Fe, Ni and Ti based alloys near the critical point of water and during supercritical water gasification and oxidation of municipal sludge

Supercritical water gasification (SCWG) and oxidation (SCWO) were promising technologies for treating municipal sludge; however, corrosion hindered their development. To obtain the candidate material for preheaters, corrosion characteristics of 316, 316 L, Incoloy 800, 825, and TA-10 were investigated at 350 °C and 400 °C. For SCWG and SCWO reactors, corrosion behaviors of 316, Incoloy 800, 825, Inconel 600, 625, and Hastelloy C276 were explored at 450 °C and 520 °C, with and without oxidants. Near the critical point of water, corrosion rates of all materials were below 0.4 mm·a−1, with 316 L being the candidate material. According to the pH variation, materials underwent activation (350 °C) and passivation (400 °C) pathways. During SCWG and SCWO, Incoloy 825 and Inconel 625 were prioritized at 450 ℃ and 520 ℃, exhibiting corrosion rates below 0.40 mm·a−1 and 0.50 mm·a−1, respectively. Chemical corrosion dominated and double-layer oxide films (Fe3O4-FeCr2O4 and NiO-Cr2O3) formed.

Numerical and experimental studies on dissimilar joining of Hastelloy C-276 and SS-316L using microwave hybrid heating at 2.45 GHz

Dissimilar joints of SS-316L and C-276 (Hastelloy) were developed using C-276 powder with microwave exposure 600 s in microwave applicator (2.45 GHz, 900 W). A multi-physics model was validated with experimental studies and simulation were carried out to analyse the microwave-joint interaction characteristics. The simulation results showed that a concentrated electric field (5.86 × 104 V/m) and higher resistive losses (3.07 × 107 W/m3) at the joint region facilitated rapid heat generation locally. Microstructural characterization of the joint revealed the formation of cellular grains such as Fe-Ni intermetallic phases with Mo, Cr and W-carbides along the grain boundaries. Joints exhibited average microhardness of 290 HV, and tensile strength of 425 ± 10 MPa and 14% elongation with failure due to both ductile and brittle fracture modes.

Influence of process parameters on forming quality of largesize nickel-based alloy tubes

In order to improve the forming quality of largesize nickel-based alloy chemical tubes, the influence of different tube specifications and mandrel/tube clearances on the bending forming quality of largesize Hastelloy C-276 alloy tubes was studied. A finite element (FE) analysis model for NC rotary drawing bending (RDB) was established and verified. The results show that with the increasement of the clearance, the wall-thinning ratio [Formula: see text] of different tube specifications gradually decreases, and the wall-thickening ratio [Formula: see text] and ovality [Formula: see text] gradually increase. As the measuring angle increases, the [Formula: see text] of different specifications initially increases and then decreases. The [Formula: see text] exhibits a trend of initially increasing and then decreasing. It is reasonable to take about 1/8 of the wall thickness t for the mandrel/tube clearance. It is of great significance for guiding the bending forming of largesize nickel-based alloy chemical tubes and development of intelligent forming equipment.

Microstructure and Tensile Properties of Microwave Welded Hastelloy C-276 Joints

Microstructure and Tensile Properties of Microwave Welded Hastelloy C-276 Joints

Prediction of HVAF thermal spraying parameters and coating properties based on improved WOA-ANN method

In this study, high-velocity air fuel (HVAF) thermal spray technology was utilized to deposit Hastelloy C276 powder onto 316 L stainless steel substrates. The effects of various spray process parameters such as propane pressure, air pressure, spray distance, and powder feeding rate on the microstructure, microhardness, and corrosion resistance of the coatings were investigated. In addition, the coupling effects among multiple spray parameters were considered by employing a combined approach with the Improved Whale Optimization Algorithm (IWOA) and Artificial Neural Network (ANN) model, and the mapping relationships between the spray process parameters and coating porosity, microhardness, and corrosion current density was established. The results revealed that the prepared C276 coating exhibits lower porosity, higher microhardness, and exceptional corrosion resistance. And the IWOA-ANN model outperforms the ANN model and WOA-ANN model in the prediction accuracy and stability for all three performance measures, particularly for porosity and microhardness. Furthermore, the comparison between experimental results and predicted results validates the reliability and accuracy of the trained IWOA-ANN model, demonstrating its efficacy in predicting HVAF spray parameters and coating properties.

Corrosion behaviors of single-layer and double-layer nickel alloy coatings fabricated by arc spraying and high-velocity oxy-fuel

This study investigates single-layer and double-layer thermally sprayed nickel alloy coatings (bond and top coatings). Ni-5 wt% Al and Ni-20 wt% Cr were used as bond coatings, whereas highly alloyed Ni-based coatings, Hastelloy C276 or Inconel 625 were used as top coatings. Arc spraying (A) and high-velocity oxy-fuel (HVOF) techniques were used to create the coatings on a 304 stainless steel substrate. The samples were studied by performing potentiodynamic polarization tests in a 20 vol% H2SO4 solution at room temperature. The scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDS) and wavelength dispersive X-ray spectroscopy (WDS) techniques were used to investigate the microstructure and chemical composition of the coatings. The arc sprayed coatings are composed of a lamellar microstructure with low porosities, unmelted particles, and high oxides at the intersplats. A uniform and compact coating with minimal oxides and porosity was achieved for all coatings via HVOF technique. In single-layer coatings, arc spray coating surpasses HVOF coating owing to its oxide layers, which impede sulfuric solution penetration and bolster resistance against electrolyte infiltration. Double-layer coatings, comprising a bonding layer and a top coating, using the same thermal spray method have shown to enhance corrosion resistance.

Characterization of the spin arc welding technique for dissimilar materials Hastelloy C-2000 and C-276

Hastelloy C-2000 and C-276 are primarily employed in the petrochemical and pharmaceutical industries. Finding an effective way to combine these alloys is still a complex task in industry. The main focus of this study is to investigate the potential efficacy of the spin arc welding process on Hastelloy C-2000 and C-276. The welding process was carried out under various conditions, such as weld current, spinning speed, and spin diameter. ERNiCrMo-4, with a diameter of 1.2 mm, was employed as a filler. Optical microscopy, XRD and FESEM were used for microstructural examination. The mechanical properties of the welded samples were critically analyzed. The results of the ultimate tensile strength (UTS), hardness value (HV), and impact tests of spin arc welding were compared with those of the multipass pulsed current gas tungsten arc welding process (MPCGTAW). In spin arc welding, Hastelloy C-2000 and C-276 exhibited higher UTS, HV, and toughness compared to MPCGTAW because there was no secondary TCP phase formation in the weld centre and hot cracking in spin arc weldments. Additionally, compared to MPCGTAW, the elongation with spin arc welding was noted to be lower. Moreover, microstructural analysis revealed no evidence of grain segregation, which may have contributed to the improved UTS and HV of the materials during spin arc welding. Thus, spin arc welding proves to be superior for dissimilar Hastelloy joints of C-2000 and C-276.

Mechanical properties of CO2 laser beam butt-welded plates of Hastelloy c-276

In the current investigation, thermo-mechanical analysis is carried out for Hastelloy C-276 using laser beam welded butt joints. The Gaussian heat source model is used for transient thermal analysis, and the maximum temperature at the weld area resulted in residual stresses within safe limits. To validate, the experimentation was carried out with CO2 Laser beam welding using an L4 orthogonal array. Sample 2 had the least-residual stresses in the weldment, and the mechanical and metallurgical properties studies were carried out. The residual stress distribution was measured using X-ray diffraction and was acceptable within the yield limits of the material. Finite Element Analysis (FEA) and experimental residual stresses were compared; the FOS was 2.088, and the remaining samples were more than 2.0 compared to the base material tensile strength. Tensile tests confirmed that the strength of the weld zone is higher than that of the parent metals.

Microstructure and properties of laser welding Ni-based alloy/austenitic stainless steel with filler wire for nuclear reactor pump can end sealing

The current study investigates the microstructure and properties of laser welding involving Hastelloy C-276 and 304 stainless steel with filler wire, which is closely related to nuclear reactor pump can end sealing. The experimental results indicate the presence of an unmixed zone (UZ) and a small amount of Mo-rich secondary phase in weld seam, and microstructure of UZ is composed of austenite and ferrite phases. Laser welding enhances the ratio of low-angle misorientation and the uniformity of elements macro-distribution. The end sealing property of nuclear reactor pump can is characterized by anti-peel property of weld joints. The welded joint has local fracture and through fracture in the test of anti-peel property. The weld with local fracture exhibits superior anti-peel property. The joint crack starts at the bottom of the UZ. The anti-peel property of the welded joint is 239.6 ± 4.7 N/mm and mainly related to the weld penetration. The corrosion property of welded joints is determined by the elements of the weld, and the welded joints showcasing a better integral corrosion property than that of 304 base metals. Laser welding Ni-based alloy/austenitic stainless steel with filler wire has significant technical advantages for end sealing of nuclear reactor pump can.

Modeling and Optimization of Turning Hastelloy C-276 under Sustainable Machining Environments

Due to their numerous applications in the aerospace, chemical, and nuclear power industries, environmentally responsible superalloy machining is a major problem in the current production environment. Additionally, Ni-based superalloys are regarded as difficult to manufacture because of their great strength under hot and chemically reactive settings. Therefore, it is necessary to machine these materials using adequate cooling and lubricating solutions. Current study has been based on the optimisation and modelling of turning Hastelloy C-276 under dry, flood, and least lubrication system. A Taguchi L-9 arrangement was used as plan of experiment and modeling was enabled through ANOVA, regression analysis and Taguchi optimization. The results depicted optimal parameters for surface roughness and temperature at v2-f1-d1-CE3 and v1-f2-d1-CE3. Likewise, for CRC and shear angle the best combination was observed at v3-f3-d2-CE2. From ANOVA analysis, the benefaction of C.E, depth of cut and feed rate on S.R been listed as 46.70%, 40.44% and 10.66%. Likewise, for temperature cutting speed has benefaction of (53.09%), cooling environment (23.94%), depth of cut (6.10%) and feed rate 5.49% . In similar fashion, CRC and Shear angle were influenced by feed rate and cutting speed having contribution of 62.89% and 5.15% respectively. Furthermore, minimum standard error between the fitted and observed values for S.R., temperature, CRC, and shear angle were calculated as 0.0149, 7.66, 0.267, and 1.80 units. Finally, the marginal reduction of cutting temperature and surface roughness through utilization of MQL implies the sustainable machining conditions.

An investigation on the effect of heat input to wear behavior and corrosion-cavitation erosion mechanism of Hastelloy C-276 coating by cold metal transfer

Cold metal transfer (CMT) technology based on wire-arc manufacturing has attracted wide attention because of its advantages of high manufacturing efficiency, low heat input (HI) and near-net-shape. In this study, a CMT-Hastelloy C-276 superalloy surface modification coating by optimizing HI is used to solve the problem of premature failure of key over-flow components of stainless steel in marine engineering. When the HI is increased from 269 J/mm to 358 J/mm, the serious cavitation erosion (CE) damage caused by pore defects and excessive residual tensile stress due to excessive low HI of Hastelloy C-276 coating can be avoid, which is attributed to the effective Orowan strengthening and high proportion of low angle grain bounds (LAGBs: 70.2%). In addition, high contents of Cr, Mo and W elements can promote it's passivation film to maintain excellent self-healing ability during CE to provide continuous and stable protection effect (Rct = 75.68 kΩ·cm2) in the 3.5 wt% NaCl artificial seawater. Therefore, even after 10 h-CE, it still maintains the highest corrosion resistance from both of the thermodynamic (Ecorr = −193.5 ± 3.6 mV) and kinetic perspective (Icorr = 69.3 ± 3.1 μA·cm−2) and has the lowest mean depth erosion rates (MDER, 0.94 ± 0.07 μm/h). However, further increase of HI will cause coarsing of grains (89.6 ± 2.7 μm → 342.8 ± 9.7 μm), excessive precipitation of brittle Mo-rich p phase and excessive dilution of elements from the substrate, resulting in changes in the wear mechanism and deterioration of strength and corrosion resistance. Moreover, the potential of zero charge (PZC) measurements and Mott-Schottky (M-S) test confirmed the decreasing trend of the repulsive ability to Cl ions (ΔE = 0.58 V) and the increased ion doping concentration (ND = 5.94 ± 0.02 × 1022 cm−3) of the weakened n-type passivation films. The optimal combination of wear resistance, corrosion resistance and CE resistance of Hastelloy C-276 coating is obtained by regulating HI, which can lay a theoretical foundation for the related production and application of marine engineering.