Iron-based Alloys Research Articles

Durability of Fe-SMA/steel single-lap joints exposed to hygrothermal environments

Due to the adverse impact of hygrothermal environments and fatigue load, the performance degradation of existing steel structures necessitates repairs to extend their service life. Structures retrofitted by bonding iron-based shape memory alloy (Fe-SMA) have been demonstrated as an active non-destructive repair method. Nevertheless, the deterioration of the adhesives triggered by hygrothermal environments is a crucial challenge in its practical reinforcement applications. In this study, 54 Fe-SMA/steel single-lap joints (SLJs) are aged in 55°C and 98 % relative humidity environments for 30, 60 and 110 days, and tested under shear loads. The long-term performance, failure patterns, load-displacement responses and shear-resistance capacity of the SLJs are investigated, considering the essential parameters of aging time, overlap length and adhesive types. The experimental results exhibit that the failure patterns of aged Fe-SMA/steel SLJs depend highly on the adhesive types. The shear-resistance capacity of Fe-SMA/steel SLJs decreases dramatically with the prolongation of aging time. After 110 days of aging, the shear-resistance capacity of type-C, type-S and type-P SLJs decreases by about 14 %, 39 % and 49 %, respectively. When the overlap length increases from 50 mm to 150 mm, the shear-resistance capacity of type-C, type-S and type-P Fe-SMA/steel SLJs improves by 21 %, 39 % and 22 %, respectively, increasing the overlap length can safeguard the optimal functionality and long-term performance of the retrofitted steel structures. While the environments are relatively aggressive, it is recommended to use type-C adhesive to obtain the satisfactory serviceability of the retrofitted steel structures. The experimental achievements are significant for repairing deteriorated steel infrastructures by bonding Fe-SMA, guaranteeing the long-term performance and normal-use safety of structural reinforcement design, and reducing carbon emissions due to the avoidance of reconstruction.

Comparative Analysis of Concentrically Braced Frames with FeSMA and Steel BRBs Under Long-Duration Earthquakes

ABSTRACT Owing to high fatigue life, the iron-based shape memory alloy (FeSMA) buckling-restrained braces (BRBs) are emerging as a promising candidate against long-duration earthquakes. However, the corresponding analysis cannot be found. Current emphasis is paid on unveiling the seismic response differences between concentrically braced frames (CBFs) with FeSMA and steel BRBs when they are attacked by long-duration earthquakes. To directly assess the effect of earthquake duration, this paper selects a total of 90 pairs of short- and long-duration earthquake records, which are record-to-record spectrally equivalent over a wide range of fundamental periods, for nonlinear time history analysis. A benchmark six-story CBF is selected for demonstration purposes. In the numerical simulation process, the fatigue-induced damage is particularly considered. A preliminary examination is first conducted in the case study, in which a representative pair of short- and long-duration records is selected. In what followed, the statistical results from the ground motion suites are analyzed. This work not only highlights the higher failure risk of steel BRBs than FeSMA BRBs under long-duration earthquakes associated with maximum considered earthquake hazard level, but also confirms the advantages of FeSMA BRBs over steel BRBs in controlling residual deformations.

Neutronic Analysis of Accident-Tolerant Cladding Materials in 3D Full Core BEAVRS PWR Benchmark Using OpenMC Code

After the Fukushima Daiichi nuclear accident in 2011, the performance of nuclear fuel during accidents became a matter of great concern. To address this, a new type of fuel technology called accident-tolerant fuel (ATF) has been developed with the goal of enhancing the ability of light water reactors (LWRs) to withstand severe accident conditions. Iron-based alloys have been suggested as potential candidates for fuel cladding due to their favourable thermomechanical properties, lower reactivity with steam, and lower hydrogen generation. This study evaluates the neutronic performance of C26M (a 2nd generation nuclear grade FeCrAl alloy), APMT™, 310SS, and 304SS cladding materials by comparing them with Zircaloy-4 cladding in a 3D PWR core at the beginning of the cycle (BOC) using OpenMC code. The results revealed that the neutronic penalty varied for different alternative cladding materials where C26M exhibited the lowest neutronic penalty value of -12551 pcm, while 310SS demonstrated the highest with a value of -17855 pcm. Additionally, important parameters in the reactor core such as neutron spectrum, reactivity coefficients, boron worth, control rod bank worth, power distribution, and radial thermal neutron flux distribution are evaluated and discussed. The analysis results showed that C26M provided a significantly higher level of neutronic performance compared to APMT™, 304SS, and 310SS. Although this study primarily focused on the neutronic performance of PWRs at BOC, future research should encompass fuel depletion analysis to delve deeper into the potential of alternative cladding materials.

Self-centering of steel braced frames equipped with Fe-SMA TADAS dampers

This study proposes a novel triangular added damping and stiffness (TADAS) damper that uses the shape memory effect of iron-based shape memory alloy (Fe-SMA) to provide a self-centering system to recover the initial shape of a structure after significant inelastic deformation induced by nonlinear response of fused elements, without the need for difficult and expensive replacement procedures of conventional TADAS systems. Unlike most studies which consider simplified uniaxial behavior of Fe-SMAs, the present non-linear finite element simulations cover the full 3D material non-linearity of Fe-SMA component based on the SMA constitutive law to capture both flexural and shear behavior in various coupled thermomechanical loadings, including the mechanical loading/unloading, the heating, and the final cooling (as the recovering process). Simulations performed on a one-bay steel frame for different drift ratios reveal that although the dissipation energy of the new device is at most 10% less than the ordinary one, it enjoys the self-centering property to recover the initial shape of the frame before loading, showing that the proposed damper is an effective alternative to ordinary TADAS yielding dampers to achieve the self-centering characteristics.

Post-fire performance of iron-based shape memory alloy: Experimental study, prediction equations and constitutive models

To expand the application of iron-based shape memory alloy (Fe-SMA) for fire resilience improvement, this paper presents a systematic investigation on the mechanical properties of post-fire Fe-SMA. In tests, the specimens of China-made Fe-SMA were heated to target temperatures up to 1000 ℃, then cooled to room temperature in air or water, and finally subjected to tensile tests. The variation trends of mechanical properties with different cooling methods were analyzed, accompanied by the residual factor comparison with high strength steels Q460, S460, A36, A572 and A992, as well as with austenite stainless steel S30408. Finally, the prediction equations of residual factors and the post-fire constitutive model of Fe-SMA were proposed. Experimental results indicate that the exposed elevated temperature and cooling method significantly influence the post-fire performance of Fe-SMA. Compared with commonly used high strength steel and austenite stainless steel in civil engineering, Fe-SMA has unique post-fire performance, with a noticeable enhancement after exposure to elevated temperatures below 800 ℃. Therefore, the targeted theoretical prediction of post-fire Fe-SMA performance is significant and can be used as the investigation foundation for the fire resilience improvement application of Fe-SMA in civil engineering.

A Superb Iron-Based Glassy-Crystal Alloy Fiber as an Ultrafast and Stable Catalyst for Advanced Oxidation

A Superb Iron-Based Glassy-Crystal Alloy Fiber as an Ultrafast and Stable Catalyst for Advanced Oxidation

Experimental study on improving the fire performance of the concrete beams with Fe-SMA

The conventional approach to satisfying the fire resistance requirements in designing reinforced concrete (RC) structures is to ensure enough concrete cover depth for the steel reinforcements. The objective is to prevent the temperature of steel reinforcements from rising too quickly. However, excessive concrete cover depth may increase the risk of concrete spalling during a fire and lead to a larger crack width. Fire is a natural heat source that can activate the shape memory effect of iron-based shape memory alloys (Fe-SMA) to generate recovery stress. This study proposes a new active approach for improving the fire performance of RC structures based on the Fe-SMA. The main objective is to investigate the feasibility of improving the fire performance of RC structures through the recovery stress generated by Fe-SMA under fire. The fire test of nine Fe-SMA RC beams was conducted. The temperature profile in the furnace was similar to ISO834, and the maximum temperature exceeded 800 °C. The flexural behavior of the concrete beams reinforced with Fe-SMA during and after the fire was tested. The experimental results demonstrate that the Fe-SMA has great potential in improving the fire performance of RC structures. The mid-span deflection of the Fe-SMA RC beams under fire is significantly lower than the conventional RC beams. The fire resistance of Fe-SMA RC beams increases from 97 min to 133 min at load level 0.3 and from 69 min to 103 min at load level 0.5. The residual deformation of Fe-SMA RC beams reduces from 46.3 mm to 27.6 mm at load level 0.3 and from 34.7 mm to 19.8 mm at load level 0.5. In addition, after 1 h of fire exposure, the Fe-SMA can develop permanent prestress after the beam cools to room temperature, improving the mechanical properties after fire. The residual bearing capacity and residual stiffness of the Fe-SMA RC beams are 21% and 86%–121% higher than the conventional RC beams, respectively. The prestress generated by Fe-SMA after 1 h of fire exposure was estimated using the equivalent section method.

Development of novel carbon-free cobalt-free iron-based hardfacing alloys with a hard π-ferrosilicide phase

Recently, iron-based alloys with a π-ferrosilicide phase have emerged as potential alternatives to cobalt-based hardfacing alloys. Here, we present the development of two π-ferrosilicide containing alloys: one with a ferritic matrix and the other with a ferritic-austenitic matrix. In the as-cast condition, both alloys revealed fine Ni- and Si-rich coherent cubic shaped D03 precipitates in the BCC matrix. The π-ferrosilicide phase was found to have an orientation relationship with the ferrite phase, nucleating within ferrite matrix and from ferrite grain boundaries. In contrast to carbide-strengthened hardfacing Fe-alloys, here the dissolution of the π-ferrosilicide phase at 1200 °C enables easy thermomechanical processing of these alloys, which results in refinement of the π-ferrosilicide and additional formation of χ-phase precipitates in the ferrite. Nano-scratch tests provided evidence of a resilient silicide-ferrite interface, likely to due to it possessing some coherency. Both alloys also displayed compressive strengths approaching 2 GPa and ductility in compression of approximately 25 %. The combination of processability and attractive mechanical properties suggests that these alloys have the potential to serve as alternatives to carbide-reinforced hardfacing Fe-alloys.

Intergranular Attack of Low Carbon Steel in Molten Aluminum Chloride

AISI 1018 carbon steel exhibits intergranular attack in molten aluminum chloride. To explore grain boundary corrosion initiation and propagation, tests have been conducted on several iron-based alloys, heat treated to recrystallization temperature, and using molten aluminum chloride and its mixture with other molten chlorides environments. Pure iron, A106, and AISI 1018 carbon steel have been exposed to both pure aluminum chloride and ferric chloroaluminate melt in both their recrystallized and as-received, cold-worked conditions. Intergranular corrosion is observed in both 1018 and A106 carbon steels in all the salts whereas pure iron only shows pitting. Materials processing has varying effects on the corrosion depths of 1018 and A106 carbon steels. The grain boundary microchemistry of 1018 carbon steel is examined with in situ fracture Auger spectroscopy where molybdenum and carbon segregation are found, and a mechanism is proposed to explain the present corrosion phenomenon.

Measuring traction–separation relationships of bonded Fe-SMA double cantilever beam joints

Adhesively bonded strengthening systems using self-prestressing iron-based shape memory alloys (Fe-SMA) have demonstrated significant potential. However, the premature nonlinear behavior of Fe-SMA during debonding failure presents challenges in ensuring the integrity of the adhesive joint. A recent study indicated that this behavior may lead to premature joint failure, and a similar conclusion can be drawn concerning plasticity in thin adherends. To characterize the failure process of Fe-SMA bonded joints, a method capable of measuring traction–separation relationships of thin adherends bonded with tough adhesives is essential. An algorithmic method, supported by an analytical nonlinear beam-on-foundation model and a minimization scheme, is shown to offer a solution. To benchmark the method against the J-integral approach, experiments are conducted using two types of adherends: thick steel with thickness-limiting plasticity and Fe-SMA with material behavior that inevitably leads to nonlinear deformation. Comparison of methods shows both measurement method are valid and allow for proper predictive modeling using the finite element method. The proposed method can be readily employed to characterize various thin adherends with elasto-plastic material behavior.

Crack-free hard facing options for orifice plate used in oil refinery applications

The purpose of this study is to select a suitable tubular wire electrode as an alternative hardfacing material for Stellite 1 in the production of SS304 orifice plates used in oil refineries. It is also intended to develop an efficient deposition procedure for crack-free hardfacing. Compatible cobalt, nickel, and iron-based hardfacing alloys were selected so as to match the hardness and hot hardness properties of stellite 1. Moving heat source analysis was performed to find the heat affected zones and the thermal stress distribution during hardfacing. The significance of weld speed, bead width, and weld concentration on the weld deposition process was analysed using ANSYS, to extract an efficient deposition procedure. The hardfacing alloys were tested for stress and deformation at working temperature (up to 815 οC) to understand the performance. Seven materials were taken into consideration as options along with six parameters. The results revealed a higher longitudinal residual stress of 2000 MPa for Talonite and Tribaloy hardfacing alloys. Colmonoy 6 was found to be having the least stress value of 2186 MPa. Furthermore, the von mises stress values arrived for different conditions showed that the optimal welding condition is 5 mm/s welding speed, 3 mm radius of beam and 455 °C preheat temperature. Microstructural study revealed the dendrite growth in the surface of Colomony 6 hardfacing during solidification, which led to the improvement in mechanical properties.

MS-informed misfit approximation model for the interaction energy between substitutional atoms and screw dislocations in BCC iron-based alloys

This study presents a molecular statics (MS)-informed misfit approximation (MA) model for estimating the interaction energies between substitutional atoms and screw dislocations in BCC iron-based alloys. The MA model is transplanted into the BCC system and verified by MS and DFT. Based on the MS-constructed screw-kink structures, the dominate mechanism for solute elements varies with misfit sizes. Specifically, the larger size is relevant with direct interaction between substitutions and kinks, while the indirect movement from inside to outside the screw core is involved for the smaller one. The predicted solute hardening effects are consistent with experimental results, demonstrating the applicability of the MA model to estimate the solute-kink interaction energies in BCC-Fe alloys.

High-temperature corrosion-resistant alloy for waste-to-energy plants: Alloy designing, fabrication, and possible corrosion-resistance mechanism

This study designed a novel high-temperature corrosion-resistant alloy through thermodynamic equilibrium computations. The strength was determined by the integration of precipitation-strengthening species of nickel boride and tungsten solid solution strengthening, while high-temperature corrosion-resistant property was realized through optimized compositional design. Phase stability was enabled by the presence of a face-centered cubic structure. The alloy was fabricated and its corrosion-resistance performance was experimentally compared with other commercially available nickel- and iron-based alloys under simulated municipal solid waste combustion. The designed alloy with a composition of Ni-5B-6W-28Cr-13Al showed a low corrosion rate of ∼72 % < 13CrMo4-5TS and 1.08 % > Inconel 625. Economic analysis showed that Ni-5B-6W-28Cr-13Al has a cost-effectiveness ratio of 1:1.57 with respect to Inconel 625 and 1:0.09 with respect to 13CrMo4-5TS. Corrosion-resistance mechanism was explored using scanning electron microscopy coupled with energy dispersive spectroscopy, x-ray diffractometer, and DFT computations. The corrosion resistance occurred through the formation of a uniform tungsten-chromium-oxide film which inhibits inward diffusion of corrosive chlorine species. These findings provide insights into the development of alloys for high-temperature technologies.

The effect of γ′-martensite on the corrosion resistance of an Fe-Mn-Al-Ni-Cr shape memory alloy in a sodium chloride solution

The martensitic phase transformation in iron-based shape memory alloys has a strong influence on the corrosion properties. To investigate the effect of different amounts of martensite, potentiodynamic polarization measurements were conducted on specimens that were subjected to varying prestrain levels prior to the corrosion experiments. While the passive behavior deteriorates with an increasing martensite amount, the observed corrosion damage changes as well. While an entirely austenitic specimen is characterized by a predominantly surface corrosion with some randomly distributed pitting corrosion, the introduction of the martensitic phase results in micropitting and selective corrosion of the martensite plates.

Effect of Heat Treatments on Microstructure and Mechanical Properties of Fe-Mn-Ni-Al-Gd Shape Memory Alloy

There are significant scientific and industrial efforts to develop and optimize Iron-based shape memory alloys (SMA) such as FeMnNiAl for cost-sensitive applications. This alloy system shows shape memory and superelastic properties across a large temperature range. However, many studies have pointed out the need for rather complex thermo-mechanical treatments for the optimization of the SMA properties. In addition, works considering the effects of alloying on the development of microstructures that are more conducive to pseudo-elasticity in this system remain limited. Hence, systematic studies aiming at the investigation of the microstructural evolution of the FeMnNiAl(Gd) system are of great interest. In this study, solution heat treatment is done to tune the microstructure for optimum mechanical properties. The effect of phase distribution on mechanical properties is investigated at different heat treatments. Whereas cyclic heat treatment induced abnormal grain growth (AGG) in all samples, so large grains were obtained. The phase variation and elemental composition are analyzed by X-ray diffraction and Energy Dispersive Spectroscopy, respectively. The microstructure and phase distribution are observed using Scanning Electron Microscope and then related to the microhardness results. The microstructure has a good correlation with mechanical properties where the fine distribution of phases results in a higher hardness number.

Ізотермічне гартування залізовуглецевих сплавів, суміщене з їх виливанням

Isothermal hardening (Austempering) of iron-based alloys with medium and high carbon content, which creates a metallic structure called bainite, is used to increase the strength and impact toughness of the metal. The parts are heated to a temperature approximately 200-300 °C below the solidification temperature of the metal, then cooled (hardened) fairly quickly to the temperature of the beginning of the bainite transformation, avoiding the martensitic transformation, and kept for a time sufficient to obtain the given bainite microstructure. IG is particularly advantageous for castings from high-strength cast iron (HC), adding to the high foundry performance of the growth of the mechanical characteristics of this alloy to the level of steel strength at a lower cost, density and energy consumption of HC casting compared to steel. The article examines methods of heat treatment of castings removed in a hot austenitic state from a sand mold, as a type of heat treatment of iron-carbon alloys combined with their casting. For this, casting according to gasification models was used, in which, due to the high fluidity of the dry sand of the casting mold, it is not difficult to remove hot castings from the mold for tempering. A number of IG methods previously patented by the FTIMS Institute of the National Academy of Sciences of the Russian Academy of Sciences have been supplemented by a new method of such hardening in a dosed amount of water, taking into account the effect of its film boiling. The new method includes the calculation of the optimal mass of quenching liquid - water with the aim of heating this mass of water to its boiling point at the time of cooling of the casting to the given temperature of the bainite transformation of the metal. The method saves the quenching liquid, simplifies the control of the duration of cooling, during which it allows the transportation of castings between the foundry and heat-treatment sections, which, in general, saves time, energy resources and the area of the workshop for obtaining heat-treated castings. Keywords: isothermal hardening, heat treatment, castings, austenite, lost foam casting.

Experimental and theoretical study on mechanical performance of Fe-SMA/steel single lap joints

The activated iron-based shape memory alloy (Fe-SMA) can introduce considerable prestress in the damaged zone of deteriorated steel structures through bonding technologies. In China, it has been successfully applied to several kilometer-span steel bridges, such as Sutong Bridge and Hangzhou Bay Bridge. The shear and interfacial performance of steel-to-Fe-SMA plates are crucial issues in bonding Fe-SMA to reinforce deteriorated steel structures, which remain unclear. This paper investigates the shear characteristics of Fe-SMA/steel single lap joints (SLJs), considering the effects of adhesive types, adhesive layer thicknesses and overlap lengths. The stress distribution and the interfacial shear stress at the overlap zone are obtained through experiments, and the damage evolution and load-transfer mechanisms of adhesive layers are analyzed. The experimental outcomes indicate that the maximum tensile stresses of Fe-SMA plates can reach 61 % of their ultimate strength. The failure modes and ultimate load of Fe-SMA/steel SLJs are affected by adhesive types. Interface failure occurs in CH 120 and PCMdur™-15 specimens, whereas interface, cohesive and mixing failure are formed in Sika 31 specimens. Due to the adverse effects of adhesive layer defects, out-of-plane bending moment, and damage accumulation of the adhesive layers, the distribution of surface strain and interfacial shear stress of all specimens are mainly at the effective overlap zone. For an efficient engineering design, the linear and polynomial fitting models of cohesive zone models with different adhesive types and adhesive layer thicknesses are proposed based on experiments. The experimental and theoretical achievements can provide design recommendations for deteriorated steel structures rehabilitated by bonding Fe-SMA.

Bonded and prestressed fatigue crack retarders based on Fe-SMA

A bonded and prestressed retarder concept is proposed in this work. The shape memory effect of an iron-based shape memory alloy (Fe-SMA) has been exploited to realize a desirable self-prestressing mechanism, resulting in compressive stresses in the parent structure. The synergistic prestressing and added fail-safe features of bonded and prestressed Fe-SMA retarders desirably restrain the fatigue crack growth. The fatigue crack growth behaviour in metallic plates reinforced with bonded and prestressed retarders is experimentally studied in this work. A test campaign has been implemented to investigate the effects of prestressing, as well as the influence of the relative location between the Fe-SMA retarders and the initial crack tip on the crack growth behaviour and fatigue crack life extension. The experimental results show that the prestressing of retarders desirably extends the fatigue crack growth life. More extension in fatigue life can be achieved by positioning the bonded prestressed retarders from 40 to 20 mm before the initial crack tip, the desirable retardation due to beneficial compressive prestressing and added load path on the small crack is significant. The findings in this work imply that it is beneficial to proactively reinforce the fatigue-prone locations in metallic structures with bonded and prestressed Fe-SMA retarders in order to extend the service life.

Interaction of solute manganese and nickel atoms with dislocation loops in iron-based alloys irradiated with 2.8 MeV Fe ions at 400 °C

In reactor pressure vessel materials, the formation of Mn- and Ni-rich nanoclusters is a major cause of neutron irradiation embrittlement. The segregation of these solute atoms into dislocation loops has attracted attention as a mechanism to accelerate solute clustering. In this study, the behaviors of solute Mn and Ni atoms in Fe-0.6wt.%Ni, Fe-1.4wt.%Mn, and Fe-1.4wt.%Mn-0.6wt.%Ni alloys irradiated at 400 °C up to 3 dpa were analyzed using three-dimensional atom probe tomography. Solute atom clusters were observed in all materials, and their shapes were spherical, flat, and torus in FeNi, FeMn, and FeMnNi, respectively. In ternary alloy FeMnNi, Mn and Ni atoms were concentrated in the sample in the form of arcs, and the orientation of the plane containing the arcs was estimated by comparing field desorption images. The size, number density, and orientation of this structure were found to be in good agreement with those of both types of dislocation loops, namely, b = 1/2 〈111〉 and b = 〈100〉, identified in a previous study using the same material. The positions of Ni and Mn enrichment did not fully overlap. Ni atoms tended to be concentrated more in the inner part of the loop than the Mn atoms. Mn atoms were enriched only in the vicinity of the dislocation loops, whereas Ni atoms showed a higher concentration inside the dislocation loops than in the bulk.

Experimental study on flexural performance of prestressed concrete beams strengthened by Fe-SMA plates

Shape memory alloy (SMA) is an innovative intelligent material, capable of restoring its shape before deformation upon reaching the critical activation temperature. This property promotes its promising applications in civil engineering. This paper proposes a novel reinforcement method and aims to investigate the reinforcing effect of iron-based shape memory alloy (Fe-SMA) plates on prestressed concrete (PC) beams through four-point bending tests on one reference beam without reinforcement and three Fe-SMA reinforced beams, as well as with three beams reinforced by carbon fiber-reinforced polymer (CFRP). The results show that Fe-SMA can effectively reduce concrete cracks, and improve stiffness and characteristic loads of beams without negative effects. Under the same loading conditions, new cracks of Fe-SMA reinforced beams were relatively fewer than those of CFRP reinforced beams. Besides, Fe-SMA exhibited superior performance when utilizing the same cross-sectional reinforcement material to enhance the bending capacity of beam, and proved more advantageous for improving stiffness and characteristic loads of beam under the identical initial tensile force. Furthermore, the reinforcing effectiveness of Fe-SMA positively correlates with the cross-sectional area (thickness) and recovery stress (pre-stretch level and activation temperature) of Fe-SMA. Increasing the thickness of Fe-SMA plates by 100%, while maintaining other parameters constant, resulted in a 33% increase in cracking load. Similarly, elevating the recovery stress from 314 MPa to 340 MPa led to a 12.5% rise in cracking load. This paper investigates the reinforcement effect of Fe-SMA plates on PC beams, and provides a reference for the application of Fe-SMA in PC beam reinforcement, laying a foundation for promoting the utilization of Fe-SMA in civil engineering.