Thermal Stress Research Articles

Numerical Investigations of a Single Loop Pulsating Heat Pipe for Cryogenic Applications

Abstract The thermohydraulics of a single-loop pulsating heat pipe (PHP) for cryogenic applications have been simulated. The 120 mm long PHP tube is made of a 1.5 mm diameter inner tube of thickness 0.83 mm. The CFD analysis performed with the ANSYS Fluent software is a two-dimensional numerical study using pure nitrogen as the working fluid in binary phases. The boundary condition on the evaporator is of constant heat flux, while the same on the condenser is of constant temperature. The phase behaviour of the liquid and vapour and their interactions are accounted for through the volume of fluid (VOF) method and the Lee model. The numerical model is validated using the existing experimental data, with an agreement of less than 8% between them. The thermo-hydraulic variations of temperature, pressure, and velocity are simulated for different heat loads and fractional liquid contents (fill ratios). The temperature and pressure oscillations set in the PHP-fluid increase with the heat added to the evaporator while the fluid velocity remains independent. The heat load and the fill ratio dictate the effective thermal conductivity - attaining nearly 3400 W/mK for a fill ratio of 70% in the chosen PHP geometry. An alteration has been made in the Jacob number to predict the dominance of sensible heat over latent heat in a PHP, postulated by other researchers. The constant fill ratio assumption is not truly valid as it indicates a small yet finite variation with the change in the heat load.

The effect of the composition of hepatoprotective action on biochemical and morphostructural changes in the body of laying hens under thermal stress

To reduce the negative effects of hyperthermia on the body of farm animals and poultry, various drugs and feed additives are currently used. Which do not have sufficiently adaptogenic and antitoxic properties. We studied the effect of a hepatoprotective composition consisting of dried live yeast, amorphous silicon dioxide, propylene glycol, calcium propionate, ascorbic acid, manganese, copper and zinc chelates, methionine and choline chloride on the variability of biochemical and morphological parameters of the body of laying hens under temperature stress. It was simulated by increasing the air temperature in a building where laying hens were kept from 18.0 ± 1.0 °C to 28.0 ± 1.0 °C for 48 hours. Due to hyperthermia, changes in biochemical and morphofunctional parameters were observed in the tissues and organs of birds. The obtained values of the biochemical parameters of blood serum in the birds of the control group indicated the intensity of the adaptive capabilities of their body. A complex of morphological changes confirmed a violation of protein metabolism and the regenerative-compensatory process. Pathological changes in the structure of the duodenum, characteristic of catarrhal-necrotic duodenitis, were identified. The stress reaction was also reflected in the condition of the heart muscle, in which an inflammatory process developed against the background of granular dystrophy of cardiomyocytes. The results of biochemical studies of blood serum in birds of the experimental group indicated an increase in the anti-stress response to a temperature stimulus under the influence of the studied composition (tendency to increase glucose and calcium, increase alkaline phosphatase activity by 47.4 %). The introduction of a hepatoprotective composition into the diet of laying hens during periods of temperature stress did not lead to disruption of the structure of tissues and organs, preserving cellular metabolic mechanisms. The

Overcoming the Tradeoff of Visible Transparency and Electrical Conductance via Dual Smoothing of Dielectric/Metal Interfaces in Cu-Thin-Layer-Based Transparent Electrodes.

The rapid advancement of flexible optoelectronic devices, such as light-emitting diodes, solar cells, and electrochromic devices, necessitates the development of high-performance flexible transparent electrodes (TEs). Dielectric/metal/dielectric (DMD)-type TEs are promising alternatives to conventional indium tin oxide (ITO) due to the high electrical conductance, excellent visible transparency, and sufficient mechanical flexibility. However, the tradeoff between electrical conductance and visible transparency poses a challenge to performance enhancement. This study introduces an Ar-ion-mediated interface modification method to address this tradeoff by dual smoothing of dielectric/metal interfaces in TiOx/Cu/ZnO TEs. Implementing this dual smoothing methodology significantly enhances both electrical conductance and visible light transmittance, achieving a Haacke figure of merit 200% higher than that of an unmodified otherwise identical structure. The highest figure of merit is 0.113 Ω-1, a record high for Cu-thin-layer-based DMD TEs, far surpassing ITO electrode values. Further, the enhanced optoelectronic performance remains highly durable under severe and simultaneous electrical, thermal, and mechanical stresses, showcasing the potential for significant advances in flexible optoelectronics.

Study on the deterioration of mechanical properties of stainless steel S35657 exposed to overall stage of fire

Fires often have destructive effects on steel structures, putting the safety of building structures at serious risk. As a new austenite stainless steel, grade S35657, its in-fire and post-fire mechanical behavior has not been reported, which limits its application. In this paper, a total 68 stainless steel S35657 coupons were designed and tested, with 34 coupons used for in-fire tests and 34 for post-fire tests. The effects of heating temperatures, loading rates, and heating soaking times on the mechanical properties were investigated. The failure modes, as well as the stress-strain curves and mechanical properties, were acquired. Electron microscopy scanning analysis were also conducted on the coupons to study the fracture mechanisms at elevated temperatures. The test results showed a rapid decline in in-fire mechanical properties when the temperature exceeded 600 °C. The yield strength of the coupon at 1000 °C is only 9.1 % of that at room temperature. As the tensile rate increased, the strength of the coupon increased gradually. For post-fire coupons, there is no significant change in the mechanical properties of coupons at temperatures ranging from 20 °C to 900 °C. However, after reaching a temperature of 1000 °C, the coupon experienced a reduction in yield strength (up to 27.8 %) and an expansion in elongation (up to18.0 %), compared to the coupon at ambient temperature. This related to the change in grain size of the coupons after exposure to high temperatures. The heating soaking time has an insignificant effect on the post-fire mechanical properties of stainless steel S35657. Existing constitutive models in the literature cannot be well applied to stainless steel S35657, new constitutive models to predict the in-fire and post-fire mechanical properties have been established. Moreover, reduction factors for the key mechanical properties were compared with existing values, and new unified equations for stainless steel S35657 were proposed. Finally, a reliability analysis was performed to evaluate the proposed design rules, and it was deemed that the proposed design rules were reliable. The findings of this study will provide a reference for engineers in evaluating the in-fire and post-fire residual strength of stainless steel S35657, and offer guidance for fire resistance design and high-temperature repair reinforcement.

Study on the effect of variable laser power on residual stress distribution in laser directed energy deposition of Ti6Al4V

In the laser directed energy deposition (LDED) process, cyclic thermal stress loading induces significant temperature variations on the surface and subsurface of the workpiece during repeated heating, leading to the formation of residual tensile stress during cooling. This adversely affects the mechanical properties of the parts, causing deformation and defects. In this study, a heat transfer model and a three-dimensional stress model were established based on finite element analysis. A variable laser power (VLP) deposition strategy was proposed to dynamically simulate the temperature and stress fields of Ti6Al4V titanium alloy under different deposition strategies. The model was validated by collecting substrate temperature variations using thermocouples and measuring residual stress with an X-ray diffractometer (XRD). Experimental results showed that the temperature error between the simulation and the experiment ranged from 6.25 % to 10.12 %, with an average stress simulation error of 6.92 %. Among the four strategies, the samples using the VLP strategy showed a reduction in the average substrate temperature by 12.68 % to 15.08 % compared to the other three strategies. The maximum principal stress in the layer was reduced by 7.8 % to 32.14 %, and the residual stress distribution was more uniform in all directions. The microstructure of the deposition layer further indicated that the VLP strategy improves residual stress distribution and leading to better deposition quality.

Study on the Stress Distribution Characteristics of Rock in the Bottomhole and the Influence Laws of Various Parameters Under the Impact of a Liquid Nitrogen Jet

This study presents research on the stress distribution characteristics of rock in the bottomhole and the influence laws of various parameters under the impact of liquid nitrogen jet. A multi-field coupled numerical model considering transient flow field, conjugate heat transfer, and nonlinear solid deformation was established to investigate the damage-induced fracturing mechanism of rock under liquid nitrogen jet. The study compares the impact effects of liquid nitrogen jet and water jet on rock and analyzes the variations in the stress field under different parameters. Due to its extremely low temperature, the liquid nitrogen jet creates a strong thermal stress gradient in a short time, significantly increasing the maximum principal stress and Mises stress in the rock compared to a water jet. Solid parameters, particularly the confining pressure and elastic modulus of the rock, have a more significant impact on stress distribution, while fluid parameters such as outlet pressure and fluid temperature have a smaller and more volatile effect. An increase in confining pressure inhibits tensile failure in the rock, while a higher elastic modulus enhances both tensile and shear failure. The initial rock temperature significantly affects the stress distribution, with optimal tensile failure observed at intermediate temperatures. The liquid nitrogen jet achieves a higher maximum velocity and overflow velocity than the water jet, contributing to more effective rock fracturing. The results provide a theoretical basis for the optimization of liquid nitrogen jet drilling parameters, which can help improve drilling efficiency.

Potential of thermosyphon for passive cooling of nuclear fuel storage vault

This study evaluates the potential of thermosyphon for passive cooling of nuclear fuel storage vaults. For this work, a thermosyphon was specifically designed and manufactured. Experiments were conducted by varying heat load (300–600 W) and filling ratio (40–120 %). Optimal performance was obtained with a 60 % filling ratio. The experimental data obtained with the optimal filling ratio were used to calculate the effective thermal conductivity of thermosyphon and determine the number of thermosyphons needed for the vault. Two geometric vault ventilation models; one featuring a thermosyphon and the other without these were developed. The operations of these vault ventilation systems were simulated using the CFD model. The airflow patterns and temperature distributions within the storage vault were compared. The findings ascertain the utility of thermosyphons as an effective passive cooling device in the nuclear fuel storage vault.

Optimal shift control for new dual-clutch full-powershift transmission of heavy-duty tractor based on genetic algorithm–particle swarm optimization

The calculation of a linear quadratic regulator (LQR) control weighting matrix determines whether it can achieve optimal control. In order to solve the problem of complex calculation and low efficiency of this matrix, this paper proposed genetic algorithm–particle swarm optimizatio algorithm (GAPSO) combining genetic algorithm and particle swarm algorithm to solve the weighting matrix of LQR clutch oil pressure control strategy, so as to control the design efficiency and precision of the strategy. Subsequently, the shifting quality of a tractor was improved. A dynamic model of the shifting process was established using a comprehensive indicator that combined jerk and sliding friction work as a quadratic function. An LQR-weighted matrix calculated using GAPSO enabled optimal control strategy designing for clutch hydraulic pressure. Furthermore, the shift process from the 11th to 12th gear was analyzed via simulations during plowing operations. The simulation results show that the genetic operation of crossover and variation is introduced into PSO, and the optimization ability of PSO is improved effectively. Compared with the clutch oil pressure control strategy calculated by GAPSO with LQR weighted matrix and LQR clutch oil pressure control strategy calculated by PSO with LQR weighted matrix, the clutch heat load is slightly increased, the smoothness of shifting is greatly improved, and the shifting quality of tractors is improved. Overall, this study provides valuable insights for designing and computationally analyzing optimal clutch LQR control.

Analysis of composite wavelength multilayer dielectric film damage based on the field-thermal effect

Taking SiO2/HfO2 multilayer dielectric films as the research object, when the total laser energy is the same, the effects of different laser parameters on film damage under 1064 nm and 355 nm composite wavelength pulse irradiation are analyzed. The results show that different energy ratios lead to exponential differences in the electron number density inside the film, but they are far from reaching the field damage threshold. Comprehensive analysis shows that film damage is mainly affected by thermal melt and stress. The greater the difference between an energy ratio of 1ω and 3ω, the greater the thermal stress in the film, the higher the stress peak, and the more obvious the damage effect of thermal stress on the film. Under the condition of 50%1ω, the thermal effect in the film is minimal, which can ensure that the film is not damaged as much as possible. The model method used in this paper only takes the current film system as an example for specific research and can be extended to all film systems for analysis.

SH guided wave excitation in rails for defect and stress monitoring

Monitoring rail defects and thermal stress is imperative in ensuring the safety of railway transportation. Guided-wave-based inspection techniques emerge as a promising solution for concurrently detecting both the defects and thermal stress in rails. However, the substantial multimodal and dispersive nature of guided waves in the rail poses limitations on the application and advancement of this technology. This study systematically investigates the propagation characteristics of the SH0-like wave (the lowest-order shear horizontal-like wave) in the rail and its effectiveness in defect and axial stress monitoring through finite element simulations and experiments. A method based on dual opposite polarization active elements, and the corresponding piezoelectric transducers are proposed to excite SH0-like wave in the rail web and rail foot. Results show that SH0-like wave can travel stably across a broad frequency range in the rail web and rail foot. Additionally, both the simulations and experiments confirm that the SH0-like wave in the rail web is suitable for monitoring axial stress, as its velocity changes linearly with axial stress variations. Furthermore, the ability of the SH0-like wave to detect cracks and hole defects in the rail web is experimentally demonstrated. Given that the SH0-like wave is quasi-nondispersive in a broad frequency range and an SH0-like wave with high SRN can be effectively generated using the proposed method, this research aims to offer a practical technical solution to overcome the challenges of multimodal and dispersive effects in the guided-wave-based rail inspection techniques. It also sets the stage for developing a comprehensive system capable of simultaneously monitoring the defects and thermal stress in rails.

Modelling Marine Heatwaves Impact on Shallow and Upper Mesophotic Tropical Coral Reefs

Abstract Coral reefs ecosystems, often compared to rain forests for their high biodiversity, are threatened by ocean warming causing coral bleaching when the symbiotic relationship between dinoflagellates and corals breaks under high ocean temperatures. Thermal stress from marine heatwaves occur both at the surface and subsurface with subsurface marine heatwaves lasting longer with potentially higher cumulative intensities. However, global coral bleaching models generally ignore the differences in thermal stress between surface and sea-bed levels. Here, we define marine heatwaves at sea-bed level to model coral bleaching with daily resolution from May 6th 1993 to December 31st 2023, for 9944 tropical coral reefs between 0 and 50m depths. We show that deeper reefs experience on average higher thermal stress and bleaching compared to surface reefs. Using surface temperature data to model bleaching for deeper corals underestimates bleaching intensities by an average of 6 ± 9% compared to the subsurface calibrated model. Our study is a starting point for more accurate coral bleaching modelling, providing additional evidence to reshape our perception of deeper coral reefs as potential refugees from climate change. 

Thermo-mechanical coupling characteristics of the shearer’s guiding shoe during the friction

The reliability and longevity of the guiding shoe are crucial for the proper functioning of coal mining machines. The heavy wear of the sliding surface under thermal stress coupling is the primary factor influencing the service life of the guiding shoe. To reveal the heat flow distribution patterns and the thermo-stress coupling mechanisms of the guiding surface, a thermo-mechanical coupling model of the guiding shoe and the pin row is established. The transient thermodynamic behavior of the guiding shoe under different load and speed conditions is studied using the coupled temp-displacement analysis method in Abaqus. The results indicate that the overall temperature of the guiding shoe friction surface experiences a rapid increase during the initial running-in phase, followed by a progressively slower temperature increase over time. Temperature and stress concentration regions on the friction surface primarily localize at the corners of the shoe groove, and the distribution of temperature and stress shows a strong coupling. Furthermore, elevated traction speed and mechanical load exacerbate the thermo-elastic instability of the guiding shoe, consequently augmenting thermal stress on the friction surface. The increase in support load results in significant thermal shock on the lower area of the left side of the guiding shoe. The research provides a reference for exploring the fatigue failure and wear mechanisms of the guiding shoe while considering thermal effects.

Environmental Conditions Associated with Four Index Cases of Pacific Oyster Mortality Syndrome (POMS) in Crassostrea gigas in Australia Between 2010 and 2024: Emergence or Introduction of Ostreid herpesvirus-1?

Warm water temperature is a risk factor for recurrent mass mortality in farmed Pacific oysters Crassostrea gigas caused by Ostreid herpesvirus-1, but there is little information on environmental conditions when the disease first appears in a region—the index case. Environmental conditions between four index cases in Australia (2010, 2013, 2016 and 2024) were compared to provide insight into possible origins of the virus. Each index case was preceded by unusually low rainfall and higher rates of temperature change that could increase oyster susceptibility through thermal flux stress. Water temperature alone did not explain the index cases, there being no consistency in sea surface, estuary or air temperatures between them. Tidal cycles and chlorophyll-a levels were unremarkable, harmful algae were present in all index cases and anthropogenic environmental contamination was unlikely. The lack of an interpretable change in the estuarine environment suggests the recent introduction of OsHV-1; however, viral emergence from a local reservoir cannot be excluded. Future events will be difficult to predict. Temperature flux and rainfall are likely important, but they are proxies for a range of undetermined factors and to identify these, it will be necessary to develop comprehensive protocols for data acquisition during future index cases.

Analysis of erosion and sealing characteristics of V-regulating ball valves for coal chemical industry

Purpose This study aims to research the erosion wear characteristics and sealing performance of V-regulating ball valve in coal chemical process pipelines, which provides a theoretical reference for improving its antiwear and sealing performance. Design/methodology/approach Taking the V-regulating ball valve as the research object, based on the computational fluid dynamics and the theory of erosion wear, the authors studied its erosion characteristics under different medium parameters and analyzed the sealing performance under the heat-fluid–solid coupling working condition. Findings The erosion wear mechanism of the valve sealing surface is the simultaneous action of cutting and deformation. When the medium flow velocity, particle mass flow rate and particle size increase, the maximum erosion rate and average erosion rate in the V-regulating valve increase. The inner diameter Mises contact stress of the sealing surface is symmetrically distributed in a “wing shape,” and the contact stress of the outer diameter is distributed in a “butterfly shape.” Due to the superposition of thermal stress and pressure stress in the contact transition zone to produce a significant stress concentration. Practical implications The findings will provide a theoretical basis for improving the erosion resistance and sealing performance of V-regulating ball valve in coal chemical industry. Social implications V-type regulating ball valve is widely favored by coal chemical enterprises and petrochemical enterprises because of its wide adjustment ratio and good erosion resistance. Originality/value The V-regulating ball valve wear mechanism for cutting and deformation simultaneously, and its wear rate is positively correlated with the medium flow rate, particle mass flow rate and particle size. After the valve is opened, there is a significant stress concentration occurs in the contact transition zone due to the superposition of thermal stress and compressive stress. The findings will provide a theoretical basis for improving the erosion resistance and sealing performance of V-regulating ball valve in coal chemical industry. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2024-0205/

Study of thermal stress deformation in hybrid 3D printing and milling process of PEEK material

Hybrid manufacturing can enable rapid production of personalized artificial bones that are made of Polyether-ether-ketone (PEEK) by integrating 3D printing and milling. A main challenge, however, is the thermal stress deformation that arises from the fused deposition process, leading to warping and shrinkage. As a result, the fabrication accuracy is significantly diminished. This work aims to address this challenge by investigating the thermal stress deformation behavior of PEEK in hybrid manufacturing. The main contributions of this work, therefore, include the development of a model for this thermal deformation behavior, and the identification of key parameters such as cross-section length ( Ls), printed layer thickness ( Lh), and current workpiece height ( He). Further, experiments are conducted based on response surface methodology (RSM) to explore the relationships between temperature variation rate (Δ T), end surface height difference (Δ S), and length shrinkage rate (Δ L) with critical hybrid processing parameters. Optimal parameter combinations are then identified. Our experiments demonstrate that the proposed methods effectively reduce the effects of warping and shrinkage.

Research on Safety of Aero-Engine Oil Pipe Under Heating Conditions Based on Fluid–Solid Thermal Coupling

This paper examines the safety of aero-engine pipelines under different heating conditions. Based on the fire test standard documents, a model of an aero-engine oil pipe was constructed, and its safety under heating conditions that meet the standard was analyzed using fluid–solid thermal coupling. The pipe material was stainless steel 1Cr18Ni9Ti, and the oil inside the pipeline was China RP-3 kerosene. To simulate the different working conditions or pump failure scenarios, various kerosene inlet flow rates were used for the calculations. The results indicate that the pipe wall exhibits an uneven temperature distribution under standard heating conditions. As the kerosene flow rate decreases, the pipe wall temperature rises, and heat transfer deterioration occurs. The increase in the pipe wall temperature reduces the material’s strength, while the uneven temperature distribution generates thermal stress, further increasing the safety risk. When the kerosene flow rate is reduced to a certain level, the equivalent stress in the pipe wall exceeds the material’s yield strength, leading to a high risk of rupture.

Multi-criteria study and machine learning optimization of a novel heat integration for combined electricity, heat, and hydrogen production: Application of biogas-fueled S-Graz plant and biogas steam reforming

The current research introduces an environmentally friendly heat design method by employing biogas fuel, aiming to yield electricity, hydrogen, and heating load simultaneously. The proposed arrangement consists of a biogas-powered S-Graz plant and a biogas steam reforming cycle. Although methane-fueled S-Graz plants for multigeneration purposes have been studied in previous studies, research on employing biogas fuel to launch a S-Graz plant and integrating a biogas steam reforming cycle with such a plant has yet to be examined. The model is simulated using the engineering equation solver software, and the study includes thermodynamic, exergoeconomic, and sustainability assessments to show the potential of the suggested configuration. By conducting a sensitivity study, a machine learning optimization method within MATLAB is implemented to exhibit the final optimal solution for the proposed arrangement. This optimization uses artificial neural networks and a non-dominated sorting genetic algorithm-II algorithm in a triple-objective framework based on energy efficiency, sustainability index, and products’ specific cost. The optimization demonstrates that the mentioned objectives reach optimal values of 58.26 %, 4.56, and 15.56 $/GJ, respectively. Also, the optimal net output power and hydrogen production rate equal 5746 kW and 1.45 m3/s, respectively. Besides, the process determines the optimal exergy efficiency, total net present value, and payback period as 52.70 %, 50.3 M$, and 8.96 years, respectively. The total investment cost rate for this system also is found to be 219.8 $/h.

AN AERODYNAMIC INVESTIGATION OF A HIGH-PRESSURE TURBINE USING ROTOR CASING STATIC PRESSURE MEASUREMENTS AT ENGINE REPRESENTATIVE CONDITIONS WITH DIFFERENT TIP DESIGNS, TIP GAPS AND INLET TEMPERATURE PROFILES

Abstract A rotating High-Pressure (HP) turbine, in modern aircraft engines, is subjected to high cyclic thermal and mechanical loads. Shroudless turbines experience high heat loads on the rotor tip and casing, which makes them one of the life-limiting components for an engine. If the rotor tip starts to erode, then the tip clearance increases which increases the over-tip leakage flow, resulting in reduced stage efficiency and ultimately, the engine lifetime. The Oxford Turbine Research Facility (OTRF) is a high- speed rotating transient test facility that allows unsteady aerodynamics and heat transfer measurements, at engine representative conditions. This paper presents an experimental investigation, of the HP turbine rotor casing aerodynamics, performed in the OTRF. Steady and unsteady casing static pressure measurements were acquired, using pneumatic lines and high-frequency response (∼ 100 kHz) Kulite pressure transducers respectively. The single-stage HP turbine consisted of cooled vanes (featuring film and trailing edge slot cooling), and uncooled rotor blades. Three different tip designs (two squealers and one flat) were tested, at two tip gaps, and with two inlet temperature profiles that included a spatially uniform total temperature profile and an engine representative HP turbine inlet total temperature profile. In parallel, a numerical investigation of the experimental test cases is presented using unsteady Computational Fluid Dynamics (CFD) predictions. The experimental results from this study provide a unique dataset to validate numerical models.

Thermal Stress as a Critical Factor in the Viability and Duration of Spittlebug Eggs

The spittlebug Mahanarva spectabilis (Distant, 1909) (Hemiptera: Cercopidae) is an important pest that causes significant losses in the production of forage crops for cattle feed. Information on the thermal requirements of this insect during the egg stage is crucial in assessing the interaction between insects and forage. The aim of this research was to evaluate the effects of constant and oscillating (diurnal/nocturnal) temperatures on the viability of M. spectabilis eggs and the duration of the egg stage. Temperatures of 20 °C to 30 °C were ideal for the development of this insect pest, resulting in greater viability and faster development of the embryos. In addition, it should be noted that a variation of up to 8 days is feasible for synchronizing the phenological stages of the forage plants and the eggs to be laid on these plants when subjected to 30 °C (16.6 days) or 20 °C (25.7 days) without significantly altering the viability of the eggs. Notably, a temperature oscillation of 25 °C during the day and 15 °C at night increased the viability of the eggs after exiting diapause. These results are essential for the rearing of M. spectabilis in the laboratory, allowing for the supply of eggs for experiments and contributing to advances in studies aimed at developing effective integrated management strategies for this pest.

Architecture of a remelted layer with the nano-lamellar structure at the surface of Fe[sbnd]B materials via laser remelting to resist liquid aluminum corrosion

In this work, a significant enhancement of corrosion resistance of Fe-B materials in liquid Al (750 °C), with a corrosion rate one order of magnitude lower than that of H13 die steel, has been achieved by constructing nano-lamellar structures in the matrix. Results indicate that the nano-lamellar structure can not only effectively obstruct the interdiffusion between the Al and Fe atoms, restricting the growth of corrosion layers, but also accommodate sufficient growth and thermal stresses, suppressing the spallation of corrosion products. Furthermore, the ceramic nanoparticles in-situ formed in the nano-lamellar structure can inhibit the inward diffusion of Al atoms, greatly enhancing the corrosion resistance of α-Fe matrix. Besides, they also provide a robust pinning effect on the corrosion interface, improving the adhesion strength of corrosion products with the matrix. The architecture of nano-lamellar structure with nanoparticles may provide a novel strategy against liquid Al corrosion and shed new light on the development of corrosion-resistant materials.