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Corrosion Resistance of Cast Duplex Steels

P. Müller V. Pernica V. Kaňa

Archives of Foundry Engineering | 2022 | vol. 22 | No 3 | 5-10 | DOI: 10.24425/afe.2022.140230

Keywords Cast duplex steel Pitting resistance equivalent number Ferric chloride Critical pitting temperature Mechanical properties

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Abstract

The aim of this work is to investigate the resistance of cast duplex (austenitic-ferritic) steels to pitting corrosion with respect to the value of PREN (Pitting Resistance Equivalent Number). Pitting corrosion is one of the most common types of corrosion of stainless steels. In most cases, it is caused by the penetration of aggressive anions through the protective passive layer of the steel, and after its disruption, it leads to subsurface propagation of corrosion. The motivation for the research was a severe pitting corrosion attack on the blades of the gypsum-calcium water mixer in a thermal power plant operation.
In order to examine the corrosion resistance, 4 samples of 1.4517 steel with different concentrations of alloying elements (within the interval indicated by the steel grade) and thus with a different PREN value were cast. The corrosion resistance of the samples was evaluated by the ASTM G48 – 11 corrosion test in a 6% aqueous FeCl3 solution at room and elevated solution temperatures. To verify the possible effect of different alloying element concentrations on the mechanical properties, the research was supplemented by tensile and Charpy impact tests. Based on the results, it was found that a significant factor in the resistance of duplex steels to pitting corrosion is the temperature of the solution. For the components in operation, it is therefore necessary to take this effect into account and thoroughly control and manage the temperature of the environment in which the components operate.

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Bibliography

[1] Reardon, A. (2011). 12.5 Duplex Stainless Steels. In metallurgy for the non-metallurgist (2nd Edition). Ohio: ASM International, ISBN 978-1-61503-821-3, Retrieved from https://app.knovel.com/hotlink/pdf/id:kt009JBTT4/metallurgy-non-metallurgist/duplex-stainless-steels
[2] McGuire, M.F. (2008). Duplex stainless steels. in stainless steels for design engineers (91–108) [online]. Materials Park, Ohio 44073-000: ASM International, [cit. 2020-05-19]. ISBN 978-1-61503-059-0., Retrieved from: https://app.knovel.com/hotlink/pdf/id:kt008GRPY2/stainless-steels-design/duplex-stainless-introduction
[3] O'Brien, A. ed. (2011) Stainless and Heat-Resistant Steels. In Welding Handbook, Volume 4 - Materials and Applications, Part 1 [online]. 9th Edition. Miami: American Welding Society (AWS), p. 351 [cit. 2020-05-27]. ISBN 978-1-61344-537-2. Retrieved from https://app.knovel.com/hotlink/pdf/id:kt0095SGE2/welding-handbook-volume/duplex-sta-composition
[4] Revie, R.W. ed. (2011). In Uhlig’s Corrosion Handbook [online]. Third edition. Duplex stainless steels. (695–705). Hoboken, New Jersey: John Wiley & Sons, 2011 [cit. 2020-06-14]. ISBN 978-1-61344-161-9. Retrieved from https://app.knovel.com/hotlink/pdf/id:kt008TZY32/uhlig-s-corrosion-handbook/duplex-sta-history
[5] Prošek, T. & Šefl, V. (2018). Corrosion resistance of stainless steel in drinking water treatment plants and water storage units. Koroze a ochrana materialu. 62(4), 141-147. DOI: 10.2478/kom-2018-0020.
[6] Cicek, V. (2014). Corrosion engineering. Hoboken, New Jersey: Scrivener Publishing/Wiley. ISBN 978-1-118-72089-9. Retrieved from https://app.knovel.com/hotlink/toc/id:kpCE00004B/corrosion-engineering/corrosion-engineering.
[7] Marcus, P. ed. (2012). Corrosion mechanisms in theory and practice. Third edition. Boca Raton: CRC Press, Corrosion technology (Boca Raton, Fla.). ISBN 978-1-4200-9463-3.
[8] G48 - 11(2015). Standard test methods for pitting and crevice corrosion resistance of stainless steels and related alloys by use of ferric chloride solution. West Conshohocken: ASTM International, 2015.
[9] Jargelius-Pettersson, R.F.A. (1998). Application of the pitting resistance equivalent concept to some highly alloyed austenitic stainless steels. Corrosion. 54(2), 162-168. DOI: 10.5006/1.3284840.
[10] (2015). Austenitic-ferritic (duplex) casting materials [online]. Otto Junker, 2015 [cit. 2020-06-25]. Retrieved from: https://www.otto-junker.com/cache/dl-Austenitic-Ferritic-DUPLEX-Casting-Materials-aa4d1dd1db00d37343728c6ba0598a75.pdf

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Authors and Affiliations

P. Müller

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V. Pernica

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V. Kaňa

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Brno University of Technology, Czech Republic

Wettability of the System of Cast Iron and Magnesia Ceramics with Graphite

M. Hosadyna-Kondracka R. Nowak P. Turalska G. Bruzda Ł. Boroń M. Wawrylak

Archives of Foundry Engineering | 2022 | vol. 22 | No 3 | 25-33 | DOI: 10.24425/afe.2022.140233

Keywords Composites Metal-ceramic bonding Wettability Sessile drop method Cast iron

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Abstract

In this paper examinations of high-temperature wetting tests of 3 systems of liquid alloy – cast iron in contact with ceramic materials: magnesia ceramics in combination with natural graphite were presented. After wettability testing, the microscopic observations of the morphology of the sample surface and the cross-section microstructure with the chemical composition in micro-areas were examined. One of the objective of this work was also to verify whether the graphite content would affect the wettability of the magnesia ceramics. The study of high-temperature wetting kinetics of the liquid alloy in contact with the ceramic material, by the "sessile drop" method with capillary purification (CP) procedure was conducted. Under the test conditions, at a temperature of 1450°C and time 15 minutes, all 3 experimental systems showed a non-wetting behaviour. The average contact angle for the system with cast iron drop on magnesia ceramics was 140°, on magnesia ceramics with 10 parts per weight of graphite was 137° and on magnesia ceramics with 30 parts per weight of graphite - 139°.
Microscopic observations revealed that in the case of the sample consisting of the cast iron drop on the substrate with magnesia ceramics, the formation of fine separations was not observed, unlike the systems with the substrate with magnesia ceramics and the addition of natural graphite. Numerous, fine droplets accumulate on the graphite flakes and consist mainly of Si as well as Fe and O. On the other hand, the rough MgO grains have a gray, matt surface, without fine separations. The conducted observations indicate the mechanical nature of the bonding - liquid metal penetrates into the pores of the rough ceramics of the substrate. However, in the case of systems of cast iron drop with magnesia ceramics and addition of graphite, probably the adhesive connection and the physical attraction of elements derived from cast iron drop with the flake graphite appeared as well.

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Bibliography

[1] Sobczak, N., Sobczak, J.J., Kolev, M., Drenchev, L., Turalska, P., Homa, M., Kudyba, A. & Bruzda, G. (2020). High-temperature interaction of molten gray cast iron with Al2O3-ZrO2-SiO2 ceramic. Journal of Materials Engineering and Performance. 29, 2499-2505. DOI: 10.1007/s11665-020-04695-z. [2] Malaki, M., Fadaei Tehrani, A., Niroumand, B. & Gupta, M. (2021). Wettability in metal matrix composites. Metals. 11(7), 1034. DOI: 10.3390/met11071034. [3] Sobczak, N., Singh, M. & Asthana, R. (2005). High-temperature wettability measurements in metal/ceramic systems – Some methodological issues. Current Opinion in Solid State & Materials Science. 9(4-5), 241-253. DOI: 10.1016/j.cossms.2006.07.007. [4] Szafran, M., Rokicki, G., Lipiec, W., Konopka, K. & Kurzydłowski K. (2002). Porous ceramics infilted with metals and polymers. Composites. 2(5), 313-317. (in Polish). [5] Madzivhandila T., Bhero, S. & Varachia F. (2019). The influence of titanium addition on wettability of high-chromium white cast iron-matrix composites. Journal of Composite Materials. 53(11), 1567-1576. DOI: 10.1177/0021998318804616. [6] Asthana R. & Sobczak N. (2000). Wettability, spreading, and interfacial phenomena in high-temperature coatings. Retrieved September 28, 2021, from https://www.researchgate.net/profile/Natalia-Sobczak/publication/234787198_Wettability_Spreading_and_Interfacial_Phenomena_in_HighTemperature_Coatings/links/02e7e51acdbb31120a000000.pdf. [7] Janas, A., Kolbus, A. & Olejnik, E. (2009). On the character of matrix-reinforcing particle phase boundaries in MeC and MeB (Me = W, Zr, Ti, Nb, Ta) in-situ composites. Archives of Metallurgy and Materials 54(2), 319-327. [8] Moreira, A. B., Sousa, R. O., Lacerda, P., Ribeiro, L. M. M., Pinto, A. M. & Vieira, M. F. (2020). Microstructural characterization of TiC–white cast-iron composites fabricated by in situ technique. Materials. 13(1), 209. DOI: 10.3390/ma13010209. [9] Sobczak, N., Nowak, R., Radziwill, W., Budzioch, J. & Glenz A. (2008). Experimental complex for investigations of high temperature capillarity phenomena. Materials Science and Engineering 495(1-2), 43-49. DOI: 10.1016/j.msea.2007.11.094. [10] ASTRA Reference book. IENI, Report, Oct. 2007 [11] Liggieri, L. & Passerone, A.(1989). An automatic technique for measuring the surface tension of liquid metals. High Temperature Technology. 7, 80-86. [12] Bacior, M., Sobczak, N., Homa, M., Turalska, P., Kudyba, A., Bruzda, G., Nowak, R. & Pytel, A. (2017). High-temperature interaction of molten vermicular graphite cast iron with Al2O3 substrate. The Transactions of the Foundry Research Institute. 4/2017, 375-384. DOI: 10.7356/iod.2017.41. [13] Shen, P., Zhang, L., Zhou, H., Ren, Y. & Wang, Y. (2017). Wettability between Fe-Al alloy and sintered MgO. Ceramics International. 43(10), 7674-7681. DOI: 10.1016/J.CERAMINT.2017.03.067

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Authors and Affiliations

M. Hosadyna-Kondracka

e-mail:

ORCID:

R. Nowak

P. Turalska

G. Bruzda

Ł. Boroń

M. Wawrylak

Łukasiewicz Research Network - Krakow Institute of Technology, Poland

Inoculation of Gray Cast Iron Intended for Large Scale and Heavy Weight Castings of Bottom Plates and Counterweights Manufactured in the Krakodlew S.A.

A. Szczęsny D. Kopyciński Edward Guzik

Archives of Foundry Engineering | 2022 | vol. 22 | No 3 | 19-24 | DOI: 10.24425/afe.2022.140232

Keywords Heavy castings Large scale casting Grey cast iron Inoculation

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Abstract

The paper presents research carried out during the development of new technology for the production of heavy-weight castings of counterweights. The research concerns the procedure of inoculation gray cast iron with flake graphite and indicates guidelines for the development of new technology for obtaining inoculated cast iron for industrial conditions.
The research was conducted in order to verify the possibility of producing large size or heavy-weight castings of plates in a vertical arrangement. The aim is to evenly distribute graphite in the structure of cast iron and thus reduce the volumetric fraction of type D graphite. The tests were carried out using the ProCast program, which was used to determine the reference chemical composition, and the inoculation procedure was carried out with the use of three different inoculants. The work was carried out in project no. RPMP.01.02.01-12-0055 / 18 under the Regional Operational Program of the Lesser Poland Voivodeship in Krakow (Poland).

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Bibliography

[1] Benedetti, M., Torresani, E., Fontanari, V. & Lusuardi, D. (2017). Fatigue and fracture resistance of heavy-section ferritic ductile cast iron. Metals. 7(3), 88.
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[3] Wang, Q., Cheng, G. & Hou, Y. (2020). Effect of titanium addition on as-cast structure and high-temperature tensile property of 20Cr-8Ni stainless steel for heavy castings. Metals. 10(4), 529.
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[5] Kalandyk, B., Zapała, R., Sobula, S., Górny, M. & Boroń, Ł. (2014) Characteristics of low nickel ferritic-austenitic corrosion resistant cast steel. Metalurgija-Metallurgy. 53(4), 613-616.
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Authors and Affiliations

A. Szczęsny

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ORCID:

D. Kopyciński

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ORCID:

Edward Guzik

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AGH University of Science and Technology, Department of Foundry, ul. Reymonta 23, 30-059 Kraków, Polska

Mechanical and Microstructural Characterization of Aluminium Alloy, EN AC-Al Si12CuNiMg

G.G. Sirata K. Wacławiak M. Dyzia

Archives of Foundry Engineering | 2022 | vol. 22 | No 3 | 34-40 | DOI: 10.24425/afe.2022.140234

Keywords Mechanical properties Metallography Microstructure Fracture properties Aluminium alloy

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Abstract

Aluminum alloys have low density and good mechanical properties, making them suitable for the manufacture of mechanical structures where low weight is critical. However, when these alloys are subjected to elevated temperatures, their mechanical properties deteriorate significantly. The aim of this study is to investigate the effect of temperature on the mechanical properties of aluminium alloy, EN AC-Al Si12CuNiMg. For this purpose, an experimental investigation was performed at ambient and elevated temperatures on aluminium alloy samples prepared by casting. Tensile and hardness tests were carried out to characterize the mechanical properties of this material. Additionally, an optical microscope was used to examine the microstructures of this alloy. Finally, a scanning electron microscope was used to analyze the fracture modes of this material. The results show that the mechanical properties such as tensile strength, yield strength, and Young's modulus of this alloy dramatically decrease when the temperature exceeds 250C. The microstructural investigation reveals several factors that are detrimental to the mechanical properties of this alloy. This includes coarse-grained structures, micro-pores, and several intermetallic compounds. Furthermore, fractography reveals a minor cleavage-like pattern and micro-cracks on the fracture surface of all failed samples under various temperatures, indicating semi-brittle fracture mode.

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Authors and Affiliations

G.G. Sirata

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ORCID:

K. Wacławiak

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ORCID:

M. Dyzia

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ORCID:

Department of Materials Technologies, Faculty of Materials Engineering, Silesian University of Technology, Krasińskiego 8, 40-019 Katowice, Poland

Elimination of Zinc from Aluminum During Remelting in an Vacuum Induction Furnace

Albert Smalcerz Leszek Blacha B. Węcki D.G. Desisa J. Łabaj M. Jodkowski

Archives of Foundry Engineering | 2022 | vol. 22 | No 3 | 11-18 | DOI: 10.24425/afe.2022.140231

Keywords Mass transfer coefficient Zinc evaporation Vacuum induction furnace Meniscus

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Abstract

In this paper, the results of the study on aluminium evaporation from the Al-Zn alloys (4.2% weight) during remelting in a vacuum induction furnace (VIM) are presented. The evaporation of components of liquid metal alloys is complex due to its heterogeneous nature. Apart from chemical affinity, its speed is determined by the phenomena of mass transport, both in the liquid and gas phase. The experiments were performed at 10-1000 Pa for 953 K - 1103 K. A significant degree of zinc loss has been demonstrated during the analysed process. The relative values of zinc loss ranged from 4 to 92%. Lowering the pressure in the melting system from 1000 Pa to 10 Pa caused an increase in the value of density of the zinc evaporating stream from 3.82⋅10-5 to 0.000564 g⋅cm-2⋅s-1 at 953 K and 3.32⋅10-5 to 0.000421 g⋅cm-2⋅s-1 for 1103 K. Based on the results of the conducted experiments. it was found that evaporation of zinc was largely controlled by mass transfer in the gas phase and only for pressure 10 Pa this process was controlled by combination of both liquid and gas phase mass transfer.

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Bibliography

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Authors and Affiliations

Albert Smalcerz

e-mail:

ORCID:

Leszek Blacha

e-mail:

ORCID:

B. Węcki

e-mail:

ORCID:

D.G. Desisa

e-mail:

ORCID:

J. Łabaj

e-mail:

ORCID:

M. Jodkowski

e-mail:

ORCID:

Department of Testing and Certification "ZETOM", Poland
Department of Industrial, Informatics Silesian University of Technology, Joint Doctorate School, Poland
Faculty of Materials Engineering, Silesian University of Technology, Poland

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Corrosion Resistance of Cast Duplex Steels

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Wettability of the System of Cast Iron and Magnesia Ceramics with Graphite

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Inoculation of Gray Cast Iron Intended for Large Scale and Heavy Weight Castings of Bottom Plates and Counterweights Manufactured in the Krakodlew S.A.

Abstract

Bibliography

Authors and Affiliations

Mechanical and Microstructural Characterization of Aluminium Alloy, EN AC-Al Si12CuNiMg

Abstract

Authors and Affiliations

Elimination of Zinc from Aluminum During Remelting in an Vacuum Induction Furnace

Abstract

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Authors and Affiliations