Browsing by Author "Duarte Martinez, Fabian"

Now showing 1 - 8 of 8
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    Chlorine-induced stress corrosion cracking of single crystal superalloys at 550 °C
    (Springer, 2024-08-05) Duarte Martinez, Fabian; Dawson, Karl; Tatlock, Gordon; Leggett, J.; Gibson, G.; Mason-Flucke, J. C.; Nicholls, John; Syed, Adnan; Morar, N.; Gray, Simon
    This study has investigated the effect of NaCl and different gaseous environments on the stress corrosion cracking susceptibility of CMSX-4 at 550 °C. The presence of SOx leads to the rapid dissociation of NaCl into Na2SO4 and the release Cl2 and HCl, which then trigger an active oxidation mechanism and stress corrosion cracking. The incubation time for crack initiation at 690 MPa and in the presence of a sulphur containing environment is 10 min. A working hypothesis is that stress corrosion cracking occurs due to the hydrogen released at the oxide/alloy interface when metal chlorides are formed; however, this hypothesis needs to be further explored.
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    Data for the paper "Molecular dynamics simulation of the elliptical vibration assisted machining (EVAM) of pure iron"
    (Cranfield University, 2018-07-31 16:20) Goel, Saurav; Duarte Martinez, Fabian; Giusca, Claudiu
    Data files used for figures 3 and 5 in the associated article from the Journal of Micromanufacturing. These need to be opened in the Origin software (https://www.originlab.com/).
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    Effect of NaCl and SO2 on the stress corrosion cracking of CMSX-4 at 550°C
    (Taylor and Francis, 2023-05-01) Duarte Martinez, Fabian; Syed, Adnan; Dawson, Karl; Tatlock, G. J.; Morar, N. I.; Kothari, M.; Tang, C.; Leggett, J.; Mason-Flucke, J. C.; Gibson, G.; Nicholls, Nicholls, John R.; Gray, Simon; Castelluccio, Gustavo M.
    In the pursuit of more efficient gas turbine engines, components are required to operate for longer times at elevated temperatures. This increased time in service, together with a complex loading regime, can expose the material to environmental attack. This work has demonstrated that the interaction of stress, NaCl and a sulphur-containing environment is critical to cause crack initiation in the early stages of the exposure and accelerated corrosion rates in CMSX-4 at 550°C. The effect of having small concentrations of moisture in the gaseous environment or as water crystallisation in the salt is still to be investigated. A working hypothesis is that the interaction of alkali chlorides with a sulphur-containing atmosphere is the trigger to a self-sustaining cycle where metal chloride formation, vaporisation and oxidation lead to high amounts of hydrogen injection in a rapid manner and, therefore, hydrogen embrittlement.
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    Environmentally assisted cracking of a single crystal nickel-based superalloy
    (Taylor and Francis, 2023-03-03) Dawson, Karl; Duarte Martinez, Fabian; Gray, Simon; Nicholls, John; Gibson, G.; Leggett, J.; Tatlock, G. J.
    Single crystal material, of CMSX-4® alloy composition, was cast and secondary orientation was controlled at the machining stage, to produce c-ring cross-section tubes with known crystallographic orientations. The c-ring tubes were coated with NaCl before being subject to loading up to 700MPa and heated for durations of up to 2 hrs at 550°C in flowing environments containing air and SO2. No cracking was observed in short term tests that were run in the absence of either NaCl, or SO2, indicating a symbiotic interaction is required to initiate cracking. Experiments confirm the presence of oxygen, chlorine and sulphur at the crack tips, formed along {001} crystallographic planes, however, they were distributed discretely, with several oxide and sulphide phases observed. In this work, we image, analyse and identify the phases formed during the cracking and corrosion of CMSX-4® superalloy and hypothesise on the complex chemical interactions that take place during crack initiation.
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    Investigation into the environmental assisted crack initiation mechanism of CMSX-4 in simulated aero engine environments at 450 - 550°C.
    (Cranfield University, 2023-03) Duarte Martinez, Fabian; Nicholls, J. R.; Gray, Simon; Castelluccio, Gustavo M.
    The aviation industry has continued to increase the efficiency of gas turbine engines, which are now designed to operate on a wide variety of flight routes. In general, the efficiency drive has led to components spending longer times at temperatures, where accelerated corrosion can occur. This has led to a complex degradation mechanism being identified in the lower shank region under the platform of single-crystal turbine blades. This research aims to understand the mechanism of crack initiation due to the synergistic effect of stress and high temperature corrosion environments on CMSX-4 in the lower operating temperature range, 450°C - 550°C, of an aero gas turbine blade. The first part of the investigation consisted in comparing the effect of different salt deposits in a 50 ppm SO₂ - air environment at 550°C. A 50 ppm SO₂ – air concentration was considered because the air going through the lower shank is fed directly from the compressor, and not from the combustor (which is the main source of sulphur). Characterisation of the resulting scales were carried out using scanning electron microscopy, energy dispersive spectroscopy and X- ray diffraction. Results from thermodynamic modelling are also presented. The first part of the investigation showed that CMSX-4 sample under an applied stress and no applied salt did not experience accelerated corrosion attack or crack formation when exposed to 50 ppm SO₂ - air in a 400-hour period. The same observation was made for a CMSX-4 sample under an applied stress and salted with CaSO₄. Sea salt caused accelerated corrosion attack with cracks up to 1.3 mm through the substrate formed after 400 hours of exposure. Further tests using NaCl salt in 50 ppm SO₂ – air showed that cracks can initiate after just 10 minutes of exposure at 550°C. Crack growth rates are significantly reduced after two hours of exposure within a 50-hour salt cycle. Cracks with NaCl in 50 ppm SO₂ – air have also been observed at temperatures as low as 450°C. When NaCl salt was applied to CMSX-4 and exposed to air only for 50 hours, the corrosion attack was reduced considerably, and the initiation of cracks is either suppressed or significantly delayed beyond a 50-hour period. Although this PhD has only focused on a 50-hour period, longer exposure times should be carried out to determine if air exposures delay crack initiation time, or if crack initiation is completely supressed. This thesis has therefore shown that the interaction of stress, NaCl and a sulphur- containing environment are critical to cause early crack initiation in single crystal nickel-based superalloys in the temperature range 450 - 550°C. The effect of having small concentrations of moisture in the gaseous environment or as inclusions retained in the salt are still to be investigated. A working hypothesis is that that the interaction of alkali chlorides with a sulphur-containing atmosphere is the trigger to a self-sustaining cycle where metal chloride formation, vaporisation and oxidation leads to high amounts of H₂ formed at the scale/alloy interface. Potentially, the H₂ formed at the alloy/scale interface may dissociate into atomic hydrogen, and lead to hydrogen embrittlement. For further verification of this hypothesis, a set of tests have been suggested.
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    A microscopy study of nickel-based superalloys performance in type I hot corrosion conditions
    (Taylor and Francis, 2023-03-10) Waeytens, Manon; Syed, Adnan U.; Roberts, Tracey; Duarte Martinez, Fabian; Gray, Simon; Nicholls, John R.
    Alloy material selection for sustainable, efficient, and cost-effective use in components is a key requirement for both power generation and aerospace sectors. Superalloys are manufactured using a combination of different elements, selected carefully to balance mechanical performance and environmental resistance to be used in a variety of different service conditions. Therefore, a fundamental understanding of each element is critical to alloy design. In this paper, the interaction of alloy chemistry, particularly chromium as a corrosion-resistant element along with titanium and molybdenum, and their effect on alloys performance for the relevant gas turbine industries were discussed. Based on the findings, the single-crystal alloy is found to be a better corrosion resistant alloy exhibited higher corrosion resistance in comparison to polycrystal alloys and proved that microstructure has a significant impact on alloy performance. This study also established that molybdenum level in chromia former alloys can significantly enhance the corrosion damage.
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    Molecular dynamics simulation of the elliptical vibration-assisted machining of pure iron
    (SAGE, 2018-05-23) Goel, Saurav; Duarte Martinez, Fabian; Zare Chavoshi, Saeed
    It is well known that diamond wears out rapidly (within several metres of cutting length) when machining low carbon ferrous alloys and pure iron. The past few years have seen a growing interest in the field of elliptical vibration-assisted machining (EVAM) due to it being successful in the micromachining of difficult-to-cut materials including steel. During EVAM, a cutting tool is prescribed an oscillatory motion perpendicular to the direction of cutting, thereby causing the tool to be relieved intermittently from chemical and physical contact with the workpiece. This phenomenon serves as a guideline to develop the simulation test bed for studying EVAM in this work to compare it with conventional cutting. The pilot implementation of the EVAM came as a quasi-3-dimensional (Q3D) elliptical cutting model of body-centred cubic (BCC) iron with a diamond cutting tool using molecular dynamics (MD) simulation. The developed MD model supplemented by the advanced visualization techniques was used to probe the material removal behaviour, the development of the peak stress in the workpiece and the way the cutting force evolves during the cutting process. One of the key observations was that the cutting chips of BCC iron during conventional cutting underwent crystal twinning and became polycrystalline, while EVAM resulted in cutting chips becoming highly disordered, leading to better viscous flow compared to conventional cutting.
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    Optimized AI methods for rapid crack detection in microscopy images
    (MDPI, 2024-12-06) Lou, Chenxukun; Tinsley, Lawrence; Duarte Martinez, Fabian; Gray, Simon; Honarvar Shakibaei Asli, Barmak
    Detecting structural cracks is critical for quality control and maintenance of industrial materials, ensuring their safety and extending service life. This study enhances the automation and accuracy of crack detection in microscopic images using advanced image processing and deep learning techniques, particularly the YOLOv8 model. A comprehensive review of relevant literature was carried out to compare traditional image-processing methods with modern machine-learning approaches. The YOLOv8 model was optimized by incorporating the Wise Intersection over Union (WIoU) loss function and the bidirectional feature pyramid network (BiFPN) technique, achieving precise detection results with mean average precision (mAP@0.5) of 0.895 and a precision rate of 0.859, demonstrating its superiority in detecting fine cracks even in complex and noisy backgrounds. Experimental findings confirmed the model’s high accuracy in identifying cracks, even under challenging conditions. Despite these advancements, detecting very small or overlapping cracks in complex backgrounds remains challenging. Our future work will focus on optimizing and extending the model’s generalisation capabilities. The findings of this study provide a solid foundation for automatic and rapid crack detection in industrial applications and indicate potential for broader applications across various fields.