Cr3C2-NiCr and WC-Ni thermal spray coatings as alternatives to hard chromium for erosion-corrosion resistance

Cr₃C₂-NiCr and WC-Ni coatings are widely used for wear applications at high and room temperature, respectively. Due to the high corrosion resistance of NiCr binder, Cr₃C₂-NiCr coatings are also used in corrosive environments. The application of WC-Ni coatings in corrosive media is not recommended due to the poor corrosion resistance of the (pure Ni) metallic matrix. It is well known that the addition of Cr to the metallic binder improves the corrosion properties. Erosion-corrosion performance of thermal spray coatings is widely influenced by ceramic phase composition, the size of ceramic particles and also the composition of the metallic binder. In the present work, two types of HVOF thermal spray coatings (Cr₃C₂-NiCr and WC-Ni) obtained with different spray conditions were studied and compared with conventional micro-cracked hard chromium coatings. Both as-sprayed and polished samples were tested under two erosion-corrosion conditions with different erosivity. Tungsten carbide coatings showed better performance under the most erosive condition, while chromium carbide coatings were superior under less erosive conditions. Some of the tungsten carbide coatings and hard chromium showed similar erosion-corrosion behaviour under more and less erosive conditions. The erosion-corrosion and electrochemical results showed that surface polishing improved the erosion-corrosion properties of the thermally sprayed coatings. The corrosion behaviour of the different coatings has been compared using Electrochemical Impedance Spectroscopy (EIS) and polarization curves. Total material loss due to erosion-corrosion was determined by weight loss measurements. An estimation of the corrosion contribution to the total weight loss was also given.     

Influence of HVOF parameters on the corrosion and wear resistance of WC-Co coatings sprayed on AA7050 T7

Thermal spray WC-based coatings are widely used in the aircraft industry mainly for their resistance to wear, reworking and rebuilding operations and repair of worn components on landing gear, hydraulic cylinders, actuators, propeller hub assemblies, gas turbine engines, and so on. The aircraft industry is also trying to use thermal spray technology to replace electroplating coatings such as hard chromium. In the present work, WC-Co coatings were built up on an AA 7050 aluminum alloy using high velocity oxygen fuel (HVOF) technology and a liquid nitrogen cooling prototype system. The influence of the spray parameters (standard conditions, W19S, increasing the oxygen flux, W19H, and also increasing the carrier gas flux, W19F) on corrosion, friction, and abrasive wear resistance were also studied. The coatings were characterized using optical (OM) and scanning electron (SEM) microscopy, and X-ray diffraction (XRD). The friction and abrasive wear resistance of the coatings were studied using Rubber Wheel and Ball on Disk tests. The electrochemical studies were conducted using open-circuit potential (E_OC) measurements and electrochemical impedance spectroscopy (EIS). Differences among coated samples were mainly related to the variation of the thermal spray parameters used during the spray process. No significant differences were observed in the wear resistance for the coatings studied, and all of them showed a wear rate around 10 times lower than that of the aluminum alloy. The results of mass loss and wear rate were interpreted considering different mechanisms. Comparing the different spray parameters, the oxygen flux (higher flame temperature) produced the sample which showed the highest corrosion resistance in aerated and unstirred 3.5% NaCl solution. Aluminum ions were detected on the surface almost immediately after the immersion of samples W19S and W19F in chloride solution, showing that the electrolyte reached the substrate and galvanic corrosion probably occurred. For sample W19H, aluminum ions were not detected even after 120 min of immersion in NaCl solution.     

Comparative study of Cr3C2-NiCr coatings obtained by HVOF and hard chromium coatings

In the present work the corrosion resistance of micro-cracked hard chromium and Cr₃C₂-NiCr (HVOF) coatings applied on a steel substrate have been compared using open-circuit potential (E_OC) measurements, electrochemical impedance spectroscopy (EIS) and polarization curves. The coatings surfaces and cross-section were characterized before and after corrosion tests using optical microscopy (OM) and scanning electron microscopy (SEM). After 18 h of immersion, the open-circuit potential values were around −0.50 and −0.25 V/(Ag∣AgCl∣KCl_sat) for hard chromium and Cr₃C₂-NiCr, respectively. The surface analysis done after 12 h of immersion showed iron on the hard chromium surface inside/near surface cracks, while iron was not detected on the Cr₃C₂-NiCr surface even after 18 h. For longer immersion time hard chromium was more degraded than thermal sprayed coating. For hard chromium coating a total resistance values between 50 and 80 kΩ cm² were measured and two well-defined time constants were observed, without significant change with the immersion time. For Cr₃C₂-NiCr coating the total impedance diminished from around 750 to 25 kΩ cm² as the immersion time increased from 17 up to 132 h and two overlapped time constants were also observed. Polarization curves recorded after 18 h of immersion showed a lower current and higher corrosion potential for Cr₃C₂-NiCr coating than other samples studied.     

Analytical prediction of composite beams response in fire situations

In this paper an extension of the method of the Fourier series expansion to the fire analysis of composite beams is presented. In particular the extension concerns the introduction of the temperature dependent interaction of all the components: steel beams, concrete slab and steel connectors. These last are considered of finite stiffness, and a proper account is given to the combined effect of thermal degradation of the properties, and stress amplification caused by the differential thermal expansion across the interface.The proposed method compares very well with some experimental fire tests of simply supported and framed composite beams. Due to its relative simplicity and speed, it can be used for design purposes in evaluating the critical temperature in terms of critical deflection. Finally we recall that the method is capable of dealing with every type of fastening distribution, such as discontinuous or variable length.     

Modeling iron binding to organic matter

The aim of the present work is to model iron speciation during its interaction with natural organic matter. Experimental data for iron speciation were achieved with an insolubilised humic acid used as an organic matter analogue for 30microM to 1.8 mM total iron concentrations and 2< or = pH< or = 5.5. IHA was found to be able to impose its redox potential to the solution and therefore the Fe(ll)/Fe(lll) ratio. Model VI and the NICA-Donnan model have been adjusted to experimental results of acid-base titrations, total iron measurements, and redox speciation in solution. They both describe well pH and concentration dependence of iron adsorption. For high iron concentration, Fe(lll) solution activity is limited by precipitation of a poorly ordered Fe oxyhydroxide with a higher solubility (log Ks = 5.6-5.7) than ferryhydrite described in the litterature.     

Evaluation study of the effectiveness of the integrated genetic-algorithm-based strategy for the tomographic subsurface detection of defects

An assessment is presented of the integrated genetic-algorithm strategy based on a numerically computed Green's function for subsurface inverse scattering problems arising in nondestructive evaluation/testing industrial applications. To show the effectiveness and current limitations of such a microwave technique in dealing with various scenarios characterized by lossless and lossy host media as well as in noisy environments, several numerical experiments are considered. The results obtained confirm the effectiveness of the approach in fully exploiting the available a priori information through a suitable scattering model, which allows a nonnegligible enhancement of the reconstruction accuracy as well as a reduction of the overall computational burden with respect to standard imaging approaches.     

A way to super resolution by a sampling method using the spectral properties of one-dimensional multilayer systems

A way to perform sampling of the evanescent spectrum of an object is considered by using a photonic bandgap (PBG). The coupling between the scattered field from the object and the PBG is discussed, showing a connection of the guide modes with selected spectral components of the scattering object in free space. Some useful examples have been discussed, showing good agreement between numerical results and theoretical previsions.     

Experimental study of retrofit solutions for damaged concrete bridge slabs

Accurate information on the actual performance of the structural system after retrofit is an essential part of a cost-effective bridge management program. This paper summarizes the results of a thorough experimental program concerning the reinforced concrete deck of a real 40 year-old viaduct. The structure exhibited severe damage at the extrados mainly due to environmental agents, chemical attack and action of asphalt milling machines. Samples of the deck were cut and carried to the laboratory in order to assess the possibility of retrofit. The design of retrofit was aimed at increasing the load carrying capacity through replacement of the deteriorated concrete with a new concrete overlay and strengthening in flexure for both negative (hogging) and positive (sagging) bending moments. Experimental testing on small specimens and nondestructive techniques were carried out to identify the material properties and to evaluate the level of damage. The bonding between external reinforcement and the original or new (standard or polymer-modified) concrete was assessed through single-shear push–pull tests on 33 prismatic specimens of 100 × 200 × 500 mm³ strengthened with CFRP strips. The efficiency of the retrofit techniques was checked at the structural level through four-point bending tests on eight slabs of 500 × 200 × 2000 mm³. This research can contribute to guidelines for concrete patch repair of FRP-retrofitted concrete bridge decks, to ensure better long-term performance under service loads and environmental effects.     

Self-organized Ce(1-x)Gd(x)O(2-y) nanowire networks with very fast coarsening driven by attractive elastic interactions

Assembling arrays of ordered nanowires is a key objective for many of their potential applications. However, a lack of understanding and control of the nanowires' growth mechanisms limits their thorough development. In this work, an appealing new path towards self-organized epitaxial nanowire networks produced by high-throughput solution methods is reported. Two requisites are identified to generate the nanowires: a thermodynamic driving force for an unrestricted elongated equilibrium island shape, and a very fast effective coarsening rate. These requirements are met in anisotropically strained Ce(1-x)Gd(x)O(2-y) nanowires with the (011) orientation grown on the (001) surface of LaAlO(3) substrates. Nanowires with aspect ratios above ≈100 oriented along two mutually orthogonal axes are obtained leading to labyrinthine networks. A very fast effective nanowire growth rate (≈60 nm min(-1)) for ex-situ thermally annealed nanostructures derives from simultaneous kinetic processes occurring in a branched network. Ostwald ripening and anisotropic dynamic coalescence, both promoted by strain-driven attractive nanowire interaction, and rapid recrystallization, enabled by fast atomic diffusion associated with a high concentration of oxygen vacancies, contribute to such an effective growth rate. This bottom-up approach to self-organized nanowire growth has a wide potential for many materials and functionalities.