Periodic Reporting for period 1 - i-Weld (Integration of advanced experiments, computation and data for Duplex Stainless Steel joininginnovation)
Periodo di rendicontazione: 2019-05-01 al 2023-02-28
Welding and joining of advanced alloys such as Stainless steels (SS) and related systems are one of the most important R&I areas directly relevant to economies, health, and environments. Advanced grade Duplex stainless steel (DSS) with a mixed ferrite-austenite (+) structure, has superior mechanical and corrosion resistance with increased applications in many industries.
The complex alloying system naturally results in complicated microstructural zones, phases and properties, which is difficult to control and predict for welding, joining and related processes due to the thermal-mechanical-physical processes. The issues become more challenging for situation such as multi-pass welding, hybrid structures and dissimilar materials. This is a critical issue affecting the development of data-led R&I, wider applications and management of the materials as well as development of more efficient manufacturing/production processes
The overall objective of the project is to develop systematic collaborative advanced research on the key controlling structures, phases and properties with integrated experiments, physical modelling, computer aided engineering (CAE) and data science approaches. This will enhance the combined functional performances, applications, materials design and manufacturing techniques. It will contribute to the current global effort in knowledge based digital manufacturing by tackling the critical scientific issues. The general objectives (GOs) are to be focused on researcher development, enhance research capacities, developing long term collaborations in the consortium and with the wider R&D, as well as enhancing the understanding and impact of using complex science and data in design and manufacturing of an advanced material group important to the society. The scientific objectives are to be achieved through 7 collaborative work packages following the original plan within a dynamic mechanism. The main technical works during the reporting period has been focused on developing in-depth understanding and data of compositions, microstructure, phase ratio (e.g. ferrite/austenite, precipitations) of the fusion zones and heat affected zones; the key controlling factors and mechanisms of surface treatment and corrosion resistance; and development of computer aided engineering (CAE) system with advanced data. Objectives for on-going and future work is to be focused on establishing the effect of element solutions on the fundamental physical and interface parameters through physical modelling, welding and joining of dissimilar/hybrid material systems supported by the data and modelling system developed.
The complex alloying system naturally results in complicated microstructural zones, phases and properties, which is difficult to control and predict for welding, joining and related processes due to the thermal-mechanical-physical processes. The issues become more challenging for situation such as multi-pass welding, hybrid structures and dissimilar materials. This is a critical issue affecting the development of data-led R&I, wider applications and management of the materials as well as development of more efficient manufacturing/production processes
The overall objective of the project is to develop systematic collaborative advanced research on the key controlling structures, phases and properties with integrated experiments, physical modelling, computer aided engineering (CAE) and data science approaches. This will enhance the combined functional performances, applications, materials design and manufacturing techniques. It will contribute to the current global effort in knowledge based digital manufacturing by tackling the critical scientific issues. The general objectives (GOs) are to be focused on researcher development, enhance research capacities, developing long term collaborations in the consortium and with the wider R&D, as well as enhancing the understanding and impact of using complex science and data in design and manufacturing of an advanced material group important to the society. The scientific objectives are to be achieved through 7 collaborative work packages following the original plan within a dynamic mechanism. The main technical works during the reporting period has been focused on developing in-depth understanding and data of compositions, microstructure, phase ratio (e.g. ferrite/austenite, precipitations) of the fusion zones and heat affected zones; the key controlling factors and mechanisms of surface treatment and corrosion resistance; and development of computer aided engineering (CAE) system with advanced data. Objectives for on-going and future work is to be focused on establishing the effect of element solutions on the fundamental physical and interface parameters through physical modelling, welding and joining of dissimilar/hybrid material systems supported by the data and modelling system developed.
The work has established key in-depth knowledge of structure and properties of different welding processes of Duplex stainless steels and related manufacturing. For example, the structure and composition in multi-pass welding is established in detail, including the critical conditions for the formation of sigma phases, which is detrimental to the properties of the weldment. As another example of advance of the work, the project developed a user subroutine integrating mathematical modelling, engineering simulation and experimental data for predicting the microstructure with different thermal histories including the volume fraction of ferrite and austenite phases in the welding zones, critical cooling rate for some precipitation particles and residual stresses, all of which are important for controlling the structures and properties of the material and joint.
The main work on corrosion tests and surfaces treatment has covered advanced tests and analysis for different conditions. The effect of key elements and surface conditions on the corrosion resistance and the operating mechanisms is established. Some key data includes the critical pitting temperatures for TIG welded duplex stainless steels, effect of post-weld cleaning of duplex stainless steel, influences of surface roughness, key elements (Mn, O, N, etc.) in the DSS vs. single phased stainless steels. Extensive experimental work on Passivation treatment of stainless steel and developing data from potentiodynamic tests of citric acid passivated stainless steels has helped to develop the correlation between chemical composition (Cr and Mn content) and corrosion resistance. The in-depth knowledge is complimentary to conventional industrial available data and provide key data for establishing the critical corrosion limiting structural parameters. Another typical new development is on the microstructure characteristics and pitting corrosion of a duplex stainless steel (DSS) manufactured by laser metal deposition with wire (LMDw) in as-deposited (AD) and heat-treated (HT) conditions. The new data of the phase volume between ferrite and austenite and corrosion resistance is important for enhancing the use of layer-by-layer LMDw process and the advanced materials efficiently.
The main work on corrosion tests and surfaces treatment has covered advanced tests and analysis for different conditions. The effect of key elements and surface conditions on the corrosion resistance and the operating mechanisms is established. Some key data includes the critical pitting temperatures for TIG welded duplex stainless steels, effect of post-weld cleaning of duplex stainless steel, influences of surface roughness, key elements (Mn, O, N, etc.) in the DSS vs. single phased stainless steels. Extensive experimental work on Passivation treatment of stainless steel and developing data from potentiodynamic tests of citric acid passivated stainless steels has helped to develop the correlation between chemical composition (Cr and Mn content) and corrosion resistance. The in-depth knowledge is complimentary to conventional industrial available data and provide key data for establishing the critical corrosion limiting structural parameters. Another typical new development is on the microstructure characteristics and pitting corrosion of a duplex stainless steel (DSS) manufactured by laser metal deposition with wire (LMDw) in as-deposited (AD) and heat-treated (HT) conditions. The new data of the phase volume between ferrite and austenite and corrosion resistance is important for enhancing the use of layer-by-layer LMDw process and the advanced materials efficiently.
The work has laid a solid and dynamic foundation of framework and knowledge for technological, scientific development and innovation as well as impact generations. The data and programs developed so far will directly help further systematic work, in particular, the scientific understanding of phase structure formation and the effective integration of engineering modelling with neural network and machine learning. This has also laid a practical framework for developing in-depth knowledge/data studying the behaviours of secondary precipitation for balancing mechanical, thermal properties and corrosion performances in similar and dissimilar materials systems. The in-depth data and knowledge will all contribute to the data system development.
Work on the main scientific objectives has made contribution of the action to the improvement of the R&I potential within Europe and/or worldwide in this area. The work has delivered many seminars, conference presentation, contributed to EU workshops and journal publications. The R&D and networking has led to many new joint projects and proposals worth of several millions of euros, some of which was already granted during the first stage.
The activities for general objectives for researcher development and impact are closed integrated with scientific objectives and activities through all the WPs. The work has already made impact on enhancing the potential and future career prospects of the staff member. The project has helped establishing the career of several of ECRs to be engaged in R&D in industry and academia in leading international companies and university. The intersectoral secondments and the networking activities implemented has enhanced the development new research collaborations. The partners are not only working together on the R&D, they are also collaborating on education and training development impacting on wider communities. The new proposals developed by the partners involved many new partners in Europe, Asia and Africa building on the framework of i-weld which will further enhance the development of the consortium in the next stage of the project and beyond. The work has enhanced the R&D capacity of the industrial partners and innovation including on-going new patent developments by the industrial partner. The project has made impact to industrial practice through open days, engagement, training, and the new proposals have attracted new industrial partners. All these activities have laid a solid framework for future impact generation in the next stage and beyond.
Work on the main scientific objectives has made contribution of the action to the improvement of the R&I potential within Europe and/or worldwide in this area. The work has delivered many seminars, conference presentation, contributed to EU workshops and journal publications. The R&D and networking has led to many new joint projects and proposals worth of several millions of euros, some of which was already granted during the first stage.
The activities for general objectives for researcher development and impact are closed integrated with scientific objectives and activities through all the WPs. The work has already made impact on enhancing the potential and future career prospects of the staff member. The project has helped establishing the career of several of ECRs to be engaged in R&D in industry and academia in leading international companies and university. The intersectoral secondments and the networking activities implemented has enhanced the development new research collaborations. The partners are not only working together on the R&D, they are also collaborating on education and training development impacting on wider communities. The new proposals developed by the partners involved many new partners in Europe, Asia and Africa building on the framework of i-weld which will further enhance the development of the consortium in the next stage of the project and beyond. The work has enhanced the R&D capacity of the industrial partners and innovation including on-going new patent developments by the industrial partner. The project has made impact to industrial practice through open days, engagement, training, and the new proposals have attracted new industrial partners. All these activities have laid a solid framework for future impact generation in the next stage and beyond.