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Adjusting the friction response of the wheel-rail interface is a key factor in the mitigation of wear and rollingcontact fatigue (RCF) in rails. The use of top-of-rail (TOR) friction conditioners has the potential to reduce maintenance costs significantly. Unfortunately, conflicting results on the use of commercial TOR conditioners have been presented in the literature. In this work, the performance of commercial TOR conditioners and a laboratory-made formulation were tested, both on the lab scale and in field measurements. Friction results are discussed together with the structural and chemical analysis of the tested materials.
Die Beständigkeit von hochlegierten korrosions- und säurebeständigen Stählen wird primär durch den Chromgehalt bestimmt. Allerdings gibt es entlang der Wertschöpfungskette von der Stahlerschmelzung bis zum fertigen Produkt eine Vielzahl weiterer Einflussfaktoren. Dem Schleifen kommt hier eine besondere Bedeutung zu, da es je nach Wahl der Prozessparameter sowohl zu einer signifikanten Verschlechterung als auch zu einer Verbesserung der Korrosionsbeständigkeit führen kann. Im vorliegenden Beitrag wird aufgezeigt, dass die erzeugte Rauheit nur eine begrenzte Aussagekraft bietet. Vielmehr erhöhen lokale Mikrodefekte die Anfälligkeit gegen Lochfraß – je nach Ausprägung und Anzahl. Die Automatisierung für die Innenbearbeitung von Behältern im pharmazeutischen Apparatebau kann dabei zu einer signifikanten Verbesserung der Oberfläche und einem homogeneren Erscheinungsbild führen.
Die Fähigkeit zur Erzeugung einer nur wenige Nanometer dicken Passivschicht gelingt nichtrostenden Edelstählen aufgrund deren chemischer Zusammensetzung. Die erzielte Korrosionsbeständigkeit wird allerdings darüber hinaus als Systemeigenschaft von einer Vielzahl von weiteren Faktoren beeinflusst. Die vorliegende Arbeit befasst sich fokussiert mit dem Einfluss der schleiftechnischen Oberflächenbearbeitung von zwei ausgesuchten metastabilen austenitischen Legierungen auf deren Korrosionsverhalten.
Obwohl beide Legierungen eine vergleichbare Beständigkeit gemäß der chemischen Zusammensetzung besitzen, kann gezeigt werden, dass infolge von unterschiedlicher Oberflächenbearbeitung und unterschiedlichem Umformgrad eine starke Variation des Korrosionsverhaltens möglich ist. Es kann ebenfalls nachgewiesen werden, dass die Ausprägung und Anzahl von lokalen Oberflächendefekten hierfür verantwortlich ist. Dem eingesetzten Schleifkornwerkstoff kommt hierbei eine besondere Bedeutung zu.
Pitting susceptibility of metastable austenitic stainless steels as a function of surface conditions
(2019)
The influence of surface roughness and local defects on pitting susceptibility of type 304 (UNS S30400) and type 301 (UNS S30100) in chloride solution were investigated. Because the mechanical properties can be regarded as decisive for the achieved surface quality, different properties of the base material were obtained by cold rolling the metastable austenites. This was done before the surfaces were finished. Therefor the surfaces were treated by different grinding parameters to generate different surface conditions and different defects. As a reference, different standardised surface finishes were used.
By using and comparing different methods for the characterization of surface roughness and surface texture, it is possible to find a relationship between the quantity and characteristics of local defects on the one hand and pitting susceptibility on the other hand. For the machining parameters used, a ranking of the influencing factors on the corrosion resistance achieved could be determined.
The automated application of software-based solutions for estimating the pitting susceptibility of machined surfaces and components will be discussed using concrete examples.
Pitting susceptibility of metastable austenitic stainless steels as a function of surface conditions
(2019)
Fachvortrag auf der 10th International European Stainless Steel Conference and 6th European Duplex Stainless Steel Conference (ESSC & DUPLEX 2019), 30.09. – 02.10.2019, Vienna, Austria
This paper presents the current state of development and selected technological challenges in the application of ecologically and economically sustainable nets for aquaculture based on ongoing development projects. These aim at the development of a new material system of high-strength stainless steel wires as net material with environmentally compatible antifouling properties for nearshore and offshore aquacultures. Current plastic netting materials will be replaced with high-strength stainless steel to provide a more environmentally friendly system that can withstand more severe mechanical stresses (waves, storms, tides and predators). A new antifouling strategy is expected to solve current challenges, such as ecological damage (e.g., due to pollution from copper-containing antifouling substances or microplastics), high maintenance costs (e.g., cleaning and repairs), and shorter service life. Approaches for the next development steps are presented based on previous experience as well as calculation models based on this experience.
The corrosion resistance of stainless steels is massively influenced by the condition of their surface. The surface quality includes the topography of the surface, the structure and composition of the passive layer, and the surface near structure of the base material. These factors are influenced by final physical/chemical surface treatments. The presented work shows significantly lower corrosion resistance for mechanical machined specimens than for etched specimens. It also turns out that the rougher the surface, the lower the corrosion resistance gets. However, there is no general finding which shows if blasted or grinded surfaces are more appropriate, but a dependency on process parameters and the characteristics on corrosive exposure in terms of corrosion behavior. The results show that not only the surface roughness Ra has an influence on corrosion behavior but also the shape of peaks and valleys which are evolved by surface treatments. Imperfections in the base material, like sulfidic inclusions lead to a weaker passive layer, respectively, to a decrease of the corrosion resistance. By using special passivating techniques the corrosion resistance of stainless steels can be increased to a higher level in comparison to common passivation.
This paper compares the surface morphology of differently finished austenitic stainless steel AISI 316L, also in combination with low temperature carburization. Milled and tumbled surfaces were analyzed by means of corrosion resistance and surface morphology. The results of potentiodynamic measurements show that professional grinding operations with SiC and Al2O3 always lead to a better corrosion resistance of low temperature carburized surfaces compared to the untreated reference in the used acidified chloride solution. Big influence on the corrosion resistance of vibratory ground or tumbled surfaces has the amount of plastic deformation while machining, that has to be kept low for austenitic stainless steels. Due to the high ductility, plastic deformation can lead to the formation of meta stable pits that can be initiation points of corrosion. The formation of meta stable pits can be aggravated by low temperature diffusion processes.
Hot isostatic pressing (HIP) allows the production of complex components geometry. Generally, a high quality of the components is achieved due to the well managed composition of the metal powder and the non-isotropic properties. If a duplex stainless steel is produced, a heat treatment after the HIP-process is necessary to remove precipitations like carbides, nitrides and intermetallic phases. In a new process, the sintering step should be combined with the heat treatment. In this case a high cooling rate is necessary to avoid precipitations in duplex stainless steels. In this work, the influence of the HIP-temperature and the wall thickness on corrosion resistance, microstructure and impact strength were investigated. The results should help to optimize the process parameters like temperature and cooling rate. For the investigation, two HIP-temperatures were tested in a classical HIP-process step with a defined cooling rate. An additional heat treatment was not conducted. The specimens were cut from different sectors of the HIP-block. For investigation of the corrosion resistance, the critical pitting temperature was determined with electrochemical method according to EN ISO 17864. An impact test was used to determine the impact transition temperature. Metallographic investigations show the microstructure in the different sectors of the HIP-block.
The project aims for the development of a new material system from high tensile stainless steel wires as net material with environmentally compatible antifouling properties for off-shore fish farm cages. Therefore, current net materials from textiles (polyamide) shall be partially replaced by high strength stainless steel in order to have a more environmentally compatible system which meets the more severe mechanical loads (waves, storms, predators (sharks)). With a new antifouling strategy current issues like reduced ecological damage (e.g. due to copper disposal), lower maintenance costs (e.g. cleaning) and reduced durability shall be resolved.
Durch Beanspruchungen bei der Fertigung oder in der Anwendung können metastabile austenitische Stähle eine Phasenumwandlung von ?- Austenit zu ?‘-Martensit durchlaufen. Verbunden damit sind Eigenschaftsänderungen, welche sich signifikant auf das Werkstoffverhalten unter mechanischer, tribologischer oder korrosiver Belastung auswirken können.
Um möglichen negativen Auswirkungen wie ungewollte Magnetisierbarkeit oder Beeinflussung von Fertigungsparameter sowie Korrosionseigenschaften zu unterbinden muss die martensitische Phase zunächst erfasst und quantifiziert werden.
Für diese Aufgabe stehen neben den bekannten und kostenintensiven Verfahren wie EBSD und XRD für die praxisnahe Anwendung das magneto-induktive Messverfahren und verschiedene Ätzmethoden zur Verfügung.
Anhand von Applikationen aus Anwendung, Fertigung und Forschung werden die Wirkweisen, Vorteile und Grenzen verschiedener Ätzverfahren und dem magneto-induktiv messenden FERITSCOPE® MP30 aufgezeigt. Ebenso werden ergänzende Methoden bzw. Techniken zur Validation der Verfahren diskutiert und erläutert.
The electrochemical behavior for different surface conditions and different degrees of deformation of metastable austenitic stainless steel AISI 304 UNS S30400 were studied using critical pitting potential and electrochemical noise measurements. The influence on corrosion resistance by using different abrasives (silicon carbide and corundum) for surface finish by grinding is illustrated. For the characterization of local defects and surface topography, scanning electron microscopy (SEM) and tactile measurements were used. An inverse correlation between occurrence of local defects on the surface and critical pitting potential was found by using image processing. Therefore, gray scale values of different surfaces were compared. The influence of mass content of α'-martensite on the corrosion resistance is shown by comparing different qualities of surface finish. For smooth machined surfaces it can be shown that an increasing numbers of strain induced martensite is decreasing the corrosion resistance lightly. For low abrasive machining an inverse correlation between the critical pitting potential and surface roughness is given. However, for higher abrasive machining parameters, this correlation could not be found.
Einfluss der Oberfläche
(2018)
Einfluss der Oberfläche
(2017)
Low temperature carburizing of a series of austenitic stainless with various combinations of chromium and nickel equivalents was performed. The investigation of the response towards low temperature carburized for three stainless steels with various Cr- and Ni-equivalents showed that the carbon uptake depends significantly on the chemical composition of the base material. The higher carbon content in the expanded austenite layer of specimen 6 (1.4565) and specimen 4 (1.4539/AISI 904L) compared to specimen 2 (1.4404/AISI 316L) is assumed to be mainly related to the difference in the specimens’ chromium content. More chromium leads to more lattice expansion. Along with the higher carbon content, higher hardness values and higher compressive residual stresses in the expanded austenite zone are introduced than for low temperature carburized AISI 316L. The residual stresses obtained from X-ray diffraction lattice strain investigation depend strongly on the chosen X-ray elastic constants. Presently, no values are known for carbon (or nitrogen) stabilized expanded austenite. Nevertheless, first principle elastic constants for γ′&minus Fe4C appear to provide realistic residual stress values. Magnetic force microscopy and measurement with an eddy current probe indicate that austenitic stainless steels can become ferromagnetic upon carburizing, similar for low temperature nitriding. The apparent transition from para- to ferromagnetism cannot be attributed entirely to the interstitially dissolved carbon content in the formed expanded austenite layer but appears to depend also on the metallic composition of the alloy, in particular the Ni content.
Fachvortrag auf dem Swiss Tribology Symposium, 12.11.2019, Hightechzentrum Aargau, Brugg, Schweiz
Poster
Der digitale Seilüberwacher
(2020)
As a result of increasing needs and shrinking resources, aquaculture is gaining progressively significance in the recent years. Ecological issues such as negative effects on the ecological system due to the high fish density in the farms, the use of copper as antifouling strategy etc. are very present, particularly regarding the increasing number of fish going to be produced in farms in the future. Current trends focus on larger farms operated offshore. To make these farms working safe and economical, reliability has to be improved and maintenance costs need to be reduced. Also, alternatives with higher mechanical strength compared to current textile net materials as well as common metal wires might be necessary. In the last years, a new net system made of high strength duplex stainless steel wires with environmentally friendly antifouling properties suitable for offshore applications was developed. The first nets are operating for one year now as predator protection (i.e. seals) for fish farms and show a good performance in cleaning capability and predator protection. But in the real usage, some corrosion effects in the contact points of the net made of duplex stainless steel 1.4362 occur which were not observed in preliminary tests in laboratory and at different test sites around the world. These corrosion effects endanger the sustainable success of the net system. In this work, the observed corrosion effects are investigated. A laboratory test, which simulates the movement in the contact points of the net, was developed. Two pieces of wire are bent in the middle and get stucked into each other. One wire is fixed at both ends and the second wire is fixed on one end. On the other end, a circular movement with 1-2 rps and a 1 cm displacement is applied. The movement generates friction between the wires and the passive layer will be locally damaged. When the movement stops, a repassivation starts. The passivity breakdown and the repassivation were measured with electrochemical techniques. During the friction phase, when the surface will be activated, the open circuit potential breaks down. When the friction stops, the OCP increases. Between the movement phases, measurements of critical pitting potential were done. Thereby the quality of repassivation was investigated. The tests were done in a 3% sodium chloride solution. Different temperatures were tested as well as the influence of air saturation and low oxygen content.
Martensitic stainless steels has a wide use, for example for blades, knifes or cutter. The best corrosion resistance of these materials is in hardened condition. For better mechanical properties a tempering is normally applied to increase the durability. The tempering is also reducing the hardness and finally the corrosion resistance. Austempering is meanly used at low alloyed steels and brings a good compromise between durability, hardness and corrosion resistance. For martensitic stainless steels, austempering is normally not a topic because of the very long tempering times.
This work shows first results of austempering of some standard martensitic stainless steels and the influence to corrosion resistance. For reference, hardened and also hardened and tempered specimens were investigated. The corrosions resistance was investigated by electrochemical methods.
The first part of this work shows the development and application of a new material system using high strength duplex stainless steel wires as net material with environmentally compatible antifouling properties for off-shore fish farm cages. Current net materials from textiles (polyamide) shall be partially replaced by high strength duplex stainless steel in order to have a more environmentally compatible system which meets the more severe mechanical loads (waves, storms, predatores (sharks, seals)). With a new antifouling strategy current issues like reduced ecological damage (e.g. due to copper disposal), lower maintenance costs (e.g. cleaning) and reduced durability shall be resolved.
High strength steel wires are also widely used in geological protection systems, for example rockfall protection or slope stabilisation. Normally hot-dip galvanised carbon steel is used in this case. But in highly corrosive environments like coastal areas, volcanic areas or mines for example, other solutions with a high corrosion resistance and sufficient mechanical properties are necessary. Protection systems made of high strength duplex stainless steel wires enable a significantly longer service life of the portection systems and therefore a higher level of security.