Jana Pöpperlová

High-chromium ferritic stainless HiperFer steels were developed for high-temperature applications in power conversion equipment. The presented research describes the precipitation behavior of the Laves phase after the thermomechanical treatment of Fe-17Cr-0.6Nb-2.4W HiperFer alloys with and without the addition of 55 ppm boron. The boron-alloyed variant was produced with the aim of enhancing grain boundary strengthening and consequently increasing creep resistance. The focus is set on the effect of boron on the thermomechanically induced precipitation of (Fe,Cr,Si)₂(Nb,W) Laves phase at grain boundaries. The addition of boron modifies the diffusion conditions in the area of grain boundaries. Consequently, the formation of Laves phase is promoted and the particle growth and coarsening process are suppressed. The impact of boron addition was validated by performing creep and thermomechanical fatigue testing in the standard processing state of HiperFer steel. In the B-alloyed variant, increased creep ductility through the modification of the particle-free zone widths at high-angle grain boundaries was encountered. Nevertheless, an optimized thermomechanical treatment is necessary to fully utilize the increased ductility effect for the creep strength optimization of the B-alloyed grade.

The aim of the presented feasibility study was to systematically investigate the automation of the skimming (i.e., removal) of zinc ash from the surface of the zinc bath in order to minimise the risks for workers due to mechanical hazards (risk of falling into the zinc kettle) and chemical hazards (inhalation exposure to zinc vapours) by eliminating this activity. As part of the feasibility study, automatic separation and skimming systems from various applications, such as removal systems of slags and metal foam, were identified. For this purpose, their technical feasibility and suitability were considered. Two automated techniques, a mechanical and a gas-based skimming system, were selected for the subsequent laboratory-based evaluation. In the scope of the practical feasibility study, the selected skimming techniques were designed, constructed, and evaluated based on near-process prototype tests on a laboratory scale. The focus was on the efficiency of the skimming systems, related to the removal of zinc ash from the free surface of the molten zinc (general efficiency), as well as to the zinc ash removal with a simulated attachment system of the samples to be galvanised (task-related efficiency). The desired complete removal of zinc ash from the zinc bath surface was demonstrated with two automated methods: a pulse wave method of the mechanical skimming system and a gas-based skimming system in general, operating independently from the attachment system. Additionally, as part of the process-related simulation of the complete batch galvanising process, a fully automated combination of the zinc ash skimming and extraction system was achieved on a laboratory scale.

Fully ferritic stainless steels, strengthened by Laves phase precipitates, were developed for high-temperature application in the next generation of ultra-super-critical thermal power plants. Based on the rapid occurrence of thermomechanically induced precipitation in strengthening Laves phase particles, a novel thermomechanical process route for this class of steels was developed. A controlled precipitation of particles, in a desired morphology and quantity, and an optimization of the corresponding forging parameters was achieved on a laboratory scale. This article outlines the very first up-scaling experiment with these optimized forging parameters from the laboratory scale to the industrial scale. The precipitation behavior was analyzed, utilizing digital particle analysis of scanning electron microscopy (SEM) images, to estimate and compare the phase fraction of the precipitated Laves phase, as well as the particle size and distribution. Due to the up-scaling in the forging process, the behavior of the precipitation changed and the precipitation strengthening effect was decreased, in comparison with the laboratory scale.

The combined addition of Nb and W provides increased solid solution and precipitation strengthening by (Fe,Cr,Si)₂(Nb,W)-Laves phase particles of ferritic, 17 wt.% Cr stainless high-performance ferritic (HiperFer) steel. Based on alloy modifications and the obtained hardness, tensile, and creep testing results; a new high alloying variant is proposed as a candidate steel for future structural application up to approximately 680 °C in power engineering and the process industry.

Novel high-performance fully ferritic (HiperFer) stainless steels were developed to meet the demands of next-generation thermal power-conversion equipment and to feature a uniquely balanced combination of resistance to fatigue, creep, and corrosion. Typical conventional multistep processing and heat treatment were applied to achieve optimized mechanical properties for this alloy. This paper outlines the feasibility of thermomechanical processing for goal-oriented alteration of the mechanical properties of this new type of steel, applying an economically more efficient approach. The impact of treatment parameter variation on alloy microstructure and the resulting mechanical properties were investigated in detail. Furthermore, initial optimization steps were undertaken.

High-chromium ferritic stainless steels strengthened by Laves phase precipitates were developed for a high-temperature application in steam power plants. The impact of tungsten content on the precipitation of the intermetallic Laves phase during the newly developed thermomechanical process route was investigated. Due to rapid thermomechanically induced precipitation, a considerable reduction in processing time in comparison to the conventional solely thermal two-step processing of high chromium ferritic steels was achieved. Nevertheless, comparable mechanical properties at room temperature, i.e., the ultimate tensile strength of 712 MPa and the yield strength of 434 MPa, were obtained. The microstructure was analyzed by scanning electron microscopy (SEM) in combination with digital particle analysis, to estimate the particle size and the phase fraction of the Laves phase. The mean particle size of 52 nm and the volume fraction of 4.11% were achieved. Due to the tungsten content, an increase in the volume fraction and particle size was observed, giving rise to the higher strengthening effect.