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Corrosion-Fatigue Study of a Novel Maraging Steel: Atmospheric and Salt Fog Effects / DEAN SCOURFIELD

Swansea University Author: DEAN SCOURFIELD

  • E-Thesis under embargo until: 15th June 2028

DOI (Published version): 10.23889/SUthesis.63691

Abstract

A novel maraging steel (F1E) with both high strength & toughness has been proposed to replace the Low-Pressure Turbine (LPT) shaft within the aeroengine, which is currently manufactured using two materials joined together by an inertia friction weld process. The LPT shaft is a critical component...

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Published: Swansea, Wales, UK 2023
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Jeffs, Spencer. and Rawson, Martin.
URI: https://cronfa.swan.ac.uk/Record/cronfa63691
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first_indexed 2023-06-22T14:05:26Z
last_indexed 2023-06-22T14:05:26Z
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spelling v2 63691 2023-06-22 Corrosion-Fatigue Study of a Novel Maraging Steel: Atmospheric and Salt Fog Effects 8bbbbe636c566b98454aee222149b60e DEAN SCOURFIELD DEAN SCOURFIELD true false 2023-06-22 A novel maraging steel (F1E) with both high strength & toughness has been proposed to replace the Low-Pressure Turbine (LPT) shaft within the aeroengine, which is currently manufactured using two materials joined together by an inertia friction weld process. The LPT shaft is a critical component in the gas turbine engine operating under extreme conditions. Ultra-high strength steels are the material of choice to endure the extensive temperature differences & mechanical loading, however, steel alloy corrosion resistance is inherently dependent on the operating environment and chemical composition. The corrosion properties of F1E are not well established akin to in-service environments and the research is limited within the area of maraging steel corrosion-fatigue. The current research aims to review the corrosion-fatigue behavior and mechanisms of F1E by conducting atmospheric trials in an ISO 9223 rated environment and investigating the effect on fatigue life, ultimately assessing corrosion and fatigue separately. In addition, F1E was investigated under salt fog corrosion conditions using 3.5% NaCl in synergy with cyclic loading, thus developing an understanding of corrosion and fatigue in synergy. Atmospheric corrosion trials were conducted up to a maximum of 36 months exposure. It is believed that increased exposure time has a detrimental effect on fatigue life due to increased localized corrosion characteristics, which act as stress raising features for crack nucleation. Salt fog fatigue tests were carried out at two conditions, one of which saw a defined pre-exposure interval (72 hours) prior to synergistic cyclic loading versus 0-hour pre-exposure.The evolution of localized corrosion in both forms of testing was examined through means of pitting depth, corrosion feature density & stress concentration (Kt). In addition, the threshold stress intensity factor for crack propagation (K1Max) was calculated by employing ‘area’ as a geometrical parameter within the field of Linear Elastic Fracture Mechanics (LEFM), which assumes small defects to be cracks. Initiating pitting characteristics were determined from the fracture surface. E-Thesis Swansea, Wales, UK Corrosion, Fatigue, Maraging Steel, Atmospheric Corrosion, Salt Fog 20 4 2023 2023-04-20 10.23889/SUthesis.63691 A selection of third party content is redacted or is partially redacted from this thesis due to copyright restrictions. COLLEGE NANME COLLEGE CODE Swansea University Jeffs, Spencer. and Rawson, Martin. Doctoral EngD EPSRC doctoral training grant, Rolls Royce plc 2023-10-03T16:07:36.9361856 2023-06-22T15:01:39.6587228 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering DEAN SCOURFIELD 1 Under embargo Under embargo 2023-06-22T15:06:20.0935456 Output 29995761 application/pdf E-Thesis true 2028-06-15T00:00:00.0000000 Copyright: The Author, Dean C. Scourfield, 2023. true eng
title Corrosion-Fatigue Study of a Novel Maraging Steel: Atmospheric and Salt Fog Effects
spellingShingle Corrosion-Fatigue Study of a Novel Maraging Steel: Atmospheric and Salt Fog Effects
DEAN SCOURFIELD
title_short Corrosion-Fatigue Study of a Novel Maraging Steel: Atmospheric and Salt Fog Effects
title_full Corrosion-Fatigue Study of a Novel Maraging Steel: Atmospheric and Salt Fog Effects
title_fullStr Corrosion-Fatigue Study of a Novel Maraging Steel: Atmospheric and Salt Fog Effects
title_full_unstemmed Corrosion-Fatigue Study of a Novel Maraging Steel: Atmospheric and Salt Fog Effects
title_sort Corrosion-Fatigue Study of a Novel Maraging Steel: Atmospheric and Salt Fog Effects
author_id_str_mv 8bbbbe636c566b98454aee222149b60e
author_id_fullname_str_mv 8bbbbe636c566b98454aee222149b60e_***_DEAN SCOURFIELD
author DEAN SCOURFIELD
author2 DEAN SCOURFIELD
format E-Thesis
publishDate 2023
institution Swansea University
doi_str_mv 10.23889/SUthesis.63691
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 0
active_str 0
description A novel maraging steel (F1E) with both high strength & toughness has been proposed to replace the Low-Pressure Turbine (LPT) shaft within the aeroengine, which is currently manufactured using two materials joined together by an inertia friction weld process. The LPT shaft is a critical component in the gas turbine engine operating under extreme conditions. Ultra-high strength steels are the material of choice to endure the extensive temperature differences & mechanical loading, however, steel alloy corrosion resistance is inherently dependent on the operating environment and chemical composition. The corrosion properties of F1E are not well established akin to in-service environments and the research is limited within the area of maraging steel corrosion-fatigue. The current research aims to review the corrosion-fatigue behavior and mechanisms of F1E by conducting atmospheric trials in an ISO 9223 rated environment and investigating the effect on fatigue life, ultimately assessing corrosion and fatigue separately. In addition, F1E was investigated under salt fog corrosion conditions using 3.5% NaCl in synergy with cyclic loading, thus developing an understanding of corrosion and fatigue in synergy. Atmospheric corrosion trials were conducted up to a maximum of 36 months exposure. It is believed that increased exposure time has a detrimental effect on fatigue life due to increased localized corrosion characteristics, which act as stress raising features for crack nucleation. Salt fog fatigue tests were carried out at two conditions, one of which saw a defined pre-exposure interval (72 hours) prior to synergistic cyclic loading versus 0-hour pre-exposure.The evolution of localized corrosion in both forms of testing was examined through means of pitting depth, corrosion feature density & stress concentration (Kt). In addition, the threshold stress intensity factor for crack propagation (K1Max) was calculated by employing ‘area’ as a geometrical parameter within the field of Linear Elastic Fracture Mechanics (LEFM), which assumes small defects to be cracks. Initiating pitting characteristics were determined from the fracture surface.
published_date 2023-04-20T16:07:38Z
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score 11.013148

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