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Understanding Scale Growth on Carbon Steel Tubes During High Temperature Processing / MEGAN KENDALL

Swansea University Author: MEGAN KENDALL

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DOI (Published version): 10.23889/SUThesis.71061

Abstract

Conveyance tube manufacturing is a high temperature process which promotes rapidsurface oxidation. During heat treatment, an oxide mill scale layer grows on tube surfaces.Inconsistent spalling of this layer from the outer tube surface contributes to yield loss, surface degradation, and tool wear. Ex...

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Published: Swansea 2025
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Sackett, E.
URI: https://cronfa.swan.ac.uk/Record/cronfa71061
first_indexed 2025-12-03T13:12:33Z
last_indexed 2025-12-05T09:33:48Z
id cronfa71061
recordtype RisThesis
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spelling 2025-12-03T13:16:08.5469108 v2 71061 2025-12-03 Understanding Scale Growth on Carbon Steel Tubes During High Temperature Processing ee48db3814a5a01c393f5ec660184883 MEGAN KENDALL MEGAN KENDALL true false 2025-12-03 Conveyance tube manufacturing is a high temperature process which promotes rapidsurface oxidation. During heat treatment, an oxide mill scale layer grows on tube surfaces.Inconsistent spalling of this layer from the outer tube surface contributes to yield loss, surface degradation, and tool wear. Experimental and theoretical studies of curved surface oxidation struggle to accurately recreate industrial processes. The computational thermochemistry software, Thermo-Calc©, was used to investigate external oxidation kinetics during conveyance tube manufacturing. A model was developed using the Stefan problem, tailored thermochemical databases, and a numerical solution to the diffusion equation. Particular attention was paid to geometric effects. There was strong agreement between oxide mass gain predictions by the model and equivalent thermogravimetric experiments. However, poor agreement between oxide thickness gain predictions by the model and industrial samples revealed scope for further work addressing transient heating, porosity, and thermomechanical manufacturing operations. Continuous oxide thickness data derived from the Thermo-Calc© model were used to evaluate thermal, growth, and manufacturing-related oxide stress. An Advanced Oxide Scale Failure Diagram (AOSFD),relating critical strain to instantaneous oxide thickness, was developed using these stress data. The AOSFD was used to demonstrate the impact of the transition to induction heating technology on oxide failure, namely improved electromagnetic control and changes to temperature control margins. Overall, this project demonstrates the use of computational techniques to predict geometry-specific oxide kinetics, and how the resulting data can be used to predict the mechanical state of the oxide. The continuous data presented are ideal for the development of an AOSFD which can predict how a given thickness of oxide will fail, if at all, depending on its strain state. The AOSFD is simple to use and therefore offers a practical tool for making informed decisions during conveyance tube manufacturing. E-Thesis Swansea oxidation, modelling, steel, diffusion, heat treatment, geometric effects, failure assessment 29 10 2025 2025-10-29 10.23889/SUThesis.71061 COLLEGE NANME COLLEGE CODE Swansea University Sackett, E. Doctoral EngD COATED M2A from the European Social Fund via the Welsh Government (c80816), the Engineering and Physical Sciences Research Council (Grant Ref: EP/S02252X/1), and Tata Steel UK Ltd COATED M2A from the European Social Fund via the Welsh Government (c80816), the Engineering and Physical Sciences Research Council (Grant Ref: EP/S02252X/1), and Tata Steel UK Ltd 2025-12-03T13:16:08.5469108 2025-12-03T13:08:17.6793443 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering MEGAN KENDALL 1 71061__35736__e7a255e78c9f435abfb9d78d41bc37fa.pdf 2025_Kendall_M.final.71061.pdf 2025-12-03T13:12:12.3766290 Output 20859564 application/pdf E-Thesis – open access true Copyright: the author, Megan Elizabeth Kendall, 2025 true eng
title Understanding Scale Growth on Carbon Steel Tubes During High Temperature Processing
spellingShingle Understanding Scale Growth on Carbon Steel Tubes During High Temperature Processing
MEGAN KENDALL
title_short Understanding Scale Growth on Carbon Steel Tubes During High Temperature Processing
title_full Understanding Scale Growth on Carbon Steel Tubes During High Temperature Processing
title_fullStr Understanding Scale Growth on Carbon Steel Tubes During High Temperature Processing
title_full_unstemmed Understanding Scale Growth on Carbon Steel Tubes During High Temperature Processing
title_sort Understanding Scale Growth on Carbon Steel Tubes During High Temperature Processing
author_id_str_mv ee48db3814a5a01c393f5ec660184883
author_id_fullname_str_mv ee48db3814a5a01c393f5ec660184883_***_MEGAN KENDALL
author MEGAN KENDALL
author2 MEGAN KENDALL
format E-Thesis
publishDate 2025
institution Swansea University
doi_str_mv 10.23889/SUThesis.71061
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 1
active_str 0
description Conveyance tube manufacturing is a high temperature process which promotes rapidsurface oxidation. During heat treatment, an oxide mill scale layer grows on tube surfaces.Inconsistent spalling of this layer from the outer tube surface contributes to yield loss, surface degradation, and tool wear. Experimental and theoretical studies of curved surface oxidation struggle to accurately recreate industrial processes. The computational thermochemistry software, Thermo-Calc©, was used to investigate external oxidation kinetics during conveyance tube manufacturing. A model was developed using the Stefan problem, tailored thermochemical databases, and a numerical solution to the diffusion equation. Particular attention was paid to geometric effects. There was strong agreement between oxide mass gain predictions by the model and equivalent thermogravimetric experiments. However, poor agreement between oxide thickness gain predictions by the model and industrial samples revealed scope for further work addressing transient heating, porosity, and thermomechanical manufacturing operations. Continuous oxide thickness data derived from the Thermo-Calc© model were used to evaluate thermal, growth, and manufacturing-related oxide stress. An Advanced Oxide Scale Failure Diagram (AOSFD),relating critical strain to instantaneous oxide thickness, was developed using these stress data. The AOSFD was used to demonstrate the impact of the transition to induction heating technology on oxide failure, namely improved electromagnetic control and changes to temperature control margins. Overall, this project demonstrates the use of computational techniques to predict geometry-specific oxide kinetics, and how the resulting data can be used to predict the mechanical state of the oxide. The continuous data presented are ideal for the development of an AOSFD which can predict how a given thickness of oxide will fail, if at all, depending on its strain state. The AOSFD is simple to use and therefore offers a practical tool for making informed decisions during conveyance tube manufacturing.
published_date 2025-10-29T05:32:12Z
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score 11.089386

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