Periodic Reporting for period 2 - ACHIEF (Innovative high performance Alloys and Coatings for HIghly EFficient intensive energy processes)
Reporting period: 2022-04-01 to 2023-03-31
The ACHIEF project is developing a novel Integrated Artificial Intelligence aided Materials Toolbox with the aim to propose innovative and adapted high performance materials and protective coatings. The main ambition of ACHIEF is to produce four types of new materials: WPDC coatings with improved high-temperature corrosion and erosion resistance; Advanced Cr-steels grade with 15% improved creep resistance and higher temperature corrosion resistance; Innovative high-temperature and creep resistance materials based on HESAs models; and High-performance coatings based on HEA-nanocomposites.
In a more advanced framework, the developed materials will be implemented in industrial environments to demonstrate their performance. The uses cases will be in CONSTELLIUM (France), ArcelorMittal (Spain), and Tüpraş (Turkey). Finally, the innovative solutions to be developed in the ACHIEF project will improve energy efficiency by 20%, reduce the CO2 emissions by 20%, and increase the lifetime of the equipment of more than 20%.
In a more advanced framework, the developed materials will be implemented in industrial environments to demonstrate their performance. The uses cases will be in CONSTELLIUM (France), ArcelorMittal (Spain), and Tüpraş (Turkey). Finally, the innovative solutions to be developed in the ACHIEF project will improve energy efficiency by 20%, reduce the CO2 emissions by 20%, and increase the lifetime of the equipment of more than 20%.
Despite the challenges faced during the COVID-19 pandemic, the ACHIEF consortium has joined forces to achieve the main objectives established during the first period. Initial steps to start the project were to characterise (e.g. temperatures, chemical environment, etc) and define the specifications of the different industrial uses cases where the novel materials will be integrated in the last stage.
In parallel, based on the existing materials database, the consortium created the artificial intelligence aided toolbox that generated data of candidate materials to answer to the different challenges that the industrial use cases will bring. The working method followed was the same for the three categories of material. First enrich the database based on literature, then train the models and validate the method of selection using "stallions" materials. Then it has been possible to generate 3D materials simulations to predict theorically materials behviour under the use case environment conditions. For PDC the model development is decided to focus on refractory alloy coating. Individual phases found in the coating has been produced and their chemistry and hardness has been characterized. Characterization data is used to build atomistic simulation workflow to numerically estimate the thermal, elastic and eventually cohesive and adhesive properties, and microstructural model to estimate the effect of imperfections (like pores) in the PDC coating. For HESA the microstructural basic models for both produced types of alloys has been made. The evaluation of characterization data implementation of certain features is still underway. For Cr-steel the incorporation the effect of the precipitates is still underway.
In addition, it was developed: PDC coatings, HESAs models and Cr-steels candidates at lab scale to be fully characterised afterwards. On the same line, the industrial use case conditions were also reproduced at lab scale in order to test the novel materials in this representative environment with the aim of evaluating their performance. Results at labsacle are convincing. The two initial candidates were more challenging than expected due to manufacturability aspects. Considering this aspect, a third alloy is under development to answer use case specifications.
The current challenge is now to define the industral process to produce and apply materials and coating at larger scale and on bigger sufaces, that add edge constraints. The upscale of the deposition process involved a additional research and process development work.
Finally, the consortium has also worked on designing sensors to have the most precise evaluation of the materials behaviors and evolution over time based on the environment where they will be located. The high temperature of industrial environements require a robust system monting. The close collaboration between industrials and sensor producer helps to face this technical challenge. ACHIEF results and progress were published on the project and partners’ website as well as social media account. More than 2,100 people visited the website and the ACHIEF social media accounts (LinkedIn and Twitter) reached more 166 followers (20k impressions generated). The consortium has released 4 publications and participated in 12 events. Furthermore, during this period, three files have been uploaded on Zenodo. Finally, technology transfer activities started in M24 and two activities have been met so far: training plan and mid-term workshop.
In parallel, based on the existing materials database, the consortium created the artificial intelligence aided toolbox that generated data of candidate materials to answer to the different challenges that the industrial use cases will bring. The working method followed was the same for the three categories of material. First enrich the database based on literature, then train the models and validate the method of selection using "stallions" materials. Then it has been possible to generate 3D materials simulations to predict theorically materials behviour under the use case environment conditions. For PDC the model development is decided to focus on refractory alloy coating. Individual phases found in the coating has been produced and their chemistry and hardness has been characterized. Characterization data is used to build atomistic simulation workflow to numerically estimate the thermal, elastic and eventually cohesive and adhesive properties, and microstructural model to estimate the effect of imperfections (like pores) in the PDC coating. For HESA the microstructural basic models for both produced types of alloys has been made. The evaluation of characterization data implementation of certain features is still underway. For Cr-steel the incorporation the effect of the precipitates is still underway.
In addition, it was developed: PDC coatings, HESAs models and Cr-steels candidates at lab scale to be fully characterised afterwards. On the same line, the industrial use case conditions were also reproduced at lab scale in order to test the novel materials in this representative environment with the aim of evaluating their performance. Results at labsacle are convincing. The two initial candidates were more challenging than expected due to manufacturability aspects. Considering this aspect, a third alloy is under development to answer use case specifications.
The current challenge is now to define the industral process to produce and apply materials and coating at larger scale and on bigger sufaces, that add edge constraints. The upscale of the deposition process involved a additional research and process development work.
Finally, the consortium has also worked on designing sensors to have the most precise evaluation of the materials behaviors and evolution over time based on the environment where they will be located. The high temperature of industrial environements require a robust system monting. The close collaboration between industrials and sensor producer helps to face this technical challenge. ACHIEF results and progress were published on the project and partners’ website as well as social media account. More than 2,100 people visited the website and the ACHIEF social media accounts (LinkedIn and Twitter) reached more 166 followers (20k impressions generated). The consortium has released 4 publications and participated in 12 events. Furthermore, during this period, three files have been uploaded on Zenodo. Finally, technology transfer activities started in M24 and two activities have been met so far: training plan and mid-term workshop.
During the thirty first months of the ACHIEF project, the consortium has created a new Artificial Intelligence-based design of Multicomponent alloys and PDC coatings. On the other hand, the consortium has also developed models to predict and simulate the materials behavior with the aim of finding new and better material solutions. Based on the current situation, the existing commercialised materials do not meet the specifications imposed by industrial environments. Characterization results obtained after materials development at lab scale, were fed back to refine the models.
The ACHIEF innovative solution aims to develop novel materials with performant properties that will be used in different industries requiring a very resistant material to withstand harsh conditions. For the first type of material: High Entropy Super Alloys it is required that they have a better resitance in high temperature environment and a capacity of distortion to reduce the creep strain rate. Concerning the Polymer Devired Ceramic there is no material available on the market able to answer to the requirements of petrochemical and aluminum industries. Two formulations with promising results were developped and tested at labscale. They have been deposited on the final parts through a deep work to define the deposition process parameters. They will be tested in the next months. Four novel Chromium steel grades were produced at lab scale: The new grades show relevant improvements in term of tensile properties, hardness, and creep resistance when compared to similar existing grades, while preserving good steam side corrosion response at high temperatures. The best steel grade has been selected to be reproduced at pilot scale. . The last material HESA will be developped combining the high temperature resistance of the HESA matrix with the hardness and wear resistance of the nano-reinforcement. The two first candidates developped, presented weaknesses in the resistance to harsh conditions. A third one is under development taking into account initial results. The consortium has also worked on designing sensors to have the most precise evaluation of the materials behaviors and evolution over time based on the environment where they will be located. A metal coated fiber optic sensor for high temperature strain and temperature sensing as well as a Electrochemical Impedance Sensor are under development. These can provide the necessary robustness to withstand the working conditions of the use cases. The partners have identified 18 Exploitable Results (ER), and from these 6 of them have been considered Key Exploitable Results (KER). A preliminary market analysis of the KERs have been performed. IPR assessment of the project results that have been preliminary defined. The methodology to be followed to do ACHIEF impact assessment has been defined and an analysis of the impacts identified have been addressed.
The ACHIEF innovative solution aims to develop novel materials with performant properties that will be used in different industries requiring a very resistant material to withstand harsh conditions. For the first type of material: High Entropy Super Alloys it is required that they have a better resitance in high temperature environment and a capacity of distortion to reduce the creep strain rate. Concerning the Polymer Devired Ceramic there is no material available on the market able to answer to the requirements of petrochemical and aluminum industries. Two formulations with promising results were developped and tested at labscale. They have been deposited on the final parts through a deep work to define the deposition process parameters. They will be tested in the next months. Four novel Chromium steel grades were produced at lab scale: The new grades show relevant improvements in term of tensile properties, hardness, and creep resistance when compared to similar existing grades, while preserving good steam side corrosion response at high temperatures. The best steel grade has been selected to be reproduced at pilot scale. . The last material HESA will be developped combining the high temperature resistance of the HESA matrix with the hardness and wear resistance of the nano-reinforcement. The two first candidates developped, presented weaknesses in the resistance to harsh conditions. A third one is under development taking into account initial results. The consortium has also worked on designing sensors to have the most precise evaluation of the materials behaviors and evolution over time based on the environment where they will be located. A metal coated fiber optic sensor for high temperature strain and temperature sensing as well as a Electrochemical Impedance Sensor are under development. These can provide the necessary robustness to withstand the working conditions of the use cases. The partners have identified 18 Exploitable Results (ER), and from these 6 of them have been considered Key Exploitable Results (KER). A preliminary market analysis of the KERs have been performed. IPR assessment of the project results that have been preliminary defined. The methodology to be followed to do ACHIEF impact assessment has been defined and an analysis of the impacts identified have been addressed.