From the beginning of the project to the end of it after 42 months of activities performance, they have consisted mainly in a first step of design of materials and processses followed by the validation of new alloys, manufacturing technologies of components at lab level separately, combining new materials with new manufacturing technologies to produce component like geometries and embedded sensors and validating them at lab scale, followed by the manufacturing of prototypes checking them in industrial environment. All these activities have been supported by a continuous modelling of materials process and environmental performance . The technical project activities have been complemented with coordination activities (WP1) and dissemination and communication activities (WP7).
Main results that have been achieved are summarized underneath:
R1-A refractory stainless steel for beams manufacturing with superior properties in terms of creep and wear compared with current alloy in use (REF) identified as BEEN1 has been validated..(AZT)
R2. A refractory stainless steel with high wear and creep resistance identified as alloy R, has been validated in rings.(AZT)
R3. Printed sensors for high temperature applications have been validated at lab scale with good coherency with traditional wire based types.(CRM)
R4. High entropy alloy has been tested for application as LMD with cracks presence being non-succesful.(CEIT)
R5. A Haynes 230 superalloy applied by LMD on a ring . Wear test at lab level have shown a significant wear improvement in its performance compared with the current alloy in use.(CEIT)
R6. A new CERMET coating has been applied and validated initially at lab level, later at component like geometry and finally in one ring.(FRAU)
R7 The hydrosolidification process has been developed with a significant creep and creep crack growth rate improvement compared with a current alloy.(AZT)
R8 A combined material and process strategy has been followed in the case of LMD application the modelling has shown good coherency between predictions and results.(ESI)
R9 The set of data regarding creep and their link with microstructure have been used for material database completion for the prediction of this parameter.(QUEST).
R10 Embedded sensors have been integrated in one ceramic beam inside the furnace and their behavior has been monitored. The accuracy in measuring has been good.(CRM)
R11 A data analytics software has been used to determine main critical aspects in terms of bulk material development to achieve improved values of high temperature resistance.(AZT).
R12. Software has been adapted to each type of alloy and process under study incorporating or removing different variables depending on the case (AZT).
R13. A prototype beam has been manufactured using the industrial facilities using the developed alloy BEEN1 and introduced into the furnace.
R14. Prototype rings in the form of bulk materials (R alloy), Haynes 230 layer applied by LMD and ceramic coating applied by HVOF in rollers and inside the hot stamping furnace.(AMPO)
R15. A current running furnace is testing the prototype beams and rings. (GHI).
R16. Data captured inside the furnace through embedded sensors shows differences with sensors located in furnace walls presenting significant opportunities for better monitoring of temperature of steel blanks that need to be processed. (FRAU).
R17. Opportunities for new alloys development can be found in deep knowledge of main aspects affecting materials creep performance, available for teaching and service providing (KTH).
The results have been disseminated through the participation in conferences in congresses, the dissemination in trade fairs using posters flyers and videos, the dissemination to the industry and coordination with SPIRE08 project through workshops and the generation of scientific publications, being a significant number of them in process to be presented.
Eploitation has been focused in protecting knowledge as a patent of new refractory alloys, grouping different exploitable results in two marketable products; new hot stamping furnace and a new software for smart decission making in metal sector.
