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1、,Role of Materials Development in the Industrial Development,Shenhua Song (宋申华) Department of Materials Science and Engineering,Outline,Introduction Effect of materials development on the automotive industry Effect of materials development on the power generation industry Effect of materials develop
2、ment on the aeronautical industry,Materials are fundamentals of human being civilization,Bronze Age 2500 years ago,Stone Age 5000 years ago,Iron Age After BC 770,The human being society develops in fighting the nature. Human can make and use tools, but animals can not. This is the main difference be
3、tween human beings and animals,The tools are made of materials,First Industrial Revolution,The First Industrial Revolution began in England in the late 18th century, following in the wake of James Watt and his steam engine,Steam engine ship Steam engine train Steam blast furnace in the metallurgical
4、 industry) Steam-related machines in the coal mine industry Steam hammer, steam lathe, etc. in mechanical industry,Second Industrial Revolution,The Second Industrial Revolution began in the late 19th century, characterized by the following inventions Electricity generator (AC and DC) Motor (AC and D
5、C) Electric light Wire communication (Telephone) Wireless communication (Telegram) Television Gas engine (Internal combustion engine),Third Industrial Revolution,The Third Industrial Revolution began in the late 20th century, characterized by the following inventions,Modern computer Information tech
6、nology Nanotechnology Network Laser technology Modern aeronautical technology Space technology (Rocket, satellite, spaceship, etc.),Development of the industries which are closely related to our modern society, e.g., the automotive industry, the power industry, and the aeronautical industry, is main
7、ly determined by the development of materials,Research and development (R&D) of advanced materials is a measure of the progress in science and technology of a country,Waste gas emission from vehicles is one of the major air pollution sources in Shenzhen,Waste gas emission due to power generation is
8、also one of the major air pollution sources in Shenzhen,Effect of materials development on the automotive industry Pollution consideration - 20% of pollution from vehicles in developed countries - reducing emission of waste gas by reducing consumption of fuels - lightening the vehicle 2. Development
9、 of proper light materials to lighten the vehicles,Development of high strength and creep-resistant magnesium (1.74 g/cm3) alloys to replace some aluminium (2.69 g/cm3) alloy or steel (7.8 g/cm3) components Skin and some engine parts may be made of these light materials to lighten the vehicles Curre
10、nt situation: low quantity use because of the low reliability as well as cost consideration,镁合金压铸结构件已成为镁最主要的应用领域 镁合金压铸的快速增长主要是由欧美地区发达国家汽车工业面临汽车重量轻、耗油少、符合新的环保要求而促成的。此外,镁合金压铸件在汽车上的应用还可以改善汽车的结构和动力性能,也是目前汽车工业重视镁合金应用的原因之一。,Lightweight design measures in vehicles,Significant requirements for vehicle compo
11、nents,Value of lightweight design measures,Potential of Mg in drive train applications,Magnesium gearbox housings (operation temperature 130oC),Magnesium crankcase (operation temperature 130oC),MRI153M alloy up to 150oC MRI230D alloy up to 200oC,Possible body applications,Instrument panel (Fiat Stil
12、o),Instrument panel (BMW Mini),Mg bonnet (VW 3 l Lupo),Mg sheet applications,Mg bonnet after crash test (ODB - 64 km/h),Mg development in China,Chinas raw magnesium output in 1990-2002,In 2006: 522 kt 2 times in 2002,我国目前在镁工业方面拥有三项“世界冠军”,第一是镁资源大国，储量居世界首位。在青海盐湖蕴藏着氯化镁32亿吨，硫酸镁16亿吨。在辽宁、山西、宁夏、内蒙古、河南等省、自治
13、区菱镁矿均有很大储量，仅辽宁大石桥一带的储量就占世界菱镁矿的60以上，矿石品位高达40。,第二是原镁生产大国。2003年我国共生产原镁35.4万吨，约占全球总产量的67,第三是出口大国。年产量80以上的镁出口到国际市场。,主要问题：原镁生产技术比较落后，质量不够稳定，镁锭中的夹杂物和有害元素含量超标，难以满足压铸、板材轧制和冲压等高端产品的生产需求；出口产品多数是廉价的纯镁锭，镁合金及其制品出口比重小，因此出口利润低。,Export (10000 tons) of Chinese magnesium in 1990-2002,In 2003 Export of Chinese magnesiu
14、m: 298 kt increased by 42.6% as compared with that in 2002 including 53% raw Mg (75% in 2002), decreasing 22% Mg alloys (14% in 2002), increasing 20% Mg powder (18% in 2002), increasing,Existing problems High production cost for qualified Mg alloys and their products,Future R&D Focusing on reducing
15、production costs throughout the entire production and product development chain,Effect of materials development on the power generation industry,Thermal power generation Gas turbine power generation Nuclear power generation,Thermal power generation To reduce the consumption of fuels (coal, oil or na
16、tural gas) to reduce emission of waste gas such as CO2 and in turn to reduce the greenhouse effect,Advanced power stations with high efficiencies must be developed worldwide to reduce fuel consumption and CO2 emission,Solution,For steam turbine generators, power generation efficiency increases with
17、increasing steam operation temperature and pressure,Efficiency increase by increasing steam pressure and temperature,To increase the steam operation temperature up to 650oC, new materials for supercritical boilers and related components are required to be developed.,Requirements to materials Good hi
18、gh-temperature strength High creep resistance at high temperatures High oxidation/corrosion resistance High thermal conductivity Low thermal expansion coefficient,Candidate materials: 9-12%Cr ferritic/martensitic steels,Typical steels:,Development of 9%Cr steels,Tensile properties of E911 steel vers
19、us temperature,Results of iso-stress tests at 120 MPa for P92, E911, P91, P9 and 12Cr1MoV steels,Maximum temperature for the application of various power plant steels based on a 105h stress rupture strength under 100 MPa,TEM micrograph of P92 steel after creep deformation, 600oC, 145 MPa, 32909 h, s
20、howing carbides, nitrides, carbonnitrides, and Laves phase.,Circulating fluid bed (CFB) boiler,Inner casing of the project boxberg in 10Cr-1Mo-1W steel with a weight of 60 tons,The overview of a thermal power plant,Gas turbine power generation,Efficiency increases with increasing gas operation tempe
21、rature,The trend of development is always to increase the gas operation temperature,Limitations: High temperature oxidation without protection is severe The best superalloy can only tolerate up to 1200oC,Available materials: superalloys (usually, Ni-base or Co-base or NiCo-base),Solutions:,Oxidation
22、-resistant coating (usually, MCrAlY, M = Ni or Ni and Co; NiAl) Thermal barrier coating (usually, yttria-stabilized zirconia, YSZ) to create a temperature gradient between the metal and the gas (300-400oC),Before high-temperature operation,A thermal barrier coating system used in gas turbine compone
23、nts,APS-prepared TBC,EB-PVD-prepared TBC,(APS = air plasma spray),(EB-PVD = electron beam physical vapor deposition),1000oC,Nuclear power generation,Conventional fission reactor power generation,Future advanced fusion reactor power generation,Pressure vessels, boilers, etc.,First wall Low-activation
24、 material development,The property and performance of an airplane improves with the development of materials Screw-propeller plane (Gas engine ) jet plane (Gas turbine engine) Structural components: wood aluminium alloy magnesium alloy and polymer-matrix composite (future) Engine components: Ni-base
25、 superalloys Ti alloys (future),Effect of materials development on the aeronautical industry,Using thermal barrier coating system to increase the gas operation temperature,For the automotive industry, waste gas emission from vehicles is one of the major environmental pollution sources. Decreasing th
26、e vehicle weight, which reduces consumption of fuels and in turn diminishes environmental pollution, is the main trend of the vehicle development For the thermal power generation industry, enhancing the power generation efficiency and decreasing the fuel consumption are the main trend of development
27、. For the nuclear power industry, developing the fusion reactor power generation is the main trend of development. For the aeronautical industry, lightening the aircraft and increasing the operation efficiency of gas turbines are the main trend of development. The development of advanced materials is a key base for the development of the preceding industries.,Summary,Thank you for your attention!,