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1、Role of Materials Development in the Industrial Development Shenhua Song (宋申华宋申华) Department of Materials Science and Engineering OutlineIntroductionEffect of materials development on the automotive industryEffect of materials development on the power generation industryEffect of materials developme
2、nt on the aeronautical industry Materials are fundamentals of human being civilizationBronze Age2500 years agoStone Age5000 years agoIron AgeAfter 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 between hu
3、man beings and animalsThe tools are made of materialsFirst 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 industry)
4、 Steam-related machines in the coal mine industry Steam hammer, steam lathe, etc. in mechanical industrySecond 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 DC) Electric
5、 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 technology Nanot
6、echnology 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 mainly determine
7、d by the development of materialsResearch and development (R&D) of advanced materials is a measure of the progress in science and technology of a countryWaste gas emission from vehicles is one of the major air pollution sources in ShenzhenWaste gas emission due to power generation is also one of the
8、 major air pollution sources in Shenzhen Effect of materials development on the automotive industry1.Pollution consideration - 20% of pollution from vehicles in developed countries - reducing emission of waste gas by reducing consumption of fuels - lightening the vehicle2. Development of proper ligh
9、t 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 Current situation: l
10、ow 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。此面临汽车重量轻、耗油少、符合新的环保要求而促成的。此外外, ,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动力性能, ,也是目前汽车工业重视镁合金应用的
11、原因之一。也是目前汽车工业重视镁合金应用的原因之一。 Lightweight design measures in vehiclesSignificant requirements for vehicle componentsValue of lightweight design measures Potential of Mg in drive train applicationsMagnesium gearbox housings (operation temperature 130oC) Magnesium crankcase (operation temperature 130oC)M
12、RI153M alloy up to 150oCMRI230D alloy up to 200oC Possible body applicationsInstrument panel (Fiat Stilo)Instrument panel (BMW Mini)Mg bonnet (VW 3 l Lupo)Mg sheet applicationsMg bonnet after crash test (ODB - 64 km/h)Mg development in ChinaChinas raw magnesium output in 1990-2002In 2006: 522 kt2 ti
13、mes in 2002 我国目前在镁工业方面拥有三项我国目前在镁工业方面拥有三项“世界冠军世界冠军” ” 第一是镁资源大国，储量居世界首位第一是镁资源大国，储量居世界首位。在青海盐湖蕴藏着氯化镁。在青海盐湖蕴藏着氯化镁3232亿吨，亿吨，硫酸镁硫酸镁1616亿吨。在辽宁、山西、宁夏、内蒙古、河南等省、自治区菱镁矿亿吨。在辽宁、山西、宁夏、内蒙古、河南等省、自治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6060以上，矿以上，矿石品位高达石品位高达4040。第二是原镁生产大国第二是原镁生产大国。20032003年我国共生产原镁年
14、我国共生产原镁35.435.4万吨，约占全球总产万吨，约占全球总产量的量的6767 第三是出口大国第三是出口大国。年产量。年产量8080以上的镁出口到国际市场。以上的镁出口到国际市场。 主要问题主要问题：原镁生产技术比较落后，质量不够稳定，镁锭中的夹杂物和：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。此出口利润低。 Export
15、 (10000 tons) of Chinese magnesium in 1990-2002In 2003 Export of Chinese magnesium: 298 kt increased by 42.6% as compared with that in 2002including 53% raw Mg (75% in 2002), decreasing 22% Mg alloys (14% in 2002), increasing 20% Mg powder (18% in 2002), increasingRaw magnesium Magnesium productsExi
16、sting problemsHigh production cost for qualified Mg alloys and their productsFuture R&DFocusing on reducing production costs throughout the entire production and product development chainEffect of materials development on the power generation industry Thermal power generation Gas turbine power gener
17、ation Nuclear power generation Thermal power generationTo reduce the consumption of fuels (coal, oil or natural gas) to reduce emission of waste gas such as CO2 and in turn to reduce the greenhouse effectAdvanced power stations with high efficiencies must be developed worldwide to reduce fuel consum
18、ption and CO2 emissionAn increase in power generation efficiencyA decrease in fuel consumptionSolutionFor steam turbine generators, power generation efficiency increases with increasing steam operation temperature and pressureto increase the efficiency, increasing steam operation temperature is need
19、edEfficiency increase by increasing steam pressure and temperatureTo increase the steam operation temperature up to 650oC, new materials for supercritical boilers and related components are required to be developed. Requirements to materials1.Good high-temperature strength2.High creep resistance at
20、high temperatures3.High oxidation/corrosion resistance4.High thermal conductivity5.Low thermal expansion coefficient Candidate materials: 9-12%Cr ferritic/martensitic steelsTypical steels:Development of 9%Cr steelsTensile properties of E911 steel versus temperatureResults of iso-stress tests at 120
21、MPa for P92, E911, P91, P9 and 12Cr1MoV steelsMaximum temperature for the application of various power plant steels based on a 105h stress rupture strength under 100 MPaTEM micrograph of P92 steel after creep deformation, 600oC, 145 MPa, 32909 h, showing carbides, nitrides, carbonnitrides, and Laves
22、 phase.Circulating fluid bed (CFB) boilerInner casing of the project boxberg in 10Cr-1Mo-1W steel with a weight of 60 tons The overview of a thermal power plantGas turbine power generationEfficiency increases with increasing gas operation temperatureThe trend of development is always to increase the
23、 gas operation temperatureDeveloping new high-temperature materials for turbine components such as blade and combustion chamberLimitations: High temperature oxidation without protection is severe The best superalloy can only tolerate up to 1200oCAvailable materials: superalloys (usually, Ni-base or
24、Co-base or NiCo-base)Solutions:Oxidation-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)Thermal-insulating ceramic top coat (250 -300 m) (YSZ)Ox
25、idation-resistant metalllic bond coat (150 m) (MCrAlY)Alloy substrate (Ni-base superalloy)Before high-temperature operationThermally grown oxide (TGO) (Alumia)During high-temperature operationA thermal barrier coating system used in gas turbine componentsAPS-prepared TBCEB-PVD-prepared TBC(APS = air
26、 plasma spray)(EB-PVD = electron beam physical vapor deposition)1000h3000hYSZBond coatYSZBond coat500h100hYSZBond coatYSZBond coat1000oCNuclear power generationConventional fission reactor power generationFuture advanced fusion reactor power generationPressure vessels, boilers, etc.First wall Low-ac
27、tivation 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:
28、 Ni-base superalloys Ti alloys (future)Effect of materials development on the aeronautical industryUsing thermal barrier coating system to increase the gas operation temperature1.For the automotive industry, waste gas emission from vehicles is one of the major environmental pollution sources. Decrea
29、sing the vehicle weight, which reduces consumption of fuels and in turn diminishes environmental pollution, is the main trend of the vehicle development2.For the thermal power generation industry, enhancing the power generation efficiency and decreasing the fuel consumption are the main trend of dev
30、elopment. 3.For the nuclear power industry, developing the fusion reactor power generation is the main trend of development. 4.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. SummaryThank you for your attention!
