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Nickel Superalloy Design for Corrosion Resistance

Lead Research Organisation: Imperial College London
Department Name: Materials

Abstract

My fellowship will lead a research programme employing state of the art experimental and computational techniques to provide new, fundamental insight into the environmental degradation of nickel superalloys and steels that occur as a result of interactions with the corrosive gaseous species they encounter in-service. I have published some preliminary work from my corrosion and oxidation research program, though the full potential benefits for the development of corrosion resistant high temperature materials, have barely been explored. I plan to address these questions through advanced characterisation of samples exposed to corrosive environments in laboratory furnaces, during high temperature mechanical tests and a study of ex-service components provided by my industrial collaborators. The results will then be used to design a new generation of alloys, whose corrosion resistance will be tailored to their specific applications.

To maximise the impact of my research, I will work closely with my industrial collaborators such as Rolls-Royce plc, as well as my academic collaborators, including Prof Michael Moody (Atom probe Tomography Group, University of Oxford), to characterise the samples, inform alloy design and produce new superalloys with improved corrosion resistance. Corrosion research is extremely timely and globally important with potential for substantial future savings and component lifetime extension.

Planned Impact

My research will lead to the development of improved corrosion-resistant nickel-based superalloys. Where applicable, intellectual property rights arising from my fellowship will be protected for valuable innovations with significant commercial potential.

The Institute of Materials, Minerals and Mining (IoM3),of which I am an active member, provides me with mechanisms to reach other UK based companies with interests in corrosion resistant high temperature materials. I am a member of their High Temperature Materials Committee, which puts me in contact with industrial partners and academic collaborators on a regular basis. I will continue to attend a broad range of meetings, workshops and conferences to ensure dissemination of my research. To ensure that my work reaches industrial as well as academic audiences, I intend to organise a workshop, in collaboration with the High Temperature Materials Committee. The structure of this workshop will involve long overview presentations as well as allowing time for discussion and for setting up collaborations.

For an academic audience, the primary dissemination route will be through peer-reviewed publications and conference presentations. My fellowship will continue to produce high-quality peer-reviewed publications and submit them to respected journals in the field. Publications will be open access, therefore attracting the widest possible readership particularly from companies which may not have access to publications otherwise.

Direct industrial collaborations with leading UK enterprises such as Rolls-Royce plc, Good Fabrications Performance Exhausts and others will be direct beneficiaries of the innovations arising from my research fellowship.

Outreach and public engagement are of particular importance to me. My plan to increase the impact of my research includes the publication of articles for The Naked Scientist and Materials World, visits to local schools and public talks. I am a registered STEM ambassador and plan on continuing that work throughout my fellowship and involving my students in outreach programs too, with a particular focus on equality, diversity and women in engineering. My membership of the IoM3 High Temperature Materials Committee facilitates my involvement in outreach and public engagement activities through publications aimed at a non-specialist audience and by providing me with an education slideshow aimed at school children about high temperature materials and their uses.

Through these dissemination paths, my research will be reaching the widest possible audience of academic collaborators, industrial partners and the general public.

Publications

10 25 50

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Gasparrini C (2022) Water Chemistry in Fusion Cooling Systems: Borated Water for DTT Vacuum Vessel in IEEE Transactions on Plasma Science

 
Description Corrosion and high temperature oxidation often limit the service life of aero-engine components, oil and gas and chemical plants. Their corrosion and oxidation resistance will depend on the chemical composition of the alloy, which is often very complex (up to 10-12 elements at a time). The effect of each of them needs to be understood in order to understand, predict and influence the corrosion resistance of the overall alloy. The effect of svarious elements on the corrosion resistance of nickel-based superalloys was studied and published so far as part of this award. The effect of oxidation and under-deposit corrosion of steel was also investigated. This project is ongoing and further elemental compositions are being investigated.
Exploitation Route The findings are published in an open access format, which can be taken by others and built upon. Also the industrial collaborators Rolls-Royce plc, Royal Dutch Shell and Knauf Insulation are taking and implementing some of the outcomes in-service. All work on oil and gas is done to prevent oil/gas leaks and pipeline failures as well as to direct research towards renewable alternatives.
Sectors Aerospace

Defence and Marine

Chemicals

Energy

Transport

 
Description Our findings are informing new alloy compositions to be used in aero-engines by Rolls-Royce plc, the UK's flagship aero-engine manufacturer. Also wider discussions and dissemination with the manufacturers of industrial gas turbines for power generation are widening the industrial impact of this work and speeding up implementation. In addition, our work with Royal Dutch Shell has a direct service impact on their components. Knauf Insulation is working with us on cobalt alloys for their production line.
Sector Aerospace, Defence and Marine,Chemicals,Energy,Transport
Impact Types Economic

 
Description Alloying for impurity tolerance
Amount £198,829 (GBP)
Funding ID 2621673 
Organisation Government in Botswana 
Sector Public
Country Botswana
Start 08/2021 
End 09/2025
 
Description Corrosion of additively manufactured Ti alloys
Amount £107,903 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 09/2020 
End 10/2024
 
Description New Approaches to Understanding Hydrogen Embrittlement of Steels
Amount £88,862 (GBP)
Funding ID 2790946 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2023 
End 01/2027
 
Description New Approaches to Understanding Hydrogen Embrittlement of Steels
Amount £29,621 (GBP)
Funding ID 2790946 
Organisation Royal Dutch Shell plc 
Sector Private
Country Netherlands
Start 01/2023 
End 01/2027
 
Description New approaches to understanding hydrogen embrittlement in steels
Amount £104,903 (GBP)
Funding ID 2897405 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 11/2023 
End 11/2027
 
Description New approaches to understanding hydrogen embrittlement in steels
Amount £34,698 (GBP)
Funding ID 2897405 
Organisation Royal Dutch Shell plc 
Sector Private
Country Netherlands
Start 11/2023 
End 11/2027
 
Description Oxidation of nickel superalloys for aero-engine applications
Amount £67,000 (GBP)
Organisation Rolls Royce Group Plc 
Sector Private
Country United Kingdom
Start 08/2019 
End 10/2023
 
Description Imperial College Africa Research fund 
Organisation University of Mauritius
Country Mauritius 
Sector Academic/University 
PI Contribution £1000 was given from the Imperial College Africa Research fund to collaborate on a project with the University of Mauritius on the corrosion of steel structures exposed to their main port (salt water) conditions. It funded a Masters student
Collaborator Contribution Samples
Impact One publication submitted, awaiting review.
Start Year 2022
 
Description Rolls-Royce studentships 
Organisation Rolls Royce Group Plc
Country United Kingdom 
Sector Private 
PI Contribution This is a contrinution for two part-funded studentships, co-funded by EPSRC DTP awards and by Rolls-Royce, plus 4 summer internships which I supervised.
Collaborator Contribution Rolls-Royce co-funded and co-supervised the studentships.
Impact Two PhD students were funded, Declan Clarke and Cynthia Rodenkirchen. Declan Clarke has used the Diamond Light Source EPSIC national facility for electron microscopy. Cynthia has received an poster prize and an invitation to present said poster at the London Society for Women Engineer conference 2022.
Start Year 2019
 
Description Shell studentships 
Organisation Royal Dutch Shell plc
Country Netherlands 
Sector Private 
PI Contribution Two research studentships co-funded by Shell and the Qatar National Research Foundation work on the corrosion/oxidation of steels (Parul Bishnoi and Jiaqi Liu, doctoral candidates at Imperial College London under the supervision of Dr Stella Pedrazzini). A third studentship was offered, then converted into post-doc funding for Dr Chris Bilsland, who worked on this project for a year. In addition two more Shell iCASE awards have been awarded in support of the corrosion program, which are taken up by the candidates Chao Sun and Hao Pei, under the supervision of Dr Stella Pedrazzini.
Collaborator Contribution Funding, intellectual contributions, samples
Impact Multi discipliary collaboration which has so far resulted in further funding and 5 people being recruited to do further research. In addition, the capabilities for research (equipment) are being improved thanks to the additional funding. One publication has resulted from this partnership so far: DOI: 10.1002/adem.202300406.
Start Year 2020
 
Description Eurosuperalloys 2022 Bamberg 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Presentation at the Europsuperalloys 2022 conference
Year(s) Of Engagement Activity 2022
 
Description Great Exhibition Road Festival 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Public/other audiences
Results and Impact Workshop on corrosion at the Great Exhibition Road Festival, which was attended by 400 people
Year(s) Of Engagement Activity 2022
 
Description Invited seminar - East Midlands Materials Society 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Professional Practitioners
Results and Impact Dr Stella Pedrazzini delivered the most well-attended seminar of the east midlands materials society. The society is part of our professional body: the Institute for Materials, Minerals and Mining. They organise talks to engage industry with academia. >60 people signed up on eventbrite and attended the talk.
Year(s) Of Engagement Activity 2020
URL https://www.iom3.org/group/east-midlands-materials-society-emms/meeting.html?id=4ABFEA6C-0032-4792-9...
 
Description Invited seminar - Friedrich Alexander University of Erlangen Nuremberg 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Over 50 people (academics, students and staff) attended an invited seminar delivered by Dr Stella Pedrazzini at the Friedrich-Alexander university of Erlangen Nuremberg. The seminar led to helpful discussions and an exchange, in which a Prof from Erlangen came to deliver a seminar at Imperial College.
Year(s) Of Engagement Activity 2020
 
Description Invited seminar - London Center for Nanotechnology 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Professional Practitioners
Results and Impact over 50 people attended a London Center for Nanotechnology lunchtime seminar delivered by Dr Stella Pedrazzini. The purpose of the seminar is cross-disciplianry engagement and this led to lots of questions and helpful discussions. It also led to a further invitation to present a brunch seminar at the Salters livery company.
Year(s) Of Engagement Activity 2020
 
Description Invited seminar - University of Cambridge 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact ~50 students, staff and academics attended a lunchtime seminar delivered by Dr Stella Pedrazzini at the University of Cambridge. This led to helpful discussions and was part of a long-standing collaboration with their Rolls-Royce UTC.
Year(s) Of Engagement Activity 2020
 
Description Invited seminar - University of Sheffield 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact 50 people attended an invited seminar delivered by Dr Stella Pedrazzini at the University of Sheffield, which sparked questions and discussions afterwards.
Year(s) Of Engagement Activity 2019
 
Description Oxmet Technologies lunchtime seminar 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact 30 engineers from Oxmet technologies joined a lunchtime seminar delivered by Dr Stella Pedrazzini. Engagement was good, lots of questions and discussions followed. This sparked a new collaboration in the form of co-supervision of a PhD studentship and Masters project on corrosion of titanium alloys.
Year(s) Of Engagement Activity 2020
 
Description Representative of Imperial College on a national outreach working group for materials science 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Schools
Results and Impact I am a member of a national outreach working group who is writing articles for Materials world magazine, organising Q&A sessions with schools and building a website. The reach is mostly school children, and the purpose is to make the subject area of materials science more visible and gender balanced.
Year(s) Of Engagement Activity 2020,2021
 
Description Rolls-Royce Lunch and Learn 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact Rolls-Royce Lunchtime seminar delivered to talk about corrosion to an audience of 50 Rolls-Royce engineers. Engaging with industry built a stronger link, in order to lead to faster implementaiton of the innovations from the EPSRC fellowship.
Year(s) Of Engagement Activity 2019
 
Description Salters institute video series 
Form Of Engagement Activity A broadcast e.g. TV/radio/film/podcast (other than news/press)
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact Series of videos for the Salters institute Chemistry club, which have been viewed ~150 times each on Youtube and more times onthe Salters institute chemistry club platform. HEre are some links:
https://www.saltersinstitute.co.uk/chemistry-club-2/
https://www.youtube.com/watch?v=gyH4u7w6Ngs
https://www.youtube.com/watch?v=BI-iGGXDyHM
https://vimeo.com/680041610/cb9c3f60e2
Year(s) Of Engagement Activity 2020,2021,2022
URL https://www.youtube.com/watch?v=gyH4u7w6Ngs
 
Description TMS 2023 San Diego 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact I was on maternity leave and delegated to my Phd student to chair a session at the international conference TMS 2023
Year(s) Of Engagement Activity 2023
 
Description Thermec 2023 conference Vienna 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Keynote talk at Thermec 2023
Year(s) Of Engagement Activity 2023
 
Description Women in science talk 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact Dr Stella Pedrazzini recorded a talk on inspirational women in science, which is now live on youtube.
Year(s) Of Engagement Activity 2021
URL https://www.youtube.com/watch?v=iI1mCMdIFZQ
 
Description Youtube talk - Introduction to high temperature materials 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact Dr Pedrazzini delivered a non-specialist talk on high temperature materials which was recorded and posted on youtube in July 2020, amounting to over 500 views to date and generating social media interest on Twitter and LinkedIn.
Year(s) Of Engagement Activity 2020
URL https://www.youtube.com/watch?v=yKk6qkzzJgE&t=147s