Examples of high cycle thermal fatigue (HCTF) damage cases onPWR austenitic stainless steel components are reported. High cyclethermal fatigue risk is primarily due to mixing of cold and hot water,unexpected leaks of cold water through check valves or to turbulentpenetration of hot water running in a main pipe into a connected line.When such thermal fatigue issues are identified in PWR powerplants, manufacturing improvement such as inner surface polishingof austenitic stainless steel parts can be performed to increase thefatigue resistance of the components.

A new technique for production of bulk ultrafine grained metallicmaterials is proposed. The principle and possible design of the newtechnique, referred to as 'cone-cone method' (CCM) are outlined. Itis suggested that CCM can be used to produce sheet or strip materialswith uniform microstructure. This is substantiated by the resultsof numerical simulations that demonstrate the viability of the process.

The Arcelor research center in Liège has developed an innovativeventilated double skinner roofing system based on an AluZinccoated steel siding. A pilot experiment has been carried out in July,August and September 2006 to assess the performance of the system.It makes it possible to bring down the inside temperature of aconstruction hut by 3°C and to minimize the energy consumption ofthe air conditioning by 9%.

The application of finite element techniques to modelling the longproducts rolling process, the use of a customized interface to enablethe rapid set-up of sequential simulations, and the benefits thathave been obtained are described. The paper also discusses theenhancements to incorporate a design of experiments/design optimisationmodule and to enable material tracking.

The new grade has significantly improved corrosion resistance in chloride solutions compared with currently available super duplex stainless steels (e.g. UNS S32750) and the 6Mo austenitic stainless steels (e.g. UNS S31254). Some references in industrial heat exchanger applications are highlighted.

A new image analyzer, Thixomet®, has been developed with the abilityto create “panoramic” images of material microstructure forinvestigations. Capabilities of the Thixomet image analyzer for materialmicrostructural characterization are demonstrated with examplesof nickel-based superalloys. Practical use of the Thixomet forcontrolling material properties by characterizing their microstructureis demonstrated.

A substantial remaining fatigue life of a riser steel pipe has been verified before re-installing it in another loading buoy. The analysis involves S-N predictions, evaluation of inspection results, fracture mechanics modelling, and stochastic modelling of the fatigue process. Recent rules and regulations give useful guidelines for deterministic fatigue life verification for items used beyond the original target service life. Through a reliability analysis, the actual probabilityof failure during the life extension can be revealed and an efficient inspection strategy can be determined.

The performance of lubrication systems for cold double reductionrolling has been investigated. Pilot mill trials have been achievedwith direct and recirculated emulsion application as well as with pureoil to analyse the effect of lubrication by emulsion on role bite frictionand the associated speed effect. It is then attempted to define anoptimized lubrication system that combines the advantages affordedby the direct and recirculated application systems.

The technology of mono-metals has reached maturity and furthertechnological developments are impeded by some natural limits.Basic resources have been largely investigated and major innovativesteps should not be expected in this area. Further progress in thescience and technology of metallic materials will rather concerncomposite metals, layered composites in particular.

The structural durability of welded structures is determined by theinteraction of different influencing parameters like loading mode,spectrum shape, residual stresses and weld geometry amongothers. Examples from plant, offshore, transportation and automotiveengineering show how these parameters influence the fatigue lifeand to what extent they are considered in design codes.