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<p>Ni–Cr-B-Si–C alloys, used as hardfacing materials in fast-spectrum reactor components with liquid sodium coolant, are prone to cracking during deposition. Repairing small cracks is risky and may introduce new ones, while leaving them unrepaired risks propagation into the substrate, potentially causing failure. Interface cracks in welded dissimilar materials exhibit fracture behaviour that is significantly different from that observed in homogeneous materials, thereby necessitating the detection of crack initiation near the interface, monitoring of crack propagation, and estimation of interfacial crack length to ensure the reliable performance of hybrid multi-material structures during service. Developing a method for monitoring interface cracks helps designers create optimal repair strategies for Ni–Cr-B-Si–C alloy hardfaced components. This work utilises information entropy and the median frequency of acoustic emission signals to assess whether cracks deflect or penetrate at the interface between the hardfaced coating and the austenitic stainless steel substrate. Deflected cracks exhibit median frequencies of 400–900&#xa0;kHz and entropy values of 2.5–3.5 nats, differing significantly from those of penetrating cracks and brittle coating fractures. These metrics enable effective real-time crack monitoring. Additionally, correlations of cumulative entropy and total acoustic emission counts with the modulus of the complex stress intensity factor provide a means to estimate unknown interfacial crack length. A precise understanding of interface crack behaviour aids designers in optimising repair strategies and potentially avoiding unnecessary, high-risk repair welding. These findings also have broader implications for monitoring the fracture behaviour of hardfaced coatings and other hybrid structures fabricated by welding dissimilar materials across various industries.</p>

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Monitoring interface cracks in hardfaced coatings using acoustic emission

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年10月7日

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  • Prince Joseph,
  • Haneef T.K,
  • M. Nani Babu,
  • Anish Kumar,
  • Shaju K. Albert

摘要

Ni–Cr-B-Si–C alloys, used as hardfacing materials in fast-spectrum reactor components with liquid sodium coolant, are prone to cracking during deposition. Repairing small cracks is risky and may introduce new ones, while leaving them unrepaired risks propagation into the substrate, potentially causing failure. Interface cracks in welded dissimilar materials exhibit fracture behaviour that is significantly different from that observed in homogeneous materials, thereby necessitating the detection of crack initiation near the interface, monitoring of crack propagation, and estimation of interfacial crack length to ensure the reliable performance of hybrid multi-material structures during service. Developing a method for monitoring interface cracks helps designers create optimal repair strategies for Ni–Cr-B-Si–C alloy hardfaced components. This work utilises information entropy and the median frequency of acoustic emission signals to assess whether cracks deflect or penetrate at the interface between the hardfaced coating and the austenitic stainless steel substrate. Deflected cracks exhibit median frequencies of 400–900 kHz and entropy values of 2.5–3.5 nats, differing significantly from those of penetrating cracks and brittle coating fractures. These metrics enable effective real-time crack monitoring. Additionally, correlations of cumulative entropy and total acoustic emission counts with the modulus of the complex stress intensity factor provide a means to estimate unknown interfacial crack length. A precise understanding of interface crack behaviour aids designers in optimising repair strategies and potentially avoiding unnecessary, high-risk repair welding. These findings also have broader implications for monitoring the fracture behaviour of hardfaced coatings and other hybrid structures fabricated by welding dissimilar materials across various industries.