Open Access
Multifunctional protective PVC-ZnO nanocomposite coatings deposited on aluminum alloys by electrospinning
(MDPI, 2019) Iribarren Zabalegui, Álvaro; Rivero Fuente, Pedro J.; Berlanga Labari, Carlos; Larumbe Abuin, Silvia; Miguel, Adrián; Rodríguez Trías, Rafael; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2; Ingeniería; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa, PRO-UPNA 18 (6107)
This paper reports the use of the electrospinning technique for the synthesis of nanocomposite micro/nanofibers by combining a polymeric precursor with hydrophobic behavior like polyvinyl chloride (PVC) with nanoparticles of a corrosion inhibitor like ZnO. These electrospun fibers were deposited on substrates of the aluminum alloy 6061T6 until forming a coating around 100 m. The effect of varying the different electrospinning deposition parameters (mostly applied voltage and flow-rate) was exhaustively analyzed in order to optimize the coating properties. Several microscopy and analysis techniques have been employed, including optical microscopy (OM), field emission scanning electron microscopy (FE-SEM), atomic force microscopy (AFM), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). Water contact angle (WCA) measurements have been carried out in order to corroborate the coating hydrophobicity. Finally, their corrosion behavior has been evaluated by electrochemical tests (Tafel curves and pitting potential measurements), showing a relevant improvement in the resultant corrosion resistance of the coated aluminum alloys.
Open Access
Valorisation of red mud: disclosing the potential of an abundant residue
(MDPI, 2025-02-21) Vielma, Carlos A.; Svobodova-Sedlackova, Adela; Chimenos, Josep Maria; Fernández, A. Inés; Berlanga Labari, Carlos; Rodríguez Trías, Rafael; Barreneche, Camila; Ingeniería; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2; Gobierno de Navarra / Nafarroako Gobernua
Red mud (RM), the primary waste product of the aluminium industry, is notable for its high concentrations of metals and rare earth elements (REE). Efforts have been made to develop extraction methods for REE recovery from RM, aiming to enhance its valorisation and reduce the European reliance on external REE sources—particularly crucial for technological advancements and the transition to renewable energy. However, these methods have only been limited to low technology readiness levels (TRLs), with no economically or technically viable processing routes yet defined to enable large-scale industrialisation within a circular economy model. This study characterised RM samples from the Seydişehir region in Türkiye using different techniques and explored the experimental process for recovering metals and REE. Moreover, the study assessed the global prospective potential of RM based on technical and economic data, as well as the sustainability of the implemented process through the life cycle assessment (LCA) tool. Results showed a total REE concentration of up to 1600 ppm, with Ce, being the most abundant (426 ± 27 ppm), followed by La, Nd, and Sc. Concentration efficiencies for La and Nd ranged between 240–300%. Sc, Y, Ce, La, and Nd have significant usage in European markets and represent prime RM targets for further prospecting. The LCA revealed that the highest global warming potential of the sequential extraction process was attributed to hydroxylamine hydrochloride and hydrogen peroxide. The findings highlight the need to explore alternative, more eco-friendly reagents to improve RM valorisation.
Open Access
Mapping the research landscape of bauxite by-products (red mud): an evolutionary perspective from 1995 to 2022
(Elsevier, 2024) Svobodova-Sedlackova, Adela; Calderón, Alejandro; Fernández, A. Inés; Chimenos, Josep Maria; Berlanga Labari, Carlos; Yücel, Onuralp; Barreneche, Camila; Rodríguez Trías, Rafael; Ingeniería; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2
The global population growth has significantly impacted energy and raw material consumption, unmatched since the Industrial Revolution. Among metals, aluminium ranks second only to steel, with annual production exceeding 69 million tonnes. Due to its high demand, bauxite, the primary ore from which aluminium is extracted, is now classified as a critical material in the EU and the US, given the potential risk of supply shortages for essential applications. Geographical and production challenges surround bauxite, presenting geo-economic and environmental challenges. A critical concern in aluminium production is managing by-products, notably red mud, a bauxite residue, generating over 175 million tonnes annually worldwide. Comprehensive bibliometric research is imperative due to the high amount of bibliographical resources related to this topic, encompassing circular economy, re-valorisation, sustainability, and disposal. This study employs bibliometric methods to assess red mud valorisation, offering insights into research topics, influential authors, and key journals, shedding light on the past, present, and future of red mud research. Such bibliometric analysis not only highlights the current state of the field but also serves as a valuable tool for decision-making, enabling researchers and policymakers to identify trends, gaps, and areas for further exploration, fostering informed and sustainable advancements in the by-products of the aluminium industry.
Open Access
Comparative study of the metallurgical quality of primary and secondary AlSI10MnMg aluminium alloys
(MDPI, 2021) Bakedano, Asier; Niklas, Andrea; Fernández‐Calvo, Ana Isabel; Plata, Gorka; Lozares, Jokin; Berlanga Labari, Carlos; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2; Ingeniería
The use of secondary aluminium is increasingly being promoted in the automotive industry for environmental reasons. The purpose of this study was to demonstrate that it is possible to obtain a recycled AlSi10MnMg(Fe) aluminium alloy with equal metallurgical quality to that of a primary AlSi10MnMg alloy when an adequate melt treatment is applied. The melt treatment consisted of deoxidation, degassing and skimming in accordance with the detailed procedure described in this article. The metallurgical qualities of one primary and two secondary alloys were assessed using thermal analysis, the density index test, the macroinclusion test and the microinclusion level test before and after melt treatment. The thermal analysis allowed us to compare the variables of the solidification cooling curve (Al primary temperature and its undercooling; Al‐Si eutectic temperature and its predictive modification rate). The density index test was used to evaluate the hydrogen gas content in the melt. The macroinclusion test was used to evaluate the melt cleanliness, while the microinclusion level test was used to perform the inclusion identification and quantification analyses. This study showed the feasibility of manufacturing structural components using 100% recycled secondary aluminium alloy through V‐ HPDC technology.
Open Access
A comprehensive study on hot corrosion resistance of NiCoCrAlYTa and NiCrAl thermal-sprayed coatings for CSP applications
(Elsevier, 2023) Aristu Ojer, Daniel; Berlanga Labari, Carlos; Alberro, Mikel; Rández Diago, Xabier; Fernández, Ángel G.; Ingeniería; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2
The new generation of concentrated solar power (CSP) plants could be able to work at temperatures up 650 °C and carbonates molten salts are one of the main candidates to be used as thermal energy storage (TES) materials. Molten salt corrosion has been defined as one of the main issues and the technology demands more resistance alloys and innovative coatings. In this study, the assessment of hot corrosion resistance for NiCoCrAlYTa and NiCrAl thermal-sprayed coatings has been undertaken, tested on a ternary eutectic mixture (Li2CO3-Na2CO3-K2CO3) at a temperature of 650 °C. Electrochemical impedance spectroscopy and linear polarization resistance tests were used to evaluate the behaviour of the coatings but the obtained results reveal high values of corrosion rates accompanied by the formation of cracks. This unsatisfactory performance of the coatings, analysed by scanning electron microscopy and x-ray diffraction, can be attributed to a combination of different factors such as porosity, internal material stresses and thermal diffusion phenomena. As a result, it is concluded that further research is necessary to explore new coating application techniques.
Open Access
Relationship between microstructure and fracture types in a UNS S32205 duplex stainless steel
(ABM, ABC, ABPol, 2013) Biezma Moraleda, María Victoria; Berlanga Labari, Carlos; Argandoña Salinas, Gorka; Ingeniería Mecánica, Energética y de Materiales; Mekanika, Energetika eta Materialen Ingeniaritza
Duplex stainless steels are susceptible to the formation of sigma phase at high temperature which could potentially be responsible for catastrophic service failure of components. Thermal treatments were applied to duplex stainless steels in order to promote the precipitation of different fractions of sigma phase into a ferrite-austenite microstructure. Quantitative image analysis was employed to characterize the microstructure and Charpy impact tests were used in order to evaluate the mechanical degradation caused by sigma phase presence. The fracture morphology of the Charpy test specimens were thoroughly observed in SEM, looking for a correlation between the microstructure and the fracture types in UNS S32205 duplex stainless steel. The main conclusion is the strong embrittlement effect of sigma phase since it is possible to observe a transition from transgranular fracture to intergranular fracture as increases the percentage of sigma phase. Thus, the mixed modes of fracture are predominant in the present study with high dependence on sigma phase percentages obtained by different thermal treatments.
Open Access
Corrosion behavior in volcanic soils: in search of candidate materials for thermoelectric devices
(MDPI, 2021-12-21) Berlanga Labari, Carlos; Catalán Ros, Leyre; Palacio, José F.; Pérez Artieda, Miren Gurutze; Astrain Ulibarrena, David; Ingeniaritza; Institute of Smart Cities - ISC; Ingeniería; Institute for Advanced Materials and Mathematics - INAMAT2
Thermoelectric generators have emerged as an excellent solution for the energy supply of volcanic monitoring stations due to their compactness and continuous power generation. Nevertheless, in order to become a completely viable solution, it is necessary to ensure that their materials are able to resist in the acidic environment characteristic of volcanoes. Hence, the main objective of this work is to study the resistance to corrosion of six different metallic materials that are candidates for use in the heat exchangers. For this purpose, the metal probes have been buried for one year in the soil of the Teide volcano (Spain) and their corrosion behavior has been evaluated by using different techniques (OM, SEM, and XRD). The results have shown excessive corrosion damage to the copper, brass, and galvanized steel tubes. After evaluating the corrosion behavior and thermoelectric performance, AISI 304 and AISI 316 stainless steels are proposed for use as heat exchangers in thermoelectric devices in volcanic environments.
Open Access
Revisión y estado del arte de la corrosividad del etanol y sus mezclas con gasolina
(CENIM, 2011) Berlanga Labari, Carlos; Biezma Moraleda, María Victoria; Fernández Carrasquilla, Javier; Universidad Pública de Navarra. Departamento de Ingeniería Mecánica, Energética y de Materiales; Nafarroako Unibertsitate Publikoa. Mekanika, Energetika eta Materialen Ingeniaritza Saila
Actualmente, el etanol se presenta como una fuente importante de combustible renovable para el sector de la automoción. Se sabe que los carburantes tradicionales, como la gasolina, no han causado problemas de corrosión, debido principalmente a su baja miscibilidad en el agua. En cambio, los biocarburantes en base alcohol pueden contener una considerable cantidad de agua y, además, se puede producir la oxidación parcial de sus componentes por su exposición a la atmósfera. Estas reacciones pueden ocasionar corrosión y posterior fallo, de cualquier componente metálico en contacto con las mezclas etanol-gasolina. En consecuencia, todos los sectores relacionados con la industria que emplean este combustible, empresas productoras, logística, dispensadores y fabricantes de vehículos, pueden estar afectados por esta problemática. Esto hace que este tema sea muy interesante, tanto desde un punto de vista científico como industrial. En este trabajo se revisa sistemáticamente todos los aspectos relacionados con la corrosión que produce el etanol y sus mezclas con gasolina, con el objetivo de conocer en profundidad el estado actual de las investigaciones, así como para orientar trabajos futuros que estén afectados, tanto de forma directa o indirecta con esta temática.
Open Access
Revisión sobre la corrosión de tubos sobrecalentadores en plantas de biomasa
(CENIM, 2006) Berlanga Labari, Carlos; Fernández Carrasquilla, Javier; Ingeniería Mecánica, Energética y de Materiales; Mekanika, Energetika eta Materialen Ingeniaritza
En el diseño de plantas de biomasa es muy importante tener en cuenta la temperatura del vapor para no tener problemas de corrosión. Esto, es debido al alto contenido de potasio y cloro que tienen la mayoría de los biocombustibles y, en especial, la paja de cereal. El objetivo de esta revisión es condensar el conocimiento actual sobre la corrosión de los sobrecalentadores a altas temperaturas provocada por compuestos clorados en plantas de biomasa. El cloro puede causar corrosión acelerada debido a la pérdida de metal del sobrecalentador, ataque interno y formación de capas de óxidos no adherentes. Los problemas de corrosión más severos en una caldera de biomasa se producen en los depósitos formados sobre los tubos sobrecalentadores. En la primera parte de esta revisión, se describen los mecanismos de corrosión propuestos en función de las condiciones de trabajo predominantes en la caldera. La segunda parte, se centra en revisar los estudios realizados para comprobar el comportamiento de los materiales mediante ensayos realizados en la caldera y en el laboratorio. En primer lugar, se describen las investigaciones realizadas sobre aleaciones convencionales y después las realizadas sobre las aleaciones desarrolladas en los últimos años y recubrimientos.
Open Access
A comprehensive review of fatigue strength in pure copper metals (DHP, OF, ETP)
(MDPI, 2024) Jiménez Ruiz, Eduardo; Lostado Lorza, Rubén; Berlanga Labari, Carlos; Ingeniería; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2
Due to their exceptional electrical and thermal conductivity properties, high-purity copper (Cu-DHP) and copper alloys of similar composition, such as electrolytic tough-pitch (ETP), oxygen-free electronic (OFE) and oxygen-free (OF), have often been used in the manufacture of essential components for the electrical, electronic and power generation industries. Since these components are subject to cyclic loads in service, they can suffer progressive structural damage that causes failure due to fatigue. The purpose of this review is to examine the most relevant aspects of mechanical fatigue in Cu-DHP, ETP, OFE and OF. The impact of many factors on fatigue strength (Se), including the frequency, temperature, chemical environment, grain size, metallurgical condition and load type, were analyzed and discussed. Stress–life (S-N) curves under zero mean stress (σm = 0) were found for high-cycle fatigue (HCF). For non-zero mean stress (σm ≠ 0), stress curves were based on a combination of Gerber, Soderberg and ASME elliptic failure criteria. Stress–life (S-N) curves were also developed to correlate fatigue strength (Se) with stress amplitude (σa), yield strength (Syp) and ultimate strength (Sut). Finally, for low-cycle fatigue (LCF), strain–life (ε-N) curves that establish a relationship between the number of cycles to failure (N) and total strain amplitude (εplastic) were determined. Hence, this review, as well as the proposed curves, provide valuable information to understand fatigue failure for these types of materials.