Innovative Breakthrough: BelSU Develops Digital Twin for Next-Gen Heat-Resistant Steel

According to the TASS Science Information Agency, researchers from the Laboratory of Mechanical Properties of Heat-Resistant and Nanostructured Materials at Belgorod National Research University (BelSU) have identified the optimal chemical composition for this steel, which consists of 12% chromium and 3% cobalt. A standout feature of this steel is its low nitrogen content (30 ppm) combined with a high boron content (100 ppm), which enhances its thermal stability at elevated operating temperatures.

The team conducted extensive studies on the evolution of the new steel’s microstructure during thermal aging, simulating conditions for up to 27,829 hours at temperatures of 620°C, 650°C, and 675°C.

“Our main research objective was to determine the limits of the material we created. Although no thermal power plants in Russia currently operate at such high temperatures, this knowledge paves the way for applications in other promising industries,” explained Alexandra Fedoseeva, a senior researcher and Doctor of Engineering Sciences, alongside her colleague Evgeny Tkachev, a researcher and Candidate of Engineering Sciences.

Led by Fedoseeva, the research team meticulously examined how the new steel’s microstructure evolved under various aging conditions. From this data, they developed a comprehensive predictive model that serves as a digital twin of the material. This dynamic virtual representation quantitatively evaluates the contributions of different strengthening mechanisms at varying temperature levels.

Unlike conventional “black box” AI models, which often lack transparency in their decision-making processes, the model by BelSU scientists is grounded in physical principles. It identifies key microstructural elements – such as carbide particles and Laves phases – and describes their evolution over time and temperature using mathematical equations. The model summarizes how these elements contribute to the overall strength of the steel through established physical principles like dispersion and solid-solution strengthening.

Remarkably, this model demonstrates an accuracy rate of 85-90% when compared to experimental data – a notable achievement for such a complex task as forecasting material behaviour over 100,000 hours. This advancement opens new avenues for developing design methods for various 9-12% chromium steels that offer an optimal balance of strength and durability.

The BelSU researchers have made significant strides in their ongoing work, showcasing the successful application of modern modelling techniques to tackle critical engineering challenges in creating heat-resistant materials with predictable service lives. This research was supported by the Russian Science Foundation (Agreement No. 24-79-10112) as part of a large-scale project aimed at enhancing the creep resistance of high-chromium steels.

For more details on this study and its findings, refer to the article published in the journal Materials Science and Engineering A.