Steel Hydrogen-Induced Degradation Diagnostics for Turbo Aggregated Rotor Shaft Repair Technologies

Alexander I. Balitskii (), Valerii O. Kolesnikov, Maria R. Havrilyuk, Valentina O. Balitska, Igor V. Ripey, Marcin A. Królikowski and Tomasz K. Pudlo
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Alexander I. Balitskii: Department of Strength of the Materials and Structures in Hydrogen-Containing Environments, Karpenko Physico-Mechanical Institute, National Academy of Sciences of Ukraine, 5 Naukova Str., 79601 Lviv, Ukraine
Valerii O. Kolesnikov: Department of Strength of the Materials and Structures in Hydrogen-Containing Environments, Karpenko Physico-Mechanical Institute, National Academy of Sciences of Ukraine, 5 Naukova Str., 79601 Lviv, Ukraine
Maria R. Havrilyuk: Department of Strength of the Materials and Structures in Hydrogen-Containing Environments, Karpenko Physico-Mechanical Institute, National Academy of Sciences of Ukraine, 5 Naukova Str., 79601 Lviv, Ukraine
Valentina O. Balitska: Department of Physics and Chemistry of Combustion, Lviv State University of Life Safety, 35 Kleparivska, 79000 Lviv, Ukraine
Igor V. Ripey: Service Companies Galremenergo, PJSC “DTEK Zakhidenergo”, 15 Kozelnytska Street, 79026 Lviv, Ukraine
Marcin A. Królikowski: Department of Mechanical Engineering and Mechatronics, West Pomeranian University of Technology in Szczecin, 19 Piastow Av., 70-310 Szczecin, Poland
Tomasz K. Pudlo: Department of Mechanical Engineering and Mechatronics, West Pomeranian University of Technology in Szczecin, 19 Piastow Av., 70-310 Szczecin, Poland

Energies, 2025, vol. 18, issue 16, 1-26

Abstract: Rotor equipment material samples with varying degrees of degradation during long-term operation are characterized by lower (up to 17%) corrosion and hydrogen resistance compared to the initial state. The scheme of redistribution of carbides in structural components in the initial state and after long-term operation is presented. The schemes of the turning rotor shaft are visualized, while taking the microstructure features into account. During long-term service, the properties of steels are affected by changes in the parameters of structural components caused by the action of a hydrogen-containing environment. Based on the experimental data, the regression equation and approximation probability R 2 value describing the change in the electrochemical parameters of 38KhN3MFA rotor steel samples after 200, 225, 250, and 350 thousand hours of operation were obtained. During machining, an increase in hydrogen content was recorded in the chips, especially from degraded areas of the rotor shaft (up to 7.94 ppm), while in undegraded zones, it ranged from 2.1 to 4.4 ppm. A higher hydrogen concentration was correlated with increased surface roughness. The use of LCLs improved surface quality by 1.5 times compared to LCL p . Dispersion caused by degradation contributed to hydrogen accumulation and changed the nature of material destruction. After repair, the rotors demonstrated stable operation for over 25 thousand hours, with no reappearance of critical defects observed during scheduled inspections.

Keywords: degradation; 38KhN3MFA rotor steel; corrosion resistance; rotor shaft; power equipment; electrochemical studies; hydrogen charging; turbo aggregate rotor shaft; machining; hydrogen accumulation; steel structural components; hydrogen diffusion; screening anions; computer vision methods (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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