The new approaches that have been recently introduced to account for the potential effects of the PWR water environment on the high cycle thermal fatigue of austenitic stainless steel components have been experimentally assessed under conditions matching the actual in service loadings.

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

The Arcelor research center in Liège has developed an innovative ventilated double skinner roofing system based on an AluZinc coated 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 a construction hut by 3°C and to minimize the energy consumption of the air conditioning by 9%.

The application of finite element techniques to modelling the long products rolling process, the use of a customized interface to enable the rapid set-up of sequential simulations, and the benefits that have been obtained are described. The paper also discusses the enhancements to incorporate a design of experiments/design optimisation module and to enable material tracking.

A new image analyzer, Thixomet®, has been developed with the ability to create “panoramic” images of material microstructure for investigations. Capabilities of the Thixomet image analyzer for material microstructural characterization are demonstrated with examples of nickel-based superalloys. Practical use of the Thixomet for controlling material properties by characterizing their microstructure is demonstrated.

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 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 probability of failure during the life extension can be revealed and an efficient inspection strategy can be determined.

The performance of lubrication systems for cold double reduction rolling has been investigated. Pilot mill trials have been achieved with direct and recirculated emulsion application as well as with pure oil to analyse the effect of lubrication by emulsion on role bite friction and the associated speed effect. It is then attempted to define an optimized lubrication system that combines the advantages afforded by the direct and recirculated application systems.

The technology of mono-metals has reached maturity and further technological developments are impeded by some natural limits. Basic resources have been largely investigated and major innovative steps should not be expected in this area. Further progress in the science and technology of metallic materials will rather concern composite metals, layered composites in particular.

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