Understanding passivation in metal treatment

Hello, and welcome to another informative issue of our Mechanical Engineering newsletter. This month, we put a spotlight on Herbert A. Simon, one of the founding fathers of AI.

The industry updates section will highlight groundbreaking developments such as the world’s first carbon-sucking oil ship and Russia’s new plasma engine, showcasing how engineering ingenuity is shaping the future. Don’t miss our detailed coverage of the latest MechTech Innovations from Fraunhofer Institute that is supporting next-generation communications and quantum computing.

Read further to discover more about these groundbreaking engineering topics as we bring you the latest from the field.

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INDUSTRY UPDATES

• China reveals world’s first carbon-sucking oil ship that can pump 120,000 barrels a day

  This vessel captures its emissions and also harnesses electricity from the heat of exhaust gases.
  

• Russia’s plasma engine could reach Mars in 30 days, drastically reduce space travel time

  Using hydrogen as fuel, this engine accelerates charged particles to speeds of 62 miles/s.
  

• US coal plant to become world’s largest 350MW stellarator fusion power facility

  This Project will also develop a workforce that can operate and maintain stellarator fusion technology.
  

• Revolutionary 3D Bioprinter Creates Human Tissue Structures in Seconds

  This printer uses vibrating bubbles to 3D print cellular structures in seconds, around 350 times faster than traditional methods.
  

• Engineers create more effective burner to reduce methane emissions

  Methane has 28 times greater global warming potential than carbon dioxide over 100 years.

SPOTLIGHT

Understanding Passivation in Metal Treatment

Passivation is a critical process used across various industries to enhance the longevity and performance of metal components, particularly those made of stainless steel. This process involves creating a passive layer on the metal's surface to protect it against corrosion, which can significantly extend the life of metal systems and prevent costly maintenance and replacements.

The passivation process is particularly vital for materials that come into frequent contact with corrosive substances or operate in challenging environments. It involves treating the metal surface with a chemical solution that removes contaminants such as free iron and forms a thin oxide layer that acts as a barrier against oxidation and corrosion.

One of the most common materials to undergo passivation is stainless steel. Stainless steel naturally forms a chromium oxide layer when exposed to oxygen, which protects it from rust and corrosion. However, manufacturing processes like welding or machining can strip away this protective layer and expose the underlying metal to corrosion. Passivation restores this layer by cleaning the surface and allowing the metal to react with the air to reform the protective oxide layer.

The typical passivation process begins with a thorough cleaning of the metal surface to remove all contaminants, oils, and debris. This is crucial because any residue on the metal can prevent the formation of an even and effective oxide layer. The cleaned parts are then treated with a passivation solution, commonly citric acid or nitric acid. Citric acid is becoming more popular due to its safety and environmental benefits compared to nitric acid.

After treatment in the acid solution, the parts are thoroughly rinsed with water to remove any remaining chemicals, preventing further chemical reactions or damage. Following rinsing, the metal is dried and exposed to air, allowing the oxide layer to form and develop its protective properties.

This passive layer is incredibly thin and transparent and does not alter the appearance of the metal, making it ideal for applications where aesthetics are important. More importantly, it significantly enhances the corrosion resistance of the metal, ensuring that components can withstand harsh environments and corrosive substances without degrading.

Passivation is essential for industries such as aerospace, automotive, food processing, and any field that relies on durable and long-lasting metal components. By investing in proper passivation processes, companies can reduce maintenance costs, extend the service life of their equipment, and ensure the safety and reliability of their systems.

MechTech Innovations

Next-Gen Fiber Optic Solutions Developed by Fraunhofer Institute

Researchers at Fraunhofer Institute for Applied Optics and Precision Engineering IOF, along with partners, are advancing fiber optic technologies to meet future demands from self-driving vehicles, 6G mobile communications, and quantum communications, which are currently pushing existing network capacities to their limits. 

Projects like WESORAM and Multi-Cap are enhancing data transmission efficiency using optical switches that feature liquid crystal on silicon (LCoS) mirrors. These mirrors not only minimize data packet sizes but also enable more data to be transported simultaneously by distributing signals across various fiber strands, increasing flexibility and network capacity.

The team has innovated wavelength-division multiplexing by incorporating space-division techniques, allowing signals to be switched across multiple fibers. This "cross-wiring" of signals enables dynamic routing from eight input channels to 16 output channels, optimizing long-distance data transmission, such as between cities. The result is a significant boost in network capacity and a reduction in the number of optical switches needed, which cuts both installation and operational costs.

Additionally, a newly developed spectrometer grating has quadrupled the resolution of data streams, allowing for narrower light frequencies and smaller data packets. This advancement means that fiber optics can now handle more data packets simultaneously.

Furthermore, in the Multi-Cap project, the researchers developed signal amplifiers for multi-core fibers that support up to 12 channels simultaneously, enhancing energy efficiency as only one amplifier module is needed per 12 channels, thus pushing the boundaries of current fiber optic capabilities.

MOVIE RECOMMENDATIONS

Distant (2024)
This science fiction narrative explores astronauts' journey on a mission to discover and adapt to the environments of unexplored planets.

The Windigo (2024) 
A horror story set in a remote, snowy environment, focusing on survival against a mythical creature.

Alienoid: The Return to the Future (2024)
This Korean action film combines elements of time travel and extraterrestrial encounters, presenting a complex narrative of interwoven timelines and futuristic conflicts.

T.I.M. (2024) 
Focusing on the relationship between humans and robots, this film explores themes of artificial intelligence and the moral dilemmas surrounding advanced technology.

The Silent Planet (2025)
This movie is about two inmates serving a life sentence on a distant planet. An aging convict must confront his past when a new prisoner forces him to remember his life on Earth.