Abstract
Corrosion resistance of steel has attracted substantial interest for manufacturing applications to reduce costs corresponding to part failures, unexpected maintenance, and shortening lifespan. Meanwhile, millions of tonnes of slag, non-recyclable glass, and automotive shredder residue (ASR) are discarded into landfills every year, polluting the environment. Combining these two major issues, we delivered an alternative solution to enhance corrosion resistance of high-C steel. In this research, utilisation of these wastes (which were chemically bonded into steel substrate) as sources for production of multi-hybrid layering—including the multi-phase ceramic layer, the carbide layer, and the selective diffusion layer—was successfully achieved by single step surface modification technology. High-resolution topographical imaging by SEM and chemical composition analysis in micron-volume by electron probe micro analyser (EPMA) were performed. Nano-characterisation by atomic force microscopy (AFM) using the PeakForce quantitative nanomechanical mapping (PF-QNM) method was conducted to define Young’s modulus value of each phase in detail. Results revealed improvement of corrosion resistance by 39% and a significantly increased hardness of 13.58 GPa. This integrated approach is prominent for economic and environmental sustainability, consolidating industry demands for more profits, producing durable, steel components in a cost effective way to reduce dependency on new resources, and minimising negative impacts to the environment from disposal of wastes to the landfills.
Highlights
In recent years, the utilisation of metal alloy parts has extensively increased in automotive, pharmaceutical, and mining industries, but they are prone to corrosion degradation over time, which can lead to uncertain maintenance cost [1,2]
The bonding of multi-hybrid layering in the steel substrate occurred during the heat treatment process, which attributed to the disintegration of organic compounds and the production of C-saturated gas by automotive shredder residue (ASR)
Covalent bonds of C–C in polymers began to decompose, and reduction reactions occurred. An illustration of this was when C reacted with O2 in iron (III) oxide (Fe2 O3 ), magnesium oxide (MgO), and silicon dioxide (SiO2 ), mainly from waste slag and glass, to generate CO and CO2
Summary
The utilisation of metal alloy parts has extensively increased in automotive, pharmaceutical, and mining industries, but they are prone to corrosion degradation over time, which can lead to uncertain maintenance cost [1,2]. Various attempts have been made to enhance the corrosion resistance properties of steels, such as adding alloying elements (e.g., Cr, Ni), involving multiple steps of heat treatment processes [5], applying surface protective films or coatings [6], and cold spray treatment [7]. These methods are effective for improving the corrosion resistance of steels; they have some limitations that need to be considered. Improving corrosion resistance through addition of alloying element steel can sacrifice other properties, such as hardness, tensile strength, and wear resistance [5].
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