Abstract
In this paper, we used two mass-produced industrial technologies, namely, thermal spraying and anodization methods, to enhance the surface characteristics of AISI 1045 medium carbon steel for use in special environments or products. The anodic film can effectively improve the surface properties of carbon steel. A sequence of treatments of the carbon steel substrate surface that consist of sandblasting, spraying the aluminum film, annealing, hot rolling, cleaning, grinding, and polishing can increase the quality of the anodized film. This paper proposes an anodization process for the surface of carbon steel to increase the corrosion resistance, hardness, color diversification, and electrical resistance. The resulting surface improves the hardness (from 170 HV to 524 HV), surface roughness (from 1.26 to 0.15 μm), coloring (from metal color to various colors), and corrosion resistance (from rusty to corrosion resistant). The electrochemical corrosion studies showed that the AISI 1045 steel surface with a hard anodized film had a lower corrosion current density of 10−5.9 A/cm2 and a higher impedance of 9000 ohm than those of naked AISI 1045 steel (10−4.2 A/cm2 and 150 ohm) in HCl gas.
Highlights
Carbon steel is the earliest and most used basic material in modern industry
This paper presents an in-depth study on the effect of current density on the quality of sprayed aluminum after anodization, including the microstructure, film thickness, hardness, surface roughness, and anodization efficiency
We focused on applying different current densities and finished a detailed study of the influence of current density on anodic film thickness and anodization efficiency at −4 ◦C and a final voltage of 75 V for 40 to 100 min
Summary
Carbon steel is the earliest and most used basic material in modern industry. At present, the output of carbon steel accounts for about 80% of the total steel output in the word. The thermal spraying of metals, oxides, composites, and ceramics has been used on the AISI 1045 medium carbon steel [10] to improve its corrosion resistance, sliding friction, surface hardness, lubrication, high temperature resistance, and anti-sticking applications in biomedical implants [11], the automobile industry [12], electronics [13], and medical tools [14]. Ceramic coatings produced by thermal spraying are widely used in a range of industrial applications to provide wear and erosion resistance, corrosion protection, and thermal insulation to metallic substrates. Particles may fall off in the chamber, thereby exposing the substrate to corrosion, or loose coating materials may become a problem due to the high melting point of aluminum oxide being directly sprayed on the chamber wall or component. The resulting protective film can effectively improve the color, hardness, electrical insulation, and corrosion resistance of the carbon steel surface. This paper presents an in-depth study on the effect of current density on the quality of sprayed aluminum after anodization, including the microstructure, film thickness, hardness, surface roughness, and anodization efficiency
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