Study the variation of current density & corrosion behavior of modified M2 tool steel: Simulation & experimental

Abstract

In this study, the simulation of the current density was carried out through COMSOL Multiphysics on surface-modified M2 high-speed tool steel. The results demonstrated that in the presence of the nitride layer on the surface of M2, the current density was increased remarkably in the nitride layer and M2 was immune, and consequently, it can be predicted that the corrosion resistance was increased. For verification, the surface modification through plasma nitriding was applied on the M2 steel corrosion resistance and was evaluated through polarization and electrochemical impedance spectroscopy (EIS) in the 3.5 wt% of NaCl solution. The results confirmed the simulation outcomes; therefore, optimization of the parameters was performed. The impression of the variation of the process parameter of plasma nitriding such as temperature (500, 550, and 600 °C), time (4, 6, and 8 h), and ratio of inserted gases (N2/H2: 1:3, 1:1, 3:1) on the growth of the diffusive layer was assessed by X-Ray Diffractometry (XRD). Outcomes illustrated that applying plasma nitriding causes the formation of the different nitride phases on the top surfaces of the M2 substrate and Fe3N is the dominant phase. The diffusive nitride layer has a higher current density based on simulation results. The microhardness of the surface increased remarkably and 2414 HV was reached as a maximum surface hardness. By considering the obtained results, 500 °C, 6 h, and a ratio of 1:1 of N2/H2 were chosen as optimum conditions of the plasma nitriding of M2 high-speed tool steel, and a corrosion rate of 1.62 mpy was calculated.