Mild Carbon Steel Research Articles

Effect of cutting conditions on power demand and surface roughness through sustainable turning of mild carbon steel

Sustainable turning is a lathe machining process to carry out production in particular by paying attention to the sustainability of machinery without reducing production output. The machining process is done by optimizing the turning process parameters when carrying out the cutting process on medium carbon steel. Some parameters affect the lathe process, including speed, feed rate, and cooling. The purpose of this study was to determine the machining conditions in order to optimize the electric power consumption and surface roughness of the medium carbon steel turning process. The research method used was experimental and analysed using the ANOVA method. From the results of the research, it was concluded that the minimum electricity consumption was obtained in the process of turning steel St 42 without cooling with a speed of 237 rpm and a feeding of 0.157 mm/rev. The lower surface roughness was obtained in the turning process of St 60 steel with a rotation speed of 840 rpm and a feed rate of 0.157 mm/rev. The results of data analysis using ANOVA analysis method to get optimal conditions in order to minimum power demand and low surface roughness at 425 rpm of speed and 0.052 mm/rev of feed rate.

Electroless Deposition of Ni-P Composite and Multilayer Coatings: Applications and Perspectives

Considerable economic losses occur every year due to erosion-corrosion in parts of machines and equipment during service. In order to reduce this loss, properties of the surface of the materials should be improved. Among the various surface processes, electroless plating is one of the appropriate methods to deposit coatings on metals without applying an external electrical voltage, which provides coatings with uniform thickness, crack free nature, appropriate adhesion to the substrate, high hardness, and high wear resistance. The electroless deposition is a promising method to prepare durable metal films on both conducting and non-conducting substrates of different geometries. In the present study, Ni-P composite coatings were successfully electroless plated on mild carbon steel from acidic baths reinforced with ceramic and polymeric micro and nano-particles, as single and multilayer deposits. The effect of the electrolyte composition as well as the nature of the dispersed phase on the phosphorus co-deposition, particles incorporation, surface morphology and structure of the deposits have been investigated and evaluated. The use of multilayer or hybrid techniques in surface engineering has often been cited as the way to improve the mechanical, tribological and electrochemical properties of coatings. Especially, the multilayer coating with layers having different corrosion potential Ecorr was an effective solution to improve the corrosion-resistance of the no-sacrificial coatings. Multilayered coatings were produced by stacking layers of different composition by successive electroless plating with rinsing steps in between. This study will discuss new applications and perspectives of these coatings as anti erosion-corrosion surface treatments. The impact of the plating approach on the microstructure of the coatings as well as on their mechanical properties and corrosion resistance is presented.

The Weldability of Duplex Stainless-Steel in Structural Components to Withstand Corrosive Marine Environments

There is still a considerable gap in the definition of the weldability of Duplex Stainless Steel (DSS). A lack of clarity that is explained by the standard specification of the maximum content of equivalent carbon that defines a “weldable” steel coupled with the fact that the alloying elements of DSS exceed this defined limit of weldability. In this paper, welding quality in an inert environment and in presence of chlorides is analyzed with the aim of defining optimum welding conditions of 2001, 2304, and 2205 DSS. The same procedure is followed for a hybrid weld between DSS 2205 and a low carbon mild steel, S275JR. As main output, this study defined the optimal welding conditions with tungsten inert gas without filler for each type of DSS weld that showed excellent anti-corrosion performance, with the exception of the DSS 2205-S275JR weld where widespread corrosion was observed. Additionally, this study established a relationship between the thermal input during welding and the content of alloying elements in defect-free joints. Furthermore, it demonstrated that an increase in ferrite content did not lead to a worse corrosion resistance, as expected after passivation.

Pomegranate Peel Plant Extract as Potential Corrosion Inhibitor for Mild Carbon Steel in a 1 M HCl Solution

Herein, Pomegranate Peel plant extract was assessed as a low-cost, green and efficient corrosion inhibitor for mild carbon steel in 1 M hydrochloric acid solution using weight loss, potentiodynamic polarisation, an atomic absorption Spectroscopy test, surface roughness test and surface studies by optical microscopy (LOM). Increasing Pomegranate Peel extract concentration increases the charge transfer resistance as a result of the adsorption of Pomegranate Peel extract on the mild carbon steel surface. The polarisation results showed the mixed-type inhibition behaviour of the studied extract with an inhibition efficiency (%IE) of 90.193% achieved with the addition of 4% vol. of Pomegranate Peel plant extract. The adsorption isotherm model of Pomegranate Peel plant extract on a mild carbon steel surface followed the Langmuir adsorption isotherm in a HCl solution. The inhibition mechanism of Pomegranate Peel plant extract was explained according to the increase in the IE% with concentration and the activation parameters which suggested significant chemisorption of the Pomegranate Peel plant extract on the mild carbon steel surface. LOM studies confirmed the formation of a protective layer of Pomegranate Peel plant extract on a mild carbon steel surface. Results obtained by different techniques showed good agreement that confirm the potential use of Pomegranate Peel plant extract as a corrosion inhibitor for mild carbon steel in an acidic media.

Switching Autowaves in Materials with Dislocations and Martensitic Transformations

The paper focuses on the investigation of the strain kinetics at the yield point of materials with shear dislocations and martensitic transformations at a microlevel. In both cases, the autowave propagation and localized plastic deformation occur. The autowave propagation velocity depends on the nonlinear speed of the crosshead movement. It is found that its nature is the same both in low carbon mild steel and titanium nickelide.

High‐strength steel and dissipative fuse solutions for seismic‐resistant building structures

AbstractExtended keynote paper of Eurosteel 2021The robustness of steel structures during severe earthquakes is largely based on the calibration of stiffness, strength and ductility. Such a robust system dissipates the energy by plastic deformations in the plastic members (fuses) made from mild carbon steel (MCS), while the other members remain elastic. In the case of concentrically braced frames (CBF), the fuses can be in the form of buckling‐restrained braces (BRB), while for eccentrically braced frames (EBF), the short links could take on this role. In the case of shear walls (SW), slender steel plates can be used. To avoid oversized elastic members, they can be made of high‐strength steel (HSS). Structures made from HSS and MCS are called dual steel (DS) structures. In order to ease the post‐earthquake intervention, the fuses can be detachable. Furthermore, their replacement is less costly if the structure is re‐centred using moment‐resisting frames (MRF) connected to the main dissipative system, i.e. a dual frame (DF) structure. This paper presents the concept of DS DF structures and some examples.

A corrosion evaluation of mild carbon steel in reclaimed refinery stripped sour water

Reclaiming water for cooling systems in oil refineries has been strongly encouraged over the past years for decreasing the large consumption of fresh water, thus contributing to the efficient use of this valuable resource. In a recent study [Journal of Environmental Management 261 (2020) 110229], some of the authors studied the retention of phenols in refinery wastewater through reverse osmosis (RO) and found rejections of up to 98% of phenols and 99% of both chemical oxygen demand (COD) and total organic carbon (TOC). The permeates complied with the quality standards for make-up water in cooling processes. A missing aspect, important for the water to be used in the oil and gas industry, was the level of corrosivity of the new permeates. In this work the corrosion of mild carbon steel in the permeates and in the original cooling tower make-up water was studied by electrochemical techniques. The corrosion rate of steel in the permeates in aerated conditions was lower (between 0.053 ± 0.006 and 0.123 ± 0.011 mm year−1) than in the make-up water (0.167 ± 0.030 mm year−1), confirming their suitability for replacing make-up water in the cooling towers. The low corrosion of carbon steel was attributed to the low conductivity and absence of oxidizing species in the fluids, compared to fresh water.

Characterization of electrodeposited Ni–Cr/hBN composite coatings

In this study, Ni–Cr/hBN composite coatings with different hBN content were deposited on AISI 1040 mild carbon steel using electrodeposition. The coatings were characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffractometry (XRD), cyclic voltammetry (CV), 2D surface profilometery, nano-indentation, corrosion and wear tests. While some cracks were observed in the Ni–Cr alloy coatings, more compact and crack-free surfaces were obtained in the Ni–Cr/hBN composite coatings under all deposition conditions. XRD analysis of the Ni–Cr/hBN layer revealed the presence of a predominant Ni phase with Cr, Cr2Ni3B6, (Ni2Cr23)0.16, and hBN phases in the structure. Depending on deposition parameters, the microhardness and nanohardness of the Ni–Cr and Ni–Cr/hBN coatings were found to range between 308 and 538 HV and 1,86–7,69 GPa respectively. hBN acted as a solid lubricant in the wear tests; the friction coefficient decreased and wear resistance was improved. Among the composite coatings, the corrosion resistance of the coating with 20 g/l hBN was found to be 12 and 3.3 times higher than the steel substrate and Ni–Cr alloy, respectively. The hBN additive provided better mechanical properties and corrosion resistance in the range of 5–20 g/l hBN, but after 20 g/l hBN agglomeration became a problem and impaired the mechanical properties. The highest corrosion and abrasion resistance was obtained with 20 g/l hBN.

Evaluation of corrosion protection performance of electroplated zinc and zinc-graphene oxide nanocomposite coatings in air saturated 3.5 wt. % NaCl solution

This work aimed to compare and evaluate the microstructure and corrosion behavior of electroplated pure Zn and Zn-graphene oxide nanocomposite coatings with considering the effects of brightener additives as surfactant, and various concentrations of graphene oxide as colloid in electroplating solution. Zn and Zn-GO nanocomposite coatings were electrodeposited galvanostatically over a mild carbon steel substrate. It was found that incorporation of GO into the Zn matrix and the presence of brightener additives lead to the production of a coating with finer morphology and glossy appearance compared to pure Zn coating. Also, it was revealed that adhesion strength of Zn-GO nanocomposite coating was two times higher than that of pure Zn coating. In order to comparing the corrosion behavior of the coatings, potentiodynamic polarization, electrochemical impedance spectroscopy (EIS), potentiometric and salt spray tests were carried out in air saturated 3.5 wt. % NaCl solution. Based on the results, Zn-GO nanocomposite coated mild steel has a higher corrosion resistance compared to pure Zn coated mild steel. In general, the corrosion resistance of the mild steel coated with Zn-GO nanocomposite was improved up to ∼5-fold (from 105 to 510 Ω cm2), while its corrosion rate was reduced by up to 15-fold (from 32 to 2.4 mpy) compared to the mild steel coated with pure Zn. Fine-grained microstructure and high impermeability of GO to corrosive agents such as oxygen and chloride are responsible for greater corrosion resistance performance of the Zn-GO coatings when compared to pure Zn coating.

Optimization of the Sintering Parameters for Materials Manufactured by Powder Injection Molding

The properties of sintered and heat-treated steels produced from the Catamold 8740 material by powder injection molding were examined. Parts made of the Catamold 8740 low-alloy mild carbon steel are used in the military, automotive, and other industries where high reliability and resistance to dynamic loads are required. The Catamold 8740 chemical homogeneity was studied as a function of powder injection molding parameters: heating rate, sintering temperature, holding time, and subsequent heat treatment. Microscopic analysis showed that Catamold 8740 was a mechanical mixture of powders in various sizes (carbonyl iron, nickel, Fe–Mo, Fe–Cr, Fe–Si-Mo, Fe–Si). When the heating rate of the Catamold 8740 powder mixture increased from 2 to 5 °C/min, the microstructural heterogeneity caused by uneven compaction decreased and the alloy formation process activated at 900–1340°C. The impact strength of Charpy V-notch test samples changed from 10.39 to 11.52 J/cm2 with higher sintering temperature and heating rate increasing from 2 °C/min (1270°C) to 5 °C/min (1340°C). When holding time increased from 30 to 90 min at a sintering temperature of 1340°C, the material became denser, the pores rounded, and the ferrite matrix homogeneous. However, the impact strength decreased by a factor of 1.4 because of coarser grain sizes and brittle fracture. Heat treatment processes reduced the impact strength after sintering. The results obtained were used to optimize the powder injection molding parameters. The influence of chemical and dimensional inhomogeneity of the starting Catamold 8740 powders and sintering kinetics on the structure and mechanical properties of parts operating under impact loads was established.

A Mathematical Model for A Cladding Fastener to Estimate the Maximum Pull-Out Force Capacity

In the last few years, considerable attention has been paid to the roof cladding systems due to their progressive use in the construction of low-rise buildings. The design of such systems has been gaining importance since they are subjected to severe damage and failure caused by high wind events, particularly at their fastener connection points. To offer a solution for predicting the maximum pull-out force capacity of cladding fasteners, this article presents a mathematical model for a fastener made of high strength steel austenitic 316. In this model, the two basic parameters of the fastener, namely the thread depth and the thread angle are included as the main elements of the contact surface between threads and the low carbon mild steel batten/purlin sheets. This mathematical model will be proposed to estimate the maximum pull-out force capacity of the cladding fasteners made of cold-formed A2 316 stainless steel. After finding the parameters of the mathematical model by using an optimization method based on a genetic algorithm (GA), a comparison will be made between the mean estimation error of the new model and the formerly proposed ones.

The Significant Study of using Vegetable Oil as a Cutting Lubricant on Conventional Lathe Machine

The occurrence of tool wear in machining is a natural phenomenon that cause failure. The deformation during cutting at the interface between the tool face and workpiece tends to generate high cutting temperature. The application of flood coolant to reduce the friction at the tool-work piece may create several environmental problems. The introduction of Minimum Quantity Lubrication (MQL) as an alternative technique which is the process of pulverizing a very small amount of oil (< 30ml/h) can be regarded as replacement of dry machining while it may also be considered as an alternative to flood cooling. The effect of vegetable oil lubricant and cutting speed on tool wear and surface integrity were the research scope. Three machine speed; 120, 141, and 174 m/min were used in the experimental setup on mild steel and carbon steel on work material using cemented carbide tools. The result of surface roughness and tool wear using canola oil mixing with 2 weight percent (wt%) of Zinc-dialkyl-dithio-phosphate (ZDDP) were compared against synthetic oil coolant. Comparison results show that canola oil mix can perform better compare to the synthetic oil coolant in term of surface finish. From tool wear perspective, canola oil mix show 26.5% smaller area compare to the synthetic oil coolant.

Development of predictive force models for oblique cutting of mild carbon steel (CS1030) incorporating tool flank wear

Predictive force models for oblique metal cutting incorporating tool flank wear was carried out using a CNC lathe machine to turn mild carbon steel CS1030. The developed models are based on the fundamental mechanics of orthogonal cutting process, in which inclination angle is 00. Workpieces were Cylindrical with wall thickness of 3mm and diameter of 100mm. Cut thickness levels were 0.1, 0.17, 0.24 and 0.31mm; cutting speeds were 100, 150 and 200 m/min; tool rake angle levels were −5, 0

The Use of Citrullus Lanatusfor Corrosion Inhibition of A36 Steel in a CO2Saturated Saline Solution: A Thermodynamic and Kinetic Model Approach

Citrullus lanatus was tested for its suitability as an Inhibitor on Mild Carbon Steel in a Carbon (IV) Oxide (CO2) saturated saline solution. The mechanism of corrosion was investigated with and without Inhibitor additive in order to compare the effectiveness of the Inhibitor. Thermodynamic computations namely Enthalpy, Entropy and Gibbs free energy were used to determine the Inhibitive property of the Citrullus lanatus Extract. In addition, four Kinetic Models namely; Langmuir, Temkin, Flory-Huggins and Frumkin were also used to fit the experimental data. Gas Chromatography-Mass Spectroscopy and Fourier Transfer Infrared Spectroscopy were used to characterize the Watermelon Seed Extract. Analysis of the results shows that Inhibitor efficiency decreases with increasing Temperature. The result also shows Inhibition efficiency within the range of 17.39%-71.79%. From the Result, the test sample without Inhibitor has the least Activation Energy in comparison with those with Inhibitor additives. The investigation also revealed that the Frumkin model at 50oC best fits the Experimental data with a Coefficient of determination, R2 of 99.9%, though; the other Models also fit the Experimental data.

Finite Element Modeling of a Thin Circular Disc Manufactured by Forming Process used in Cyclic Loading and Unloading Applications

Abstract The presented work focuses on numerical modelling and analysis of the forming process of a thin circular disc of negligible thickness, that is later subjected to vibration-induced loading and unloading cycles (fatigue) during application. During the forming process, the material of the pre-form (Mild-Carbon Steel, AISI-1075) is shaped into the required profile of the disc, using a fast moving punch that impacts on a die underneath. The profile consists of a hole at the center of the disc and predefined surface gradations along the periphery. This punching process is followed by heat treatment to relax the residual stresses developed. This paper discusses the development of a detailed thermo-mechanical coupled model using the finite element method, to simulate the different stages of the forming process; namely, the punching process, the instantaneous punch release and structural creep, and the subsequent heat treatment to induce stress relaxation. The numerical model is intended to predict the amount of residual stress and equivalent plastic strain that are developed in the disc at the end of each stage of the forming process. The stress concentration in the disc has serious implications on the subsequent cyclic loading and unloading application. The results obtained from standard tests indicate initiation and propagation of cracks in the disc during application. The intensity and occurrence of crack initiation have a direct connection to the maximum residual stress developed in the disc during the forming process. In addition, the heat treatment model is also intended to investigate the temperature distribution in the disc, during the heating and the subsequent cooling operations. The results of the finite element model are then validated with experimental measurements for each of the stages of the forming process. The finite element packages, Abaqus/Explicit and Abaqus/Standard, are used in conjunction for the aforesaid modeling

Process parameter optimization and performance comparison of AISI 430 and AISI 1018 in resistance spot welding process

Resistance spot welding (RSW) process plays an important role in the sheet metal fabrication process, in which metal joining is obtained by heat developed through electric resistance against the current flow in the metals contact area. In this work, the impact of weld time, squeeze time, weld current and hold time on weld strength of 1.2 mm thickness ferritic stainless steel (AISI 430) and low carbon mild steel (AISI 1018) sheets by using RSW process were investigated and compared. The Design of experiment (DoE) was used to formulate the number of experiments with variations in input conditions. Welding of similar metals of AISI 430 and AISI 1018 was done according to the number of experiments obtained using DoE. The welded samples were subjected to tensile shear failure load and micro-hardness testing. The output responses were analyzed through Response surface methodology (RSM) to find the optimum control parameters to achieve higher weld strength.

Effect of laser remelting on the microstructure and mechanical properties of meta inert gas welded low carbon mild steel

In this study, laser remelting has been performed on the Metal Inert Gas welded (MIG) low carbon mild steel at varying laser power inputs (400 W &amp; 600 W). To investigate the influence of laser remelting on the joint properties, optical microscope observation, scanning electron microscope observation, microhardness measurement and mechanical tests have been conducted. The experimental results revealed that the surface appearance of the laser remelted MIG welded joints have been found to be smooth and the microstructure of its fusion zone possesses fine equiaxed dendrites as compared with that of the MIG welded joints. In addition, the fracture surface of the laser melting carried at low power (400 W) on the MIG welded joint has exhibited a ductile fracture whereas, the MIG welded joint has undergone brittle fracture. The laser remelting carried out at 400 W on the MIG welded joint has resulted in 12% increase in both the ultimate tensile strength and percentage of elongation as compared to that of the MIG welded joint and this has been ascribed to the presence of equiaxed grains in the microstructure.

Shock-induced twinning and texture in a mild carbon steel

Deformation twinning is investigated in a polycrystalline mild steel under shock compression to about 12 GPa. The free surface velocity history is measured to calculate twinning stress. The postmortem sample is characterized with electron backscatter diffraction (EBSD). We provide a method to calculate the activated twinning systems in all twinned grains from EBSD data. Twinning is completely activated and suppressed for grain size above 36μm and below 4μm, respectively. For intermediate grain sizes (14–30μm), twinning tends to occur in the grain orientations near 〈101〉, consistent with the Schmid factor analysis. Almost all the twins nucleate on the twinning systems with the largest or second largest Schmid factors. The twinning stress is 1.16 GPa, and critical resolved shear stress for twinning is 0.47 GPa. Twinning in weakly textured sample can induce a strong 〈001〉 fiber texture, as a result of its following the Schmid’s law.

Effect of Near-Dry Machining (NDM) on surface roughness through sustainable turning of mild carbon steel using coated carbide

Sustainable production as a global word, content important elements on all the fields as well as machining processes. Turning is one of the most fundamental and indispensable processes of metal removal in the industry. Increasing pollution preventing initiatives globally and consumer focus on environmentally conscious products has put increased pressure on industries to minimize or eliminate the use of cutting fluids. The use of Near-Dry Machining (NDM) in machining operation is one of the most effective strategies in this direction to achieve sustainable machining system. This study was purposed to determine the influence of NDM coolant system on surface roughness when turning of mild carbon steel, include power demand. A detailed comparison has been made with dry cutting to assess the process performance on the basis of surface roughness and power demand. The results indicate that providing a reduction on surface roughness and power demand more effectively than dry cutting at high-speed conditions, thereby to achieve sustainable machining system.

Caffeine as A Natural Corrosion Inhibitor for Mild Steel in Nacl Solution

Corrosion inhibitors are substances that added to the environment in small concentration and can effectively reduce the corrosion rate that of a metal surface. Natural inhibitors are one types of inhibitor being researched as it brings less environmental impact on the environment. This research was focused on the application of caffeine as inhibitor for corrosion of mild steel in seawater condition. The objective of this project was to develop the relationship between caffeine concentration on the corrosion of mild carbon steel in both static and moving solution contained 3.5-wt% NaCl. Three types of solution were prepared, which are NaCl without addition of caffeine, NaCl with 1-wt% of caffeine and NaCl with 2-wt% of caffeine. Corrosion testing was carried out by weight loss measurement. The microstructures of corroded mild steel specimens were observed under optical microscope. The experimental results indicated that by adding caffeine into the environment medium, weight loss of mild steel specimen was reduced. The corrosion rate of specimens was decreased when more caffeine was added to the environment. From optical microscopic observation, caffeine performed its inhibition effect likely by forming a protective layer which acts as barrier to prevent further corrosion of mild steel in NaCl solution.