Carbon Steel Substrate Research Articles

Active brazing of cBN micro-particles with AISI 1045 steel using ceramic reinforced Ag-based fillers

cBN micro-particles have been brazed to medium carbon steel substrate using a new formulation of low-temperature, ceramic reinforced Ag-Cu-Ti alloy and evaluated for their wear resistance in developing cBN brazed tools. TiN and TiB2 microparticles were added as reinforcements independently in different proportions to Ag-Cu-2Ti (Ag-Cu-2wt%Ti) filler alloy and cBN tools were brazed. Wear characteristics of the ceramic reinforced alloys showed that the TiB2 added Ag-Cu-2Ti alloy exhibited excellent abrasion resistance with an improvement of 91–95 % over the commercial Ag-Cu-2Ti alloy. Conversely, the wear performance of the TiN added Ag-Cu-Ti alloys was poor owing to the weak bonding of TiN microparticles by the alloy matrix. The results were compared with 5 wt% TiB2 and TiN added Ag-Cu-5Ti alloys. However a significant improvement in the mechanical properties was not observed and the wetting on cBN was lower for reinforced Ag-Cu-5Ti alloy. Tensile tests showed that the Ag-Cu-2Ti-5TiB2 alloy demonstrated higher tensile strength (305.89 MPa) when compared to the Ag-Cu-2Ti and Ag-Cu-2Ti-5TiN filler materials. Low and high impact dynamic joint strength tests were further carried out on the 2 and 5 wt% reinforced Ag-Cu-2Ti and Ag-Cu-5Ti alloys. TiB2 added Ag-Cu-2Ti alloy displayed sufficient joint strength with TiN added Ag-Cu-2Ti alloys performing marginally better. Bearing in mind the excellent mechanical properties of the Ag-Cu-2Ti-5TiB2 filler and its appreciable joint strength, Ag-Cu-2Ti-5TiB2 filler can be used as an efficient filler material in developing cBN brazed tools for grinding applications.

Effect of Heat Treatment on Crevice Corrosion Behavior of 304 Stainless Steel Clad Plate in Seawater Environment.

With the application of stainless steel clad plate (SSCP)-enlarging in the marine engineering field, awareness of the consequences of heat treatment on ameliorating microstructure and mechanical properties in stainless steel (SS)/carbon steel (CS) joints is being raised. However, carbide diffusion from a CS substrate to SS cladding may damage the corrosion resistance during inappropriate heating. In this paper, the corrosion behavior of a hot rolling-produced stainless steel clad plate (SSCP) after quenching and tempering (Q-T) treatment, especially crevice corrosion, was studied by electrochemical and morphological methods, such as cyclic potentiodynamic polarization (CPP), confocal laser scanning microscope (CLSM) and scanning electron microscopy (SEM). Q-T treatment led to more significance in carbon atoms diffusion and carbide precipitation, which made the passive film of the SS cladding surface on the SSCP unstable. Subsequently, a device for measuring the crevice corrosion performance of SS cladding was designed; the Q-T-treated cladding showed lower re-passivation potential (-585 mV) during CPP when compared to as-rolled (-522 mV), with the maximum corrosion depth ranging from 70.1 μm to 150.2 μm. In addition, the processing of crevice corrosion on SS cladding could be divided into three parts, including the initiation, propagation and development stages, which were driven by the interactions between corrosive media and carbides. The generation and growth mechanism of corrosive pits in crevices were revealed.

Laser beam remelting of stainless steel plate for cladding and comparison with conventional CMT process

Progressing towards circular economy requires smarter and more efficient use of energy and resources. Laser beam can be efficient and flexible tool for melting different metals, commonly used in cladding and additive manufacturing (AM) with a wire and powder feedstock. As an alternative, feedstock in the form of plates and sheets can be used for cladding to achieve corrosion resistant surfaces. Compared to powder or wire, plates are easier to process, less costly to use, and may come as scrap metal. This leads to smarter and more efficient resource utilization. However, processing plates in such way is not mature and requires more in-depth investigation to be competitive with well-established methods. In this work, 2.0 mm thick 316L stainless steel plates were remelted by a high-power fibre laser beam for cladding on carbon steel substrates. It was compared to the conventional cold metal transfer (CMT) welding-based arc cladding which is frequently used due to a low heat input. In the first phase, different defocusing distances were studied to understand the laser remelting process capabilities to optimize the productivity. It was found that a highly defocused laser beam provided unstable melt pool conditions with low track quality. Compared to CMT, the laser remelting provided enhanced productivity, reduced heat input by 50% per pass, and lower distortions. Microhardness testing showed an increase in hardness in the intermediate layer towards the fusion line due to carbon diffusion. Despite a higher delta ferrite formation in laser-remelted tracks, a comparable corrosion protection to CMT was observed. The proposed method is promising for reducing CO2 emissions with respect to reusing scrap metal in the form of plates or use of ordinary plates instead of filler wires which opens possibilities for further enhancements.

Mechanical properties optimization of Cr3C2-NiCr coatings produced by compact plasma spray process

Chromium carbides are widely used as functional coatings on steel structures in high-end applications, from energy to marine and aerospace sectors thanks to their corrosion and wear resistance at elevated temperatures. In the present work, a low-power compact plasma spray (CPS) equipment was used to deposit Cr3C2-based cermet coatings on carbon steel substrate. Design of experiment was applied to select and optimize the spraying parameters, namely current, stand-off distance, scanning speed, plasma gas rate and powder feeding rate. ANOVA analysis was conducted to estimate the effect of the spraying variables on morphology and mechanical properties of the coatings and evaluate the optimal spraying condition. Dense and compact coatings were fabricated by using the CPS. By optimizing the processing parameters, coating hardness equal to approximately 600 HV and average thickness ranging around 600 μm were obtained, while the adhesion strength was approximately equal to 14 MPa. Intermediate phases of Cr carbides were produced by the dissolution of the primary Cr3C2 induced by melting and re-solidification of the particles. The presence of weaker carbide phase, inter-lamellae different features and porosity also caused the scattered hardness values observed in the coatings.

Corrosion Resistance of 309L Stainless Steel Claddings on Carbon Steel Produced with Wire-Fed Directed Energy Deposition

Additive manufacturing (AM) tools are capable of applying overlay austenitic stainless steel (SS) claddings to carbon steel components. The benefits of this approach over arc welding include a smaller heat-affected zone, residual stress reduction, and material savings. In particular, wire-directed energy deposition is a suitable technique because of its low material cost and high rate of production compared to other AM methods. However, metallurgical variations in composition, phase fraction, and microsegregation can potentially influence the corrosion behavior of such claddings. In this work, 309L SS is clad on carbon steel substrates and electrochemical methods are used to measure their general and pitting corrosion resistance in simulated marine environments (3.5 wt% NaCl solutions). Two-layer claddings are fabricated with four laser powers to understand the effects of bulk chemical composition, austenite/δ-ferrite phase fractions, and individual phase compositions on corrosion behavior. The two-layer claddings are compared to a single-layer cladding, wrought 304 SS, and the carbon steel substrate for a comprehensive assessment of corrosion performance. The two-layer claddings are remarkably resistant to general corrosion in the 3.5 wt% NaCl environment because of their high Cr content (21.6 wt% to 23.3 wt% Cr). The single-layer cladding exhibits localized corrosion at unmixed Fe-rich peninsulas that originate at the dissimilar metal boundary and protrude into the first cladding layer. All two-layer claddings possess higher pitting corrosion resistance than wrought 304 SS, demonstrating their effectiveness as a corrosion-resistant barrier. The pitting corrosion resistance is superior for claddings made with lower laser powers, due to low dilution and greater δ-ferrite contents.

Comparison of Inhibition and Adsorption of a Flower extract of Rumex vesicarius L. on the Corrosion of carbon steel in acid media 1 N; HCl and H2SO4

Green corrosion inhibitors are biodegradable and free of heavy metals. Some research groups have reported the successful use of naturally occurring substances to inhibit the corrosion of metals in acidic and alkaline environments. Among the various eco-friendly inhibitors, plant extracts are becoming more and more popular. In this study, the inhibitive and adsorption properties of the flower extract of Rumex viscarius L. as corrosion inhibitors of the carbon steel XC70 in the 1N; HCl and H2SO4 medium were investigated using the weight loss method of monitoring corrosion. The significance of the corrosion inhibition in the 1N; HCl and H2SO4 medium has been discussed. The corrosion rate was found to decrease with an increase in the concentration of both inhibitors in an acidic medium. But the corrosion rates were observed to be increased in the presence of inhibitors in an HCl medium. The maximum inhibition efficiency in H2SO4 and HCl was found to be 95.58 and 91.58% with 12.5% (v/v) concentrations of the inhibitor, respectively. The adsorption mechanism between the extract and the carbon steel substrate is found to obey Langmuir and Temkin isotherms. We also studied the impact of temperature on the corrosion, with non-attendance and attendance the optimum concentration in the temperature range from 265 to 353 K.

Influence of Repeated Bending Loading on the Residual Stresses in Multilayer Coating Materials

The technology of multilayer thin films to improve performance is widely used in the fields of semiconductors and functional composite materials. However, each layer of the multilayer film generates a residual stress during deposition due to differences in Young's modulus and coefficient of thermal expansion. In addition, the residual stress of the coating material is significantly affected by the mechanical load during use. In this study, the coated materials with deposited multilayer thin films were subjected to repeated bending loads, and the effects on the residual stresses in the thin films and substrates were investigated. Carbon steel (JIS: S45C) was used as the substrate material for the specimens. The thin films were deposited by sputtering. Three kinds of specimens were used, in which Cu, TiN and SiO2 films were deposited as a single Cu layer, a Cu/TiN double layer and a SiO2/Cu/TiN multilayer. The residual stress values of the Cu layer within the thin films were evaluated by X-ray stress measurement method using 311 and 222 diffractions of Cu. As a result, the tensile residual stress values in the Cu layers within each thin film were approximately 60~70 MPa for the single layer and 110~120 MPa for the double and multi-layer films. The residual stress values in the substrate, carbon steel, were evaluated using 211 diffractions of α-Fe. As a result, a tensile residual stress of about 30 MPa is existed. When all the coated materials were subjected to repeated bending loads, the change in the residual stress values of Cu layer showed that the residual stresses relaxed rapidly after several cycles of repeated loading and saturated to a value of about 30 MPa after 100 cycles. On the other hand, the residual stress evaluation by 222 diffractions of Cu showed that for all coated materials the residual stress values increased and decreased repeatedly with increasing number of repeated loadings. For the carbon steel substrate, the residual stress values hardly changed due to repeated loading.

Corrosion Behavior of Coated Low Carbon Steel in a Simulated PEMFC Environment.

Here, potential metallic bipolar plate (BP) materials were manufactured by laser coating NiCr-based alloys with different Ti additions on low carbon steel substrates. The titanium content within the coating varied between 1.5 and 12.5 wt%. Our present study focussed on electrochemically testing the laser cladded samples in a milder solution. The electrolyte used for all of the electrochemical tests consisted of a 0.1 M Na2SO4 solution (acidulated with H2SO4 at pH = 5) with the addition of 0.1 ppm F-. The corrosion resistance properties of the laser-cladded samples was evaluated using an electrochemical protocol, which consisted of the open circuit potential (OCP), electrochemical impedance spectroscopy (EIS) measurements, and potentiodynamic polarization, followed by potentiostatic polarization under simulated proton exchange membrane fuel cell (PEMFC) anodic and cathodic environments for 6 h each. After the samples were subjected to potentiostatic polarization, the EIS measurements and potentiodynamic polarization were repeated. The microstructure and chemical composition of the laser cladded samples were investigated by scanning electron microscopy (SEM) combined with energy-dispersive X-ray spectroscopy (EDX) analysis.

Synthesis of Ni/Co/Ni−G Composite Coatings and Analysis of Their Corrosion Resistance Properties to Q235 Carbon Steel

AbstractIn this work, nickel‐modified graphene nanosheets (Ni−G) were prepared by hydrothermal method for the first time. The microscopic morphological analysis showed that the nickel nanoparticles were successfully reductively deposited on the surface of Ni−G with uniform distribution. Ni−G can be uniformly and stably dispersed in the electrodeposition solution. Then Ni/Co/Ni−G composite coating was prepared by pulsed current co‐deposition method to provide corrosion resistance protection for Q235 carbon steel. The microstructure and morphology analysis of the composite coating shows that Ni−G were homogeneously incorporated in the coating and the composite coatings were uniform, dense and crack‐free. The hardness test results showed that the doping of Ni−G improved the hardness of the composite coating. The influence of the added amount of Ni−G in the electrodeposition solution on the anti‐corrosion performance of the composite coating was investigated. The electrochemical results illustrated that the composite coating prepared by adding 20 mL Ni−G dispersion achieved 98.04 % protection efficiency ( EIS) against carbon steel substrate in 3.5 wt.% NaCl solution, the Ni/Co/Ni−G20 composite coating has the best corrosion resistance.

Tribological performance under abrasive wear of Fe-Cr-C+Nb coating deposited by FCAW process

This paper aims to investigate the abrasion resistance performance of Iron-Crhomium-Carbon + Niobium (Fe-Cr-C + Nb) coatings deposited by Flux-Cored Arc Welding (FCAW) process. Two coatings conditions were prepared in a 1-layer setup, with a selfshielded tubular wire over SAE 1020 carbon steel substrate, varying the FCAW parameterization levels, searching to reproduce different conditions of welding energy and their respective effects on the coatings' properties. Optical Microscopy (OM) and Scanning Electron Microscopy (SEM) were employed in the microstructure and wear micromechanism analysis. X-ray Energy Dispersive Spectroscopy (EDS) was used for chemical composition assessment and Vickers microdurometer for hardness evaluation. In the tribological attempt, it was used the dry/sand rubber wheel apparatus according to ASTM G65. From the results, in neither sample of the two coating conditions, deleterious defects were observed on the surfaces, as well as in the cross-sections, such as lack of fusion and process interruptions. Dilutions were sufficient to ensure metallurgical bond without compromising layer geometry. Cold cracking characteristics of the process and material were observed, which did not significantly influence the performance of the coatings. The microstructure of both coatings showed CrC and NbC carbides dispersed in the Fe-matrix, whose volume fraction and mean free path between them varied as a function of dilution. The greater Nb-content and less intense heat input in the lower dilution coating provided greater refining of the CrC, NbC, and Fe-matrix strength, which was reflected in higher hardness, lower wear rate, and less severe abrasive wear micromechanism.

Synthesis, spectroscopic analysis and electrochemical studies of novel organic compound based on N-alkylphthalazinone chemistry as corrosion inhibitor for carbon steel in 1M HCl

The adsorption affinity and corrosion protection of two synthesized N-alkylphthalazinone derivatives 2(a-b), namely: 2-(prop-2-yn-1-yl)-4-(p-tolyl)phthalazin-1(2H)-one (a) and 4-(4-chlorophenyl)-2-(prop-2-yn-1-yl)phthalazin-1(2H)-one (b) on carbon steel (CS) in an acidic environment using electrochemical and mass loss methods. The mass loss test at the highest inhibitor concentration produced a maximum corrosion efficiency of 93.4% for inhibitor (a). Thermodynamic parameters were determined while the inhibitors' adsorption process was investigated. The inhibitory molecules adsorption on the CS substrate accompanied the Langmuir isotherm. As a function of inhibitor concentration, the thermodynamic activation functions of the dissolution process were calculated. Surface examination such as scanning electron microscopy (SEM), fourier transfer infrared spectroscopy (FTIR), and atomic force microscopy (AFM) techniques were used to confirm the adsorption phenomenon. Also investigated were quantum chemical parameters to approve the donor-acceptor system of the synthesized N-alkylphthalazinone derivatives. The theoretical values are in good correlation with the experimental values.

Enhanced corrosion resistance properties of Fe–Al–Cr laser cladding coatings on 1045 carbon steel substrates

Fe–Al–Cr coatings with different content of Cr additive were prepared on 1045 carbon steel substrates by a laser cladding process. The incorporation of Cr atoms can effectively enhance the corrosion resistance of the coatings. In particular, the Fe–28Al–5Cr laser cladding coating exhibits the best film quality without phase segregation. In addition, the interfacial adhesion between the Fe–28Al–5Cr coating and the 1045 carbon steel substrate is improved. As a result, the Fe–28Al–5Cr laser cladding coating exhibits the best corrosion resistance in a 3.5 wt% NaCl solution under both immersion and electrochemical conditions. However, excessive Cr additive lead to the formation of Al8Cr5 in the grain boundaries, resulting in inferior corrosion resistance. Therefore, the new findings demonstrated in this work may inspire the design of high-quality coatings with excellent corrosion resistance.

Degradation of Two Anti-Corrosion and Anti-Fouling Coating Systems in Simulated Diurnal Cycling Immersion

The degradation process and the electrochemical behavior of two anti-corrosion and anti-fouling coating systems (FW-1 and FW-2) in a simulated diurnal cycling immersion environment (3.5% NaCl, 35 °C 12 h + 25 °C 12 h) were investigated by electrochemical impedance spectroscopy (EIS) technology. Combined with the coating gloss, color difference, adhesion strength and scanning electron microscopy (SEM) tests, the micro morphologies and the variations of the performance parameters were comparatively analyzed. The results showed that in the 160 days of immersion, with the hydrolysis of the FW-1 topcoat resin and some pigments dissolved and released, the surface micro-morphology of the coating changes from rough to smooth, thereby increasing the gloss. While, for the FW-2 topcoat, the occurrence of micro pores and tiny cracks results in an increase in the roughness and a decrease in the gloss. The release of the copper ion particles in the antifouling topcoat has an influence on the color, manifesting as obvious rise in the color difference of the coating. The low-frequency impedance (|Z|0.01 Hz) values of both coating samples decreases slowly, presenting a very good shielding to the carbon steel substrate. The self-polishing of the topcoat has no big effect on the electrochemical performance of the whole anti-corrosion and anti-fouling coating system; the protective performance of the coating system mainly depends on the integrity of the primer and the intermediate paint.

Preparation, Wear Resistance, and Corrosion Performance of Arc-Sprayed Zn, Al, and Zn-Al Coatings on Carbon Steel Substrates

Preparation, Wear Resistance, and Corrosion Performance of Arc-Sprayed Zn, Al, and Zn-Al Coatings on Carbon Steel Substrates

Insight into polymer concentration, temperature, CO2 content, and Cl− content on corrosion of N80 steel tubing in polymer flooding

AbstractThe corrosion of N80 steel in polymer flooding is studied, and the safe service life of N80 steel tubing is calculated. The results show that the temperature is the main factor affecting the corrosion of tubing during the process of polymer flooding, and the safe service life of N80 carbon steel tubing at 75°C is only 11.1 years. The polymer is connected by molecular chains to form a network structure and then adsorbed on the surface of the steel. As the polymer concentration increases, the space between polymer molecules becomes smaller; the exposed surface area decreases; and the corrosion rate of N80 steel decreases. Both temperature and Cl− ions destroy the adsorption capacity of the polymer on the carbon steel substrate. The negatively charged chloride ion repels the negatively charged polymer, leading to the resolution of the polymer and reduction of the corrosion inhibition of the polymer. High temperature destroys the polymer's intramolecular and intermolecular aggregation, and also wrecks the long molecular chain polymer structure, significantly inhibiting the corrosion inhibition effect of the polymer.

Effect of Damage on the Corrosion Performance of Thermal Spray Aluminium (TSA) Coating in Synthetic Seawater

A widely used coating system for corrosion mitigation of offshore steel structures is thermally sprayed aluminium (TSA). Even though these coatings have been used for decades, it is not always clear how they perform in service over long periods, particularly if damaged during installation or in service. To understand the corrosion behaviour of damaged TSA coatings in seawater and their tolerance to levels of damage, TSA coatings (1050 Al) were prepared on carbon steel substrates using wire arc spray and tested in synthetic seawater. Prior to testing, various levels of holidays or damage (~5%, 10%, 15% and 18%) reaching the steel substrate were drilled on the front surface of the coated specimens. Open circuit potential was measured and linear polarization resistance technique was used to calculate the corrosion rate. The work showed that the TSA coatings polarised steel to potentials below −800 mV (Ag/AgCl) at 25 °C, even in the presence of damage or holiday (up to ~18%). The SEM/EDX and XRD data confirmed the presence of brucite and aragonite in the damage region. The presence of damage impacted the short-term corrosion rate at the start, but did not significantly affect the overall corrosion performance of the TSA coatings in 420 days of testing.

Durable Nanofluids‐Infused Hierarchical Surfaces with High Corrosion and Abrasion Resistance

The design of robust and durable ultra‐lubricated surfaces having an efficient corrosion resistance ability is concerned with practical applications. Here a new optimized strategy to significantly improve the performance of ultra‐lubricated surfaces by injecting slippery nanofluids into the hierarchical surfaces (SNHSs) is proposed. Herein, cobalt–nickel hierarchical surfaces reinforced by micro SiO2 particles are achieved on carbon steel substrate by electrochemical deposition and the functionalized nanofluids are injected into the hierarchical structure. Compared with nanostructured ultra‐lubricated surfaces, SNHSs exhibit better lubricity and corrosion resistance when subjected to water flow shear for more than 20 h. The tribo‐electrochemical tests are introduced to demonstrate that the SNHS has a lower coefficient of friction (0.39), more shallow wear marks (5 μm), and more complete surface morphology by directly comparing the wear resistance and self‐healing ability. The hierarchical substrate has more advantages than the nanostructured substrate in the practical application of ultra‐lubricated surface. Furthermore, the SNHS with robust mechanical durability can be a promising alternative technique for corrosion protection.

High-throughput assessment of corrosion inhibitor mixtures on carbon steel via droplet microarray

A high-throughput screening method for rapid laboratory evaluation of corrosion inhibitors was developed based on microarray consisting of up to 200 droplets of corrosion inhibitor solutions on one carbon steel substrate. The extent of corrosion on the steel under each single droplet was studied by tracking the variation of the 3D morphology of the corrosion product. Using this high-throughput screening platform, we evaluated the corrosion inhibition effect of benzotriazole and Ce(NO3)3 mixture and identified their best mixing ratio. The enhanced inhibition of the inhibitor mixture was discussed based on the corrosion experimental data and the molecular dynamic simulation.

Exploration of the Corrosion Behavior of Electroless Plated Ni-P Amorphous Alloys via X-ray Photoelectron Spectroscopy

A Ni-P amorphous alloy was deposited on a low carbon steel substrate via electroless plating. Further, the prepared samples were crystallized under the high temperature with a range from 200 °C to 500 °C in air for 1 h. The crystallization process was studied via XRD, AFM, and XPS, and anodic electrochemical behavior was investigated by potentiostatic methods in a 3.5 wt% NaCl solution. The experimental results indicate that the diffusion, dissolution, and enrichment of the component elements in the Ni-P alloy are essential during crystallization because the various corrosion behaviors corresponding to Ni and P are directly affected. More importantly, under the 400 °C treatment, H2PO2- was enriched in the alloy, which effectively hinders the anodic dissolution of nickel and forms a complete adsorption layer on the surface of the alloy. Our results demonstrate that P can effectively block the anodic dissolution of Ni during the corrosion process, and the crystallization process can effectively promote the surface enrichment of P to improve the corrosion resistance of the coating.

Corrosion inhibitors for carbon steel: A review

AbstractCorrosion inhibitors are one of the practical and cost‐effective way of preventing and inhibiting corrosion. An inhibitor's primary function includes creating a barrier by forming one or more molecular layers to protect against corrosive attacks. Organic molecules are one of the most popular, efficient, and practical corrosion inhibitors, and all studies demonstrate that organic compounds, preferentially those containing nitrogen (N), sulphur (S), and oxygen (O), have high inhibitory efficiency. Also, corrosion inhibitors include inorganic compounds. Since inorganic and organic inhibitors are both toxic and expensive; emphasis is being placed on developing green corrosion inhibitors as well as on modification of inhibitors. We are focusing on carbon steel (CS) substrate in this review as it is the first‐line material and is widely employed in various industrial applications. Whereas corrosion resistance of CSs in acidic environments is a constantly evolving topic, working on better performance of CSs as more cost‐effective alternatives to other alloys.