Carbon Steel Research Articles

Dry Sliding Wear Behavior of Cemented Carbide at Elevated Temperatures

The material for a cutting tool needs to be carefully selected to withstand high temperatures during cutting and have good wear performance. The use of cutting tools made from cemented carbide material was studied due to its potential in terms of mechanical properties that are ideal at high temperatures up to 1000 °C and being cheaper than other materials. This investigation of the dry wear of this cutting material focused on temperatures of 25 °C, 200 °C, and 300 °C, with loads of 50 N, 100 N, and 150 N. The weight loss, friction coefficient, and change of the pin microstructure were determined. It was found that the higher the temperature and load applied to the cemented carbide pin, the more the microstructure changed, and the percentage of weight loss increased up to 0.55%. The wear rate on the cemented carbide pins was higher when applied to a stainless steel disc compared to a mild steel disc. The simulation revealed that the von Mises stress on the stainless steel disc was 51.759 Pa, while that on the mild-steel disc was 60.379 Pa. This indicates that both materials did not fail because the von Mises stress was lower than the disc yield stress.

Corrosion inhibition effect of sodium iodide for mild steel in 1 M hydrochloric acid: mathematical, surface morphological, and kinetics studies

Corrosion inhibition effect of sodium iodide for mild steel in 1 M hydrochloric acid: mathematical, surface morphological, and kinetics studies

Tribological behavior of carbon steel 45 and brass H90 in dry sliding on bearing steel GCr15 in the sand-dust environment

Purpose Machinery operating in a sand-dust environment is more susceptible to sand particles. The purpose of this paper is to investigate the impact of sand particle deposition rate, surface hardness and normal load on the tribological performance. Design/methodology/approach A predictive model to approximate the number of sand particles within the pin-on-disc contact surface is proposed. The efficacy of the model is validated through experimental method, which replicates a sand environment with two distinct particle deposition rates. Dry sliding friction experiments are also conducted using 45 carbon steel and H90 brass pins against GCr15 bearing steel discs. Findings When at high particle deposition rate [6.89 × 10–5 g/(s·mm2)], the contact surfaces are separated by particles, resulting in an indirect metal contact. While at low deposition rate [6.08 × 10–8 g/(s·mm2)], there is an alternating occurrence of direct and indirect metal contacts. In sand environment, the specific wear rate of 45 and H90 decreases by 50% and 33%, respectively, compared to non-sand environment when the applied load is 2.45 N. However, it is only 0.18% for 45 but remains significant at 25% for H90 at load of 9.8 N. Originality/value The predictive model and experimental method used in this paper are helpful for understanding the interaction between particles and sliding surfaces, thereby providing a solid foundation for material selection and load optimization of friction pairs influenced by sand-dust environments. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0155/

Extension of the displacement method by measuring reference pieces using multiple sensors for on-machine surface profile measurement

On-machine measurement is crucial in industrial production because it allows the measurement of the surface properties of products without having to remove them from the machine tool; however, measurement results are superimposed with the motion error caused by the table traverse. Therefore, eliminating motion errors is this field's main objective. This paper discusses measuring a surface profile using an extension of the displacement method to eliminate motion errors. The displacement method can separate the surface profile and motion error of the stages in measurement results; however, it introduces a specific cumulative error. The tolerance of the accumulated error was first investigated by simulating a one-axis measurement. The displacement method was extended to a two-axis stage to measure the surface profile and correct the stage tilt to each axis. Moreover, carbon steel finished using a face mill was measured in the experiments, and a coordinate measuring machine was used to compare the results with those of the extended displacement method. It was found that the extended displacement method was able to remove the motion error. Applying the displacement method resulted in an improvement of approximately 88.9%. Error analyses were also formulated and evaluated for sensor drift, reference piece measurement, motion error, table rotation, and thermal expansion, and the percentage of these errors in the total was clarified. The results showed that the motion error and table rotation for the y-axis of the prototype experimental apparatus were larger than the others. These errors are discussed to analyze each error and listed in the error budget. The proposed extended displacement method can eliminate motion errors despite the simplicity of the measurement principle and can be easily integrated into machine tools and other tables.

Mitigation of biocorrosion of X80 carbon steel by a shale microbiome biofilm using a green biocide enhanced by d-amino acids

Microbiologically influenced corrosion (MIC) in shale gas field is a major threat with the hydraulic fracturing fluid injected into the subsurface. In this study, the microbiome collected from a shale gas produced water sample was extracted and cultivated in ATCC 1249 medium modified with 10 g/L NaCl anaerobically at 30 °C. d-amino acids, which were reported as biocide enhancers, were found to enhance 2,2-dibromo-3-nitrilopropionamide (DBNPA) biocide on the mitigation of shale microbiome MIC on X80 carbon steel. The combination of 50 ppm (w/w) d-leucine + 50 ppm d-alanine + 1 ppm d-tyrosine had the best enhancement effect on 50 ppm DBNPA with 84 % less weight loss, and 67 % lower corrosion current density (icorr) compared to 50 ppm DBNPA alone. The corrosion data were consistent with the enhanced biofilm inhibition observation. The experimental data also indicated that d-tyrosine used alone at a low dosage of 1 ppm enhanced DBNPA considerably, with 44 % less weight loss and 47 % less icorr. The electrochemical results showed the positive response of shale gas microbiome biofilm to the injected magnetite nanoparticles indicating the extracellular electron transfer might be a main mechanism for its corrosion.

Investigating the corrosion inhibition properties of a Schiff base on mild steel in HCl solution: experimental and theoretical insights

Investigating the corrosion inhibition properties of a Schiff base on mild steel in HCl solution: experimental and theoretical insights

N-(4-(1,3-benzothiazol-2-ylcarbamoyl)phenyl)isonicotinamide as corrosion mitigator for mild steel in 1 M HCl: A multifaceted study integrating synthesis, characterization, and molecular modelling

Newly synthesized, cost-effective corrosion inhibitor, N-(4-(1,3-benzothiazol-2-ylcarbamoyl)phenyl)isonicotinamide (BIA) was evaluated for mild steel/1M HCl interface. BIA showed a maximum inhibition efficiency of 90.40 % at 100 ppm and 303 ± 1 K, with efficiency increasing with concentration but decreasing with temperature. Inhibitor’s adsorption followed Langmuir isotherm via physicochemical interactions. Activation parameters revealed BIA retards both metal dissolution and hydrogen evolution held in unimolecular process. Potentiodynamic polarization (PDP) divulged BIA as a mixed-type, impeding charge-transfer. Electrochemical impedance spectra (EIS) confirmed BIA forms a protective double layer, blocking active sites at the interface. Surface analysis supported a protective film formation. Global and local reactivity descriptors using DFT/B3LYP/6-311G++(d,p) were calculated to relate inhibition efficiency with BIA’s electronic properties. Molecular dynamics simulation (MDS) showed an interaction energy of −224.7 kJ/mol between BIA and Fe(110) at 303 K, with Radial Distribution Function (RDF) showing bond lengths under 3.5 Å, confirming a chemical interaction. Theoretical results align with experimental data.

Corrosion behavior of mild steel in aqueous solutions of ammonium nitrate and urea

Corrosion behavior of mild steel in aqueous solutions of ammonium nitrate and urea

Investigation of Joints between AISI 1020 Carbon Steel and Monel400 Produced by Friction Stir Welding

Investigation of Joints between AISI 1020 Carbon Steel and Monel400 Produced by Friction Stir Welding

Aluminide Coatings by Means of Slurry Application: A Low Cost, Versatile and Simple Technology

The present study focused on demonstrating the versatility of the slurry deposition technique to produce aluminide coatings to protect components from high-temperature corrosion in a broad temperature range, from 400 to 1400 °C. This is a simpler and low-cost coating technology used as an alternative to CVD and pack cementation, which also allows the coating of complex geometries and offers improved and simple repairability for a lot of industrial applications, along with avoiding the use of non-hazardous components. Slurry aluminide coatings from a proprietary water-based-Cr6+ free slurry were produced onto four different substrates: A516 carbon steel, 310H AC austenitic steel, Ti6246 Ti-based alloy and TZM, a Mo-based alloy. The resulting coatings were thoroughly characterised by FESEM and XRD, mainly so that the identification of microstructures and appropriate phases was reported for each coating. The importance of surface preparation and heat treatment as key parameters for the coating final microstructures was also evidenced, and how those parameters can be optimised to obtain stable intermetallic phases rich in Al to sustain the formation of a protective Al2O3 oxide scale. These coating systems have applications in diverse industrial environments in which high-temperature corrosion limits the lifetime of the components.

Extract of Silybum marianum (L.) Gaertn Leaves as a Novel Green Corrosion Inhibitor for Carbon Steel in Acidic Solution

In this work, leaves of Silybum marianum (L.) Gaertn were extracted by a one-step extraction method using ethanol as a solvent, and the Silybum marianum (L.) Gaertn extract (SMGE) was firstly employed as a green corrosion inhibitor for carbon steel in 0.5 mol/L H2SO4. The corrosion inhibition performance was studied using weight loss and electrochemical methods, and the anti-corrosion mechanism of SMGE is further analyzed through some surface characterizations and theoretical calculations. The results indicate that SMGE can act as a mixed-type corrosion inhibitor and possess superior corrosion inhibition performance for carbon steel in H2SO4 solution, and the optimum corrosion inhibition efficiency reached 93.06% at 800 ppm SMGE combined with 60 ppm KI. The corrosion inhibition efficiency increased with the rising inhibitor concentration. Surface characterizations illustrated that the inhibitor could physico-chemically adsorb on a metal surface, forming a hydrophobic, protective film.

Experimental and theoretical corrosion inhibition efficiency investigation of selenium dioxide nanoparticles coated on carbon steel alloy in a saline medium

Experimental and theoretical corrosion inhibition efficiency investigation of selenium dioxide nanoparticles coated on carbon steel alloy in a saline medium

Inhibiting effect of the essential oil of the Schinus Terebinthifolius fruits on corrosion of E24 carbon steel in 1 M HCl

Inhibiting effect of the essential oil of the Schinus Terebinthifolius fruits on corrosion of E24 carbon steel in 1 M HCl

Experimental study on rotary inter-module connections with corrosion-resistant metal materials: Under axial tension

Modular construction is an innovative construction technology that has attracted considerable attention for its pronounced advantages in reducing reliance on on-site labor, speeding up construction, enhancing productivity, and ensuring superior quality. To extend the applicability of modular construction to structures in corrosive environments, such as ocean floating structures for exploring renewable energy, a rotary inter-module connection employing corrosion-resistant metal materials was proposed herein. Six full-scale inter-module connection specimens made of grade S30408 austenitic stainless steel, grade S220503 duplex stainless steel, and grade A96061-T6 aluminum alloy were tested under axial tension. The load-displacement relationships of each specimen were recorded to enable a thorough analysis of the strength, stiffness, and ductility of the tested specimens. As compared to the conventional carbon steel counterparts, the stainless steel specimens showed superior load-bearing capacity with improved ductility, while the aluminum alloy specimens experienced brittle fracture at the bolt shank-bottom plate junction with reduced load-bearing capacity. Three typical failure modes were identified in the experimental study, namely, plastification of the connector and lower corner fitting, plastification of the connector and both corner fittings, and fracture of the bolt. The load-strain relationships of each specimen were also discussed to analyze the load transfer mechanism and structural behavior of the connection. In addition, the applicability and accuracy of the simplified calculation methods based on beam bending theory and Navier solution for rectangular thin plates, respectively, were discussed based on the test results.

STUDY OF THE INFLUENCE OF THE CHEMICAL COMPOSITION OF RAILWAY AXLE STEEL ON THE UNIFORMITY OF THE FINAL MICROSTRUCTURE

The relevance of the work. For modern railway transport, increasing the strength and operational reliability of rolling stock parts, in particular railway axles, is an urgent task. It is known that the inhomogeneity of the distribution of chemical elements in the structure of structural grade carbon steels is formed mainly during their crystallization and may subsequently affect the final structural state and set of properties. Purpose. Study of the influence of the chemical composition of steels for railway axles on the uniformity of the structure. Methodology. Experimental ingots of different chemical compositions with different amounts and ratios of the main chemical elements within the range of OS and EA1N were produced in laboratory conditions. The grain structure was studied on microsections after etching with nital. Chemical inhomogeneity (“traces” of the dendritic structure) − the distribution of chemical elements in the microstructure of cast samples was detected by etching in a hot solution of sodium picrate. Metallographic analysis was performed on a light (optical) microscope “Axiovert 200 M MAT” manufactured by “Carl Zeiss”. The results. The effect of changing the chemical composition of carbon steel, which is intended for the manufacture of railway axles, on the peculiarities of the formation of ferrite-pearlite heterogeneity and grain size is determined. It is shown that in samples of steels corresponding to the EA1N brand with a lower carbon content, the distribution of phases is uneven. The mechanism of formation of such a structure is explained from the point of view of two theories. In samples of steels with an average carbon content, which correspond to steel of the OS grade, the distribution of the pearlite and ferrite phases is more uniform, the relationship between the size and the degree of darkening of the pearlite areas with the order of the former dendritic branches has been established. Based on the results of the quantitative analysis of the final grain structure, it was established that OS steel with an average carbon content at different Mn/Si ratios has a more uniform grain structure. EA1N steel with a lower carbon content has a pronounced grain size, with an increase in the Mn/Si ratio, the largest maximum of the dependence of the distribution shifts to a larger grain size (smaller number). Practical results. Increasing the homogeneity of the final microstructure contributes to increasing the plasticity and viscosity of steel, which directly affects the reliability and durability of railway axles.

Parametric investigation on surface responses of TIG cladded medium carbon steel substrate with TiO2–SiC powder

The present research work consists of surface modification of a medium-carbon steel substrate with TiO2–SiC powder of the same weight percentage. A Taguchi L9 orthogonal array was used for the design of experiments. Different input process parameters, such as current (A), scan speed (mm/s) and gas flow rate (L/min), have played a significant role in controlling geometrical surface responses. The relationship between different input parameters and response surfaces (clad height, clad width) was plotted and discussed. Diagrams have been utilized to demonstrate the combined impacts of any two process factors on clad height and clad width, such as TIG current–scan speed, TIG current–gas flow rate and gas flow rate–scan speed. Experimental observations revealed that cladding input parameters have a significant influence on response surfaces. TIG current has the maximum impact on clad height. Observations showed that with the increment of current up to a certain amount clad height increased. It was also observed that with an increment of current, clad width increases. Observations revealed that as the gas flow rate rises, clad height decreases but clad width increases. It was further noted that with an increase in scan speed, clad height and clad width follow a downward trend.

Inhibitive Effect of Mangifera Indica Extract on Mild Steel in Hydrochloric Acid Solution

This research investigated the corrosion inhibition potential of Mangifera Indica Peel Extract (MIPE) for mild steel in a 1 M HCl solution. The study explored the effects of extract concentration, solution temperature, and immersion time on the inhibition potential of MIPE using weight loss measurements at extract concentrations of 0, 1.0, 1.5, and 2.0 g/L, temperatures of 303 K and 323 K, and immersion times of 1, 2, 4, 6, and 8 h. Experimental results showed that MIPE significantly reduced the corrosion rate of mild steel, with maximum inhibition efficiency reaching 97.26% and 94.83% at 2.0 g/L MIPE concentration and solution temperatures of 303 K and 323 K, respectively. The uninhibited mild steel experienced increased corrosion rates with rising temperatures and longer immersion times. The inhibition efficiency of MIPE improved with higher extract concentrations and immersion periods. These findings underscore the potential of MIPE as an effective and environmentally friendly corrosion inhibitor in acidic environments.

Superhydrophobic nickel/manganese alloy coatings on carbon steel with corrosion resistance and robustness capabilities prepared via one-step electrodeposition method

Superhydrophobic nickel/manganese alloy coatings on carbon steel with corrosion resistance and robustness capabilities prepared via one-step electrodeposition method

Maleic hydrazide derivative as green corrosion inhibitor for Q235 mild steel in 1 M HCl: synthesis, experiments and theoretical studies

In this study, a novel maleic hydrazide derivative (NOMAM) containing multiple reactive groups was realized. Corrosion experiments show that its corrosion inhibition efficiency reached 95.12 % at 0.2 g L−1 and a maximum of 97.01 % at 0.5 g L−1 on Q235 mild steel in 1 M HCl. Scanning electron microscopy (SEM) and confocal laser scanning microscopy (CLSM) have also confirmed its excellent inhibition performance. Density functional theory (DFT) calculations and molecular dynamics (MD) simulations show that maleic hydrazide derivative molecules adsorb onto the mild steel surface with heteroatoms as reactive sites to form hydrophobic protective barriers. Thermodynamic results show that adsorption follows the Langmuir isotherm and is a hybrid type dominated by chemisorption. The derivative is micro-effective with simple and inexpensive synthesis process. This work could provide a reference for green corrosion inhibitors on mild steel.

Toughness enhancement of low carbon steel through bainitic transformation

Toughness enhancement of low carbon steel through bainitic transformation