Carbon Steel Research Articles

Fracture Behavior of Mild Steel Based on Numerical Algorithm

Fracture Behavior of Mild Steel Based on Numerical Algorithm

Flexural Behaviour and Environmental Impact of African Fan Palm Reinforced Concrete Beams under Symmetrical Loading Conditions

The paper presents the results of investigation on reinforced beams adopting eco-friendly materials for sustainable concrete. The use of African fan palm is explored to mitigate the environmental impact aimed at reducing carbon emissions associated with the production and use of steel reinforcement. The beams were tested under a four -point loading system with the ends simply supported. The test comprised twenty-three beams that were reinforced with African fan palm bars whilst two beams were reinforced with mild steel bars to serve as control beams. The study investigated the flexural strength and deformation characteristics of the beams under monotonic loading. Two concrete strengths of 15.34N/mm2 or 22.37N/mm2 were adopted and proposed optimal tensile ratios for an under reinforced fan palm section. The parameters considered included the tension bars ratio (ρ), concrete compressive strength, span-to-effective-depth ratio and loading conditions. A linear elastic behaviour of both fan palm and steel reinforced concrete beams was observed to the point of first crack load beyond which the beam stiffness continued to reduce until failure. A comparison of the experimental results with results of theoretical analysis of the beams revealed that a 1.22% increase in the tensile ratio of steel in the control beams increased the cracking moment (Mcr) to 36%, while the fan palm beam of the same size and same concrete strength with a higher tensile ratio of 9.69% exhibited a lower Mcr of 11.86%. This shows a significant effect of reinforcing steel bars on concrete cracking compared to the fan palm. The averages of experimental to theoretical failure loads of fan palm to steel were compared with failure loads of 36.52kN to 20.19kN and 32kN to 19.78kN respectively. These results of the study based on the failure mode, and failure loads, highlights the suitability of using African fan palm as substitute reinforcing material for low rise buildings. Furthermore, the study also proposed minimum and maximum tensile ratio of 0.76% and 5.60% respectively for fan palm reinforced concrete beams based on the Indian Standard and modulus of elasticity of steel.

Synergistic Effect of Sn Doping in TiO2 Nanoparticles as an Additive in Anti‐Corrosion Coatings

ABSTRACTCorrosion is a major problem and protective coatings offer an effective solution. However, organic coatings are often associated with microcracks caused by the evaporation of solvents during coating preparation. This study investigates the use of titanium dioxide (TiO2) nanoparticles as a coating additive to protect mild steel surfaces. Additionally, doping TiO2 with tin (Sn) is believed to enhance its properties due to the reduced size of the nanoparticles. These nanoparticles were synthesised using the sol–gel method and subjected to various analyses. The coated mild steel samples were prepared using the dip‐coating method and immersed in 3.5 wt.% sodium chloride (NaCl) solution for 30 days. Electrochemical impedance spectroscopy (EIS) and Tafel polarisation showed that the Sn‐doped TiO2 nanoparticles as an additive improved the corrosion resistance, as evidenced by a positive shift in corrosion potential (Ecorr) and reduced corrosion current density (Icorr).

Corrosion inhibition of tetrabutylphosphonium benzotriazolate on carbon steel in acidic medium

The inhibition effect of tetrabutylphosphonium benzotriazolate (TBPB) on carbon steel in a 1 mol·L−1 HCl solution was investigated using a combination of analytical techniques, including polarization curve, electrochemical impedance spectroscopy, scanning electron microscopy, atomic force microscopy, and X-ray photoelectron spectroscopy. The study revealed that TBPB acts as a mixed corrosion inhibitor for carbon steel in acidic conditions. The efficiency of corrosion inhibition was observed to increase gradually with rising TBPB concentrations, reaching a maximum of 92 % at a concentration of 10 mmol·L−1. This enhancement in corrosion inhibition efficiency is attributed to the adsorption of TBPB on the metal surface, effectively isolating it from the corrosive medium and thereby preventing corrosion reactions. Importantly, this mechanism aligns well with the Langmuir isothermal adsorption model.

A comprehensive investigation of oxygen/graphite carbon nitride smart Nano coatings for sustainable maintenance and sacrificial anode protection of mild steel

AbstractBACKGROUNDThis study enhancing the corrosion resistance of mild steel (MS) by incorporating photo‐catalyst‐doped graphitic carbon nitride (g‐C₃N₄) nano‐sheets containing silver (Ag) and oxygen (O₂) into a solar light‐active photoelectrochemical anticorrosion paint with polyester (PE). The objective is to provide sacrificial anode protection through visible light activation.RESULTSThe developed paint forms a uniform film on the MS surface, effectively providing anodic protection under visible light. Characterization techniques, including energy‐dispersive X‐ray spectroscopy (EDX), transmission electron microscopy (TEM), Fourier‐transform infrared spectroscopy (FTIR), and UV–Vis spectroscopy, confirm the molecular structure of the nano‐sheets. Corrosion resistance, assessed through weight loss measurements and open circuit potential (OCP) tests, shows significant improvement with the addition of Ag/g‐C₃N₄ and Ag‐O₂/g‐C₃N₄ nano‐sheets at an optimized concentration of 15 mg. The protection efficiency is ranked as follows: O₂‐g/C₃N₄ > O‐g/C₃N₄ > Ag‐O₂/g‐C₃N₄ > Ag‐g/C₃N₄ > g‐C₃N₄. After 28 days of immersion in seawater, MS coated with O₂/g‐C₃N₄ exhibited the least weight loss, with an inhibition efficiency of up to 99%. Electrochemical impedance spectroscopy (EIS) further demonstrated enhanced coating resistance for the O₂/g‐C₃N₄ coating (Rct = 3.76 kΩ.cm2, Rcoat = 1.69 kΩ.cm2) compared to pure PE (Rct = 0.005 kΩ.cm2, Rcoat = 0.096 kΩ.cm2).CONCLUSIONThe synthesized O₂/g‐C₃N₄ and Ag‐O₂/g‐C₃N₄ nano‐sheets exhibit high surface areas and enhanced water dispersibility, which contribute to significant corrosion protection of MS. The electrochemical performance, including weight loss and OCP measurements, highlights the potential of these nano‐sheet photo‐catalysts in advancing corrosion resistance technologies, with broad implications for materials science and engineering applications. © 2024 Society of Chemical Industry (SCI).

Surface engineering of Q235 carbon steel through a superamphiphobic composite coating enabling robust corrosion resistance and antifouling

Developing an efficient strategy to ensure the resistance of corrosion on Q235 carbon steel from liquid-based contaminants is a challenging work. Although superhydrophobic and superamphiphobic coatings have been fabricated, their susceptibility to oily liquids and poor mechanical robustness still limits their ability to tackle corrosion. Herein, the synthesis and fabrication of a new robust superamphiphobic nanocomposite was presented by combining the reinforcement properties of silicon oxide and the mechanical and thermal stability of zinc oxide into a polytetrafluoroethylene polymer matrix via a colloidal homogenization route. The newly developed composite exhibits a hierarchical bumpy structure, leading to excellent water and oil repellent properties. Importantly, the composite possesses a robust mechanical stability to sandpaper abrasion over a distance of 2000 cm under a 100 g load and a stronger adhesion to substrate. As a result, Q235 coated with this composite exhibits an excellent corrosion resistance in saline water for up to 120 days, and a good self-cleaning and antifouling abilities in most corrosive media. This finding reveals a new pathway for resisting the corrosion attacks on Q235 carbon steel and thereby rendering this strategy with practical application in industrial and marine settings.

Texture and surface morphology influence of A106 carbon steel pipe on mechanical properties and corrosion resistance after welding process

The surface morphology influenced the corrosion resistance, which depended on the welding process and its parameters. In this study, we investigated the relevance of the welding process that produces excellent mechanical properties and corrosion resistance, which gives the best working performance for carbon steel pipes that transfer refined oil products in an Iraq oil refinery. AISI 1020-A106 carbon steel pipes are welded using shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW). Electrochemical corrosion tests were performed in 3.5% NaCl and immersion tests in heavy Naphtha at 50, 75, and 100 °C. The results show that retained austenite, ferrite, pearlite, and martensite phases are produced after the SMAW process. In contrast, ferrite, pearlite, and a small amount of martensite are produced after GTAW. The ultimate tensile strength of the SMAW samples was higher than those of the GTAW samples, but the GTAW samples had higher fracture elongation, and all samples had no cracks in the welding area during the bending test. The electrochemical and immersion corrosion rates of the samples welded with SMAW are higher than those welded with GTAW. The corrosion rate increases when the naphtha temperature increases and has a higher and unacceptable value at 100 °C.

Synergistic inhibition effect of diolefinic dye and silver nanoparticles for carbon steel corrosion in hydrochloric acid solution

The current work looks at the inhibitory effects of a diolefinic dye, namely 1,4-bis((E)-2-(3-methyl-2,3-dihydrobenzo[d]thiazol-2-yl) vinyl) benzene iodide salt, in relation to CS corrosion mitigation in hydrochloric acid (HCl) environment. This study uses a variety of experimental methodologies, including weight loss (WL) analysis, electrochemical tests, and theoretical considerations. The synergistic effect of diolefinic dye and AgNPs on the corrosion inhibition of CS in 1 M HCl was investigated. The inhibition efficiency (IE) displays a notable enhancement as the concentration of the dye is elevated and as the temperature raises the IE increases. The diolefinic dye exhibited % IE of 83% even at low concentration (1 × 10–4 M) whereas 90% in the presence of (2.26 × 10–10) AgNPs. Tafel graphs demonstrate that the dye follows a mixed type inhibitor. The adsorption of the dye on CS surface follows Langmuir model. Moreover, the influence of temperature and the activation parameters disclose that diolefinic dye is chemisorbed on the CS surface. The synergistic coefficient of the diolefinic dye and AgNPs under various concentration conditions was greater than unity. The surface morphology of CS sheets was confirmed by scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX). Density Functional Theory (DFT) calculations provide theoretical support for the inhibitory effects of the examined dye. Notably, there is a high agreement between the findings of practical studies and theoretical expectations.

Improving Corrosion Resistance of Low Carbon Steel through Surface Mechanical Attrition Treatment Duration

Improving Corrosion Resistance of Low Carbon Steel through Surface Mechanical Attrition Treatment Duration

Experimental Investigation of Energy Harvesting by Employing Piezoelectric Element and Metallic Cantilever Beam

In this paper, in response to the worldwide energy crisis, a piezoelectric element (0.2*35*50) mounted on a host metallic cantilever beam (0.8*37*220) will be presented as a unique contribution to power generation via the micro-electrical mechanical system. It's made out of aluminium and low carbon steel, both of which have a Young modulus of elasticity of 6.8 and 196 GPa, respectively. In order to take advantage of the engine's vibration as an exciting external force to collect energy in the aforementioned piezoelectric device, the whole rig has been coupled to a diesel engine 5kw 3000 rpm (50 Hz). The average power generated by the aluminium beam was 943 microWatts, while the power generated by the low carbon steel beam was 335 microWatts, an increase of 256%. In addition, for both scenarios, (45) mm from the cantilever beam's fixed point was where the engaged piezoelectric element performed best. The used two metals have different stiffnesses, and this accounts for the obtained difference between the induced powers; increasing the stiffness will result in relatively more power created, and vice versa.

First-Principles Study of Sulfur Corrosion Mechanism at Carbon Steel Grain Boundaries

First-Principles Study of Sulfur Corrosion Mechanism at Carbon Steel Grain Boundaries

First Principles Investigations of Mild Steel Corrosion Inhibition by Dopamine Derivatives in HCl Solution

First Principles Investigations of Mild Steel Corrosion Inhibition by Dopamine Derivatives in HCl Solution

Aromaticity of Heterocyclic Compounds and Their Corrosion Inhibition Property: Experimental and Theoretical Analysis.

Heterocycle derived moieties, namely, N-(4-methoxyphenyl)-1-(1H-pyrrol-2-yl)methanimine (MPM), 1-(furan-2-yl)-N-(4-methoxyphenyl)methanimine (FMM), and N-(4-methoxyphenyl)-1-(thiophen-2-yl)methanimine (MTM), were synthesized followed by analysis of their structural aspects using FTIR and 1H NMR spectroscopic techniques. The corrosion retarding abilities of the same were distinguished by gravimetric and certain electrochemical measures for mild steel in 0.5 M H2SO4, and MTM was obtained with maximum inhibition efficiency of 97.93% at 250 mg L-1 concentration; the thermodynamic and activation parameters were recorded in this regard. The results were further seen to be supported by various surface studies: SEM-EDS, XPS, AFM, contact angle, and UV-visible spectroscopy. Potentiodynamic polarization studies unveiled the mixed nature of heterocyclic inhibitors with overriding anodic effect. Furthermore, the adsorption of inhibitors over mild steel coupons demarcates the prevalence of physical and chemical interactions in the environment. In addition, the computational studies, global and local reactivity, molecular dynamics, and density functional theory, were employed and the experimental results obtained were found in correlation with the theoretical results.

Thermodynamic Insights into the Influence of Welding Current on Oxygen Levels in the Submerged Arc Welding Process

Welding current is an essential parameter for submerged arc welding process. In submerged arc welding, the enormous heat generated by the current promotes the decomposition of the oxides in the flux, releasing oxygen and increasing the oxygen level in the metal, which further affects the microstructure and mechanical properties of the weld joint. Although previous studies have developed various models to evaluate oxygen content, the thermodynamic mechanism by which current influences oxygen levels in metal remains inadequately understood. This study integrates CALPHAD technology with welding thermodynamics to predict and simulate the impact of the welding current on oxygen content in metals. By combining experimental data with thermodynamic modeling, the research investigates how different current settings affect oxygen content in the metal across various welding zones, specifically when using CaO-Al2O3 fluxes with low and high basicity indices for the welding of typical carbon steel. This study selected two current values, 300 A and 600 A, for modeling analyses of the welding process, along with two typical fluxes with basicity indices of 1.6 and 0.4. The results indicate that the proposed method outperforms the BI model and can predict the metallurgical effects of current on oxygen content in the droplet and molten pool zones. The thermodynamic mechanisms that govern the metal oxygen level are also evaluated. These findings aim to enhance the understanding of the thermodynamic mechanism that governs oxygen behavior under different current conditions, thereby contributing to the optimization of submerged arc welding process.

Fluorine-free superhydrophobic Ni/Mn-TiO2 composite coatings on carbon steel via one-step electrodeposition for enhanced durability and corrosion resistance

The application of superhydrophobic coatings on carbon steel (CS) surface represents an effective strategy for mitigating corrosion in these materials. This study presents the preparation of superhydrophobic Ni/Mn-TiO2 composite (SNMT) coatings on CS substrates through a facile one-step electrodeposition technique. The formation mechanism of SNMT coatings was meticulously analyzed under varying conditions of nanoparticle types and concentration levels. The inclusion of TiO2 nanoparticles, with an optimal additive concentration of 1 g, facilitated the formation of numerous low surface energy, cauliflower-like microstructures on CS interface. Surprisingly, the results indicate that SNMT coatings maintained commendable superhydrophobicity even post-exposure to superficial damages such as tape peeling, sandpaper wear, and knife-scratch, as evidenced by a static contact angle (CA) exceeding 158° and a sliding angle (SA) below 2°. Furthermore, the corrosion inhibition efficacy of SNMT coatings was quantitatively assessed via dynamic potential polarization curves in a simulated seawater environment. The results demonstrated that SNMT coatings exhibited excellent corrosion inhibition performance in simulated seawater solution, with a protection efficiency (PE) reaching 96.5%. In conclusion, superhydrophobic surfaces can effectively inhibit the penetration of corrosive liquids. The durability and robustness of such superhydrophobic surfaces advocate for their potential widespread application in enhancing the longevity and reliability of CS in corrosive environments.

Corrosion protection performance of poly(PyM-co-GMA)/SWCNT nanocomposites coating on mild steel

Recently, there has been significant emphasis on developing electroactive functional methacrylate polymers for anticorrosive applications. In this context, we have synthesized Poly[(3,5-dimethyl-1H-pyrazole-1-yl) methyl methacrylate-co-glycidyl methacrylate] [Poly(PyM-co-GMA)] and its nanocomposite with single- walled carbon nanotubes (SWCNTs) [Poly(PyM-co-GMA)/SWCNT]. The resulting materials were characterized using Fourier Transform Infrared spectroscopy (FT-IR) and X-ray Diffraction analysis (XRD). Morphological changes due to the incorporation of SWCNTs were examined using field-emission scanning electron microscopy (FE-SEM) and high-resolution transmission electron microscopy (HR-TEM). The optical properties of Poly(PyM-co-GMA) and Poly(PyM-co-GMA)/SWCNT (0.5, 1.0, and 1.5 wt. %) were investigated. The thermal behavior of Poly(PyM-co-GMA) and its SWCNT nanocomposites was analyzed through thermogravimetric analysis (TGA). The anticorrosive performance of the prepared materials was evaluated on a mild steel substrate (MS) in a 3.5% (w/v) NaCl medium using electrochemical techniques. Results from potentiodynamic polarization and electrochemical impedance spectroscopy indicate that the Poly(PyM-co-GMA) and Poly(PyM- co-GMA)/SWCNT coatings (0.5, 1.0, and 1.5 wt. %) provide effective barrier protection for mild steel against marine environments.

Exploring the Corrosion Potential of Three Bio-Based Furan Derivatives on Mild Steel in Aqueous HCl Solution: An Experimental Inquiry Enhanced by Theoretical Analysis.

This research deals with the corrosion inhibition of mild steel in a highly corrosive aqueous HCl medium with a concentration of 0.5 M, using three different corrosion inhibitors: furan-2-carboxylic acid (1), furan-2,5-dicarboxylic acid (2), and furan-2,5-diyldimethanol (3). Various electrochemical tests, such as potentiodynamic polarization (PP or Tafel curve) and electrochemical impedance spectroscopy, were systematically performed. The experimental results underscore the remarkable corrosion mitigating properties of inhibitors 1-3 on mild steel, showing inhibition efficiencies of 97.6, 99.5, and 95.8%, respectively, at a concentration of 5 × 10-3 M and temperature T = 298 K. Notably, the inhibition efficiency of each inhibitor 1-3 shows a positive correlation with its concentration. In addition, consistent results from all electrochemical methods confirm that 1-3 act as mixed inhibitors. These findings remain robust across different experimental techniques, ensuring the reliability and comprehensiveness of the results. Theoretically, the inhibitors were optimized using the Density Functional Theory/B3LYP/6-311++G(d,p) method in gas and aqueous phase to evaluate their reactivity and stability. Among them, compound 2 stands out for its enhanced reactivity and stability, highlighted by optimal EHOMO and ELUMO values. Negative electrostatic potential mapping suggests potential reaction centers, while Fukui functions reveal localized sites of reactivity, supported by a favorable electronic distribution and specific interactions with metal surfaces. Reduced density gradient analysis also confirms the suitability of this compound for noncovalent interactions, in agreement with experimental data.These theoretical results are in good agreement with experimental data, confirming the excellent performance of compound 2 as a corrosion inhibitor.

Effects of carbon levels and surface area variations on mild steel strength: A comparative study

This study investigates the dynamic interplay between carbon levels and surface area variations on mild steel strength during the rolling process. Focused on understanding the nuanced relationship between these factors and steel durability, the research adopts a systematic approach. Controlled adjustments in carbon levels and surface area variations are employed to assess their impact on the structural integrity and tensile strength of mild steel. Through rigorous analysis and measurement, this study aims to unveil the intricate connections between carbon content, surface area alterations, and steel strength, offering critical insights for optimizing rolling processes in industrial settings. The experimental works have been conducted with carbon levels variations and surface area variations. The samples were tested in two different laboratories, however, the results of two laboratories are almost similar. The higher carbon content increases strength and yield strength varies with different carbon level and surface area. The surface area variations are affected the mechanical properties of mild steel. The maximum stress recorded was 700 MPa and the breaking point observed at 540 MPa. The findings aspire to contribute significantly to refining manufacturing techniques and developing more resilient steel products, thereby advancing our comprehension of material behavior in mechanical applications.

Fabrication and Characterization of Graphene Oxide – Cadmium Sulphide Nanocomposite Coating for Corrosion Inhibition of Mild Steel Specimen

Abstract The oil and gas sector play a significant role in the Sultanate of Oman’s economic growth and contribute major revenue. Corrosion is a global concern and that strongly affects the industrial sectors. The corrosion problems in oil pipelines would be successfully resolved by means of novel control techniques. This research focused on the fabrication of Graphene oxide (GO) - Cadmium sulphide (CdS) nanocomposite for controlling corrosion in mild steel specimen. Graphene oxide was synthesized from Alovera extract by carbonization process. GO - CdS nanocomposite was prepared and deposited on a mild steel pipe by self-assembly technique. The coated material was used for stability studies at varying pH conditions and exposure period followed by corrosion studies. The testing methods adopted are Atomic Force Microscopy (AFM), Scanning Electron Microscopy (SEM), X-Ray Diffraction (XRD), Energy Dispersive X-Ray analysis (EDX), and Fourier Transform Infrared Spectroscopy (FTIR). Wet/Dry test and Atmosphere tests were conducted to examine the performance of coating material towards corrosion. The atomic force microscope (AFM) operated in non-contact mode was used to study surface topology of the coated specimen. From the outcome of the corrosion studies, it was established that the GO- CdS Nano composites thin film acted as an ecofriendly corrosion inhibitor to enhance the lifespan of the mild steel pipe. This novel research is aligned with the United Nations Sustainability Goals (UNSD - 9: Industry, Innovation and Infrastructure & UNSDG 12 – Responsible consumption and production) and Oman vision 2040. The results from the study validates that the GO - CdS thin films coated on mild steel pipe could be a viable solution to corrosion issues in oil pipelines owing to their good film stability, minimum film thickness, high durability, and ecofriendly approach.

Corrosion mitigation of carbon steel in sulfuric and hydrochloric acid solutions by Syzygium polyanthum (Wight) Walp. leaf extract

It is widely recognized that corrosion has been a persistent issue throughout human history. Over time, various effective strategies have been suggested and successfully employed to combat this problem. Among them, the utilization of inhibitors stands out as a promising, versatile, and easily applicable method. Considering the drawbacks associated with previous substances such as environmental concerns and high operational expenses, plant extracts have emerged as an effective alternative. In there, Syzygium polyanthum (Wight) Walp. stands out as a popular species characterized by a high concentration of polar compounds that is crucial for the formation of a protective film layer on carbon steel. Consequently, this work centers on investigating the corrosion inhibition behavior of Syzygium polyanthum (Wight) Walp. leaf water-extract (SPWE) for carbon steel in different solutions, including 1.0 M HCl, 0.5 M H2SO4, and co-volume acidic mixture, by employing electrochemical and surface techniques. The findings reveal that 2000 ppm of SPWE proved inhibition efficiency exceeding 94.24, 66.27, and 95.02% (estimated by Tafel extrapolation) for carbon steel in 1.0 M HCl, 0.5 M H2SO4, and acidic mixture solutions, respectively. High inhibition performance was also ensured by high polarization resistances (Rp) observed on electrochemical impedance spectroscopy (EIS) and linear polarization resistance (LPR). Increasing corrosion resistance could be due to the protective layer formed on the inhibited samples, while severe corrosion occurred on the uninhibited steel due to extensive damage across the entire surface. Hence, the study underscores the noteworthy impact of chloride and sulfate ions on corrosive inhibition process of SPWE.