Composite Steel Research Articles

Iterative multi-objective design of hydrogen embrittlement resistant high-strength steels using Bayesian optimization

The infiltration of hydrogen can weaken the strength and toughness of materials, especially in high-strength steel. Considering the inherent trade-off between strength and toughness in steel design, balancing these two factors with the material's hydrogen embrittlement sensitivity has become a huge challenge in steel design. The long cycle nature of hydrogen embrittlement testing makes the iteration of traditional trial and error methods infeasible for steel development. This work adopts active learning algorithms based on Bayesian and Pareto optimization to iteratively optimize the chemical composition and processing technology of high-strength steel, in order to simultaneously improve its hydrogen filled tensile strength (UTS_H) and hydrogen filled total elongation (TEL_H). After two rounds of iterative optimization, the iterative optimization algorithm significantly improved the strength prediction of materials after hydrogen charging. The machine learning model found 16 types of steel from over 15 million unknown materials. Eight materials showed better comprehensive performance than known data, with one material having a tensile strength exceeding 1800 MPa and an elongation of 12.6%. Subsequent experiments showed that the optimization algorithm demonstrated an understanding of the impact of austenite content on hydrogen embrittlement sensitivity in multiple experiments, and designed high-strength steel resistant to hydrogen embrittlement through the austenite content of martensitic steel.

BUILDING LIFE CYCLE ASSESSMENT OF A COLLECTIVE HOUSING BUILDING IN PORTUGAL CONSIDERING DIFFERENT STRUCTURAL MATERIALS

AbstractIn recent years, the focus on reducing the environmental impact of construction has shifted from operational carbon emissions to embodied carbon or materials due to the constant decarbonization of the energy sector. This paper compares the life‐cycle assessment (LCA) of a collective housing building in Portugal, examining four structural solutions: composite steel and concrete, light steel framing, prefabricated reinforced concrete, and cross‐laminated timber load‐bearing walls. This study aims to aid construction professionals in making environmentally informed decisions by comparing design options composed of different materials and highlighting potential improvements in environmental performance.

Assessing crack susceptibility in blended copper-stainless steel compositions during laser directed energy deposition-based additive manufacturing

This study investigates the effect of composition and process parameters on the crack susceptibility of the Cu -SS304L system during laser directed energy deposition (LDED). The microstructure of LDED deposits is analysed aiming at elemental distribution and crack susceptibility. The trapping behaviour of Cu changes with Cu concentration. The crack susceptibility reduces with Cu concentration and escalates with an increase in laser power and scan speed, irrespective of composition. The mode of solidification cracking varied from the rupture of Cu film to crack-assisted porosity. Furthermore, the critical solidification cooling rate is estimated for LDED of different blended Cu -SS for crack-free deposition. The above findings offer insights into cracking behaviour and provide processing guidelines for LDED of Cu -SS.

MgAl2O4–C refractories with balanced properties for a delivery device used in the double-roll thin strip continuous casting

To realize the double-roll thin strip continuous casting process for the production of high-quality steels, it is necessary to seek a new type of refractory material tailored for delivery device employed in this process. Therefore, the present study aimed to design and prepare MgAl2O4–C refractories for this purpose as well as to study their physical and mechanical properties, thermal shock resistance, oxidation kinetics, and to perform molten steel experiments after pre-oxidation treatment. The results of the present study demonstrated that the specimens could maintain high mechanical and thermal shock properties even after pre-oxidation treatment. After pre-oxidation at 1100 °C/1 h, the cold compressive strength of the specimen reached 17.63 MPa, with a residual strength ratio (thermal shock resistance) of 77.99%. Analysis of oxidation kinetics based on the shrinking core model indicated an increase in the effective diffusion coefficient and complete oxidation time with higher pre-oxidation temperature. Pre-oxidation of MgAl2O4–C refractories has been shown to be effective in reducing carbon penetration into the molten steel from carbon-containing refractories, thus maintaining the stability of the molten steel composition. This effect was attributed to enhanced contact and wettability between the steel and refractories, an augmented thickness of the pre-oxidized decarburized layer, the formation of a dense magnesium oxide layer, and the emergence of the MgAl1·9Fe1O4 phase. Consequently, an MgAl2O4–C refractories designed for the delivery device was proposed along with anticipated applicability in the double-roll continuous casting process.

Research on the surface characteristics of 42CrMo alloy steel pulse electrochemical machining

Electrochemical processing, due to its unique material removal mechanism compared to mechanical processing, often results in significantly different micro-morphologies. It is widely used in areas such as aerospace component processing, surface finishing, passivation, micro-structure mold processing, etc. The complexity of alloy steel composition makes uniform etching difficult to achieve, and the post-etch micro-morphology is also complex, making it challenging to describe and analyze. Therefore, it is difficult to analyze the surface morphology of electrochemical etching under different parameters. In this study, a self-developed electrochemical etching device with adjustable DC voltage, pulse width voltage, and pulse width positive and negative voltage output was used. Different parameters of pulse voltage were used to etch the surface of 42CrMo alloy steel. Due to the strong relationship between surface roughness parameters and the chosen measurement scale, as well as the surface morphology and waviness errors introduced by specimen preparation and etching processes, a wavelet filtering method was used to remove the low frequency components in the surface morphology, and only the surface roughness part was retained for fractal parameter calculation and analysis. The research showed that fractal analysis can also be applied to analyze the surface morphology after electrochemical etching. Pulse voltages with characteristic voltages, characteristic pulse frequencies, and duty ratios can achieve better surface quality during positive pulse etching. Positive and negative pulse etching can obtain better surface morphology than positive pulse etching, but the etching amount is lower, making it suitable for precision finishing.

Cyclic Response of Composite Steel Gravity Framing Connections in Multibay System-Level Tests

Cyclic Response of Composite Steel Gravity Framing Connections in Multibay System-Level Tests

Comparison of the Mechanical Properties and Approach to Numerical Modeling of Fiber-reinforced Composite, High-Strength Steel and Aluminum

The performance of carbon fiber reinforced polymer (CFRP) composite materials under quasi-static and high strain rate loading can be predicted with a high level of accuracy using the non-linear finite element analysis (FEA) method. Experimental validation tests under uniaxial tensile loading have shown a good correlation with FEA predictions for thermoset polymer composites, using commercially available epoxy resin MTM710 with carbon fiber reinforcement and for comparative tests on DP600 steel and aluminum alloys (AC170 and 5754 series). The physical and numerical results comparison of composite, aluminum, and high-strength steel indicates that the composite may be used as an alternative to aluminum and high-strength steel since the composite was shown to have almost the same strength as steel and higher strength than aluminum with the advantage of being lightweight and possessing similar mechanical behavior under quasi-static conditions. The results demonstrated that the strain rate range used did not significantly affect the strength of the composite materials. The selection of materials can be optimized reliably by FEA based on mechanical properties, cost, and weight. This will significantly reduce the new product introduction timescale, which is essential for the wider use of polymer composites for structural applications, especially in the automotive industry.

A study on low-frequency vibration mitigation by using the metamaterial-tailored composite concrete-filled steel tube column

The bandgap properties exhibited by local resonant metamaterials provide a potential approach for structural vibration reduction. In this work, we introduce the local resonance mechanism into the composite structure for the first time and propose a novel metamaterial column with 33.8–47.2 Hz low-frequency vibration mitigation based on practical engineering materials and utilizing material shear deformation. By vertically arranging metamaterials, the metamaterial concrete-filled steel tube column with low-frequency vibration reduction bandgap is designed. Its equivalent bandgap model is proposed by combining the Timoshenko beam and Bloch theorem. The bandgap formation mechanism and vibration mitigation effect of the metamaterial are clarified by finite element analysis. It is revealed that the bandgap generation depends on the contrary motion between the resonator and the substrate, thus the reaction force from the relative motion can cancel the external excitation. Then, the bandgap vibration mitigation effect of the metamaterial column is proved by shaking table tests at different amplitudes. This also supplies a feasible solution for vibration mitigation control and even earthquake protection for buildings, bridges, and major infrastructures. Finally, the theoretical, numerical, and experimental results are discussed to verify the validity of the theoretical approach and numerical model, and the rubber damping is found to widen the bandgap but weaken the vibration reduction capacity.

Seismic behavior of resilient composite steel plate shear wall using experimental investigations

Using composite encased steel plate shear wall (C-SPSW) has been attractively raised for enhancing the lateral seismic performance and increasing the useful floor area. Although, the experimental investigations have proved excellent dynamic behavior of C-SPSWs, structural damage as well as residual displacements are the main disadvantages of C-SPSWs, which are not consistent with low damage design (LDD) approaches. In the current study, the C-SPSWs performance is improved using the self-centering (SC) technique to control the both structural damage and reduce residual displacements as well. Five tests on C-SPSWs including three SC composite encased steel plate shear walls (SC-C-SPSWs) were conducted under gravity and lateral cyclic loads. The SC-C-SPSW consists of C-SPSW equipped with unbonded posttensioned tendons (UPT) to have resilience ability. For this aim, two symmetrical gaps were provided at the ends of the wall, and the UPTs were mounted at the wall ends and crossed into the foundation through the middle of the gaps. Under lateral load, the gap opening allows the elongation of UPTs that induce a high restoring forces, forcing the wall to have rocking movement above the foundation. In comparison with C-SPSWs, the SC-C-SPSWs exhibited low damages, higher shear strength capacity between 28% and 35%, larger ultimate drift capacity and more displacement ductility as 45–136% in average. Furthermore, the SC ability and the UPTs restoring forces effectively reduced the residual drift and the SC moment causes the recovery of the residual drift between 90% and 105%. Moreover, compared to C-SPSWs, the residual lateral strength of SC-C-SPSWs was improved by 30% in average.

Impact of various heat treatment processes and welding speeds on the mechanical properties and microstructures of soft/hard composite joints

There is a certain contradiction between the formability and strength of auto parts. In this work, the whole-process processing technology of hot stamping soft steel was designed, and 500 MPa grade mild steel (500HS) with uniform microstructure was prepared. To take into account the strength and formability of hot stamping soft steel, here, based on laser welding technology, 500 MPa grade soft steel, and 1500 MPa grade hard steel are benignly composited, and by adjusting the laser welding speed and heat treatment process, the loss of mechanical properties caused by the weld seam is eliminated. A soft/hard composite steel for automobiles with excellent strength, ductility and formability is obtained. To maintain excellent deformation resistance and bonding force of the weld, the heat-affected zone of 500HS retains part of bainite and pearlite, which is beneficial to the strain compatibility and stress partitioning with the microstructure of the base metal, and the hardness is low. After heat treatment, which helps to transfer the stress concentration effect to the 500HS base metal with strong energy absorption capacity, so that the clad steel has excellent comprehensive mechanical properties. This process is developed based on existing industrialized equipment and has broad application prospects.

Mechanical properties of high-nitrogen steel produced via selective laser melting using mechanically alloyed and spheroidized powders

In recent years, the development of additive technologies has been one of the priority tasks in the sector. Primarily, additive technologies enable the effective implementation of various design and engineering ideas in high-tech industries, such as the aircraft industry, engine technology, and rocket engineering. The expanded range of standardized materials for additive technologies will facilitate their integration into large-scale production. Of significant interest is the potential use of nitrogen-containing heat-resistant powder alloys to produce complex-shaped aircraft parts using additive technologies. This paper describes the complete process of obtaining samples from powders of alloys with superequilibrium nitrogen content using the selective laser melting (SLM) method. Four different compositions of high-nitrogen steels were obtained through mechanical alloying. Subsequently, the powders of these steels underwent processing using the plasma spheroidization method to be utilized in the SLM process. The SLM method was also employed to produce samples for mechanical tests. Throughout each stage of the process, the powders were thoroughly analyzed. One of the most critical parameters was the nitrogen content in the resulting powders. At each subsequent production stage, its proportion decreased, yet it remained at the superequilibrium content level of 0.13–0.44 wt. %. The mechanical tests confirmed that the alloys fabricated by the SLM method are not inferior in terms of their properties compared to those obtained using classical metallurgical technologies.

Experimental study on RC beams shear‐strengthened with composite polymer mortar and steel strands wire mesh

AbstractThis paper presents an experimental investigation of the use of composite polymer mortar (CPM) and steel strands wire mesh (SSWM) to strengthen reinforced concrete (RC) beams in shear. In order to maximize the shear resistance of the steel strands, a new type of anchor device called wedge‐shaped steel plate hoops (WSSPHs) was developed. And the study aimed to examine the effect of shear‐to‐span ratio and prestressing level on the mechanical properties of the beams. A total of nine beams were constructed and tested under four‐point bending monotonic load, comprising three control beams and six strengthened beams. The study analyzed the damage modes, load‐deflection curves, strength, stiffness, and ductility of the beams. The test results indicated that (1) the mechanical properties of the strengthened beams were improved, with the shear capacity improving by 38.47%–71.37% after strengthening. (2) It was observed that SSWM could be utilized more effectively in high shear‐to‐span ratio beams among the strengthened beams with the same prestressing level. (3) Additionally, the larger prestressing level was found to change the design damage mode of the test beams, with RB‐2.5‐0.5 failing in bending. Finally, a model was proposed to predict the shear capacity of the test beams based on the specification GB 50011‐2010. The model considered the effect of the initial prestressing of the steel strands.

Study on the Causes and Control Measures of Mg–Al Spinel Inclusions in U75V Heavy Rail Steel

U75V heavy rail steel production uses an aluminum-free deoxidation process; however, large particles of MgO–Al2O3 inclusions form in the steel, which has a great impact on product quality. In this paper, we try to explain how spinel inclusions, which affect the metallurgical quality of heavy rail steel, are produced by thermodynamic and experimental methods, and then determined measures for avoiding such inclusions. The formation mechanism of spinel inclusions in U75V heavy rail steel was determined through the analysis of nozzle clogging in the pouring process and typical inclusions in steel. The results show that there are two types of spinel inclusions in heavy rail steel: one is pure Mg–Al spinel inclusions and the other is Mg–Al spinel inclusions coated with calcium aluminate. The small, pure Mg–Al spinel inclusions were precipitated during the solidification of the molten steel, and the precipitation temperature was related to the composition of the molten steel. The large spinel inclusions were derived from clogging of the submersed nozzle. Mg–Al spinel inclusions coated with calcium aluminate were transformed from CaO–SiO2–Al2O3–MgO complex inclusions in the steel during cooling, and the formation temperature was related to the content of Al2O3 and MgO in the inclusions. The content of Al2O3 and MgO in the inclusions was the key to the formation of the Mg–Al spinel inclusions. Therefore, in order to control the production of spinel inclusions in steel, it is necessary to strictly control the content of impurity elements such as magnesium and aluminum in the alloy auxiliary materials, to reduce the secondary oxidation of liquid steel and to reduce the erosion of refractory materials.

Numerical Study of Composite Concrete Castellated Double Channel Beams with Strengthening Techniques

Current numerical research was devoted to investigating the effect of castellated steel beams without and with strengthening. The composite concrete asymmetrical double hot rolled steel channels bolted back to back to obtain a built-up I-shape form are used in this study. The top half part of the steel is smaller than the bottom half part, and the two parts were connected by bolting and welding. The ABAQUS/2019 program employed the same length and conditions of loading for four models: The first model is the reference without castellated and strengthening; the second model was castellated without strengthened; the third model was castellated and strengthened with reactive powder concrete encased in the steel web, and the fourth model was castellated and strengthened with reactive powder concrete and lacing steel rebar's welded diagonally on two sides of the steel web. According to the Numerical results, there was an increase in ultimate load capacity compared to the reference model of about 22.74%, 51.65%, and 77.98% in the second, third, and fourth models, respectively; also, there is a reduction in deflection of 55.52%, 58.74, and 60.55% in the second, third, and fourth models, respectively, compared to the level deflection at ultimate load for the reference model, with an increase in stiffness and ductility. In comparison to the I section, the fabrication of a castellated steel beam from the double channel is more cost-effective in terms of cutting steel loss at the ends of the castellated beam, this is due to the feature of rotation and reflection of the steel channel section during cutting and forming to castellated shape.

Effect of Surface Roughness and Chemical Composition of Metastable Austenitic Stainless Steels on Electrochemical Polishing-Induced Martensitic Transformation

Herein, we analyzed the martensitic transformation kinetics during electrochemical polishing (EP) for stainless steel specimens with varying surface roughness and austenite stability. Martensite fraction measurement demonstrated that specimens with higher surface roughness and lower austenite stability exhibited relatively higher levels of martensitic transformation. To understand these phase transformation characteristics, the amount of charge build-up on the specimen surface during EP was calculated using COMSOL Multiphysics simulations for specimens with different surface roughness. The effect of charge build-up-induced stress was analyzed using previously published first-principles calculations. We found that specimens with higher surface roughness accumulated more charge build-up, resulting in greater stress and a martensitic transformation driving force. Furthermore, the critical energy required for the martensitic transformation was calculated using Thermo-Calc for specimens with different austenite stabilities. We demonstrated that the martensitic transformation kinetics during EP could be explained in terms of austenite stability, similar to the stress-induced martensitic transformation.Graphical

Simulation of Ladle Refining Reactions in Si–Mn‐Killed Steel

Steel quality, to a large extent, is controlled by ladle refining reactions. The understanding of such reactions can help to prevent the formation of unwanted phases and improve the overall high‐temperature process control. A new approach, namely, the multioxide inclusion kinetic model has been recently developed to simulate steel–inclusion reactions in liquid steel. The coupling of this kinetic model with a multicomponent, multiphase steel–slag reaction interface model leads to an overall model framework to predict the evolution of steel, slag, and inclusion composition. The current work shows the application of the model to simultaneous deoxidation and desulphurization during ladle refining of Si–Mn‐killed steel. The model shows good performance with industrial data. It is demonstrated that for ladle refining practices, silica‐rich slags should be strictly used with basicity (CaO/SiO2) between 1 and 1.2 and with Al2O3 content less than 5 wt%. Additional simulations are also carried out to reveal the capability of the model to aid in online process control. Finally, certain limitations of the current model are discussed.

Evaluation of anti-corrosion potential of Datura Metel plant extract on mild steel upon sulphuric acid exposure

ABSTRACT The present study was aimed to investigate the Datura metel plant extract’s anti-corrosion ability on mild steel against sulphuric acid. A comprehensive set of experiments using conventional methodology were employed for asserting the efficacy and velocity of corrosion inhibitory performance. It was found that the effectiveness of inhibition was 85.73%. The results showed that potentiodynamic polarisation causes inhibition regulated anodic responses. Both factors, linear polarisation resistance and corrosion current were improved by the inhibitors. The protective layer on a vulnerable surface has been induced by the phenomenon known as the ‘blanket effect’. The observed outcome may be attributed to the constraints imposed by the experimental methodology. The protective layer composition of mild steel was analysed using FTIR spectroscopy. Additionally, SEM analysis revealed the protective layer was neither smooth nor rough. In summary, the extract derived from Datura metel could be a potential green inhibitor to act as an anti-corrosion agent.

Effects of the volume fraction on the microstructural and mechanical properties of TiCp/high-manganese steel composites

To improve the adaptability to complex shaped products, TiC particulates (TiCp) reinforced high-manganese steel matrix (TiCp/HMS) composites were prepared by the squeeze casting infiltration method, and the microstructure and the mechanical properties of the composites were investigated, with different TiCp volume fractions (35%, 50%, 65%). Water glass was applied as binder in the TiCp preforms, in which iron powder was added to adjust the TiCp fractions, and Si powder to activate the bonding of TiCp/steel interface. The results showed that with the increase of the volume fraction, the hardness of the composites increases gradually, with the highest reaching 60.7 HRC at 65 % TiCp, which is 2.7 times that of the matrix. However, the bending strength decreases gradually, with the maximum 439.0 MPa obtained at 35% TiCp. The impact toughness of the composites changes slightly. Due to the use of water glass, brittle glass phase is formed at the TiCp/steel interface, which reduces the mechanical properties of the composites. The addition of Si powder can improve the comprehensive mechanical properties of the composites.

Evaluation of Mechanical Properties and Machinability Study of Aluminium Metal Matrix Composite and Mild Steel

Abstract: Machining is one of the Core operations in most of the Manufacturing firms as it consumes most of thetime material and effort. The development of any manufacturing industry lies in a proper controlled machining environment. Hence to avoid wastage of Material and ensure in time production it is necessary to optimize the machining Process. This can be achieved through optimizing certain parameters like Speed, feed, and depth of cut etc. The Controlled machining process can be achieved through Pre simulated study or predicting the values in a computational procedure. Predictive study of parameters ensures better machinability in a specified time without much wastage of resources. In the Present Work turning operation is carried out on A356 Aluminium alloy and Mild steel in a medium duty Lathe with a HSS tool with the cutting parameters of cutting speed of 140, 310, 500m/min, feed rate of 0.35, 0.66, 1mm/rev, and cutting depth 0.5mm. Evaluation of mechanical properties is being carried out to study the influence of reinforcement particles in matrix material and Regression analysis is being carried out to predict the output value with respect to the input value

Polysilazane-derived SiON coating on stainless steel weld for corrosion resistance

In this study, SiON coatings were created using perhydropolysilazane (PHPS) on the weld region and the base stainless steel region with different microstructure and composition. The influences of the weld and base steel compositions and microstructures on coating formation, composition, microstructure, mechanical properties, and corrosion resistance are discussed. The SiON coatings show a higher N content and a lower O content on the base metal than on the weld metal. Salt spray tests show that the differences in mechanical properties and compositions on the weld and base steel substrates do not significantly affect the function of the corrosion-protective coatings. However, when the coating thickness is high, the corrosion resistance decreases. This study provides important guidance regarding the desirable SiON coating and thickness for best corrosion prevention.