Steel Elements Research Articles

Thermodynamic Study of the High-Temperature Partitioning Process of Carbon Elements in Intercritical Quenching and Partitioning High-Strength Steels

Thermodynamic Study of the High-Temperature Partitioning Process of Carbon Elements in Intercritical Quenching and Partitioning High-Strength Steels

Al Alloy Melting Behavior and Interfacial Reactions with Steel Under Natural Convection

The Al alloy melting behavior and interfacial reactions during the steelmaking process of high-Al automotive steel were investigated in this study. The total dissolution time of Al bars (20 × 20 × 80 mm) in molten steel was quite short, decreasing from 21.4 s to 10.0 s with an increase in bath temperature from 1580 to 1620 °C. The Al alloy melting process at the molten steel temperature of 1600 °C included the formation of a solidified steel layer, the latter’s rapid melting, and Al alloy normal melting, while at 1600 °C, the process included a second increase in the thickness of the solidified layer. Because steel elements such as [Fe], [C], [O], and [N] could diffuse during the whole Al alloy melting process, an Fe (Al)-FeAl-FeAl2-Fe2Al5-Al diffusion layer along the direction of the Al-rich matrix could be found at the Fe–Al interface. Moreover, FexO, Al2O3, and unstable AlN inclusions could be observed in the FeAl layer. This study also investigated how to reduce the number of these easily formed inclusions. Decreasing the pre-heating process time and dissolved oxygen content could be useful in decreasing FexO and Al2O3 inclusion formation. Some small-sized AlN inclusions formed in the center of the Al bars where they could not come into contact with the molten steel directly during the melting process; even for the immersion time of only 1 second, these inclusions were not stable in molten steel at the refining temperature and disappeared during the melting process.

Analysis of the seismic fragility of slender piers on prestressed concrete viaducts

This research aims to study the seismic fragility evaluations of slender piers with single-column sections on prestressed concrete viaducts to investigate how pier height, prestressing force, and ground motion intensity are related, not only in terms of mean values but also in their probability density functions (PDFs), which inherently imply parameters such as dispersion indices. A detailed nonlinear numerical analysis was performed using a finite element model that incorporated the realistic response of concrete, steel, and infrm-FB element types for the columns. To this end, fragility curves were developed based on a probabilistic procedure that accounted for the variability of material properties, pier geometry, and seismic loading. The results show that the fragility function of high piers is hardly dependent on the shear span efficiency. Conversely, slender piers exhibit an increased level of fragility when the effect is confined to a constant prestressing force. This study highlights the need to account for the nonlinearity of pier members and variation in seismic loading when estimating the seismic fragility of slender piers. The conclusions of this study are beneficial for designing and retrofitting strategies for prestressed concrete viaducts in seismic regions.

Deformation Heat in Tension of Steel Elements

The purpose of the work is an approximate computational and experimental assessment of the specific energy intensity and heat generation at various stages of the material’s operation when the sample is stretched. The paper discusses an approximate method for estimating the specific energy intensity and heat generation at four stages of tensile deformation of a steel sample. Finite element modeling of the work of the manufactured sample under elastic-plastic tension was performed in the ANSYS multifunctional software package. The load in the digital model of the sample was applied according to the full-scale test program. The experiment used flat samples in accordance with GOST 1497, a WAW-1000 testing machine with a 100T microcomputer, and a testo 875i thermal imager with a temperature sensitivity of 0.05 °C at 30 °C. We compared the obtained values on graphs of full-scale tests and a digital model of the samples, identifying critical points and deviation values. Phased loading revealed that the development of destruction occurs on the descending branches and is accompanied by the gradual development of local instability of plastic deformation in the form of a “neck”. It is shown that the heating temperature of the tensile metal can be calculated using the formulas proposed in the paper or by calculation using the ANSYS software package. The test results showed that the surface temperatures of the samples at each stage differ significantly. Four main areas were identified on the graph of changes in the sample surface temperature at a point. An analysis of the existing database of measuring instruments and the ability to obtain and process data was carried out. Experimental values of surface temperatures during continuous quasi-static deformation exceed their calculated values (up to 5 times). The kinetics of changes in the temperature field of the sample surface was carried out using thermographic instruments.

A three-dimensional rubber-steel phononic crystal for broad and low-frequency vibration attenuation

Elastic metamaterials and phononic crystals have the potential for vibration isolation applications due to wave band gaps where elastic waves cannot propagate. However, their real-life application may be compromised by the narrow band gaps of the former and the high frequencies of the latter. In the current study, we present a three-dimensional frame structure made of steel and rubber elements that presents a wide complete band bag at low frequency. The structure provides extreme vibration isolation because it combines band gaps with high impedance mismatch between steel and rubber damping. The manufacturing process of the proposed frame structure is widely used in mounting pads, and its cost is relatively low. It provides reasonable structural strength, which makes its application in real life possible. The dynamic behavior predicted with spectral and finite element models is validated with experimental results.

Effect of Zr addition on MnS inclusion characteristics and mechanical properties in medium carbon ferrite-pearlite steel

In this paper, the influence of decreasing Zr content (0.0110wt%, 0.0044wt%) on the microstructure, MnS inclusion characteristics, and mechanical properties of medium carbon ferrite-pearlite steel was studied. The results show that the volume fraction of intragranular ferrite (IGF) in steel increases with a reduction in Zr content. The ductility of the steel is reduced by 1.83%, the impact toughness is increased by 2.5 times, and the yield strength is almost unchanged. Compound MnS inclusions are the main inclusions that induce IGF formation. The proportion of heterogeneous nucleation of MnS inclusions using oxides as nucleation sites is increased, which is the main reason for the increase in the volume fraction of IGF. Furthermore, MnS inclusions change from type Ⅲ to type Ⅰ and Ⅱ, and their distribution is gradually uniform. Thermodynamic analysis reveals that the underlying cause for the morphological transformation of MnS inclusions is the rapid surge in the supersaturation of S element in molten steel. The presence of liquid-phase low-melting inclusions (MnS-Al2O3) promotes the formation of type Ⅰ MnS inclusions. The volume fraction and the dimension perpendicular to the fracture surface of the MnS inclusions are increased by at least 33% and 111%, while their aspect ratio is reduced by a maximum of up to 19%. The change in the volume fraction of MnS inclusions is the primary factor contributing to the decrease of tensile plasticity. The toughness of steel is mainly affected by the aspect ratio and the dimension perpendicular to the fracture surface of MnS inclusions.

Validation of AISI Design of Cold-Formed Steel Beams Using Non-Linear Finite Element Analysis

In the local building industry of Pakistan, pre-engineered steel building manufacturers mainly employ their own self-developed software and Excel sheets. These systems are based on empirical formulas mentioned in the AISI manual. Under this scenario, a need was found to validate AISI flow charts using commercial software like CUFSM 5.04 and ABAQUS R2019x. This study presents a validation of the CUFSM software and the American Iron and Steel Institute (AISI) Direct Strength Method (DSM) results of channel section flexural members using the non-linear finite element method employing ABAQUS. In this study, eight standard cold-formed channel-section (C-section) steel members were modeled and analyzed using ABAQUS to simulate realistic behavior under four-point loading conditions. The non-linear finite element models incorporated material and geometric non-linearities to capture the actual response of the steel elements. The results obtained from ABAQUS were compared with those predicted by the CUFSM and DSM, focusing on critical parameters such as nominal strength, buckling modes, and deformation patterns. During this study, it was observed that out of the selected sections, the AISI charts predict conservative and even unsafe flexural capacities in some of the cases concerning other methods, with a maximum difference of 14.03%. The differences obtained using DSM and ABAQUS when compared with the results of the AISI charts varies on both the plus and minus sides. This study will not only affect the industry in terms of innovative designs for efficient structures but also the community in regards to low-budget construction.

Sequential dual-scale approach for microstructure-informed ductile fracture prediction

This study presents a novel dual-scale finite element method to establish a microstructure-informed ductile fracture criterion for ferrite–martensite dual-phase (DP) steel. At the macroscale, an anisotropic plasticity model with rate-dependent hardening was employed to simulate the material's deformation history. Simultaneously, at the microscale, a dislocation density-based crystal plasticity model was utilized to simulate deformation within a representative volume element (RVE) of the dual-phase steel, constructed using tomography aided by a plasma-focused ion beam/electron backscatter diffraction system.The material properties of the ferrite and martensite phases were determined through X-ray diffraction (XRD) analysis and load-displacement measurements obtained via nanoindentation for each phase. The RVE simulation results were validated against experimentally measured mechanical properties and microstructural changes. The local deformation history at the fracture initiation site, extracted from the macroscale model, was used as boundary conditions for the microscale RVE simulation; sequential dual-scale approach. The models were applied to specimens with varying notch radii, generating different local stress triaxialities and accumulated shear strains at fracture onset. This process allowed the establishment of a ductile fracture criterion, which was further tested in a hole expansion experiment, demonstrating close alignment with experimental data.This sequential dual-scale analysis effectively predicts the deformation behavior of multiphase metallic materials by incorporating realistic microstructures while minimizing computational costs. Consequently, the proposed ductile fracture prediction technique offers a robust method with broad applicability across various metallic materials.

Development of Approaches for Strengthening and Retrofitting of Concrete Beams Using Structural Steel

In structural analysis, the term 'frame' typically refers to a robust structure comprising various elements such as slabs, beams, columns, and footings. These components are cast together to create a monolithic construction, effectively functioning as a single integral unit. The frame is subject to various forces, which are transferred through its different components. Additionally, changes in facility usage or the introduction of additional live loads can exert further stresses on the structure. Consequently, it is imperative that the elements of the frame possess sufficient strength to withstand these loads. In this study, we focus on the development of approaches for strengthening and retrofitting concrete beams using structural steel elements. Specifically, our investigation involves the analysis of beams under different load combinations to enhance their integrity performance. To achieve this, angles and steel plates are utilized for reinforcement. We conduct numerical analysis through finite element modeling using ANSYS Workbench. Multiple beam models are created within the ANSYS platform, allowing us to study and compare various outcomes, including total deformation. This comprehensive approach aims to contribute to the advancement of methods for enhancing the structural resilience of concrete beams in real-world applications.

Experimental study on the fatigue behavior of CFRP-strengthened cracked steel plates under eccentric axial tension

In this paper, an experimental investigation has been conducted to study the fatigue behavior of single edge-notch steel plates strengthened with CFRP (laminates/sheets). The plates have been subjected to eccentric fatigue under axial loading conditions. The experimental study includes fourteen specimens and has been tested under axial loading until failure. The constant parameters in the study are steel material grade, steel plate dimensions, and fatigue loading conditions. Meanwhile, the studied parameters are steel plate initial edge crack size, CFRP configurations (length, one or two-sided, and laminates or sheets), and adhesive material strength. The experimental results revealed that the fatigue life for specimens strengthened with CFRP sheets or CFRP laminates can be improved by a factor of 1.15 to 3.87 and 1.47 to 6.32, respectively, compared with the un-strengthened specimens. The results show that using CFRP can be considered an efficient way to repair the initial cracks in steel elements under eccentric axial fatigue loading.

Quantitative modeling and uncertainty estimation for small-sample LIBS using Gaussian negative log-likelihood and monte carlo dropout methods

Laser-induced breakdown spectroscopy (LIBS) has emerged as a powerful analytical technique widely applied in materials science, environmental monitoring, and other fields. In traditional quantitative analysis, models are established for the sample-to-element content based on acquired characteristic spectra combined with specific modeling methods. Small-sample LIBS poses significant challenges to researchers due to its high dimensionality and limited sample size, making it difficult for traditional modeling methods to establish effectively generalized and robust models. Addressing the issues of overfitting during training and the uncertainty of LIBS data, we developed an artificial neural network (ANN) model. Unlike traditional ANN which uses mean squared error functions as training losses, Gaussian negative log-likelihood (GLL) functions were used to train the model. This approach allows for simultaneous consideration of the quantitative prediction of sample element concentrations and the uncertainty of the quantification model prediction. Moreover, the Monte Carlo Dropout (MCDropout) method was applied to reduce prediction bias, resulting in a more robust, generalizable, and uncertainty-aware quantitative model. Compared to traditional quantitative methods, the method proposed in this paper achieved quantitative accuracies of 0.9877, 0.9939, 0.9876, and 0.9899 for four elements (Mn, Mo, Cr, Cu) in stainless steel, respectively. The uncertainty output effectively informs data comprehension and spectral analysis. To the best of our knowledge, this study is the first to propose utilizing model-quantified spectral uncertainty in LIBS quantitative tasks. This innovative study not only provides solutions for small-sample LIBS learning but also enhances the stability and accuracy of quantitative modeling by addressing the impact of uncertainty on training and reducing uncertainty. It is crucial for overcoming the limitations of traditional methods in small-sample LIBS quantification and achieving reliable real-time, high-precision LIBS detection, taking LIBS technology a step further towards practical reliability and precision.

Analysis of the Suitability of Ultrasonic Testing for Verification of Nonuniform Welded Joints of Austenitic-Ferritic Sheets.

The purpose of the presented research was to determine the suitability of using ultrasonic testing (UT) to inspect heterogeneous, from a material point of view, welded joints on the example of the joints of a ferritic steel element with elements made of an austenitic steel. The echo technique with transverse (SEK) and longitudinal wave heads (SEL) addressed this issue. Due to the widespread use of 13CrMo4-5 and X2CrNiMo17-12-2 steel grades in the energy industry, they were selected as the test materials for the study. The objects of the presented research were welded joint specimens with thicknesses of 8, 12, and 16 mm and dimensions of 300 × 300 mm, made using the 135 metal active gas (MAG) process with the use of the Lincoln 309LSi wire-a ferritic-austenitic filler material. The stages of the research task were (1) making distance-amplitude curve (DAC) patterns from the test materials; (2) preparation of specimens of welded joints with artificial discontinuities in the form of through-holes; (3) performing UT tests on welded joints with artificial discontinuities using heads with 60° and 70° angles for the transverse wave and angle heads for longitudinal waves with similar beam insertion angles; (4) selection, by radiographic testing (RT), of welded joint specimens with natural discontinuities in the form of a lack of sidewall fusion; (5) performing UT tests on welded joints with natural discontinuities, using heads as welded joints with artificial discontinuities. It was found that (1) the highest sensitivity of discontinuity detection was obtained by performing tests on the ferritic steel side, which is due to the lower attenuation of the ultrasonic wave propagating in ferritic steel compared to austenitic steel; (2) the best detection of discontinuities could be obtained using a longitudinal ultrasonic wave; (3) there is a relationship between the thickness of the welded elements, the angle of the ultrasonic beam introduction, and the effectiveness of discontinuity detection.

Efficiency of shear connectors under combined shear and torsion

The connection of steel elements to concrete is typically achieved through embedded shear connectors (anchors) placed at the interface of concrete and steel. These shear connectors come in various types, such as headed studs, welded or coupled rebars, shear lugs, or a combination of these, designed to handle large shear forces. Shear connectors primarily resist shear forces and bending loads. However, when the load is not applied along the centroid of the shear connector, it generates a torsional moment in addition to shear- and flexure-induced moments, impacting the performance of shear connectors. To address this phenomenon, this experimental study assesses the behavior of shear connectors, including studs, shear lugs, and rebars, both individually and in combination, under three different load eccentricities relative to anchors spacing connectors (0, 0.25, 0.50, and 0.75). The results are then compared with the control specimen (without eccentricity). The findings revealed that vertical shear lugs can significantly enhance the shear capacity, and ACI 318-19 is conservative in this regard by 41.5% for a relative load eccentricity of 0.75. Nonetheless, it gives good estimations of the shear capacity of connectors without vertical shear lugs. HIGHLIGHTS Contributing to the very limited data on the performance of anchors under the combined action of shear and torsion. ACI 318-19 [1] provides reliable estimations of shear strength for studs/rebars, both with and without eccentricity. However, it tends to be conservative by 41.5% (for a relative eccentricity of 0.75) when horizontal and vertical shear lugs are utilized.

Transforming Mining Tailings into Green Steel and Rare Earth Elements

As critical components for energy and defense technologies, the U.S. rare earth element (REE) ore reserves are estimated at ~13 million tons, but domestic production is currently limited to one operational mine residing on high-grade ore deposits in Mountain Pass, CA. While low-grade REE deposits are abundant, high-grade American REE deposits are sparse. Meanwhile, hazardous REE-containing tailings pile up at the economic and environmental cost, and it is estimated that REE value locked within e.g., red mud, is $796 per ton. However, such low-grade deposits or mining tailings are challenging to access because REEs are usually locked within a mineral matrix, typically iron oxide, that renders the ore intractable to mechanical or chemical separation. Here, we propose a process for recovering REEs from low-grade deposits and tailings by electro-metallurgically removing iron oxide, hydro-metallurgically removing aluminum salt, and subsequent separating insoluble rare earth oxides. Our strategy produces not only refinable REEs concentrates but also emissions-free iron metal and supplementary cementitious materials as co-products for decarbonizing steel and cement industries, respectively. By addressing the economic and environmental challenges associated with low-grade REE deposits and mining tailings, our electrochemical approach offers a sustainable pathway for unlocking the potential of domestic rare earth resources.

Experimental Analysis of Bonding in Steel Glued into Pine Timber.

Combining steel with wood has been practised for many years. The issue is related to two main areas, i.e., bonding steel elements with wood so that they serve as connectors facilitating the assembly of wood elements and bonding steel elements to wood beams to improve their load-bearing capacity. In the first case, the adhesives used may be relatively expensive and more difficult to apply, whereas in the second one, especially when steel elements are glued inside the glulam (GL) beams, it is better if the adhesives used are more accessible to apply and cheaper. As it seems rational to reinforce wood with high-modulus ties, research has been carried out to compare the connection quality of commercially available adhesives that can be used for this purpose. Moreover, thermosetting adhesives have been applied as an alternative and cheaper solution. Thermostat adhesives also have a high pH of the bond, which prevents the steel from rusting. The research shows that the load-bearing capacity of the bond depends on whether the bars are ribbed or sheet metal. Moreover, among thermosetting adhesives, the most favourable load-bearing values were obtained using a mixture of PF/pMDI (phenol formaldehyde resin/polymeric diphenylmethane diisocyanate) and powder from recycled tyres. The shear strength of these joints was 1.63 N/mm2 and 3.14 N/mm2 for flat specimens and specimens with ribbed bars, respectively.

Influence of Elements in Steel With Anode Plasma Electrolytic Boriding on Hardness Gradient and Tribological Properties

Abstract The influence of elements in steel on anode plasma electrolytic boriding has been studied. The modified layers and surfaces on steel samples were analyzed by a scanning electron microscope, an X-ray diffractometer, a surface profiler, a microhardness tester, and a ball-disc tribometer. With 1045 steel as the control group, the same treatment parameters (treatment with 5 min, 200 V of voltage, 5% boric acid, and 10% ammonium chloride) were implemented on various steel substrates. It was found that a low content of carbon would hinder the penetration of boron, and other metallic elements can improve the mircrohardness gradient and decrease the wear-rate. Chromium and manganese can increase the maximum microhardness than treated 1045 by about 15%, but have a detrimental effect on surface flatness. Nevertheless, manganese has the ability to rapidly create a layer of oxide that enhances the tribological characteristics, leading to a remarkably low average friction coefficient of 0.26 for 1046 steel. The presence of molybdenum in the element composition of 4140 steel results in a notable enhancement of surface properties, namely in terms of wear resistance, with a minimum wear-rate 2.1 × 10−6 g/Nm for 4140 steel. Nickel does not appear to have a notable impact on the surface characteristics of the modified samples.

New insights for composition design: A novel synergistic corrosion-resistant effect of Fe–Mn–Al–Cr–Si–Mo–C lightweight steel in 3.5 wt% NaCl solution

Nowadays, a good corrosion resistance of lightweight steel is demanded for its application. However, due to the high contents of Mn and C, which are always corrosion-susceptible elements in steels, the conventional lightweight steel is not desirable for this mission. Although Cr is widely believed to be a common alloying element to improve the corrosion resistance of most steels, it is considered to be ineligible using in the lightweight steel due to the relatively high content of C. This is because the trade-off between corrosion resistance and mechanical properties by alloying Cr. In recent years, the rapid developments of additive and coating manufacturing have provided new possibilities for both the Cr alloying and microstructural modulation to improve corrosion resistance of lightweight steel. In this case, to design a certain chemical composition using in additive and coating manufacturing, it is interesting to clarify the effects of Cr alloying on the corrosion resistance of lightweight steel. To reveal it, in the present work, the Fe–Mn–Al–Cr–Si–Mo–C lightweight steel alloyed with Cr contents of 4 wt%, 8 wt% and 12 wt% are prepared. The corrosion resistances and mechanisms of Cr-alloyed lightweight steels in 3.5 wt% NaCl solution are investigated by electrochemical and immersion tests. The present work may provide new insights for the composition design of lightweight steel, especially for the directions of additive and coating manufacturing.

Steel truss reinforced concrete composite walls: Numerical investigation and design consideration

Conventional design practices for reinforced concrete (RC) structural walls in the lower stories of super high-rise buildings involve employing large thickness and dense reinforcement to ensure satisfactory seismic performance. This is necessary to withstand the considerable gravity and seismic forces caused by the superstructure. However, this approach brings a design challenge in engineering practice because excessively thick RC walls not only occupy useable space but also magnify earthquake forces due to the increased self-weight. For this reason, steel truss RC (STRC) composite walls have been developed to address the above-mentioned shortcomings of conventional designs. This paper elucidates the working mechanism of STRC walls under cyclic loading, indicating that these two diagonal embedded steel elements mainly exhibit truss behavior. The working mechanism is further verified through computational models developed in OpenSees with high accuracy and efficiency. Moreover, the design provisions in the current specification are evaluated in terms of the flexural strength and shear strength of STRC walls. Results show that the flexural strength of the design equations for STRC walls in the current specification is underestimated because the contribution of steel trusses is not considered. The findings of this study offer valuable insights into the engineering application of STRC walls.

Effect of Cr transition layer on the Al2O3/fe(ceramic/metal) interface microstructure based on binder jetting

Ceramic coating is a well-established method for enhancing the wear and corrosion resistance of metal components. Al2O3 coating has been extensively utilized in industrial applications. However, existing ceramic coating processes often yield coatings that are relatively thin with limited wear and corrosion resistance. Furthermore, achieving efficient and high-quality coatings on complex metal surfaces poses significant challenges. The poor wettability between ceramics and metals further complicates the bonding at their interface. Chromium (Cr), a commonly used alloying element in steel, exhibits excellent interfacial wettability with iron (Fe), making it an ideal transition material for the Al2O3/Fe interface. In this study, complex Al2O3-based ceramic shells were fabricated via Binder Jetting. The Cr coating was coated on the surface of the shell, and then the Fe-based metal liquid was poured into the Al2O3-based ceramic shell to achieve metallurgical bonding at the Al2O3/Fe interface by temperature control treatment. The performance of the Al2O3 ceramic matrix and the microstructure of the Al2O3/Fe interface with the Cr intermediate transition layer were investigated. The results indicate that when the solid loading of the Cr coating is 60 wt%, a uniform, and stable Cr coating can be formed on the surface of the sintered Al2O3-based ceramic. The bending strength of the Al2O3-based ceramic matrix increased from 113.79 MPa to 134.69 MPa. The Cr coating significantly improved the wettability between the Al2O3-based ceramic and the Fe-based metal, reducing the wetting angle from 98.9° to 78.4°. The interface between the Al2O3-based ceramic and Fe-based metal formed FeCr2O4 after infusion, resulting in a well-bonded interface without significant cracks.

Influence of refractories on cleanliness in high-purity C96V saw wire steel

ABSTRACT Four kinds of refractories, MgO, Y2O3, ZrO2 and MgO–CaO, were selected to smelt C96V saw wire steel to choose a suitable crucible material. In detail, the effect of refractory on number, size, composition and morphology of inclusions in steel samples has been studied. The results indicated that all of the steel samples can obtain the target composition of all the elements by using these refractories as a crucible. Both Y2O3 and ZrO2 refractory can also produce excellent steel samples; this is mainly because the order of stability of the four oxides from high to low at steelmaking temperature is CaO > Y2O3 > ZrO2 > MgO. In addition, both Y2O3 and ZrO2 have extremely high stability in the steelmaking process and are difficult to be reduced by any elements in molten steel. Nevertheless, MgO–CaO refractory still has obvious advantages in terms of smelting effect, mainly in the following aspects: the steel samples can obtain the lowest content of T. O (total oxygen content in steel), S and [Al]s, and the lowest value of Al2O3 content in composite inclusions. However, the most troublesome for MgO–CaO refractory is its tendency to absorb moisture in air and become invalid.