Ferritic Stainless Steel Research Articles

Solid‐State Bonding of Iron or Steel with Stainless Steels by Spark Plasma Sintering Bonding

In this study, pure iron, S45C carbon steel (Fe–0.45mass%C), carburized iron, and nitrided iron are bonded with two types of stainless steels, i.e., SUS304 austenitic stainless steel (Fe–18mass%Cr–8mass%Ni) with face center cubic structure or SUS430 ferritic stainless steel (Fe–18mass%Cr) with body center cubic structure by a spark plasma sintering (SPS) machine. Bonding experiments are carried out by SPS bonding. It is found that the bonding temperature of the S45C/SUS samples is lower than that of Fe/SUS samples, and carbon atoms in the S45C play important role on the bonding performance. The bonding temperature for SUS304/SUS430 sample is more than 30 °C higher than those for the Fe/SUS and S45C/SUS samples. The presence of thin chromium oxides on both stainless steels reduces the bonding performance of SUS304/SUS430 sample. Better bonding performance is found for the carburized and nitrided iron for bonding with stainless steels. However, continuous single‐phase layer on the surface leads to reduce the bonding performance. It is concluded that not only the concentration of carbon and nitrogen but also the phase configuration in the iron at interface strongly influences the bonding performance between iron alloys and stainless steels by SPS bonding.

Behaviour of eccentrically loaded concrete-filled rectangular ferritic stainless steel tubular slender columns: Numerical modelling and design

Ferritic stainless steel achieves a lower and steady price level due to low nickel content compared to duplex and austenitic stainless steels. Accordingly, the combination of ferritic stainless steel tube and concrete will have better application prospects in corrosive marine environments. However, the structural application of concrete-filled ferritic stainless steel tube (CFFSST) members is still limited due to the absence of performance data and design guidelines. Accordingly, this paper aims to comprehensively investigate the behaviour of eccentrically loaded concrete-filled rectangular ferritic stainless steel tubular (CFRFSST) slender columns using the nonlinear finite element (FE) method, and develop a suitable design method. Two different material models were introduced to simulate corner and flat regions of rectangular ferritic stainless steel tube. Good consistency was found between the simulation and experimental results against the failure mode, ultimate load and moment, and axial load versus mid-height deflection curves for eccentrically loaded CFRFSST slender columns. This is followed by the mechanism analysis and parameter study of the studied CFRFSST columns, which revealed that the longitudinal stress and Mises stress show significant changes perpendicular to the loading line direction, while there is almost no change along the loading line direction. In addition, the initial stiffness and ultimate load increased by increasing the cross-sectional aspect ratio, yield stress and concrete strength, while they decreased as the eccentricity ratio, slenderness ratio and width-to-thickness ratio increased. The outputs of the FE analysis and existing experimental results were used to examine the applicability of current design codes for designing the studied CFRFSST columns. The results demonstrated an unexpected deviation generated in the design predictions. At the end, a new design method for eccentrically loaded CFRFSST slender columns was proposed which achieved better predictive consistency.

Unveiling niobium pentoxide and cerium oxide-dispersed ferritic stainless steel for solid oxide fuel cells interconnects

Herein, the effect of niobium pentoxide (Nb2O5) and nano-sized cerium oxide (CeO2) on oxidation behavior and area specific resistance (ASR) of the ferritic stainless steel has been investigated for the development of robust metallic interconnects. An oxide-dispersed ferritic stainless steel alloy is fabricated using the powder metallurgy (PM) process. The morphologies of the alloy before and after oxidation are observed through Scanning Electron Microscope (SEM), Scanning Transmission Electron Microscopy (STEM) and Secondary Ion Mass Spectrometry (SIMS) analyses. Addition of Nb2O5 in the alloy formed a C14 Laves phase of (Fe, Cr)2(Nb, Si). The Laves phase and CeO2 controlled the oxidation behavior of the ferritic stainless steels, consequently reducing the oxide scale thickness and improving the ASR. An alloy with 1 wt% Nb2O5 and 3 wt% CeO2 showed an ASR value of 27.1 mΩ cm2 at 800 °C for 1000 h, which is similar to the ASR value of the commercial Fe–Cr alloy. The results of this study indicate that Nb2O5 and CeO2-dispersed ferritic stainless steel using the PM process can be more advantageous than the conventional process for manufacturing metallic interconnects with complex shapes and reducing production costs.

Dissimilar Welding of Thick Ferritic/Austenitic Steels Plates Using Two Simultaneous Laser Beams in a Single Pass

Dissimilar welds between ferritic and austenitic stainless steels are widely used in industrial applications. Taking into account the issues inherent to arc welding, such as the high heat input and the need to carry out multiple passes in the case of thick plates, a procedure with two simultaneous laser beams (working in a single pass) and consumable inserts as filler metal has been considered. Particular attention was paid to the choice of the filler metal (composition and amount), as well as welding parameters, which are crucial to obtain the right dilution necessary for a correct chemical composition in the weld zone. The first experimental investigations confirmed the achievement of a good weldability of the dissimilar pair ASTM A387 ferritic/AISI 304L austenitic steel, having ascertained that the microstructure of the weld zone is austenitic with a little amount of residual primary ferrite, which is the best condition to minimize the risk of hot cracking.

Cold Metal Transfer Welding of Ferritic and Austenitic Stainless Steel: Microstructural, Mechanical, and Electrochemical Studies

In the present study, cold metal transfer arc welding was employed to weld the 304L austenitic stainless steel (ASS) and Ti-stabilized 439 ferritic stainless steel (FSS) using a 309L filler electrode. Dissimilar joints were prepared using low heat input (HI; W1 ~ 247 J/mm) and high HI (W2 ~ 282 J/mm). The solidification mode for both weldments were the ferritic-austenitic mode and the weld zone (WZ) regions of both the weldments consists of columnar austenites, lathy and skeletal ferrite phases. The interfaces between WZ and ASS base metal showed the unmixed zone, whereas a conventional heat-affected zone (HAZ) was formed between the WZ and FSS base metals. The formation of ferrite stringers were observed in the unmixed zone, whereas peppery features of chromium-rich carbides were observed in HAZ. Moreover, electron backscattered diffraction technique was used to distinguish the microstructural differences between W1 and W2 weldments. Increase in the HIs resulted in decreased ferrite fraction in WZ as well as decrease in the mechanical strength of the joints. The W1 weldment depicted higher values of average micro-hardness (WZ ≈ 334.32 HV) than W2 (WZ ≈ 310.92 HV)) weldment. The electrochemical behaviour of the weldments was analysed for both the base metals and WZ of weldments. The higher degree of sensitization (DOS ~ 9.24%) of W1-WZ showed lower intergranular corrosion resistance than W2-WZ (DOS ~ 7.77%), however, the opposite trend was observed for impedance and pitting resistance.

Computational chemistry analysis of passive layer formation and breakdown mechanisms in ferritic stainless steels

Despite extensive research and proposed theories on formation and breakdown of passive layers, several questions remain unanswered. These include the reasons behind the bi-layer nature of the passive layer, the decrease in hydrogen and oxygen diffusivity upon entering the passive layer, and the influence of microstructure on passive layer formation and function in stainless steels. In this study, we employed ReaxFF molecular dynamics simulations to investigate passivation and depassivation of ferritic stainless steels in a polycrystalline structure. Through static and dynamic calculations, we elucidated the underlying mechanisms of passive layer formation, which were primarily governed by clustering. Our analysis also highlighted the significant role of hydrogen diffusion and its reaction with metallic compounds in the depassivation process. We have identified several physical phenomena involved in the processes of passivation and depassivation, which can provide explanations for the questions posed above.

An Experimental Study on the Frictional Behavior of Ultrathin Metal Sheets at Elevated Temperatures.

Hot forming is an effective approach for improving the formability of ultrathin metal sheets, such as those made of stainless steel and pure titanium. However, the increased friction coefficient between the tool and the high-temperature metal sheet negatively affects material flow during hot forming, potentially resulting in severe local thinning or even cracking. This study explores the frictional behavior of 0.1 mm thick ferritic stainless steel (FSS) and commercially pure titanium (CP-Ti) sheets at elevated temperatures. A friction testing apparatus was developed to measure the friction coefficients of these metal sheets from room temperature (25 °C) up to 600 °C. The friction coefficient of the FSS sheet increased monotonically with temperature, whereas that of the CP-Ti sheet first increased and then decreased. Post-friction testing microscopic examination demonstrated that built-up edges formed on the surfaces of the friction blocks when rubbed against the stainless steel, contributing to the higher friction coefficients. This study provides a foundation for understanding frictional behavior during the hot forming of ultrathin metal sheets.

Dynamic thermal analysis and drill bit temperature in AISI 430 stainless steel

This paper presents a novel numerical model applied specifically for the drilling of AISI 430 Ferritic Stainless Steel, a material of significant importance across various industries. The model thoroughly investigates the geometric parameters of drill bits, including Point Angle (PA), Helix Angle (HA), and rotational speed (RS), meticulously analyzing their impact on two crucial factors: heat generation and temperature distribution. The study covers a broad spectrum of PA (110°, 130°, 150°, and 170°) and HA (30°, 40°, and 50°), along with varying RS (1200 rpm, 1400 rpm, and 1600 rpm). Results indicate that the temperature of the drill bit rises with the increase in parameters such as PA, HA, and RS. Notably, a PA of 170° exhibits the highest temperature among different point angles, with the temperature at the contact surface during drilling escalating from 476 K to 520 K at a point edge angle of 130°. Furthermore, a helix angle of 50° records the highest temperature, while a 30° angle registers the lowest. Heat generation during the drilling process intensifies as PA, HA, and RS parameters advance. The developed numerical model accurately reflects drilling parameters, offering valuable insights for optimizing drilling operations.

Corrosion-resistant and ultrafine-grained boron-containing stainless steel produced by laser powder bed fusion

Ultrafine-grained stainless steel armored with borides was produced by laser powder bed fusion (L-PBF). The in-situ formed composite was characterized by refined grains of high-alloyed ferritic stainless steel matrix with hard and rigid nanoborides along the grain boundaries. Besides being hard and wear resistant, the resulted material was unsensitized and resistant against pitting corrosion, with corrosion resistance comparable to a SAF 2205 duplex stainless steel. Besides unveiling the microstructural and electrochemical nexus, this work opens positive perspectives to surpass the corrosion-wear resistance trade-off upon the in-situ formation of stainless steel matrix reinforced by hard Cr-containing nanoborides using additive manufacturing technologies.

Microstructural and Mechanical Characterization of Spot Welds on AISI 430 ferritic stainless steel sheets

Microstructural and Mechanical Characterization of Spot Welds on AISI 430 ferritic stainless steel sheets

Study on Grain Growth Tendency and Its Correlation with Recrystallization and Precipitation in High‐Nb 444‐Type Ferritic Stainless Steel during Brazing

Study on Grain Growth Tendency and Its Correlation with Recrystallization and Precipitation in High‐Nb 444‐Type Ferritic Stainless Steel during Brazing

Crystal Plasticity-Based Assessment of Constitutive Laws for Microstructure and Rolling Texture Capture in Ferritic Stainless Steel During Cold Rolling

Crystal Plasticity-Based Assessment of Constitutive Laws for Microstructure and Rolling Texture Capture in Ferritic Stainless Steel During Cold Rolling

Parameters Optimization for Electrophoretic Deposition of Mn1.5Co1.5O4 on Ferritic Stainless Steel Based on Multi-Physical Simulation

Solid oxide fuel cells (SOFCs) are an effective and sustainable energy conversion technology. As operating temperatures decrease, metal interconnects and supports are widely employed in SOFCs. It is critical to apply a protective coat on ferritic stainless steel (FSS) to suppress Cr evaporation and element interdiffusion under high temperatures. Electrophoretic deposition (EPD) is a promising approach for depositing metal oxides on FSS substrate. Here, a method based on 3D multi-physical simulation and orthogonal experimental design was proposed to optimize deposition parameters, including applied voltage, deposition time, and electrode distance. The EPD process to deposit Mn1.5Co1.5O4 particles in a suspension of ethanol and isopropanol was simulated and the effects of these three factors on the film thickness and uniformity were analyzed. The results indicate that applied voltage has the greatest impact on deposition thickness, followed by deposition time and electrode distance. Meanwhile, deposition time exhibits a more significant effect on film unevenness than applied voltage. Additionally, the particle-fluid coupling phenomenon was analyzed during the EPD process. In practice, these deposition parameters must be selected appropriately and the deposition time must be controlled to obtain a uniform coating. The proposed method can reduce cost and shorten the design period.

Initial stage oxidation corrosion of commercial ferritic stainless steels with different Cr contents at 650 °C for solid oxide fuel cells

Selecting adequate ferritic stainless steel (FSS) with a high corrosion resistance and a low cost is critical for solid oxide fuel cells (SOFCs) operating at intermediate temperature. In this study, the corrosion behaviors of four commercial FSSs involving TS430, TY441, YG442, and TY445 with a Cr content ranging from 16.18 wt.% to 21.73 wt.% are investigated at 650 °C. The oxidation mass gains, microstructures of surface oxide scale, and electrical conductivities are measured. The effects of grain size as well as doped elements are estimated together with the Cr volatilization. Flaky Cr2O3 particles are formed on TS430 and TY441 dominated by the outward migration of Cr3+. In comparison, a thin and dense layer of chromia is observed on YG442 and TY445. A high Cr content and a uniformly distributed grain size are conducive to the formation of a thin and dense chromia scale on the FSS surface during the initial oxidation process. On the other hand, the addition of Nb, Ti, and Mo weakens the outward diffusion of Cr3+ and reduces the particle size of chromia. After oxidation at 650 °C for 120 h, scattered (Mn, Cr)3O4 spinel particles occur on TS430, YG442, and TY445. TY445 and YG442 exhibit a higher conductivity although all the results of area specific resistance (ASR) are less than 6 mΩ·cm2. Meanwhile, the effect of Cr volatilization is enlarged on the estimation of mass gain at 650 °C compared with even higher temperatures.

Brazing of Ferritic Stainless Steel with Ni-25Cr-6P-1.5Si-0.5B-1.5Mo Amorphous Brazing Foil Having a Liquidus of 1243 K with Continuous Conveyor Belt Furnace in Low-Oxygen Atmosphere

Brazing of Ferritic Stainless Steel with Ni-25Cr-6P-1.5Si-0.5B-1.5Mo Amorphous Brazing Foil Having a Liquidus of 1243 K with Continuous Conveyor Belt Furnace in Low-Oxygen Atmosphere

Corrosion Behavior of Ferritic Stainless Steel Joint Brazed with Ni-Based Brazing Foil in Hydrochloric Acid Solution

Corrosion Behavior of Ferritic Stainless Steel Joint Brazed with Ni-Based Brazing Foil in Hydrochloric Acid Solution

Crystal Plasticity Analysis of the Orientation-Dependent Grain Rotation and Fragmentation Behaviors in Ferritic Stainless Steel During Cold Rolling

Crystal Plasticity Analysis of the Orientation-Dependent Grain Rotation and Fragmentation Behaviors in Ferritic Stainless Steel During Cold Rolling

Substructure heterogeneity during hot deformation of ferritic stainless steels - Experimental characterization and discussion assisted by a mean-field model

The microstructure evolution of ferritic stainless steels during hot deformation is complex and needs to be finely described. Quantifying the evolution of the misorientation of low-angle boundaries depending on the thermomechanical path is a key point in controlling the recrystallization of such steels. This paper proposes an experimental methodology based on large-scale electron back-scattered diffraction (EBSD) mapping characterization using a Symmetry 2 camera to track the low-angle boundary evolution. Different thermomechanical paths, from 900 to 1100 °C with strain from 0.3 to 0.9, were studied using uniaxial compression tests. Flow stress follows a usual hardening stage, followed by a slight softening regime, mostly attributed to continuous dynamic recrystallization. Distributions of low-angle boundary populations (density vs sub-grain size) are quantified by two populations either near grain boundaries or inside grain bulk; the proportion of sub-grains at grain boundaries increases with strain. This bimodal distribution is made with a probabilistic Gaussian mixture model. These results are discussed using a modified mean-field model of Gourdet-Montheillet. This model is insufficient to capture the transient stage of continuous dynamic recrystallization unless its set of parameters is adjusted to accommodate the saturation of the density of low-angle boundaries near grain boundaries. This saturation is a result of the low-angle boundary density gradients in the grains.

On the Possibility of Improving the Oxidation Resistance of High-Chromium Ferritic Stainless Steel Using Reactive Element Oxide Nanoparticles

High-chromium ferritic steels are current the only viable candidates for cheap interconnect materials for application in high-temperature solid oxide fuel and electrolyzer cells (HT-SOFCs/SOECs). The durability and operating characteristics of interconnects manufactured using these materials may be improved significantly by applying a protective-conducting MoCo2O4 coating and depositing an intermediate layer consisting of nanoparticles of Gd2O3—a reactive element oxide—on the surface of the steel substrate. The study demonstrated that the conditions of the thermal treatment of this layered system determine the efficacy of the applied modification with the reactive element. The persistence of this effect was tested over 7000 hours of quasi-isothermal oxidation in air at 800 °C.

Electrodeposited ZIF-67 reinforced polypyrrole coating on ferritic stainless steel substrate with durable anticorrosion performance

The harsh acidic environment containing chloride ions has created serious corrosion hazards for ferritic stainless steels. Zeolitic imidazole frameworks (ZIFs) are a promising material for corrosion protection due to their microstructural and physicochemical properties. In this study, we proposed the electrodeposited ZIF-67 reinforced polypyrrole (PPY) coating (PPY/ZIF-67) for corrosion protection of 430 ferritic stainless steel (430SS). The morphology, microstructure, and anticorrosion behavior of the pristine PPY and hybrid PPY/ZIF-67 coating systems were characterized. The successful electrodeposition of ZIF-67 nanoparticles on the surface of the PPY layer resulted in a uniform distribution and a compact coating structure, which contributed to the overall uniformity of the coating and enhanced both the barrier and activity inhibition functions of the coating. The protective performance of PPY/ZIF-67 coatings was evaluated through electrochemical tests, the results indicated that the anticorrosion efficiency of PPY/ZIF-67 coating (with 0.4 mol/L pyrrole monomer content) reached to 99 %, and the coating demonstrated a durable corrosion protection ability (744 h) in 0.1 mol/L HCl solution. Such performance of can be attributed to the combined effect of the anodic protection provided by the inner PPY film, the active corrosion inhibiting properties of the ZIF-67 nanoparticle layer, and the hindrance of aggressive species by the compact coating structure over the prolonged service time.