Low Carbon Steel Material Research Articles

Penerapan Metoda High Pressure Jet Cooling (HPJC) untuk Mengurangi Keausan Tepi Pahat pada Proses Membubut dengan Kecepatan Rendah

High Pressure Jet Cooling (HPJC) is an alternative method to the ineffective and environmentally friendly flooding method for coolant distribution at the cutting contact area. This method is widely utilized in the machining process of materials that are difficult to cut or have superior mechanical properties using various tools that have high cutting speeds. At high cutting speeds, it will be difficult for coolant to penetrate the contact area. For this reason, in this study HPJC is used to turn low carbon steel material with a tool that has a low cutting speed. By using a tool capable of providing pressure variation in coolant delivery, flank wear as a result of the turning process was observed. The results were validated using ANOVA and Fisher Least Significant Differences methods. The results show that pressure variation can reduce the tool wear rate. However, the tools used were not sufficient to distinguish the change in applied pressure from the reduction in tool life. This is because the coolant is only concentrated on the main plane of the tool. As a result, other types of wear, namely nose wear, have increased.

Evaluation of dieless hydroforming process for manufacturing of variable cross section tubular structures

The dieless hydroforming is a type of manufacturing method that forms materials using pressurised hydraulic fluid rather than dies and presses as in traditional hydroforming, resulting in significant cost savings. The dieless hydroforming of tubular structures with variable cross section has received little attention, indicating that more research is needed in this area. Therefore, this article investigated dieless hydroforming of low carbon steel material with fluid pressures ranging from 10 to 50 bar and sheet thicknesses ranging from 1 to 2.5 mm to produce tubular structures with variable cross section. The main goal is to comprehend the deformation characteristics in relation to the parameters, as well as the impact of deformation on the microstructural and mechanical behaviour. The inflation and contraction patterns of hydroformed structures are numerically determined using the finite element method at various parameters and then compared to experimental results which show a good correlation. Plastic deformation induced grain refinement in all deformed samples, as compared to as-received material. The sample hydroformed at 30 bar and with a thickness of 2.5 mm showed higher yield strength (291 MPa), tensile strength (404 MPa) and elongation (48%) than the other samples. Hydroformed tubular structures with variable cross section are created and used in electric poles to hold solar panels after the process repeatability is tested and found to be highly repeatable with greater than 97% accuracy.

Multi-Objective Parametric Optimization of Weld Strength of Metal Inert Gas (MIG) Welding by using Analysis of Variance, Taguchi, and VIKOR Techniques

Abstract: Welding is an enormously essential manufacturing technique which allows the users to create permanent joints efficiently, due to its durability this process is extensively used in various industries like automotive, construction as well as in the aviation industry. The present study focuses on the optimization of the Metal Arc Welding using VIKOR method. Four input variables Current, Voltage, Wire Feed Rate and Gas Flow Rate are considered to study their effect on three responses tensile, bending and hardness on the weldments of AISI 1008 low carbon steel material. Experiments were planned as per Taguchi‘s L9 OA. As traditional Taguchi method is not adequate to solve multi responses problem, to overcome this limitation MCDM approach VIKOR analysis has been carried out for obtaining optimal parameters setting for multi-response optimization. Three specimens (for tensile, bending, and hardness) for each experimental run are fabricated for the measurement of respective strength and hardness. Investigation is done by following the steps of VIKOR method, and optimal parameter setting for multi quality response is obtained corresponding to the lower VIKOR index value. Keywords: Metal Inert Gas (MIG) Welding, VIKOR, S/N ratio, ANOVA

PROSES PEMBUATAN ARANG BATOK KELAPA DAN TULANG SAPI MENGGUNAKAN METODE PIROLISIS SEBAGAI MEDIA CARBURIZING

Fueled by a rise in food needs as beef and oil into basic commodities has been consumed by thepublic, has lead the increasing of waste the cows and coconut shell. The main ingredient used in thisresearch is a waste product from cow bones and from the remains of the coconut shells from which no orhousehold wastes, that can be processed into charcoal. The purpose of this research which is to enhanceeconomic value of waste from cow bones and coconut shells using combustion pyrolysis system beingcharred (fixed carbon) to produce good quality charcoal, to find out the extent of the temperature used andthe composition of charcoal. The process used in this research is pack carburizing with cow bones andcoconut shell as the media at the temperature 950oC, time detention three hours with variations compositioncharcoal. It can be concluded that charcoal bone across his cattle and charcoal coconut can be used as asource of carbon that might improve the force and hardness in the material carbon steel low (low carbonsteel). The process of pack carburizing can increase the value of % C, against low carbon steel material.

Analysis Of Mechanical Properties SMAW (Shielded Metal Arc Welding) Welding Joints Of Portable Electric Hydraulic Jack Frame

Welding is a very important part of the development and growth of the industry because it has a role in engineering, reparation, and construction. Shielded Metal Arc Welding (SMAW) or the conventional arc welding process is particularly dominant in structural joints, pressure vessels and in maintenance and repair work. In welding, different metals are joined economically and at a much faster rate as compared with other fabrication processes like riveting and casting. The purpose of this research is to find out the cooling media cooler against SMAW smelter tensile strength by using the E6013 electrode. This study uses low carbon steel material that has levels Fe = 98,3%; C = 0,30%, Si = 0,23%. The material is given 75A welding current with cooling variation on the connection result using oil, water, and room temperature. The highest tensile stress value obtained in the oil cooling treatment was 844,76 N/mm2, the highest strain value was obtained on the raw materials of 16%, the highest elasticity value was obtained in the oil cooling treatment of 703.96 N/mm2. According to the research results can be concluded that the variations of cooling media greatly affect the strength of the welding connection.

Optimization of oxy-acetylene flame hardening parameters to analysis the surface structure of low carbon steel

The oxy-acetylene flame hardening is one of the surface structure modification process is also known as heat treatment process. Using of high pressure oxy acetylene gas mixture expose to the top surface of the material with around 30,000 C, and the material comes to recrystalization temperature at that time the work samples is cooled by means of sudden water quenching. This action changes the micro structural and to increase the micro hardness of the material. The low carbon steel material is selected for this investigation to improve the micro hardness value by the application of oxy-acetylene flame hardening. The increasing of hardness with the effects of flame hardening parameters are flame temperature in o C, torch cap in mm, and quenching period in sec. Taguchi L27 OA is consider for this experiment to evaluate the maximum microhardness values of specimens effectively. The factors influencing for this study is estimated through Signal to Noise ratio efficiently.

Pendinginan Pengelasan menggunakan Metode SMAW pada Kekerasan Baja Karbon ST3 dengan Media Serbuk Semen Putih dan Beban Rockwell 100kgf

Pengelasan merupakan bagian tak terpisahkan dari pertumbuhan peningkatan industri karena memegang peran utama dalam rekayasa dan reparasi produksi logam.Penelitian ini bertujuan untuk mengetahui pengaruh media pendingin terhadap kekerasan logam las dan logam HAZ (heat Affected Zone) yang diuji kekerasan menggunakan metode Rockwell. Penelitian ini dilakukan pada material baja karbon rendah ST 37 yang dilas menggunakan elektroda E6013 diameter 2,6 mm dengan sambungan tumpul, kemudian diberikan pendinginan menggunakan serbuk semen putih.Logam las yang didinginkan dengan media serbuk semen putih memiliki kekerasan yang lebih keras,karena semen putih mengandung C2S yang sulit terhidrasi dan tidak memilikin sifat panas.Setelah dilakukan pengujian pada beberapa titik maka didapatlah hasil berupa nilai rata-rata dari spesimen raw material adalah 48,3 HRB, pengelasan tanpa media isolator = 42,96 HRB dan HAZ =46,4 HRB.Spesimen yang menggunakan serbuk semen putih = 47,65 HRB dan HAZ = 48,2 HRB.Dilihat dari fenomena tersebut dan semen putih memiliki nilai kekerasan yang lebih rendah dari pada udara, dimana HAZ pada kekerasan nilai pada udara 46,4 HRB dan nilai pada semen putih lebih tinggi yaitu 48,2 HRB.

Design and implementation of a crossflow turbine for Pico hydropower electricity generation

This study covered the design, implementation and performance evaluation of a crossflow turbine at various nozzle positions. The chosen blade material was analyzed using ANSYS for stress and deformation degree under the impact of hydraulic jets to ascertain its suitability while in operation. The shaft was analyzed under static and dynamic conditions using ANSYS in order to ensure a non-plastic deformation of the shaft at both conditions. The outcome of this analysis was employed in the harmonic response analysis of the runner shaft. Convergent tests were done for both the blade and runner shaft analysis. An experiment was designed for the evaluation of the crossflow turbine performance using optimal (custom) design tool of response surface methodology and 69 simulations/runs were obtained. The factors considered in the experimental design are: nozzle distance from the shaft, nozzle height and attack angle. The crossflow turbine was constructed using computed design values for all the machine's parts. The runner blades were positioned specifically at 28° outer blade angle and 90° inner blade angle. The turbine was tested under a water head and flow rate of 6.4m and 0.0042m3/s respectively. The shaft power and efficiency were evaluated using their respective formula. The responses were optimized in order to get the optimum position of the nozzle that would give the best performance of the responses using the two factor interaction (2F1) mathematical models in coded factors, developed for each of the response. The results obtained, proved that low carbon steel material was suitable for the turbine blading and the shaft is safe at both static and dynamic conditions since the induced stresses and deformations never exceeded the permissible range. Also, each of these considered nozzle positions had a significant effect on the responses with the nozzle height and attack angle having a combined effect on the performance of the turbine. The best turbine performance was obtained at lower angle of attack, nozzle distance very close to the runner shaft and at a nozzle height that will actualize greater energy impartation to the upper and lower blade profiles. The developed mathematical models for each response has higher correlation value, suggesting that the models are suitable for predicting the responses at the considered factor levels. An optimal nozzle distance, height and attack angle of 102mm, 413mm and 5° respectively, were obtained. At this nozzle position, the alternator gave an output of 35watts and 6V. When two voltage transformers were employed, it gave 200Volts AC. The turbine can be commercialized on large scale for greater output power using the determined optimal nozzle positions.

Effect of Process Parameters on the Surface Roughness and Kerf Width of Mild Steel during Plasma Arc Cutting Using Response Surface Methodology

This study investigated the effects of process parameters of plasma arc cutting (PAC) of low carbon steel material using analysis of variance. Three process parameters, cutting speed, cutting current and gas pressure were considered and experiments were conducted based on response surface methodology (RSM) via the box-Behnken approach. Process responses viz. surface roughness (Ra) and kerf width of cut surface were measured for each experimental run. Analysis of Variance (ANOVA) was performed to get the contribution of process parameters on responses. Cutting current has the most significant effect of 33.43% on the surface roughness and gas pressure has the most significant effect on kerf width of 41.99% . For minimum surface roughness and minimum kerf width, process parameters were optimized using the RSM. Keywords: Cutting speed, cutting current, gas pressure, surface roughness, kerf width

Process Parameter Optimization in EDM using Heat Treated Al Tool and without Heat Treated Al Tool

In this experimental work , we investigated optimization of process parameters in EDM using Taguchi method by taking Low carbon steel as work piece. Process parameters chosen were Pulse on-time (Ton), Flushing pressure(P) and Pulse Current(IP) . Here we have chosen L9 orthogonal array to study the effect of main factors and interaction between factors on the response variable i.e. Surface Roughness (SR), Material removal Rate (MRR) and Tool Wear Rate (TWR). The contribution of the main factors and interaction were determine here. The MR), TWR and surface integrity are some of the important performance attributes of EDM process. The objective of EDM is to get high MRR along with achieving reasonably good surface quality of machined component with reduced tool wear rate for Low carbon steel material.

ANALISIS PENGARUH PENAMBAHAN KARBON DAN PROSES HARDENING UNTUK MENINGKATKAN NILAI EKONOMIS RODA GIGI MESIN BUBUT

In many industrial components which made of steel such as lathe gears, most of its were usually use medium carbon steel. Because this kind of steel has high wear resistance and shock resistance, but its cost more expensive than low carbon steel. Because of this reason, the author try to use low carbon steel as a base material (raw material) for lathe gear in order to to decrease production costs. However, low carbon steel material has a carbon content of less than 0,3%, so it has poor tensile, less hardness and less friction resistance. But it strength can be increased by adding carbon, namely by means of solid carburizing and hardening process. In this study the Pack Carburizing was done at a temperature of 950 o C with 1 hour holding time, and used carburizing media such as coal charcoal and Calcium Carbonat (CaCO3) as catalyst with composition of 80% + 20%. Hardening is carried out at 670 o C, 760 o C and 850 o C. The cooling method used direct cooling method and the cooling media was used oil..And then followed by material composition test, hardness test, and micro structure test. After heat treatment, there were 0.3%, increase value in hardness. The highest harness value was at 112.66 HRB and at carburizing temperature of 850 o C, Phases formed were Ferrite, Perlite and Martensite. Keywords: Pack Carburizing, Hardening, Gear

The Effect of Speed and Distance on the Achievement of Austenitization Temperature in Low carbon Steel with Thickness Variations on the Flame Hardening Process

Austenite temperature must be achieved in the surface hardening process. In the process of surface hardening by the method of flame hardening, failure is often encountered, for example, such as increasing the value of hardness that is not optimal, and the value of hardness that is less uniform The type of fire used, the distance of fire to the specimen, the speed of fire and the level of thickness of the material are factors that are very influential in the process of flame hardening. The purpose of this study is to measure and observe the profile or rate of the trend of increase and decrease in temperature in the flame hardening process in low carbon steel material. The experiment method that is carried out is by giving the variation of the rate. The measurement process uses several thermocouples mounted on the specimen and connected to a computer for the process of data recording and process monitoring. The conclusion of this study is the greater the value of the thickness of low carbon steel material that is processed by flame hardening, so to reach the temperature of austenitization by the method of flame hardening the speed of fire must be slowed. An improper combination between the distance of fire and specimens and the speed of fire can cause austenite temperature not to be reached. The heat reduction rate takes place more slowly than the rate of increase in heat the speed of fire and distance of fire to low carbon steel which has varying levels of thickness.

Corrosion Resistance of Sn-Zn Coated on Low Carbon Steel Material in Wet Gas Pipeline

Low carbon steel pipeline material is usually to transport wet gas. The presence of water in gas may lead corrosion and leakage. To enhance corrosion resistance of this material, we investigated electrodeposited of Sn-Zn on various composition Zn. Microstructure, structure, thermal properties and corrosion behaviour were analysed with Scanning Electron Microscopy (SEM), X-ray diffraction (XRD), Differential Scanning Calorimetry (DSC) and Potentiodynamic Polarization. Electrodeposited Sn-Zn with smallest Zn content shows highest corrosion rate. With various composition, XRD pattern shows tetragonal crystal structure. The various Zn content have changed the melting point and the enthalpy. Electrodeposited Sn-Zn on low carbon steel pipeline material enhance the corrosion resistance.

Effect of a moving automated shot peening and peening parameters on surface integrity of Low carbon steel

Abstract Shot peening is a widely utilized process in industry. It helps to increase fatigue and stress corrosion resistance by creating beneficial compressive residual surface stresses of materials. Whilst very good results are achieved with this process, there is always an increasing demand by industry and material researchers for improved material surface quality, system reliability, and consistency controls of the process. First main objective of this work was to study the effect of an automated moving shot peening process on the surface integrity of low carbon steel material. Second objective was to discuss and present peening saturation and intensity results and model in a new approach in terms of peening speeds along side the traditional procedure which shows peening saturation and intensity results in terms of peening times. Third objective of this study was to examine the effects of: process air pressure, nozzle stand-off distance, nozzle speed, and peening angle on coverage, saturation, and surface quality utilizing the moving shot peening. This study showed that 276 kPa air pressure, 203 mm stand-off distance, and 5.3 mm/sec nozzle speed are the optimum conditions for the shot peening process parameters examined on standard Almen strips samples which resulted in minimize surface irregularities, maximize compressed layer thickness and uniformity, and minimize process time.

Failure Analysis of Blade on Coconut Shell Crusher Machine

Blade mounted on coconut shell crusher machine was frequently having damaged while being operated in making of coconut shell powder at small and medium industries. This took place repeatedly during the operation, therefore blade repairing and replacement has to be done for every 16 hours at the wear rate of 24.28%. A research was carried out to find out the cause of damage to the metal blade material on the coconut shell crusher machine. The scope of this research included the observation on visual examination, dimensions examination, chemical composition, hardness, and metallography. The results of observations and tests showed that blade was broken due to abrasion and deformation during operation. The metal material used for the blade was low carbon steel. Chemical composition of the metal content of the blade were: C (0.103 up to 0.144 %) and Mn (0.657 up to 1.400 %). Hardness value of blade metal materials were 146 up to 148 Hv. Microstructure consisted of ferrite and pearlite. This low carbon steel material is not suitable to be used as a blade on coconut shell crusher machines for producing of coconut shell. Repairing and maintenance of welding coating methods on blades using low carbon electrodes does not give increased significant value of hardness. Blade replacement in coconut shell crusher machines must comply with the requirements of tool steel with suitable heat treatment or the use of low carbon steel with the carburization process.

Pengaruh Pengujian Hardening pada Baja Karbon Rendah Sebagai Solusi Peningkatan Kualitas Material


 Baja karbon rendah merupakan paduan yang terdiri atas unsur utama karbon dengan komposisi rendah dan besi. Sifat mekanik baja karbon rendah dipengaruhi oleh komposisi dan struktur mikro logam. Salah sifat mekanik logam yang akan dicari nilainya adalah kekerasan. Tujuan penelitian ini adalah melakukan pengujian hardening terhadap material baja karbon rendah. Hasil yang didapatkan dari penelitian ini yaitu nilai kekerasan baja karbon rendah semakin meningkat seiring bertambahnya suhu pemanasan. Selain itu, berdasarkan data hasil percobaan diketahui bahwa media pendingin air garam memiliki kekerasan lebih tinggi dibandingkan dengan oli SAE 10.

Investigation on forming–welding process chain for DC04 tube manufacturing using experiment and FEM simulation

A chained forming–welding process is to be investigated and analyzed using experimental verification and numerical simulation in which the material and mechanical properties are fully transferred between processes. The investigated part is in the form of a tube with dimension of 300 mm (l) × 20 mm (OD) × 1.5 mm (t) made of a low carbon steel material DC04 commonly used for automotive parts and support structure. At first, a series of experiment using industrial U-/O-bending machine and fully automated robotic gas metal arc welding (GMAW) process on longitudinal slot were sequentially conducted and analyzed towards final geometrical change, macrostructure, and residual stress. Further, numerical simulation method using specialized FEM software Simufact.Forming and Simufact.Welding is developed to predict the major properties following the actual process parameters during experimental forming and welding process. Throughout the simulation of forming and welding process, additive isotropic hardening plasticity model based on von Mises yield criterion is selected with a wide range of operating temperature and Goldak’s double-ellipsoid is defined as welding heat source model. Based on the analysis outcome, it can be concluded that coupled forming–welding process simulation can be suitably implemented to forecast major material and mechanical properties of tube manufacturing within accepted range of error under consideration of material history.

The need to generate entropy characteristics for fatigue life prediction in low-carbon steel

This paper presents the need to generate entropy characteristics for fatigue life prediction in low-carbon steel. Entropy generation is a manner in which the measurement of degradation can be ascertained by keeping tab of fatigue process. It helps to predict the lifespan of the specimen which undergoes repetitive cyclic load. To ensure validity, temperature evolution is measured through a fatigue crack growth test induced upon a low-carbon steel material. A thermocouple is used to keep track of the surface temperature created upon the specimen while undergoing cycles of load till it fails, thus arriving at a conclusion that the surface temperature of a specimen under fatigue crack growth test can be used to predict the fatigue point as well as the lifespan of a material. Therefore, the results show that the total entropy generation can be used to predict the fatigue life of the material. The predicted fatigue life based on temperature evolution during the fatigue crack growth test was found to be agreeable with results of the experiments.

The Initial Life and Short Crack Propagation Life for Low Carbon Steel Based on Dislocation Method

In the paper, the relationship between the grain size and fatigue life are studied. To specify the initial and short crack propagation life of low carbon steel material, three methods are used in the simulation. At first, the K. Tanaka’s model is introduced to calculate the fatigue life of a grain. Then, the Voronoi Diagram is used to generate the microstructure of grains. At last, a criteria to specify the short crack is proposed. Based on these methods, the numerical simulation is conducted. With the help of the process, the grain sizes are generated randomly in order to specify how grain sizes effect fatigue life. The computational results are in good agreement with the experimental data. The results show that the randomness of fatigue life is closely related to the randomness of grain sizes.

Electro-Chemical Behavior of Low Carbon Steel Under H2S Influence

A commercial low carbon steel material (P265GH) with application at industrial scale for natural gas delivery and transportation systems was analyzed in H2S atmosphere. The article proposed a new experimental cell in order to establish the behavior of the material in sulfur contaminated environment. In most of the industrial processes for gas purification the corrosion rate is speed up by the presence of S (sulfur) especially as ions or species like H2S. The H2S (hydrogen sulfide) is, beside a very toxic compound, a very active element in the acceleration of metallic materials deterioration especially in complex solicitations like pressure and temperature in the same time. For experiments we used a three electrodes cell with Na2SO4 + Na2S solution at pH 3 at room temperature (∼ 25 °C) to realize EIS (electrochemical impedance spectroscopy) and potentio-dynamic polarization experiments. Scanning electron microscopy and X-ray dispersive energy spectroscopy were used to characterize the metallic material surface exposed to experimental environment.