Low-cost Stainless Steel Research Articles

Multifunctional polymeric coating on stainless steel current collectors in aqueous energy storage devices

Herein, low cost stainless steel foils are employed as current collectors in aqueous Na-ion supercapacitors, while the foils are coated with following conducting polymers, namely, polyimide (PI), Schiff base polymer (SBP), polyanthraquinone sulfide (PAQS) and polyaniline (PANI). The foremost purpose of these polymeric coatings is the prevention of corrosion, and the resultant improvements in device performances. Notwithstanding, these polymeric coatings provide few additional benefits in device characteristics, and these are following: (i) enhancement of electrolyte stability window, (ii) contributing charge storage capacitance, (iii) conversion of 2D pristine substrate to 3D porous current collector. The four coating polymers are electrochemically characterized, and PI is selected for fabricating Na-ion supercapacitor cells. The PI-coating reduces the stainless steel’s corrosion rate ∼ 68 times, expands the electrolyte stability window ∼ 1.2 times, and delivers ∼ 2 times higher capacitance with respect to pristine current collector, whereas no appreciable interfacial resistances are observed. The supercapacitor cell with PI-functionality demonstrates ∼ 6.6 times improved capacitance than that of pristine cell at 25 mA/g current density, while > 95 and ∼ 90 % Faradaic efficiencies are noted for former and latter, respectively. The distinct enhancement of cell performances clearly demonstrates the effectiveness of multifunctional polymeric coating on corrosion-prone metallic current collectors.

Nanoprecipitate strengthened, alumina forming austenitic stainless steels for elevated temperature applications

Low cost stainless steels (SS) with high performance, especially with good mechanical properties and oxidation resistance at high temperature, are continuous pursuit for manufacture industry. To achieve good combination of mechanical properties, oxidation resistance and cost, nanoprecipitate strengthened alumina forming austenitic (NSAFA) SS have been developed by removing expensive elements such as Nb and Ta, lowering Ni concentration in Fe–26Ni–15Cr-1.5Mo-(2.8–3.5)Al-(1–2.35)Ti (wt.%) alloys. Microstructure investigation demonstrates that NSAFA SS are strengthened by L12 structured (Ni, Fe)3(Al, Ti) γ′ nanoprecipitates with area fraction around 25%–40%. Oxidation experiments (750 °C/480 h) in air demonstrates that all the NSAFA steels have alumina forming ability. In addition, it is found that Al and Ti are all necessary for γ′ nanoprecipitates, but additional Al and Ti facilitate formation of the Ni2AlTi phase. To ensure high volume fraction of γ′ nanoprecipitates and reduce Ni2AlTi phase, 2.8–3.0 wt% Al and 1.8–2.35 wt% Ti are preferred. Benefit from the high volume fraction of γ′ nanoprecipitates, yield strength of NSAFA steels is much higher than that of Fe-base superalloy (e.g., A286) and can compare to some Ni-base superalloys (e.g., Hayners 282 & Inconel 740H).

Leachate xenobiotics electrocatalytic degradation and simultaneous carbon quantum dots synthesis for anti-counterfeiting applications

The leachate treatment and the management of sludge after its treatment is a big challenge due to its many toxins and pollutants. The novelty of the current work resides in our attempt to address both difficulties by treating the leachate with electrofenton using low-cost stainless steel electrodes, followed by converting the sludge generated into quantum dots suited for anti-counterfeiting applications. On the electrofenton treatment of leachate, at the optimized conditions, the percentage removal of total organic carbon (TOC), UV254, chemical oxygen demand (COD), and NH3-N was found to be 79 %, 93 %, 90 %, and 90 % respectively with less energy consumption of 0.26 KWh/KgCOD. The gas chromatography-mass spectroscopy (GC–MS), 3D fluorescence spectroscopy matrix, and UV–Vis analysis confirmed the removal of xenobiotics and dissolved organic matter (DOM). The carbon quantum dots (S-CQDs) synthesized from sludge were characterized for X-ray diffraction (XRD), transmission electron microscopy (TEM), Fourier transforms infrared spectroscopy (FTIR), PL intensity (Photoluminescence), and UV–Vis. The S-CQDs are very promising in qualitative fingerprint image enhancement in terms of overall pattern, dots, and ridges and are well suited as an alternate, efficient, green anticounterfeiting material. Thus, highly polluted leachate was efficiently treated and sludge was converted into useful carbon dots with the anti-counterfeiting application.

Interfacial evolution: A hydrothermal activation strategy to boost OER activity for stainless steel

BackgroundWater electrolysis is one of the most competitive approaches to generate hydrogen. The economical stainless steel, which consists of transition metals such as Ni and Fe, has impressive catalytic tunability and tremendous application potential in hydrogen production. MethodsIn this work, a hydrothermal activation strategy is proposed for breaking the inert oxide layer of stainless steel and producing an active catalytic layer dominated by NiFe2O4 spinel nanoparticles on the surface. The molybdate further complexes with the metal ions, disrupting the initial regular crystals of NiFe2O4 and exposing more defects. At the same time, Mo atoms can further optimize the electronic structure, which is conducive to the kinetic process of the reaction. Significant FindingsConsequently, the modified stainless steel requires only 270 mV to achieve a current density of 10 mA·cm−2, much lower than 387 mV of bare 304 stainless steel (SS304). Moreover, the robust catalytic layer, evolved from the stainless steel's own elements, grows firmly on the surface and shows excellent stability in the test of 120 h. This work provides a novel strategy for developing low-cost stainless steel electrodes with superior performance and stability for oxygen evolution.

Comparative study on the role of single- and double-cathode in electro-Fenton process for treatment of Reactive Orange 16 dye bearing wastewaters

ABSTRACT The study presents the single- and dual-cathode electro-Fenton (DCEF) treatment of the Reactive Orange 16 (RO16) azo dye-bearing synthetic wastewater. Initially, the effect of operational parameters, i.e. initial [RO16] dye, [Fe+2] iron catalyst, [NaCl] electrolyte, operational pH, and current density (ρ), on the performance of the electro-Fenton (EF) process was evaluated with the application of low-cost stainless steel (SS) electrodes. At the optimum condition ([RO16] = 150 mg/L, [Fe+2] = 0.4 mM/L, [NaCl] = 0.4 M/L, pH = 3.5, ρ = 20 mA/cm2), with a total electrolysis time of 40 min, the colour (RD) and COD (RC) removals were observed to be 92.023% and 83.344%, respectively. Further, the process was upgraded by providing an additional activated graphite plate (AGP) cathode (dual cathodes), and the results indicated a significant reduction (40 min to 25 min) in the electrolysis time, with a drop in electrical energy (2.51 kW/m3 to 1.47 kW/m3). This consequently reduced the operational cost ($3.42/m3 to $1.23/m3) of the lab-scale DCEF process. The XPS analysis showed enhancement in H2O2 concentration at the surface of the additional AGP cathode. The cyclic voltammetry (CV) test confirmed the complete mineralisation of RO16 dye and the formation of intermediate products. The insight mechanism of the conventional and upgraded processes was also explored for the generated sludge and formed products using FTIR and quantum chemical (QC) analysis. The results showed that the DCEF process was highly efficient, low-cost, and an environmentally compatible technology for the treatment of dye-bearing industrial effluents.

Investigation of Surface Oxide Layer Structure to Improve Durability of Stainless Steels Under Humidified Hydrogen

We study degradation mechanism of stainless steels under SOFC operating conditions to improve durability of SOFC stack. To reduce material cost, a low-cost stainless steel is preferred because metal interconnect occupies considerable amount in the stack. From commercially available stainless steels, four types of alloy composition were chosen as model materials, which are widely used in the other applications. The alloy test pieces were exposed to hydrogen with 10%-50% H2O at 600oC-700oC, and mass gain after the test was measured. The mass gain increased with time, indicating that steam oxidation proceeded. The oxidation rate was smaller for JIS SUS430J1L than the other three types of the alloy for all the test conditions. The proficient durability came mainly from the thin Cr-rich oxide layer covering the alloy uniformly with little defect or segregation. The additives in the alloy such as Nb also may have an effect on suppressing elemental diffusion through the oxide layer. Because morphology of the surface oxide layer initially formed on the surface should affect the process of steam oxidation during SOFC operation, we investigated influence of pre-heat treatment condition (700oC-900oC) of the alloy. The surface oxide layer formed by the pre-heat treatment at 900oC in air for 2 h had an effect of reducing steam oxidation rate. Microstructure of the surface oxide layer before and after the durability test was analyzed by STEM. From the difference in the microstructure of the surface oxide layer, predominant factor to improve durability will be discussed. This paper is based on results obtained from a project, (JPNP20003), commissioned by the New Energy and Industrial Technology Development Organization (NEDO). Figure 1

Modular UV Curing Sol-Gel Coating for Invisible, Levelling and Easy to Clean Multi-Layer Systems.

Current methods for the hardening step of functional coatings over different materials imply the use of high temperatures, high energy consumption or long periods of time, which have repercussions on the speed and cost of the product. We report here a simple and low-cost methodology for the functionalization of low-cost stainless steel, which is modular, depending on the functionality pursued: a levelling layer for smoothing the surface of the material, an "easy to clean" property, or both of them. This research is based on sol-gel coatings cured under UV light without requiring high thermal hardening processes, making it applicable to plastics and other sensible materials and possessing high chemical and thermal stability. The film ensures lower processing costs and higher rates of hardening if adequate medium-pressure lamps are employed. This formulation is also well-defined for scaling up the process, so it is possible to perform a continuous coating in large areas by employing mild processing conditions (low temperature, atmospheric pressure). In addition, the sol-gel solution was fully characterized and studied in order to guarantee a long service life before deposition, with a focus on industrial applications in the domestic sector.

Promoting surface reconstruction of low-cost stainless steel catalyst for efficient oxygen evolution reaction.

The development of cost-effective transition metal catalysts for oxygen evolution reaction (OER) is critical for the production of hydrogen fuel from water splitting. Low-cost and efficient stainless steel-based catalysts are expected to replace the scarce platinum group metals for large-scale energy applications. Here in this work, we report the conversion of commonly available inexpensive and easily accessible 434-L stainless steel (SS) into highly active and stable electrodes by corrosion and sulfuration strategies. The NixFe1-xS layer as a pre-catalyst and S-dopedNixFe oxyhydroxides in situ formed on the catalyst surface are the true active species for OER.The optimized 434-L stainless steel-based electrocatalyst exhibits a low overpotential of 298 mV at 10 mA cm-2in 1.0 M KOH with a small OER kinetics (the Tafel slope of 54.8 mV dec-1) and good stability.This work reveals the 434-L alloy stainless steel with Fe and Cr as the main elements can be used as qualified OER catalysts by surface modification, along with a new mentality to solve the energy and resource waste problems.

Investigation of Surface Oxide Layer Structure to Improve Durability of Stainless Steels Under Humidified Hydrogen

Durability of low cost stainless steels, selected from the materials widely used in other applications, was investigated under humidified hydrogen of SOFC anode condition. JIS SUS430J1L exhibited higher resistance for water oxidation. The feature came mainly from the thin Cr-rich oxide layer covering the alloy uniformly with little defects or segregations. Under humidified H2 at 700oC, Mn migrated outward and the morphology changed. Durability of the alloy seems to depend on the inner side of the surface oxide layer. Although the Cr-rich oxide layer blocked outward diffusion of metal ions, the layer could not block inward diffusion of oxygen ion completely. Improvement of the durability is possible by controlling the thickness of the surface oxide layer by the pre-heat-treatment.

The Tailings of Cold War U.S. Foreign Policy

Start with manganese (Mn). With an atomic number of twenty-five, Mn sits next to chromium and iron in the middle of an industrially indispensable row of what are called “transition metals” on the periodic table. The element is named for the Greek region of Magnesia—confusingly also the origin of the chemically very different magnesium, itself not to be confused with the magnetic lodestone also associated with the region—and in its most common form as manganese oxide it has been used for pigmentation and in glassmaking since antiquity. It is also essential to good steelmaking. At high temperatures, manganese forms a high-melting sulfide, preventing the formation of liquid iron sulfide and making high temperature steel more workable. Steel alloys of between eight percent and twelve percent manganese achieve significantly higher tensile strength, and as a deoxidizer manganese helps prevent corrosion and wear, especially in low-cost stainless steel. Aluminum, vanadium, and a number of other transition metals have similar properties to manganese, but as the authors of a 1952 report to U.S. President Harry Truman’s administration on the United States’ long-term material supply needs noted, in the early 1950s—as today—there was really no practical way to produce steel at an industrial scale without manganese. And in the 1950s, with steel a vital commodity at the heart of the U.S. civilian and military economies, the United States did not produce very much manganese.1

Hydrogen embrittlement behavior in interstitial Mn–N austenitic stainless steel

The susceptibility to hydrogen embrittlement behavior was investigated in an interstitial Mn–N austenitic steel HR183 and stainless steel 316L. Hydrogen was introduced by cathodic hydrogen charging at 363 K. HR183 has stronger austenite stability than 316L despite its lower nickel content, the addition of manganese and nitrogen inhibited martensitic transformation during the slow strain rate tensile deformation. Due to the diffusion of hydrogen being delayed by the interstitial solution of nitrogen atoms and the uniform dislocation slips, hydrogen permeates more slowly in HR183 than 316L, contributing to an 84.79 μm thinner brittle fracture layer in HR183 steel. Hydrogen charging caused elongation losses in both 316L and HR183 steels associated with the hydrogen-enhanced localized plasticity (HELP) and hydrogen-enhanced decohesion (HEDE) mechanism. However, the hydrogen embrittlement susceptibility of HR183 is 3.4 times lower than that of 316L according to the difference in elongation loss between the two steel after hydrogen charging. Deformation twins trapped a lot amount of hydrogen leading to brittle intergranular fracture in 316L. The multiple directions of slip in HR183 steel suppressed the strain localization inside grains and delayed the adverse effects conducted by HELP and HEDE mechanism, eventually inhibiting server hydrogen embrittlement in the HR183 steel. This study is assisting in the development of low-cost stainless steel with excellent hydrogen embrittlement resistance that can be used in harsh hydrogen-containing environments.

Polyaniline on Stainless Steel Fiber Felt as Anodes for Bioelectrodegradation of Acid Blue 29 in Microbial Fuel Cells

This study investigated the advantages of using low-cost polyaniline-fabricated stainless steel fiber felt anode-based microbial fuel cells (PANI-SSFF-MFCs) for azo dye acid blue 29 (AB29) containing wastewater treatment integrated with an aerobic bioreactor. The findings of electrochemical impedance spectroscopy (EIS) and polarization studies showed that the PANI–SSFF anode considerably decreased the MFC internal resistance. The highest power density of 103 ± 3.6 mW m−2was achieved by PANI-SSFF-MFCs with a decolorization efficiency of 93 ± 3.1% and a start-up time of 13 days. The final chemical oxygen demand (COD) removal efficiencies for integrated PANI–SSFF–MFC–bioreactor and SSFF–MFC–bioreactor set-ups were 92.5 ± 2% and 80 ± 2%, respectively. Based on 16S rRNA gene sequencing, a substantial microbial community change was observed in MFCs. The majority of sequences were from theProteobacteriaphylum, accounting for 72% and 55% in PANI–SSFF–anodic biofilm and suspension, respectively, and 58 and 45% in SSFF–anodic biofilm and suspension, respectively. The relative abundance of the seven most abundant genera (Pseudomonas, Acinetobacter,Stenotrophomonas, Geothrix,Dysgonomonas, Shinella, andRhizobiales) was higher in PANI–SSFF–MFCs (46.1% in biofilm and 55.4% in suspension) as compared to SSFF–MFC (43% in biofilm and 40.8% in suspension) which predominantly contributed to the decolorization of AB29 and/or electron transfer. We demonstrate in this work that microbial consortia acclimated to the MFC environment and PANI-fabricated anodes are capable of high decolorization rates with enhanced electricity production. A combined single-chamber MFC (SMFC)-aerobic bioreactor operation was also performed in this study for the efficient biodegradation of AB29.

Enhanced analytical performance of disposable 3D carbon electrodes prepared with stainless steel wire mesh

This paper aims to use low-cost stainless steel wire mesh (SSWM) as uniform templates to prepare disposable three-dimensional (3D) carbon electrodes to improve their analytical performance. Native SSWM electrodes were prepared with lamination and then coated with carbon cement for bulk preparation of disposable 3D carbon electrodes with drop-casting. The electrodes were then coupled in paper-based analytical devices. Meanwhile, disposable 2D carbon electrodes were prepared with the stainless steel sheets (SSSs) for comparison under the same condition using stripping analysis of heavy metals as a model. Our results demonstrated that the sensitivity of the 3D carbon electrodes was about three times as high as that of the 2D carbon electrodes on stripping analysis of both heavy metals. The electrochemical responses of 1 μg L−1 Pb2+ at the 3D carbon electrodes were about 6 times as high as those at the 2D carbon electrodes. The improved analytical performance of disposable 3D carbon electrodes could be attributed to their increased electrochemical effective area, which was brought by replacing SSSs with SSWM. The obtained disposable 3D carbon electrodes could be used for differentiation of Pb in teethers and corns. This study not only presented the potential of SSWM in the preparation of disposable 3D carbon electrodes but also suggested a simple and effective strategy for the preparation of disposable 3D electrodes for practical applications.

Binder free cobalt iron phosphate thin films as efficient electrocatalysts for overall water splitting

Designing nanostructure based robust catalyst for the electrochemical water splitting is the great task in the energy conversion field to accomplish high electrical conductivity, low overpotential and long lasting activity. Herein, the electrochemical overall water splitting is reported by using the hydrothermally synthesized binder free cobalt iron phosphate thin films on low cost stainless steel substrates as a conducting backbone for the first time. The effect of composition ratio variation of cobalt and iron was studied on the structural, compositional, morphological, and surface electronic properties by conducting various characterizations which results in amorphous hydrous cobalt iron phosphate having mesoporosity. The as synthesized cobalt iron phosphate having composition ratio (50:50 of Co:Fe) exhibits excellent electrochemical OER and HER catalytic water splitting performance. Best performing electrode exhibits smallest overpotentials of 251.9 mV and 55.5 mV for OER and HER respectively at 10 mA/cm2 current density. To split water molecule into the H2 and O2 by overall water splitting in same alkaline medium, the potential of 1.75 V was required after long duration (100 h) catalysis. Overall analysis confirms the cobalt iron phosphate thin films are outstanding and robust for the hydrogen production as clean renewable energy source.

Testing the Sandblasting Process in the Manufacturing of Reference Spheres for Non-Contact Metrology Applications

To ensure that measurements can be made with non-contact metrology technologies, it is necessary to use verification and calibration procedures using precision artefacts as reference elements. In this environment, the need for increasingly accurate but also more cost-effective calibration artefacts is a clear demand in industry. The aim of this work is to demonstrate the feasibility of using low-cost precision spheres as reference artefacts in calibration and verification procedures of non-contact metrological equipment. Specifically, low-cost precision stainless steel spheres are used as reference artefacts. Obviously, for such spheres to be used as standard artefacts, it is necessary to change their optical behavior by removing their high brightness. For this purpose, the spheres are subjected to a manual sandblasting process, which is also a very low-cost process. The equipment used to validate the experiment is a laser triangulation sensor mounted on a Coordinate Measuring Machine (CMM). The CMM touch probe, which is much more accurate, will be used as a device for measuring the influence of sandblasting on the spheres. Subsequently, the influence of this post-processing is also checked with the laser triangulation sensor. Ultimately, the improvement in the quality of the point clouds captured by the laser sensor will be tested after removing the brightness, which distorts and reduces the quantity of points as well as the quality of the point clouds. In addition to the number of points obtained, the parameters used to study the effect of sandblasting on each sphere, both in contact probing and laser scanning, are the measured diameter, the form error, as well as the standard deviation of the point cloud regarding the best-fit sphere.

Experimental and Numerical Investigations of Wear Resistance Characteristics of XCr13 during Advanced High-Strength Steel Stamping

Owing to the high strength and hardness of advanced high-strength steels (AHSS), the die materials for AHSS sheet stamping must have superior mechanical properties. A novel carburization technology on high-chromium, low-carbon, low-cost stainless steel XCr13 was used to achieve a hardness of approximately 60 HRC, with a carburized layer of approximately 0.5 mm; these specifications meet the requirements of AHSS sheet stamping. To evaluate the wear characteristics of the treated XCr13, regular pin-on-disk wear tests were performed under dry sliding conditions at room temperature. JIS SKD11, a popular cold work die material, was also tested and compared with XCr13. A numerical simulation model for AHSS sheet flanging with a W-shaped specimen was set up in ABAQUS, and the user subroutine UMESHMOTION was used to evaluate the wear resistance of the two die materials, including the wear surface profile, wear depth, and wear severity index value. For JIS SKD11, the agreement between the simulation and experiment results was good, which verifies the reliability and accuracy of the proposed wear simulation model and method. It was found that the wear resistance of carburized XCr13 was at the same level as that of JIS SKD11 because of the carburized zone. Further, carburized XCr13 can work well as a die material for AHSS stamping.

Heat input and shielding gas effects on the microstructure, mechanical properties and pitting corrosion of alternative low cost stainless steel grade 202

The intention of this study was to create information for welders and engineers in regards to 202 (200-series) austenitic grade stainless steel as a low cost alternative for the replacement of 300-series stainless steel. The content of this paper discusses the effects of different heat inputs and different nitrogen mixes in the argon shielding gas using the GTA welding process. This paper discusses the effects to the microstructure, mechanical properties and corrosion resistance of the weld metals. The results of this study indicate that reducing the heat input when welding caused the width of the face and root of the weld bead to be narrower. The microstructure (delta ferrite, dendrite length and interdendrite spacing) tended to decrease and the hardness and ultimate tensile strength tended to rise. In addition, the percentage of elongation decreased while the pitting corrosion resistance increased. An increase of nitrogen in the argon shielding gas did not cause the width of the weld bead to change. However, the volume of delta ferrite, dendrite length and inter-dendrite spacing reduced and the hardness and ultimate tensile strength increased. The percentage of elongation was shown to decrease and the pitting corrosion resistance tended to increase. The test results of this work focused on increasing productivity and reducing the cost of production from the use low nickel stainless steel in the fabrication industries of Southeast Asia.

Stainless steel sheets as the substrate of disposable electrochemical sensors for analysis of heavy metals or biomolecules

In this paper, low-cost stainless steel sheets with excellent electric conductivity were utilized as the robust substrate for fabrication of disposable working electrodes. The stainless steel electrodes were modified with carbon cement and then coupled in paper-based analytical devices for analysis of heavy metals (cadmium and lead) in toys or indole-3-acetic acid (IAA) in plants, respectively. For stripping analysis of cadmium and lead, the dilution ratio of the carbon cement, the pH value of the buffer solution, the pre-deposition potential and time, and the bismuth concentration were optimized with the detection limits reaching 1 μg•L−1. After optimization of the dilution ratio of carbon cement, the similar devices could also be used for analysis of IAA at the concentration of less than 0.5 μM. This strategy could be successfully applied for differentiation of migratable lead in toys or in situ amounts of IAA in root tips of Arabidopsis thaliana in real time, respectively. Our results implied that the electric conductivity of the substrate could possibly be critical for the improvement of the analytical performance of the modified electrodes. This study suggested that stainless steel could become a suitable and cost-effective substrate for fabrication of disposable carbon-based electrodes used in electrochemical detection.

Evaluation of microstructure, mechanical properties and pitting corrosion in dissimilar of alternative low cost stainless steel grade 204Cu and 304 by GTA welding joint

In this present work, solutions are sought regarding the problems of dissimilar welding of austenitic stainless steel for industrial fabrication work. There is support for the popular 200 grade stainless steel as a low-cost alternate to for 300 series grade in developing countries in Southeast Asia, especially Thailand, Vietnam, Myanmar, Laos and Cambodia. This study evaluates the microstructure, mechanical properties and pitting corrosion of dissimilar welding of the alternative low cost stainless steel grades 204Cu and 304 employing a GTA welding process by using different filler metals, namely 309L and 316L. It was found that for both weld metals and both filler metals the melting area in 204Cu BM side was larger than the 304 BM side. The delta-ferrite content in the weld metal of 309L was lower than 316L, HAZ and PMZ on the 204Cu side was wider than the 304 side of both welded metals. For the mechanical properties, the hardness volume of the welded metal of the 309L was higher than the 316L. Hardness adjacent to the fusion line of the 304 side was lower than the 204Cu side of both the filler metals. The tensile strength of the welded metal of 316L was more than the 309L and both welded metals ductile fractured in the welded zone (close to the 304 BM side). The pitting corrosion resistance of the welded metal for 309L was higher than for 316L and both welded metals initiated pitting at the boundary between the austenite phase and the delta-ferrite phase.

Electronucleation mechanism of copper in wastewater by controlled electrodeposition analysis.

In order to improve the efficiency of copper deposition in wastewater containing the surfactant polyvinylpyrrolidone (PVP) and reveal the mechanism of copper crystals, a controlled electrodeposition process was developed using a low-cost stainless steel cathode and investigated using chronoamperometry (CA), electrochemical impedance spectroscopy (EIS) and infrared spectroscopy (IR). The theoretical analysis was verified by fitting them to experimental curves and calculating the kinetic parameters of the deposition process. The experimental results showed that Cu(PVP)2 was formed by the reaction between the C Created by potrace 1.16, written by Peter Selinger 2001-2019 ]]> O bond of PVP and Cu2+. When powdered, reduction of Cu2+ in the Cu(PVP)2 structure was promoted, a positively-charged PVP-coating layer was formed on the surface of the copper crystal nuclei to inhibit the growth of the copper powder. At a potential of −0.2 V, the electrodeposition crystallization curve of copper changed from progressive nucleation to instantaneous nucleation. The kinetic parameters of the deposition process were calculated by fitting the experimental curves to verify the correctness of the theoretical analysis. The EIS tests showed that removing the powder reduced the resistance of the organic solvent (PVP) film on the electrode surface and the charge transfer resistance during copper deposition. According to particle size analysis, removing the powder could reduce the growth energy of copper powder on the electrode surface, increase the area of the active part on the electrode surface, increase the current efficiency of copper powder to 84.2%, and control dust. The size of copper powder reached up to around 900 nm.