Low Carbon Mild Steel Research Articles

Carboxylated cellulose nanofibrils based on banana rachis as additive in oil-based emulsion coolant for effective flank wear reduction in lathe operation

Nitro-oxidized carboxylated cellulose nanofibrils (NOCNFs) from the banana rachis are employed in oil-emulsion coolant as an additive. The concentrations of NOCNF were 0.1, 0.2, 0.3 wt. %. The cutting parameters include the spindle speeds and depth of cut. The temperature and wear reduction were significant. The temperature at the tool flank decreased from 119°C to 76°C, corresponding to an 11% reduction in wear at the depth of cut co. 2 mm and spindle speed of 1330 rpm. The viscosity of the nanofluid and the corrosion of the low-carbon mild steel specimen are discussed. Arguably, a stable NOCNF nanofluid suspension is good against wear even at elevated temperatures. Interestingly, these results occurred at a lower NOCNF concentration co. 0.3% wt. compared to 1–2 wt. % from Al2O3 nanoparticles in literature. In this paper, banana rachis nanofibrils are attractive for developing of effective and environmentally friendly additives from biomass.

Comparing the surface hardness of mild steel processed with CO₂ and fibre lasers

The microhardness of low carbon mild steel was analysed after surface treatment by using carbon dioxide CO₂ and Fibre laser for comparison. Identical input parameters were used to compare the increase between the as-supplied material hardness and the treated surface. Microhardness testing was used to measure the surface hardness and a scanning electron microscope (SEM) was used to investigate the microstructural changes in the substrate. It was found that the laser scanning speed had a significant effect on the increased surface hardness, while the laser power was a less significant factor. The samples processed with the lower laser fluence of the Fibre laser exhibited a hardness increase of 38% with maximum depth of 200 μm, while those processed by the CO₂ laser exhibited a hardness increase of 41% with a maximum depth of 50 μm. A full design of experiment (DoE) model was modified for the optimization and prediction of the laser hardening process. The processing parameters applied were the laser beam power and the scanning speed.

Heat generation and steel fragment effects on friction stir welding of aluminum alloy with steel

ABSTRACTJoining two dissimilar materials, like aluminum and steel, has been a topic of great importance in modern engineering applications. Therefore, this research expounds on joining aluminum alloy (Al5052) with low-carbon mild steel using friction stir welding. A novel approach is employed that quantifies the discontinuities (steel debris and voids) in the weld stir zone using image analysis. Furthermore, a parametric investigation was conducted following a full factorial approach with three tool rotational and traverse speed levels, and a heat input factor (ω2/v) was derived through theoretical modeling of process parameters. The heat input factor was substantiated experimentally with thermal cycle measurements. Results revealed that both the ω2/v factor and the extent of discontinuities determined the soundness and strength of the weld joints. A low rotational speed of 386 revolutions/minute and moderate traverse speed of 140 mm/minute, having minimal discontinuities, rendered maximum joint strength of approximately 212 MPa.

Perancangan Sepatu Kuda Berbahan Dasar Polymeric Foam dan Diperkuat dengan Fiber Glass

This study aims to obtain the best design and material for horseshoes. The research method used is experimental and research target design. This research was conducted in Medan and most of the experiments were conducted at USU University Medan. The results of this research are: it is known that horse shoes will be better if they are made using polymeric foam and reinforced with glass fiber. Furthermore, it was found that other advantages of horseshoe material made of polymeric foam reinforced fiberglass when compared to low carbon mild steel A 36 material, namely: a) Light weight, so it does not burden the horse's feet. b) Flexible, so it can adjust to the horse's hooves. c) Soft, so it can reduce the risk of injury. Horseshoe made of iron, when the horse is moving, if it hits a hard surface, it can cause a reaction force that over time can damage the horse's hooves, the joints of the horse's legs and even the horse's feet, if used for a long time. d) Resistant to chemicals found in the horse's environment, for example horse urine contained in horse stables, where horse urine contains ammonia, and is mixed with other harmful substances. e) Not slippery, thus preventing the horse from slipping and reducing the risk of injury.

Performance of predictive models to determine weld bead shape parameters for shielded gas metal arc welded T-joints

Assessing weld bead shape is essential for the quality control of a welded joint. This work presents an attempt to predict the weld bead shape parameters of shielded Gas Metal Arc Welded (GMAW) fillet joints through the application of statistical design techniques and artificial neural network. Extensive tests were performed on low carbon mild steel plates ranging in thickness from 3 mm to 10 mm. Welding voltage, welding current, and moving heat source speed were considered as the welding parameters. To develop empirical equation for defining bead geometry parameters of GMAW, multiple linear regression model (MLR) was formulated. Also, an artificial neural network (ANN) model was developed and individual feature importance was studied using SHapley Additive exPlanations (SHAP). The results show that the ANN-based approach performs better in predictability and error assessment. The predictive model has been used to study the temperature profile of a joint numerically, and an excellent match has been noticed when compared with experimental measurement. This study shows the usefulness of the predictive tools to aid numerical analysis of welding.

Investigation of equal strength mild steel tenons as displacement restraining devices for long-span railway arch bridges

In this paper, Equal Strength Mild Steel Tenons (ESMSTs) have been developed as a candidate for displacement restraining device of long-span railway arch bridges. They are made of a cheap and easily fabricated material, low carbon mild steel. The geometry is designed according to the principle of equal strength beam to make full use of the ductile deformation of mild steel, increase the energy dissipation capacity and alleviate damage concentration. To begin, the design concept of ESMST is given followed by the derivation of the theoretical formula of the mechanical properties with the vertical free mechanism which is of no vertical load to guide the design. A pseudo-static experiment program is then presented for two full-scale 2.5 m tall ESMSTs. Besides, a rigorous 3D numerical model was developed in ABAQUS to reproduce the behavior of ESMSTs to guide the design of ESMST in future application. Finally, a case study is presented for the application of ESMST in one of typical long-span railway arch bridges to evaluate its efficiency and effectiveness. The test results indicate that the tested ESMSTs can meet the demands of the long-span railway arch bridges for high initial stiffness, energy dissipation and deformability under strong earthquake action. It was also found that the ESMST had good fatigue performance. In addition, the developed numerical model in ABAQUS can accurately reproduce hysteretic behavior of the ESMST and hence can be used with confidence in the future to guide the design of ESMSTs. Results from the case study show the ESMSTs can work effectively and efficiently in reducing the response of long-span railway arch bridges without imposing much additional demand on the substructure. Findings of this study can provide guidance on the design of ESMSTs as well as support for the application of the ESMSTs in long-span railway arch bridges.

Effects of Key Processing Parameters of Continuous Drive Rotary Friction Welding on Thermal Characteristics of Similar and Dissimilar Joints

In this research study, numerical modeling was present to describe the effect of key processing parameters of continuous drive rotary friction welding (CDRFW) on thermal characteristics of similar aluminum alloy joint and dissimilar aluminum alloy /low carbon mild steel joint, using (ANSYS). A mathematical model was made to describe the heat generated in the workpiece due to the frictional force and the plastic deformation, and the heat transfer throw workpiece was described based on the Fourier law of heat conduction. The parameters were: Frictional pressure (P1), forging pressure (P2), frictional time (t1), forging time (t2), and rotational speed (N). A range of welding parameters was taken. The results show that with increases in welding parameters, the welding temperature at the interface region and the axial shortening will increase for both similar and dissimilar joints. For similar and dissimilar joints, frictional pressure and rotational speed have the most effect on maximum temperature at the interface, frictional time affects less while forging pressure and forging time have no effect on maximum temperature at the interface. For similar and dissimilar joints the most influential parameter on axial shortening was frictional pressure, with little effect for forging time.

Optimization of Cutting parameters of AISI 1018 Low Carbon Mild steel in turning using green cutting fluid by Taguchi Method

The objective of this work is to optimize the response Cutting parameters (Tool wear and Material Removal Rate) of AISI 1018 Low carbon mild steel by Taguchi Method in straight turningprocess. We have taken speed, feed, depth of cut and types of cutting fluids as machining parameters with their three level values. In our study a commercial semi-synthetic cutting fluid (SSCF) and two vegetable based cutting fluids are used and values of response variables are analyzed to see if the performance of response machining parameters is increased by using Vegetable based cutting fluids for sustainable machining.For individual optimization,Taguchi‟s L9(34 ) orthogonal array and Analysis of Variance(ANOVA) are used. The optimum results are verified with the help of confirmation test

Wire Arc Additive Manufacturing of Low-Carbon Mild Steel Using Two Different 3D Printers

Wire Arc Additive Manufacturing of Low-Carbon Mild Steel Using Two Different 3D Printers

Effects of Heat Treatment on the Impact and Hardness Properties of Mild Steel [ASTM 36] Lap Welded Joint

ASTM A36 is the most used type of mild steel especially in construction and manufacturing industry. Welding process is regularly employed to fix the crack that usually occurs in low carbon mild steel after a long time use especially in construction industry. In this study, the effects of heat treatment on the mechanical properties on mild steel [ASTM A36] lap welded joint were investigated. Seven pieces of 60 mm × 300 mm mild steel bar were used for this research. Five samples were heat treated in an electric muffle furnace and soaked at 6000C for 65 minutes. Two samples were cooled in air and furnace while the remaining three were rapidly quenched in water, spent engine oil and diesel oil each.Hardness and Impact tests specimens were made from the control (as received) sample and the various heat-treated samples. The specimens were joined together using E6361 mild steel arch welding electrode, lap welding joints and Shielded Metal Arc Welding (SMAW). Hardness test and impact test are used to delineate the mechanical properties for heat treated welded specimens and control specimens. It was established from the research work that Brinel Hardness Number (BHN of ASTM A36 lap welded joint cooled/quenched in different media increased it significantly in the Heat affected Zone (HZ) in all the quenching media. There is also a substantial increase in both Impact Energy (IE) and Impact Strength (IS) of heat-treated ASTM A36 lap welded joint when cool/quenched in the air, furnace, water and spent engine oil.

The Weldability of Duplex Stainless-Steel in Structural Components to Withstand Corrosive Marine Environments

There is still a considerable gap in the definition of the weldability of Duplex Stainless Steel (DSS). A lack of clarity that is explained by the standard specification of the maximum content of equivalent carbon that defines a “weldable” steel coupled with the fact that the alloying elements of DSS exceed this defined limit of weldability. In this paper, welding quality in an inert environment and in presence of chlorides is analyzed with the aim of defining optimum welding conditions of 2001, 2304, and 2205 DSS. The same procedure is followed for a hybrid weld between DSS 2205 and a low carbon mild steel, S275JR. As main output, this study defined the optimal welding conditions with tungsten inert gas without filler for each type of DSS weld that showed excellent anti-corrosion performance, with the exception of the DSS 2205-S275JR weld where widespread corrosion was observed. Additionally, this study established a relationship between the thermal input during welding and the content of alloying elements in defect-free joints. Furthermore, it demonstrated that an increase in ferrite content did not lead to a worse corrosion resistance, as expected after passivation.

Switching Autowaves in Materials with Dislocations and Martensitic Transformations

The paper focuses on the investigation of the strain kinetics at the yield point of materials with shear dislocations and martensitic transformations at a microlevel. In both cases, the autowave propagation and localized plastic deformation occur. The autowave propagation velocity depends on the nonlinear speed of the crosshead movement. It is found that its nature is the same both in low carbon mild steel and titanium nickelide.

A Mathematical Model for A Cladding Fastener to Estimate the Maximum Pull-Out Force Capacity

In the last few years, considerable attention has been paid to the roof cladding systems due to their progressive use in the construction of low-rise buildings. The design of such systems has been gaining importance since they are subjected to severe damage and failure caused by high wind events, particularly at their fastener connection points. To offer a solution for predicting the maximum pull-out force capacity of cladding fasteners, this article presents a mathematical model for a fastener made of high strength steel austenitic 316. In this model, the two basic parameters of the fastener, namely the thread depth and the thread angle are included as the main elements of the contact surface between threads and the low carbon mild steel batten/purlin sheets. This mathematical model will be proposed to estimate the maximum pull-out force capacity of the cladding fasteners made of cold-formed A2 316 stainless steel. After finding the parameters of the mathematical model by using an optimization method based on a genetic algorithm (GA), a comparison will be made between the mean estimation error of the new model and the formerly proposed ones.

Process parameter optimization and performance comparison of AISI 430 and AISI 1018 in resistance spot welding process

Resistance spot welding (RSW) process plays an important role in the sheet metal fabrication process, in which metal joining is obtained by heat developed through electric resistance against the current flow in the metals contact area. In this work, the impact of weld time, squeeze time, weld current and hold time on weld strength of 1.2 mm thickness ferritic stainless steel (AISI 430) and low carbon mild steel (AISI 1018) sheets by using RSW process were investigated and compared. The Design of experiment (DoE) was used to formulate the number of experiments with variations in input conditions. Welding of similar metals of AISI 430 and AISI 1018 was done according to the number of experiments obtained using DoE. The welded samples were subjected to tensile shear failure load and micro-hardness testing. The output responses were analyzed through Response surface methodology (RSM) to find the optimum control parameters to achieve higher weld strength.

Effect of laser remelting on the microstructure and mechanical properties of meta inert gas welded low carbon mild steel

In this study, laser remelting has been performed on the Metal Inert Gas welded (MIG) low carbon mild steel at varying laser power inputs (400 W & 600 W). To investigate the influence of laser remelting on the joint properties, optical microscope observation, scanning electron microscope observation, microhardness measurement and mechanical tests have been conducted. The experimental results revealed that the surface appearance of the laser remelted MIG welded joints have been found to be smooth and the microstructure of its fusion zone possesses fine equiaxed dendrites as compared with that of the MIG welded joints. In addition, the fracture surface of the laser melting carried at low power (400 W) on the MIG welded joint has exhibited a ductile fracture whereas, the MIG welded joint has undergone brittle fracture. The laser remelting carried out at 400 W on the MIG welded joint has resulted in 12% increase in both the ultimate tensile strength and percentage of elongation as compared to that of the MIG welded joint and this has been ascribed to the presence of equiaxed grains in the microstructure.

Fabrication of ZnO‐functionalized polypyrrole microcomposite as a protective coating to enhance anticorrosion performance of low carbon mild steel

ABSTRACTIn the present work, PPy, ZnO, and polypyrrole/zinc oxide (PPy/ZnO) microcomposites (1, 2, and 5 wt%) were prepared and their properties have been tuned for anticorrosion applications on low carbon mild steel. The synthesized products: ZnO, PPy, and composites were characterized by various sophisticated analytical techniques such as XRD, FTIR, Raman, FESEM, EDX, UV–VIS, TGA, and BET. The band frequencies observed at 480 and 588 cm−1 in FTIR spectrum correspond to stretching vibrations of Zn‐O and N‐H bonds, respectively, broadening of the bands in the composites indicate strong interactions between ZnO and PPy matrix. The potentiodynamic polarization study of PPy and PPy/ZnO composite was carried out in 3.5% NaCl solution to investigate the corrosion resistance efficiency. PPy/1 wt% ZnO (Icorr = 190 nA) composite coating on low carbon mild steel was observed to exhibit best corrosion protection property compared to PPy (121 μA), 2 and 5 wt% ZnO (242, 295 nA) composites. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019, 136, 48319.

Heat Source Modeling for FCAW of Fillet Joints using Artificial Neural Networks

The present work deals with the prediction of heat source parameters of Goldak's double ellipsoidal model for flux cored arc welded fillet joints through an artificial neural network (ANN). Extensive experiments were carried out on low-carbon mild steel plates of thickness ranging from 3 mm to 10 mm. In each case, welding current (I), voltage (V), and speed (υ) were recorded as the welding parameters. The flux cored arc welding of fillet joint was carried out using 100% CO2 as the shielding gas. This work is based on the simple and fundamental presumption that the weld pool is the primary source of heat which is delivered from the welding arc. Therefore, the magnitude and distribution of heat can be defined through the weld pool dimensions. Hence, these dimensions were directly considered for determining the heat source ellipsoid parameters. These parameters, namely, front double ellipsoidal length (Cf), rear double ellipsoidal length (Cr), half-width of the heat source (a), and depth of the heat source (b) were measured from the welded specimens. Furthermore, the ANN model was trained and tested for the prediction of the heat source parameters. The ANN predicted data were in good agreement with the measured values. Subsequently, the ANN model was used to predict the parametric dimensions of the double ellipsoidal heat source model for a set of welding parameters. The temperature history numerically computed with the ANN-predicted parametric dimensions of the double ellipsoidal heat source model compared very well with the measured data. The proposed ANN structure, therefore, can be gainfully used as a tool for the prediction of parametric dimensions of the double ellipsoidal heat source model in case of gas metal arc welding with 100% CO2 as the shielding medium for a plate thickness range of 3–10 mm. 1. Introduction Flux cored arc welding (FCAW) is extensively used in various fabrication industries, including the ship building industry. It is widely used in semiautomatic mode for fabrication of, among other things, stiffened flat and curved panels. These are fabricated by butt welding of the plates followed by fillet welding of the longitudinal and transverse stiffeners. In thin panel fabrication, it may lead to weld induced buckling. Hence, to assess the possible behaviour during fabrication of the stiffened panels, numerical simulation is often carried out. The computation of temperature field is at the heart of numerical simulation of weld-induced distortion and residual stress. Thus, it is very important to have a model for accurate prediction of the temperature field. The temperature field again depends on the distribution and quantum of heat that gets delivered from the welding arc to the weld joint. This calls for developing a heat source model that represents the heat distribution and its magnitude as accurately as possible.

Fatigue Crack Growth Rate of the Long Term Operated Puddle Iron from the Eiffel Bridge

The paper summarises an experimental study on the fatigue crack propagation and cracks paths in ancient steel—19th-century puddle iron from the Eiffel bridge. The tests were performed with the load R-ratio equal to 0.05 and 0.5. All tests were performed under different notch inclinations (mode I + II). The fatigue crack growth rate in the tested material is significantly higher than its “modern” equivalent—low carbon mild steel. The crack closure phenomenon occurs in specimens during the process of crack growth. Understanding this aspect is crucial for the examination of a stress R-ratio influence on kinetic fatigue fracture diagram (KFFD) description. Both the experimental and numerical approach, using the HP VEE environment, has been applied to the crack closure as well as the crack opening forces’ estimation. These analyses are based on the deformation of the hysteresis loop. The algorithm that was implemented in the numerical environment is promising when it comes to describing the kinetics of fatigue crack growth (taking into consideration the crack closure effect) in old metallic materials.

Change in Yield Strength of Nb-Bearing Ultra-Low Carbon Steels by Temper-Rolling

Yield strength of low carbon mild steel decreases when temper-rolling is applied to release yield point elongation. Generally mobile dislocation used to be considered as the cause of the YS lowering. However from Bailey-Hirsch theory, strength should be higher with temper-rolling because of the increase of dislocation density. To newly explain the lowering yield strength by temper-rolling, standing at the point that a few ppm carbon change Hall-Petch coefficient , decrease in yield strength by temper-rolling is investigated using an ultra-low carbon steel. Yield strength of steel with the small amount of solute carbon increased after 2% temper-rolling and didn’t change after aging. On the other hand, yield strength of steel with the high amount of solute carbon decreased after 2% temper-rolling and increased again after aging. Despite solute carbon content, the Hall-Petch σ0 increased by dislocation strengthening of temper-rolling. Hall-Petch coefficient ky of low solute carbon steel remained at the low level even after temper-rolling or aging , however, that of high solute carbon steels significantly decreased after temper-rolling and increased again after aging. Yield strength reduction of the high solute carbon steel can be attributed to the decrease of ky.

Electroplastic Drilling of Low- and High-Strength Steels

When postforming machining operations are required on high-strength structural components, tool life becomes a costly issue, often requiring external softening via techniques such as laser assistance for press-hardened steel components. Electrically assisted manufacturing (EAM) uses electricity during material removal processes to reduce cutting loads through thermal softening. This paper evaluates the effect of electric current on a drilling process, termed electroplastic drilling, through the metrics of axial force, and workpiece temperature when machining mild low carbon steel (1008CR steel) and an advanced high strength press hardened steel. A design of experiment (DoE) is conducted on 1008CR steel to determine primary process parameter effects; it is found that electricity can reduce cutting loads at the cost of an increased workpiece temperature. The knowledge generated from the DoE is applied to the advanced high strength steel to evaluate cutting force reduction, process time savings, and tool life improvement at elevated feedrates. It is found that force can be reduced by 50% in high feedrates without observing catastrophic tool failure for up to ten cuts, while tool failure occurs in only a single cut for the no-current condition. Finally, the limitations of the developed model in electroplastic drilling are discussed along with future suggestions for industrialization of the method.