Carbon Steel Research Articles

Multiaxial stress effects on bonding strength in adhesively bonded joints

ABSTRACT This study investigates adhesive bonding as a crucial engineering technique for joining materials, with a focus on load distribution, structural enhancement, and weight reduction. Advances in adhesive formulations, surface preparation, and application techniques continue to expand its capabilities. The research addresses stresses in hybrid joints resulting from pre-tensioning bolts and subsequent axial loading, emphasizing the influence of normal stresses on the critical adhesive-steel interface. Off-axis samples are bonded to mild steel using four different adhesives: SW7240, S370, DP460 (2K-epoxies), and SF479 (2K polyurethane). The choice of adhesive significantly influences shear strength under various loading conditions. Formulating this interaction in terms of maximum shear or von Mises stresses leads to relatively complex failure criteria that make the further analysis dependent on each adhesive. On the other hand, expressing strength at maximum principal stress significantly simplifies comparative analysis, as it consistently exhibits an almost linear trend, indicating strength reduction with increasing hydrostatic pressure for all adhesives, potentially simplifying subsequent strength predictions of hybrid joints.

Quantitative phase-field model to simulate low carbon steel aqueous corrosion phenomena

A quantitative phase-field model has been developed to simulate aqueous corrosion on low carbon steel under chloride-based electrolytes at different pHs. All relevant transport phenomena are included through physically interpretable variables. In particular, both diffusion and migration charge transport are modelled. Separated electrical potentials for the electrolyte and the metal are considered, and physically meaningful boundary conditions are provided. Using this model, different polarization conditions can be predicted and many parameters not observable/challenging during experiments, can be obtained. Finally, since the proposed model includes different time scales, a segregated numerical integration algorithm is proposed to speed up simulations.

The mechanism of recrystallization of carbon steels

The mechanism of recrystallization of carbon steels

Microstructure Evolution and Fretting Wear Mechanisms of Steels Undergoing Oscillatory Sliding Contact in Dry Atmosphere.

Variations in the microstructure and the dominant fretting wear mechanisms of carbon steel alloy in oscillatory sliding contact against stainless steel in a dry atmosphere were evaluated by various mechanical testing and microanalytical methods. These included scanning electron microscopy and energy dispersive spectrometry with corresponding elemental maps of the wear tracks, in conjunction with cross-sectional transmission electron microscopy of samples prepared by focused ion beam machining to assess subsurface and through-thickness changes in microstructure, all as a function of applied load and sliding time. Heavily dislocated layered microstructures were observed below the wear tracks to vary with both the load and sliding time. During the accumulation of fretting cycles, the subsurface microstructure evolved into stable dislocation cells with cell walls aligned parallel to the surface and the sliding direction. The thickness of the damaged subsurface region increased with the load, consistent with the depth distribution of the maximum shear stress. The primary surface oxide evolved as Fe2O3 and Fe3O4 with increasing sliding time, leading to the formation of a uniform oxide scale at the sliding surface. It is possible that the development of the dislocation cell structure in the subsurface also enhanced oxidation by pipe diffusion along dislocation cores. The results of this study reveal complex phase changes affecting the wear resistance of steels undergoing fretting wear, which involve a synergy between oxidative wear, crack initiation, and crack growth along dislocation cell walls due to the high strains accumulating under high loads and/or prolonged surface sliding.

Experimental Investigations of a Springback in Hydromechanical Deep Drawing of Low Carbon Steel 1008 AISI

Hydro mechanical deep drawing (HMDD) is an emerging technology that reduces the number of sheet-forming stages and increases the production of advanced lightweight materials with intricate shapes. This study aims to verify the springback in HMDD and the effect of holding time and fluid pressure on this phenomenon (springback). The springback was measured using a new method by matching the projector p-300 axes with the cylindrical cup wall. The difference between the wall and the axis represents the springback value. Using a blank of low carbon steel (1008-AISI) with 80 mm of diameter and a thickness of 0.7 mm. The effect of holding time (1, 2, and 3 minutes) and the fluid pressure (0.6, 0.8, and 1 N/mm2) was studied. The used hydraulic oil was (code number 3803). The springback value of a cylindrical cup was calculated using the profile projector P-300. The result showed that the springback phenomenon was presented in the hydromechanical deep-drawing process but at a lower rate than the traditional deep-drawing process. The holding time and fluid pressure significantly affected the springback value. The springback decreased with increasing the fluid pressure and holding time.

High‐potent trifunctional polybenzoxazines coatings for superhydrophobic cotton fabrics and mild steel corrosion protection applications

AbstractNew trifunctional polybenzoxazines were developed and utilized as a high‐potent coating material for superhydrophobic cotton fabrics and mild steel corrosion protection applications. New trifunctional benzoxazines resin have been synthesized using trihydroxytriphenylmethane (TTM) with dimethylaminopropylamine (dmapa), 1‐(3‐aminopropyl)imidazole (ipa) and aminoethoxyethanol (aee) as amine sources with paraformaldehyde through Mannich condensation. The structural confirmation of synthesized benzoxazines was ascertained by spectral studies. The ring opening polymerization of TTM‐Bzs was studied using DSC analysis. All the three TTM‐Bz monomers show curing temperature lower than 210°C. The thermo‐stability and water contact angle (WCA) of polybenzoxazines were studied using thermogravimetric analysis and goniometer, respectively. Among the TTM‐PBz studied, the poly(dmapa) exhibit better thermo‐stability and hydrophobic behavior when compared to rest of the synthesized polybenzoxazines. Poly(TTM‐dmapa)‐coated cotton fabric exhibits the superhydrophobic behavior and mild steel (MS)‐coated specimen possesses the higher charge transfer resistance value of 3.47 × 107 Ω cm2. It was also inferred that all the TTM‐PBz‐coated MS specimens exhibit higher corrosion protection behavior as well as good thermo‐stability and hydrophobic nature. Further, the obtained results suggested that these materials can be suitably exploited for hydrophobic anticorrosion applications with improved performance and enhanced longevity.

Experimental and theoretical investigation of 1-Hexyl-3-methylimidazolium iodide as a corrosion inhibitor for mild steel in HCl environment

This study employed 1-Hexyl-3-methylimidazolium iodide to mitigate the corrosion of Q235 steel in a hydrochloric acid environment. The evaluation of corrosion inhibition effectiveness was comprehensively characterized by combining electrochemical experiments with surface morphology observation. The experimental results demonstrated the capability of the ionic liquid in establishing a film layer on the surface of Q235 steel, which effectively hindered the charge transfer process. Notably, the corrosion inhibition efficiency attained a value of 92.3% at a concentration of 1 mM corrosion inhibitor. Moreover, the process of the corrosion inhibitor adhering to the steel surface aligns with the Langmuir isotherm, demonstrating physicochemical adsorption behavior. The density functional theory (DFT) and molecular dynamics (MD) simulation were utilized for further exploration of the corrosion inhibition mechanism, and the results indicate the ionic liquid can be adsorbed onto the (110) surface of Fe in parallel through N atoms on the imidazole ring.

Surface Characteristics and Corrosion Tendency of TIG-Welded Low Carbon Steel Sheet Affected Cold Galvanizing and Processed by Immersion in Sodium Chloride Solution

Surface Characteristics and Corrosion Tendency of TIG-Welded Low Carbon Steel Sheet Affected Cold Galvanizing and Processed by Immersion in Sodium Chloride Solution

Corrosion inhibition of P110 carbon steel useful for casing and tubing applications in 3.5% NaCl solution using quaternary ammonium-based copolymers

In this study, two quaternary ammonium-based copolymers (DAC-DAD10 and DAC-DAD20) with varying hydrophilicity/hydrophobicity are synthesized, characterized, and their capacity to suppress P110 carbon steel (P110 CS) corrosion in 3.5% NaCl is examined. DAC-DAD10 and DAC-DAD20 were synthesized using diallylammonium chloride (DAC) and N1, N1-diallyl-N6-dodecyl-N6, N6-dimethylhexane-1,6-diaminium dichloride (DAD) and their inhibition potential (%IE) and mechanism were studied by different experimental and computational methods. The outcomes suggest that the %IE of DAC-DAD10 and DAC-DAD20 increases on increasing the hydrophobicity as DAC-DAD20, having a large hydrophobic alky chain, showed relatively better %IE than DAC-DAD10. DAC-DAD10 and DAC-DAD20 manifest the best %IE of 88.68% and 96.17%, respectively, at concentrations as low as 3 mgL-1. Potentiodynamic polarization studies indicate that they behave as cathodic-type inhibitors. Their adsorption on the metallic surface followed the Langmuir adsorption isotherm. Various surface analyses, including SEM-EDS, and XPS, confirm that they adsorb at the metal and electrolyte interface and build a corrosion protective layer. DFT study suggests that quaternary nitrogen atoms easily deprotonate and coordinate with the metallic surface using their unshared electron pairs. The corrosion inhibition based on experimental and computational analyses is schematically presented and described.

Effect of Friction Time on Temperature Distribution, Plastic Flow, Microstructure, and Properties in Friction Welding of 1045 Carbon Steel and AISI 430 Ferritic Stainless Steel

Effect of Friction Time on Temperature Distribution, Plastic Flow, Microstructure, and Properties in Friction Welding of 1045 Carbon Steel and AISI 430 Ferritic Stainless Steel

Comparative Investigation of the Corrosion Protection Efficacy of Spondias mombin Leaf Extracts on AA2024 Alloy and Low Carbon Steel in Acidic Medium

The anti-corrosive property of Spondias mombin (SM) leaves extract on low carbon steel (LCS) and aluminium alloy (AA2024) in 1M HCl solution was investigated using gravimetric and electrochemical methods. The results obtained from the weight loss experiment performed at various temperatures (30, 45, and 60 0C) show that the inhibition efficiency values decreased with temperature rise but increased as the inhibitor concentrations were increased. At 30 0C, optimum inhibition efficiency (IE) of 80.11% and 78.06% were obtained for LCS and AA2024 respectively. The potentiodynamic polarization (PDP) result reveal that an optimum IE values of 92.1% and 74.0% were respectively obtained for LCS and AA2024 while the electrochemical impedance spectroscopy (EIS) data show IE values of 91.5% and 74.5% for LCS and AA2024 respectively. In all cases, the values of inhibition efficiency obtained for LCS were greater than those obtained for AA2024. This implies that SM leaf extracts offers a better protective-layer on LCS surface compared to the AA2024 alloy in the acidic medium. The isotherm study reveal that Langmuir model best fitted the adsorption of the leaf extracts on LCS while Freundlich model best fitted the leaf extracts adsorption on AA2024 surface.

Unraveling the Adsorption and Corrosion Resistance Mechanisms of Pyran-Pyrazole Analogs for Carbon Steel Corrosion in Hydrochloric Acid Based on Practical Approaches and Theoretical Calculations

Unraveling the Adsorption and Corrosion Resistance Mechanisms of Pyran-Pyrazole Analogs for Carbon Steel Corrosion in Hydrochloric Acid Based on Practical Approaches and Theoretical Calculations

Zwitterion modified chitosan as a high-performance corrosion inhibitor for mild steel in hydrochloric acid solution

Herein, a novel chitosan Schiff base (CS-FGA) as a sustainable corrosion inhibitor has been successfully synthesized via a simple amidation reaction by using an imidazolium zwitterion and chitosan (CS). The corrosion inhibition property of CS-FGA for mild steel (MS) in a 1.0 M HCl solution was studied by various electrochemical tests and physical characterization methods. The findings indicate that the maximum inhibition efficiency of CS-FGA as a mixed-type inhibitor for MS in 1.0 M HCl solution with 400 mg L−1 reaches 97.6 %, much much higher than the CS and the recently reported chitosan-based inhibitors. Scanning electron microscopy (SEM), atomic force microscopy (AFM), and water contact angle (WCA) results reveal that the CS-FGA molecules firmly adsorb on the MS surface to form a protective layer. The adsorption of CS-FGA on the MS surface belongs to the Langmuir adsorption isotherm containing both the physisorption and chemisorption. According to the X-ray photoelectron spectroscopy (XPS) and UV–vis spectrum, FeN bonds presented on the MS surface further prove the chemisorption between CS-FGA and Fe to generate the stable protective layer. Additionally, theoretical calculations from quantum chemical calculation (DFT) and molecular simulations (MD) were performed to reveal the inhibition mechanism of CS-FGA.

Synergistic effect of α-alumina integrated silica ceramic nanocomposites prepared using waste beverage cans and rice husk for corrosion protection application

In this study, we investigated the synergistic effect of α-alumina-integrated silica nanocomposites as a promising material for corrosion protection. We synthesized these nanocomposites in different proportions (90 wt% silica:10 wt% alumina (AS-1) and 70 wt% silica:30 wt% alumina (AS-2)) via ball milling using rice husk and waste beverage cans as the precursor source. XRD, FTIR and EDX analysis of α-Al2O3 integrated silica nanocomposites revealed distinct peaks corresponding to both silica and α-Al2O3 components, confirming the successful formation of the nanocomposites. FESEM and TEM analyses showed that the α-alumina and silica nanoparticles were agglomerated and inhomogeneous, with sizes ranging from 150 nm to 250 nm. Electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization tests showed that pure silica, AS-1, and AS-2 had corrosion rates of 1.7648, 0.4396, and 0.0610 mm/yr, respectively. AS-1 and AS-2 exhibited higher charge transfer resistance (Rct) values of 34.54 KΩ and 48.60 KΩ, respectively, compared to pure silica (24.4 KΩ). Nyquist and Bode plots revealed the improved corrosion resistance of α-alumina-integrated silica nanocomposites compared to pristine silica-based protective coatings on mild steel. It is noted that the amount of α-alumina content enhances the corrosion resistance efficiency of the nanocomposites. The synergistic effect of the α-alumina-integrated silica nanocomposites can be attributed to the improved barrier properties and forming a protective layer on the metal substrate, effectively mitigating the corrosion process.

Embroidered Property Materials: A Novel Strategy for Developing Patterned Materials

Embroidered property materials (EPMs) represent a paradigm shift in materials engineering, offering a novel approach to conventional material modifications. Through a precise “embroidering” of properties in precise locations, EPMs optimize existing substrates without the need for additional or removal layers. This technique, realized through the activation of targeted chemical and physical phenomena, enables the local alteration of the microstructure in response to controlled external stimuli, exemplifying the deliberate design of material zones with predefined properties. Demonstrating this concept, bulk and confined laser treatment is precisely applied to standard carbon steel (C45), resulting in localized martensitic transformation. This localized microstructural change manifests in a significantly altered deformation behavior when contrasted with untreated areas, emphasizing the potent capabilities of EPMs. The potential unleashed by EPMs extends to the creation of innovative functional materials, enabling the bespoke manipulation of material properties with precision reminiscent of the art of embroidery. This approach not only expands the horizons of component design but also introduces a sustainable methodology for achieving novel material performance, thereby serving as a cornerstone for future advancements in the field. EPMs provide a versatile and powerful tool for the engineering of high‐performance materials that meet specific design and functional criteria.

Corrosion of ribbed carbon steels in ecological mortars and its influence on their rotative fatigue behavior

Ribbed carbon steel rebars were embedded in mortars manufactured with three different eco-friendly binders (alkali-activated slag, and slag and fly ash-based hybrid cements) and with a commercial cement (CEM IV). This research evaluates the corrosion of reinforcements, fully assessed by natural diffusion, and its impact on the fatigue performance of the bars. Results obtained after 17-month corrosion testing on reinforced innovative mortars reveal that different pit morphologies and locations appear on the bars depending on the mortar composition, with the extent of the attack being related to the pH and the free-chloride content in each mortar. Rotative fatigue tests of the corroded bars have proven that the reduction of the fatigue life is dependent on the global extent of the corrosive attack, when the shape and distribution of the pits correspond to those generated exclusively by chloride diffusion in mortars. Bars corroded in alkali-activated slag and CEM IV mortars shown the best fatigue performances.

Co-electrodeposition of superhydrophobic NiCo/CeO2 coating with hierarchical nano/micro structure for corrosion protection of plain carbon steel

This study aimed to develop an effective corrosion protection strategy for carbon steel by employing a superhydrophobic NiCo coating modified with CeO2 nanoparticles through the co-electrodeposition method. The superhydrophobicity was achieved by adjusting the composite coating's morphology and surface roughness. The synergistic impact of CeO2 and EDA crystal modifier on the coating's morphology, composition, topography, corrosion protection performance, and wetting properties was systematically investigated. The SEM results revealed the formation of a flower-like nano/micro morphology in the presence of EDA, and this morphology was preserved with the addition of 4 g/L CeO2 into the electrolyte. Surface wettability was significantly influenced by the hierarchical nano/micro structure of the deposited coating, with an enhanced superhydrophobicity observed in the presence of CeO2. The increase in surface roughness and compaction, achieved by incorporating CeO2 nanoparticles into the hierarchical structure of the NiCo coating, played a pivotal role in creating a superhydrophobic surface. Furthermore, polarization and EIS tests demonstrated that the superhydrophobic NiCo-EDA/CeO2 coating exhibited excellent anti-corrosion performance for the carbon steel substrate. In this case, Ecorr shifted towards positive values, icorr decreased, and both charge transfer resistance and coating resistance showed a considerable increase compared to other studied coatings. The alteration of metal wettability to a superhydrophobic state, combined with the barrier role of the coating and the presence of ceramic reinforcements (CeO2), offers comprehensive protection to the steel substrate. This approach holds great promise for effectively controlling the corrosion rate of widely used engineering metals.

Synthesis, surface activity, and corrosion inhibition capabilities of new non-ionic gemini surfactants

Several environmentally acceptable non-ionic gemini surfactants are synthesized in this work using natural sources, including polyethenoxy di-dodecanoate (GSC12), polyethenoxy di-hexadecanoate (GSC16), and polyethenoxy di-octadecenoate (GSC18). The produced surfactants are confirmed by spectrum studies using FT-IR, 1HNMR, and 13CNMR. It explored and examined how the length of the hydrocarbon chain affected essential properties like foaming and emulsifying abilities. Surface tension examinations are used to assess the surface activity of the examined gemini surfactants. The lower value of critical micelle concentrations (0.381 × 10−4M) is detected for GSC18. Their spontaneous character is shown by the negative values of the free energy of adsorption (ΔGads) and micellization (ΔGmic) which arranged in the order GSC18 > GSC16 > GSC12. Based on theoretical, weight loss, and electrochemical investigations, these novel surfactants were investigated for their possible use in inhibiting carbon steel from corroding in 1 M HCl. Measuring results show that GSC18 inhibits corrosion in carbon steel by 95.4%. The isotherm of adsorption evaluated for the investigated inhibitors and their behavior obeys Langmuir isotherm.

PERFORMANCE OPTIMIZATION OF BS970 MILD STEEL TURNING PARAMETERS UNDER SiC-MoS2 HYBRID NANOFLUID USING HYBRID DEEP BELIEF NETWORK BASED COOT OPTIMIZATION

In the modern world of competitive manufacturing, turning is a basic and important process that needs to be optimized for the fast-evolving industrial nature. It has its application in various fields involving numerous materials. This research study deals with modeling with optimization on the turning process parameters of turning E2-BS970 mild steel with cryogenically treated tungsten carbide tool under NFMQL having [Formula: see text] nanofluid. The parameters considered as the input factors are spindle speed and depth of cut along with feed rate and lubrication condition. The design of the experiment is done based on Box–Behnken design for 27 trials in the response surface method. The Deep Neural Network (DBN) and the Coot optimization algorithm are employed using MATLAB software for the prediction modeling. The prediction model developed by the DBN sigmoid function gave minimal error with prediction regression values of 0.99988 for MRR, 0.99516 for Cutting temperature, and 0.99545 for Tool life. The optimized result by CO shows a value of 188.89 rpm for spindle speed, 0.2318[Formula: see text]mm/rev for feed rate, Doc of 1.45[Formula: see text]mm, and 0.5015[Formula: see text]vol.% nanofluid MQL condition. The optimized values of MRR are 3.35[Formula: see text]mm3/min, [Formula: see text]C cutting temperature, and 1543.12[Formula: see text]s of tool life. The DBN model combined with the Coot algorithm shows minimal deviation compared to the experimental results validation and confirmatory analysis and is deemed suitable for efficient prediction.

Corrosion behavior and protection mechanism of carbon steel coated with ethylene chlorotrifluoroethylene (ECTFE)

Corrosion behavior and protection mechanism of carbon steel coated with ethylene chlorotrifluoroethylene (ECTFE)