Carbon Steel Research Articles

Effect of Change in Sulfuric Acid Concentrations and Different Temperatures on Corrosion of Heat-Treated Moderate Carbon Steel

This study looked at the effects of successive heat treatments (first quenching, first tempering, second quenching, and second tempering) on the corrosion rate of moderate carbon steel in a methodical manner. Using distilled water, the specimens were cooled at 10 oC following the initial quenching and at different temperatures (0, 10, 20, 30 oC) following the second quenching. Based on the results of repeated heat treatment experiments and corrosion rate experiments in these models, the moderate carbon specimens that underwent the heat treatments have a high corrosion resistance compared to the original models (prior to the application of the heat treatments). At different temperatures (298, 303, and 313 K) and concentrations (0.2, 0.3, and 0.4 N–H2SO4), in an acidic moderate. The study also showed that corrosion resistance decreases with concentration and with increasing corrosion-moderate temperature in heat-treated models. Another finding is that the models with the best corrosion resistance were those that underwent a second quench and cooling process. Another finding shows that the models with the highest corrosion resistance were those that experienced a second quench and were cooled in water at zero oxygen content.

Anti-corrosive efficacy of indanyl methacrylate copolymers ratio on mild steel in salt water and DFT investigations

Anti-corrosive efficacy of indanyl methacrylate copolymers ratio on mild steel in salt water and DFT investigations

Long-term anticorrosion performance of a modifier-free Ni-graphene superhydrophobic coating

The inherent corrosion vulnerability of mild steel triggered by harsh environments significantly affects its service life and leads to economic losses. Superhydrophobic coatings have been developed to inhibit this issue, and the robustness and facile preparation processes of water-repellent surfaces are crucial for their application. Herein, this study investigated the long-term anticorrosion capability of a modification-free Ni-graphene superhydrophobic coating prepared on mild steel using electrodeposition. Immersion tests, electrochemical measurements, and surface analyses were conducted to verify its durability. The corrosion behavior of the as-prepared coating was characterized in two stages. In the initial stage, the air cushion between the hierarchical structures effectively reduced the direct contact area at the coating-electrolyte interface. Over an extended period, the graphene-embedded coating with refined grains exerted a durable shielding action by providing a tortuous diffusion path for the penetration of corrosive agents. Through in-depth exploration, the anticorrosion mechanism of the Ni-graphene superhydrophobic coating was synergistically determined by the superhydrophobic features endowed by the surface structure and the shielding effect provided by the inner structure, which offers potential guidance for addressing the demands for corrosion protection of mild steel in long-term service processes.

Failure and optimization of composite-to-steel adhesive bonded Y-joints under three-point bending

This paper aims to investigate damage behavior and failure mechanism of adhesive-bonded Y-joints consisting of carbon fiber-reinforced polymer (CFRP) skins, PVC cores, and steel plates under three-point bending loading. Five three-point bending tests are adopted to study the load-bearing characteristic and damage mode of joint under different skin thicknesses and bending positions. Meanwhile, a procedure is developed to characterize the composite material failure by user-defined subroutine VUMAT, and numerical simulation is performed to reveal the flexural behavior and failure mechanism. Subsequently, structural optimization of the Y-joint is carried out in conjunction with ABAQUS-Isight, considering the thickness and lap length of CFRP skins. Reasonably good agreement is achieved when comparing the flexural behavior between experimental results and numerical predictions. These studies reveal that the bending load capacity of the Y-joint exhibits an increase with greater plate thickness, and the damage of plates and core is more serious when the bending location is near the core. Furthermore, the load-bearing capacity of Y-joint increases by 20.4% when the number of CFRP layers is 7 while the overlap lengths are 140 mm and 85 mm, respectively. This finding indicates that the optimized joint achieves a higher load-bearing capacity with a minor increase in mass.

Epoxy nanocomposites with dual filler system: Improving surface protection against wear and thermocyclic corrosion

This investigation explores the influence of dual nanofillers - multi-walled carbon nanotubes (MWCNT) and silicon nitride nanoparticles (SiN) - on the properties of epoxy (EP). Analyses of tribological characteristics show hybrid nanocomposite of 0.25/ 0.75 wt% of SiN/MWCNT filler system improves the wear resistance by 96 % compared to EP. Raman spectroscopy reveals a novel curing mechanism induced by SiN nanoparticles when incorporated into epoxy at room temperature, while DSC thermograms show SiN's role in enhancing the crosslinking density. Creep studies indicate that EP/SiN nanocomposites at 0.5 wt% loading reduced the creep rate by 99 % compared to EP over a 10-min duration at 60 °C. Dynamic mechanical analysis (DMA) illustrates a significant increase in storage modulus and a 13 °C increment in the glass transition temperature (Tg) for 0.5 wt% EP/SiN nanocomposites. High-resolution transmission electron microscopy (HR-TEM) ascertained the homogeneous dispersion of nanofillers in hybrid nanocomposites, suggesting improved and uniform stress transfer. SiN-based composites are more effective than MWCNT-based composites in protecting mild steel from corrosion with a coating efficiency of 87 %. The potential of SiN to reduce free amine groups responsible for the corrosion process is presented, while physisorption tests are conducted to evaluate pore size and volume in the corroded samples. Field emission scanning electron microscopy (FE-SEM) is employed to analyze worn-out and corroded surfaces comprehensively. In EMI shielding, SiN reduces reflectivity without affecting the absorptive capacity of MWCNTs, making them suitable for coatings in stealth applications.

Application of Resistometric Sensors for Real-Time Corrosion Monitoring of Coated Materials

Highly sensitive resistometric sensors were applied for the real-time corrosion monitoring of carbon steel protected with a polyolefin coating with and without an inhibitor under static and dynamic atmospheric and immersion conditions. The results were compared with conventional electrochemical impedance spectroscopy (EIS) data. An increase in the coating thickness from 20 µm to 50 µm and an addition of 1wt.% tannic acid significantly improved the coating corrosion stability. Based on the real-time corrosion data, the drying stage of atmospheric exposure in a chloride-rich environment was found to be the most critical. The highest corrosion rate was detected at 50% relative humidity when the electrolyte corrosiveness in coating defects reached the maximum. Resistometric sensors have the potential to become an interesting alternative for evaluating coating performance and degradation mechanisms in both laboratory and industrial applications.

Investigation of NALCO® EC1005A corrosion inhibitor on internal corrosion of pipelines

AbstractThe oil and gas industry relies mainly on pipelines to transport crude and refined petroleum, so crude oil is mostly transported via pipelines. The work presented the study of light naphtha solution collected at the Al-Diwaniyah Refinery in southern Iraq, along with four different pipeline materials (Ductile Iron, Carbon Steel X60, Carbon Steel X80, A105), in which NALCO® EC1005A (neutralizing amine) was used to inhibit corrosion at three concentrations: 0.03, 0.04, and 0.05%, respectively. Analysis of acidity content and immersion method were used to test all samples. This study examined the effects of temperature 45 and 55 °C and light naphtha content. The corrosion resistance of A 105 for pipe samples is highest; ductile iron has the lowest value, and X80 steel and X60 steel is moderately valued.

A chloride deposition model for predicting the categories of atmospheric corrosivity in coastal areas

Background: Marine atmospheres are the most corrosive, primarily because they contain sea salts. To assess the category of atmospheric corrosivity, the deposition rate of chloride ions should be measured by experimental methods for at least 1 year, which requires significant expenses and is not always feasible due to the time frame required for the design and erection of structures. Methods: In this study, a fairly simple model for predicting the chloride deposition rate in the coastal zone depending on the wind pattern of the test site, namely wind direction, average speed, and duration in each wind speed range, the distance from the coastline, and the magnitude of marine aerosol generation for each wind speed range, has been developed. The results of comparing the calculated chloride deposition rates with experimental data obtained by the ‘wet candle’ method are presented. Significant findings: The applicability of the model for predicting the categories of atmospheric corrosivity toward typical metals (carbon steel, zinc, copper and aluminum) using dose-response functions has been demonstrated.

Rare Earth 4‐Hydroxyphenylacetate Complexes: Synthesis, Structural Characterization, and Corrosion Inhibition Properties#

Four different structural types of rare earth aqua 4‐hydroxyphenylacetate complexes {[Ce(L)3(H2O)2]⋅H2O}n (a), {[RE2(L)6(H2O)]⋅4H2O]}n (RE = Nd (b), Gd (c)), {[RE2(L)6(H2O)]⋅3H2O]}n (RE = Dy (d), Y (e)), {[RE2(L)6(H2O)]⋅5H2O]}n (RE = Er (f), Yb (g)), (L = 4‐hydroxyphenylacetate) have been synthesized by the metathesis reactions of corresponding rare earth metals chlorides or nitrates and sodium 4‐hydroxyphenylacetate (NaL). All compounds were obtained as 1‐D polymeric structures, with a common carboxylate coordination mode of chelating bridging. The structure of a differs in being a monometallic repeating unit and having two coordinated waters whilst the others have binuclear repeating units that resulted from the alternating coordination of one water molecule along the chain. Corrosion tests by the weight loss method and potentiodynamic polarisation tests revealed that {[Gd2(L)6(H2O)]⋅4H2O}n has the best corrosion inhibition properties for mild steel in 0.01 M NaCl. Furthermore, all a‐g complexes are more effective corrosion inhibitors than both the aqua and 2,2’‐bipyridine (bpy) complexes of unsubstituted phenylacetate indicating that 4‐OH substitution of phenylacetate enhances anti‐corrosion properties.

Unravelling the role of calcareous deposits on hydrogen uptake: The duality in the calcite behavior

The permeation of hydrogen in carbon steel immersed in deaerated NaCl and artificial seawater solutions under various cathodic polarization is investigated using the Devanathan and Stachurski method combined with in-situ electrochemical impedance spectroscopy (EIS). The results indicate calcite's dual role in hydrogen uptake: it promotes uptake for bare samples and lower cathodic currents, but inhibits it for preformed deposits and higher cathodic currents. Deposits are characterized through in-situ EIS and scanning electron microscopy, providing further insights into the specific morphology of calcite. These findings are correlated with hydrogen permeation results, elucidating a mechanism for the dual behavior of calcite.

Research on Influence Mechanism of Nozzle Structure on Properties of Thick Carbon Steel Plate by Laser Cutting

Aiming at problems such as slow cutting speed, poor cutting quality and inability to cut thick plates effectively with traditional single-layer nozzle structure, it is proposed to add an outer ring core to form a double-layer nozzle structure on the basis of the single-layer nozzle structure to improve its cutting performance. The three-dimensional entity of single- and double-layer nozzle is established, and the simulation model of auxiliary gas flow field is established by using N-S equation and SST k-ω turbulence model assisted by laser cutting in this paper. The simulation results show that under the same cutting parameters, the auxiliary gas flow rate, oxygen concentration, mass flow rate, shear force and dynamic pressure of the double-layer nozzle structure are higher than those of the single-layer nozzle structure. In addition, compared with the single-layer nozzle structure, the double-layer nozzle structure can effectively improve the attenuation of oxygen concentration in the direction of sheet thickness. Two nozzle structures were used to laser cutting carbon steel plates with a thickness of 20 mm in the experiment, and the experimental parameters of cutting speed were 1.2–1.6 m/min. The comparison results show that the cutting speed and cutting section quality of the double-layer nozzle are better than those of the single-layer nozzle, and the results of simulation analysis are consistent with the cutting test results.

Smart Coating of Carbon Steel Using Polystyrene Clay Nanocomposites Loaded with Cerium and Silanol Inhibitors: Characterization and Electrochemical Study.

Local Khulays clay was modified to prepare polystyrene clay nanocomposite (PCN) coatings on carbon steel. The PCN coatings were added to microcapsules (MCs) loaded with the corrosion inhibitor PCN(MC). The microcapsules were prepared by the encapsulation of rare-earth metal Ce+3 ions and isobutyl silanol into polystyrene via the double emulsion solvent evaporation (DESE) technique. From characterization techniques, Fourier-transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), transmission electron microscopy (TEM), and scanning electron microscopy (SEM) with EDX. SEM and FT-IR confirmed the success of the preparation of the PCN(MC). Nanoindentation tests were performed on the thin-film samples. A significant reduction in both the hardness and the reduced modulus was observed for the PCN film compared to the PS film. Electrochemical impedance spectroscopy (EIS) and electrochemical frequency modulation (EFM) all showed an enhanced protection efficiency (%PE) of 3% PCN(MC) over 3% PCN at high temperatures and at different times. The smart coatings were proven by applying the thermal and the mechanical triggers for the 3% PCN(MC) coating. The mechanism of the release of inhibitors was discussed. The self-healing properties of 3% PCN(MC) were evaluated. The enhanced properties of the developed PCN(MC) coatings make them attractive for potential applications in the oil and other industries.

Surface modification to mitigate gaseous hydrogen effects in a 1800 MPa martensitic steel

A 0.8 % carbon steel was heat treated in air, resulting in an ultimate tensile strength of 1800 MPa and a highly ductile, dense and adhering decarburized ferritic layer, approximately 50 µm thick. The chemical composition and mechanical properties of this ferritic layer were thoroughly examined. Tensile testing and fractography revealed that the decarburized ferritic layer serves as a barrier, protecting the ultra-high strength martensitic steel from gaseous hydrogen-assisted fracture. This outcome implies that, in terms of preventing hydrogen-assisted fractures, the low hydrogen permeability of a protective surface layer is less critical compared to adjusted mechanical properties of the bulk material and surface layer.

Development of Costing Model for Butt Joint Process using Mild Steel with Robotic GMAW: A Malaysian Context

This paper is about the development of a costing model aimed at determining the pricing strategy for a component manufactured through the welding process. Cost estimation in welding processes is crucial for industries due to various influencing factors like welding time, length, and joint type. Calculating welding costs involves considering various methods and factors. One method compares theoretical filling metal amounts with on-site welding material consumption, factoring in the welding difficulty coefficient. Additionally, Time Driven Activity Based Costing (TDABC) is one of the costing methods used to analyze input data and estimate welding costs accurately and efficiently, specifically in the GMAW process. Moreover, a comprehensive costing model developed by ESAB incorporates variables such as labor costs, electrode expenses, shielding gas usage, and overall power costs. In this paper, the selected welding design configuration is a double Vgroove butt joint using mild steel, ER70S-3 as filler wire, and S235 mild steel as substrate. Based on the chosen design, the welding cost model will be developed to analyze the cost of the butt joint welding process based on timedriven activity-based costing (TDABC) method. The outcome of this study is the total cost to manufacture the Double V-Groove butt joint project in terms of materials, labor, and equipment. Furthermore, subsequent efforts will be directed toward systematically enhancing the welding cost model to include a broader spectrum of materials, various part dimensions, and differing deposition rates.

Preparation of tannic acid-based conversion coating and corrosion protection performances for steel in chlorinated simulated concrete pore solution

A tannic acid-based conversion coating (TACC) has been developed on steel surface to protect carbon steel within a chlorinated simulated concrete pore solution (Cl-SCPS). The morphology, composition, and protective efficacy of TACC for carbon steel are examined through using SEM, FT-IR, Raman, EDS, XPS, and electrochemical measurements. The findings reveal that TACC significantly enhances the corrosion resistance of carbon steel. The TACC with a 2-min treatment showcases the optimal corrosion protection for steel, sustaining a protection efficiency of 99.84 % even after a 7-day exposure period. As the samples are exposed to the Cl-SCPS, the passivation products formed serve to fill the pores in the TACC, thereby enhancing its compactness and protective capabilities.

Corrosion Risk Prediction of Carbon Steels by Hyperspectral Analysis

Corrosion Risk Prediction of Carbon Steels by Hyperspectral Analysis

Application of Admittance Analysis for Corrosion Rate Evaluation of Carbon Steel with Rust Layer in Electrochemical Impedance Spectroscopy

Application of Admittance Analysis for Corrosion Rate Evaluation of Carbon Steel with Rust Layer in Electrochemical Impedance Spectroscopy

Relation between Surface Appearance and Corrosion Depth Distribution of Carbon Steel under Atmospheric Corrosion Environment

Relation between Surface Appearance and Corrosion Depth Distribution of Carbon Steel under Atmospheric Corrosion Environment

Sterilized Chicken Feather as Eco-friendly Corrosion Inhibitor for Mild Steel in a Water- Based Drilling Mud – Gravimetric and FTIR Assessment

This research evaluated the corrosion performance of mild steel in sterilized and unsterilized alkaline mud corroding systems using chicken feather powder (CFP) obtained through the usual hydrolysis and acid neutralization protocol. Insightfully, gravimetric analysis revealed that bacterial infestation of the unsterilized environment caused its corrosion performance to be lower at 10.3% while the sterilized counterpart stood at 49% at 92 days of exposure to the environments respectively. The functional groups, C=N, O=C=O, H-C=O etc, revealed by FTIR to be present in the protein saturated feather were overwhelmed by microbial activities rendering them inactive to perform as inhibitors.

SELECTION OF TOOLS AND MACHINING PARAMETERS FOR PIPE WALLS

This review paper examines the techniques and factors involved in pipe wall processing, with a focus on the essential technologies utilized in this field. The study revealed crucial elements, such as ASTM A350-LF2 Class 1 carbon steel, renowned for its exceptional mechanical qualities and ability to withstand low temperatures. An exhaustive analysis has been conducted on the chemical makeup of this steel to comprehend its capacity to adjust and endure in various operational environments. The study focused on examining several particle separation processes, including as turning, milling, drilling, and grinding, in order to determine the exact equipment and criteria needed for each technique. The cooling and lubricating process received particular emphasis, with thorough investigation of several agents, including CASTROL HYSOL T15, and their impact on surface quality and tool longevity. The utilization of these compounds has been discovered to substantially decrease tool temperature and enhance machining quality. Upon closer examination of the processing techniques specified in section A-A of the tube wall, it was determined that advanced procedures such as floating plug drawing and micro-sized spiral tube hydroforming were discovered. These techniques allow the attainment of superior surface quality and precise dimensions, which are crucial for guaranteeing the structural integrity of the pipe. Cutting tools, processing equipment, and coolants and lubricants are essential components in the manufacturing of pipe walls. Nanoparticulate cooling and lubrication systems, which are advanced technologies, have demonstrated their effectiveness in minimizing friction and heat during machining. As a result, these systems enhance productivity and prolong the lifespan of tools. According to the article, the essential components for attaining high-quality manufacture of pipe walls are cutting tools, processing equipment, and coolants and lubricants. Additional study is advised to enhance processing parameters, create eco-friendly coolants and lubricants, and utilize artificial intelligence for predictive modeling and optimization of processing. This establishes the groundwork for future research and innovation in the pipe wall production business, with the objective of attaining enhanced efficiency and sustainability in production processes.