Carbon Steel Research Articles

The effect of forming conditions and treatment process applied to the material on springback

Abstract Heat treatment is often used to optimize the balance between the strength and formability of a material. However, aging during treatment affects the ability to return to its original shape after deformation. In this study, the effects of surface treatments during the painting of mild steel and aging time in the W-temper heat treatment on springback were investigated. Consequently, because of artificial aging during surface treatment, the material precipitates certain phases and enhances the mechanical properties of the material, which leads to the pre-painted mild steel being more sensitive to springback. On the other hand, it is also noted that springback is highly dependent on the transfer time between the W-temper heat treatment of high strength aluminum alloy and forming operations, and the change in shape increases with time. In summary, the springback phenomenon is a result of the interaction between the material properties, treatment procedures, and forming circumstances.

WITHDRAWN: Moroccan Cannabis sativa L plant extract as green corrosion inhibitor for mild steel in 1 M HCl solution

Cannabis Sativa L Extract (CSLE) action on the electrochemical properties of mild steel in 1M HCl solution was studied, using potentiodynamic polarization and electrochemical impedance spectroscopy. The findings revealed an improvement in corrosion inhibition efficiency when extracts concentrations increase, achieving an inhibitory efficiency of 96.68% at 10% (v/v) of CSLE. Moreover, the temperature influence on the effectiveness of the extract has been studied over a range of 293-338K and findings proved the inhibitor adsorption according to mono-layer barrier film conformed to Langmuir isotherm. Corrosion kinetics and thermodynamic factors were calculated and discussed. Furthermore, the DFT method has been exploited to describe the corrosion inhibitory mechanism.

Reuse and Recovery of Water from Industrial Textile Dyeing Effluent Using High-Performance Electrodes Continuous Flow Electrocoagulation Reactor

The dye effluents released from the textile and printing industries contain strong colorants, inorganic salts, and other toxic compounds. The conventional coagulation technique of dye effluent treatment is plagued with issues of low removal rate of color, generation of large quantities of sludge, and toxic end-products. Recently electrocoagulation technique gained immense attention due to its high efficiency. This technique involves the dissolution of the sacrificial anodes to provide an active metal hydroxide as a strong coagulant that destabilizes the pollutants and removes them by precipitation or flocculation. This study is about the efficiency of the electrocoagulation process using titanium coated - aluminum and mild steel electrodes to treat industrial dye wastewater. Effects of parameters such as current density & initial dye concentration were investigated. It was observed that, for the same current density, electrode consumption was higher with TiO2/Al electrode than with mild steel electrode, resulting in more color removal efficiency (CRE) using TiO2/Al electrode. The settling rate of the flocs was higher in the rector having TiO2/Al electrode at the 100 mL with current density (2.5 mL.min-1 to 5.3 mL.min-1), while in the reactor with mild steel electrode, the settling rate was very less. The results showed that dye removal was 95.11% and 92.1% for mild steel and titanium-coated electrodes, respectively. It was observed that 50 % of Aluminum was removed from the treated effluent after the final stage of filtration. Based on the multicriteria analysis to identify the optimum operational parameters to be applied at the field level, it was observed that maximum CRE may be obtained with TiO2/Al electrode and the applied current of 1 Amps with a flow rate of 100 mL.min-1. It can be concluded that electrocoagulation is a highly efficient and the fastest method to treat dye effluents from industries.

Exploration on the corrosion inhibition performance of Salvia miltiorrhiza extract as a green corrosion inhibitor for Q235 steel in HCl environment

Salvia Miltiorrhiza, extensively distributed and commonly employed as a traditional Chinese medicinal herb, has garnered significant attention. In this study, the Salvia Miltiorrhiza extract (SME) was prepared by one-step water extraction method, and was firstly used as a novel corrosion inhibitor for Q235 steel in 1 mol/L HCl solution. As identified via liquid chromatography-mass spectrometry, the findings reveal that Salvianic acid A, tanshinone II A, danshenxinkun D, dihydrotanshinone, and methylene tanshinquinone are the primary constituents of SME. The optimum corrosion inhibition efficiency reached 92.8 % at 200 mg/L and maintained at 90.4 % after 72 h. Based on in-situ scanning vibration electrode technology (SVET) monitoring, the adsorption of inhibitor molecules on metal surface greatly retarded the propagation of localized corrosion. AFM examination of the corroded surface reveals that the samples supplemented with SME exhibit a smoother surface compared to the blank group. The force curve graph for the SME-added group demonstrates a more evenly distributed point array and an elevated average adhesion force, indicating that the addition of SME improves the corrosion resistance of the metal surface. XPS characterization illustrated that SME interacted with iron ions to form insoluble precipitate. This work investigated the application of SME as an eco-friendly corrosion inhibitor for carbon steel in acidic medium, providing a new approach for the high value-added utilization of Salvia Milliorrhiza.

P23-19 Cell-specific responses to mild and stainless steel welding particles in bronchial epithelial and macrophage-like cells

P23-19 Cell-specific responses to mild and stainless steel welding particles in bronchial epithelial and macrophage-like cells

Optimization, molecular dynamics and quantum parameters simulations of Zingiber officinale rhizome as a green corrosion inhibitor

This study combines experimental and theoretical approaches to investigate ginger root extract (GRE) as an eco-friendly corrosion inhibitor for mild steel in acidic environments at temperatures ranging from 303 to 333 K. Experimental techniques, including weight loss measurements, were used to assess the inhibiting performance and adsorption behavior of GRE, while GC-MS, FT-IR, and UV–visible spectrophotometric methods provided further characterization. Results indicated that the inhibition efficiency of GRE increased with higher concentrations and decreased with temperature, highlighting its potential to effectively prevent corrosion in H2SO4 medium. GC-MS analysis identified four major phenolic compounds—6-gingerol, 6-isoshogaol, zingerone, and vanillyl glycol—and two secondary metabolites, α-Farnesene and β-Bisabolene. Among these, 6-gingerol, the most active and abundant constituent, was selected for computational studies. Optimal corrosion inhibition of 81.3 % was achieved at 303 K with a GRE concentration of 10 g/L for 1 h. Thermodynamic activation parameters suggested a temperature-dependent process, and alignment with the Langmuir isotherm indicated a physical adsorption mechanism. Quantum chemical calculations for 6-gingerol revealed highest occupied molecular orbital energy (EHOMO) and lowest unoccupied molecular orbital energy (ELUMO) values of -6.286 eV and -0.366 eV, respectively, in its protonated state, and -8.338 eV and -0.247 eV, respectively, in its neutral state. Molecular simulations showed a binding affinity of -4.736 kJ/mol between 6-gingerol and the steel surface, supporting the experimental findings and underscoring the potential of GRE as an effective corrosion inhibitor.

Experimental and Quantum Chemical Studies of a Green Corrosion Inhibitor for Mild Steel in Acidic Chloride Solution

AbstractA green corrosion inhibitor was prepared from the bio‐based platform compound 5‐hydroxymethylfurfural through a green synthetic route, which avoid the use of toxic reagent. The inhibition performance and mechanism of this compound for the corrosion of mild steel in 0.1 M HCl was investigated by using the weight loss experiments, polarization measurements, EIS measurements and quantum chemical calculations. The corrosion inhibition efficiency by weight loss measurement (ηWLM%) of this inhibitor can reach up to 90.3 % at 303 K with 1.2 mM concentration. Moreover, the electrochemical experiments revealed that this corrosion inhibitor acts as a mixed‐type inhibitor. Thermodynamic studies gave the values of the standard Gibbs free energy , fall within the range of −20 kJ/mol to −40 kJ/mol, suggested the adsorption of this compound is a spontaneous process involving both physisorption and chemisorption. In addition, quantum chemical calculations were conducted to further validate the formation of an effective absorption layer by this inhibitor on metal surfaces, which showed that the electron density iso‐surfaces of HOMO was mainly distributed on chloride ions, while LUMO tended to be distributed on furan rings and aldehyde groups. Besides, the other quantum chemical parameters of this inhibitor were also calculated to explore the molecular activity, such as, the molecular volume (ν, 333.105 Å), global hardness (η, 4.706 eV), global softness (σ, 0.2125 eV), electronegativity (χ, 4.93 eV), dipolemoment (μ, 13.1429 D) and vertical ionization energy (VIE, 7.2646 eV).

Use of Tungsten Inert Gas Welding on Mild Steel Weldment to Optimize Welding Process Variables on Electrode Melting Rate

One of the most crucial factors taken into account when evaluating the performance of Tungsten Inert Gas (TIG) welding is the Electrode Melting Rate, which shows how much of the heat deposited by the welding operation is used to generate melting. A dense weld pool forms in the field of welding when there is a good melting rate. Therefore, this paper investigates the use of tungsten inert gas welding on mild steel weldment to optimize welding process variables on electrode melting rate employing Artificial Neural Networks and Response Surface Methodology in the analysis. The ideal electrode melting rate of 4.6539 mm/s can be achieved by combining the following parameters: wire diameter of 2.55 mm, welding speed of 3.02 mm/s, and welding current of 208.22A, according to the RSM results. R values of 0.9119 were displayed by the RSM for the electrode melting rate. A regression plot of the ANN results indicates that the total R value is 0.93807. Because the Artificial Neural Network's output fits the experimental data more closely than the Response Surface Methodology's, it is chosen as the superior predictive model.

Defect Evaluation in Mild Steel Plate Using Harmonic Ratio Induced by Square Wave Excitation Field and Nonlinear Magnetization

Defect Evaluation in Mild Steel Plate Using Harmonic Ratio Induced by Square Wave Excitation Field and Nonlinear Magnetization

Experimental and theoretical study of two Salen-type Schiff bases: green synthesis, characterization, corrosion inhibition efficiency, and biological activity

As eco-friendly corrosion inhibitors, antioxidants, and antibacterial agents, this study assesses 1,3-bis(2-hydroxybenzylidene) thiourea (B1) and 1,3-bis(2-hydroxybenzylidene) urea (B2), two new Schiff bases, on their performance in these areas. We successfully synthesized these Schiff bases in just 15 minutes using an environmentally friendly approach, and the yield was rather good, ranging from 69.8% to 87.53%. When compared to B2, B1 showed more effective corrosion inhibition and better antioxidant activity. Both chemicals were highly effective against microbes, while B1 was particularly effective against Aspergillus. B. We measured the weight loss to examine the corrosion inhibition impact of XC48 carbon steel in 1M HCl. The findings revealed that at the ideal concentration of 5.10–4 M, the estimated IE% of the Schiff bases was 63.8% for B2 and 87.28% for B1. This study employed the Langmuir isotherm model to determine a number of thermodynamic and kinetic characteristics, all of which pointed to a physical adsorbed state. Promising electrical characteristics and robust adsorption on metal surfaces for B1 were corroborated by theoretical investigations employing density functional theory (DFT) and molecular dynamics (MD) simulations. Both the theoretical and practical aspects align with one another.

Study of the fatigue fractography of dual phase low carbon steel used in automotive industry

Fatigue properties play a crucial role as they are vital to ensuring the durability and integrity of components subjected to repeated loading conditions over long periods. The main objective of this work is to investigate the fatigue behavior of dual-phase low-carbon steels used in automotive applications using a rotating bending fatigue machine. Heat treatments were carried out to analyze the microstructure's effect on the fatigue properties, including quenching low-carbon steel samples at 800 °C and 900 °C. Hardness and tensile tests were performed, and the microstructure was inspected to examine the constitute phases. With the assistance of a scanning electron microscope, fractographic analyses were carried out to reveal the fracture features of the samples at different lifetime ranges. The results show that various failure mechanisms occur depending on the stress levels. Additionally, the specimens quenched at 900 °C exhibited higher fatigue strength.

Facile fabrication of ZnO nanoparticles via non-thermal plasma technique and their anti-corrosive effects on X60 API 5L steel in 1M HCl solution

This work aims to explore the efficiency of ZnO nanoparticles synthesized via the non-thermal gliding arc discharge-assisted plasma (NT-GAD) technique for inhibiting the corrosion of X60 API 5L steel in a 1M HCl environment. The XRD pattern revealed that the ZnO nanoparticles exhibit hexagonal wurtzite structure with average particle size of ∼24 nm. UV–visible spectroscopy analysis revealed an absorption peak centering at 365 nm, corresponding to an energy band gap of 3.29 eV. SEM and TEM analysis revealed that the nanoparticles exhibit an agglomerated and irregular morphology. The corrosion inhibition of ZnO NPs was investigated via the electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization tests (PDP), while varying both concentration and temperature. The results revealed that the increase in inhibitor concentration resulted in a higher activity at ambient temperature, with an optimal efficiency of 93 % at a concentration of 100 mg/L. However, the increase in temperature remarkably reduced the inhibition efficiency, suggesting a physisorption behavior of ZnO NPs onto the steel surface. AFM and FE-SEM analysis confirmed the formation of a protective layer on the X60 API 5L steel surface. This study emphasizes the significant potential of ZnO NPs synthesized via the NT-GAD assisted plasma technique as corrosion inhibitor for X60 API 5L carbon steel in 1M HCl corrosive media.

Revealing the microstructural evolution and mechanical response of repaired Fe–Cr–Si based alloy by directed energy deposition

This study investigates the microstructure and mechanical properties of wear-resistant hardfacing structures fabricated on an AISI 1045 carbon steel substrate using a specially designed Fe–Cr based powder for directed energy deposition (DED). Electron backscatter diffraction (EBSD) analysis reveals that the texture predominantly consists of cube rotated {001}<110> and cube {001}<110> textures, in addition to weaker Brass {112}<111> texture components. These textures contribute to the random orientations of martensitic grains and facilitate the tracing of austenite reconstruction. Notably, the as-printed samples exhibited superior yield strength (999.4 ± 86.3 MPa) and ductility (9.6 ± 2.6%) along the build direction (BD), compared to conventional samples, which demonstrated a tensile strength of 790 MPa and ductility of 2%. This improvement is primarily attributed to the hardening effects associated with a low volume fraction of retained austenite and the precipitation of Cr carbides. Comprehensive mechanical response, nanoindentation hardness profile across the interface, and microstructural analyses were conducted to confirm the feasibility of using a Fe-based hardfacing alloy for DED. The findings underscore the outstanding balance of strength and ductility exhibited by as-printed hardfacing alloy, further enhanced by its high printability, highlighting its potential in producing wear-resistant structures for repair applications.

Durable microstructure-based superhydrophobic composite with photothermal performance for multifunctional application

Nowadays, multifunctional superhydrophobic coating has drawn widespread attention by virtue of its great water-repellent property, whereas the fragile mechanical and chemical durability of superhydrophobic coating greatly limits its practical application. Herein, a robust and multifunctional superhydrophobic composite coating (CFRE-SP@Fe3O4) with anti-corrosion, delay-icing and self-deicing performance is constructed via simple imprinting-demolding process on the carbon fiber reinforced epoxy resin (CFRE) surface and post-deposition modification with polydimethylsiloxane (PDMS) and epoxy resin modified Fe3O4 nanoparticles. The obtained CFRE-SP@Fe3O4 coating displays a superhydrophobic property with a WCA of 155° ± 1.2°. By virtue of the protection effect of the robust micro-grid structures for the inner superhydrophobic Fe3O4 nanoparticles (SP@Fe3O4), the CFRE-SP@Fe3O4 coating still maintains great superhydrophobicity after linear friction for 100 times. Additionally, compared with the carbon steel treated with CFRE, the impedance modulus at lowest frequency of CFRE-SP@Fe3O4 coating treated group further increase with a value of 107 Ω·cm2, confirming the excellent anti-corrosion performance. Owing to the air pocket captured by the micro-/nanostructure on the superhydrophobic surface, the icing time of the CFRE-SP@Fe3O4 surfaces extends from 60 s to 2130 s. Moreover, combined with the photothermal conversion performance of carbon fiber and Fe3O4 nanoparticles, the ice on the CFRE and CFRE-SP@Fe3O4 coatings surfaces begin to melt 137 s, displaying the excellent self-deicing performance.

Development of Phased Array Ultrasonic Testing System Using Distributed Architecture

Abstract With more rigorous requirements for reliability and safety of structures and materials, high resolution and fast imaging have been urgent needs of Phased Array Ultrasonic Testing (PAUT). In order to improve the detection resolution and efficiency of complex structures and materials such as ultra-thick carbon steel and honeycomb plate, a PAUT system is proposed in this paper. The system uses a distributed architecture, which not only divides hardware resources, improves system performance, but also is scalable. PA, single- and multi-channel conventional UT, and TOFD (Time Of Flight Diffraction) modalities are combined, and PA modality is carried by the fully parallel non-multiplexed 128 PE (Pulse Echo) electronics with independently adjustable emitting and receiving parameters. In addition, the ultrasound analog front-end circuit is designed using discrete devices, providing more powerful analog performance than integrated chips. GTX (Gigabit Transceiver) and PCIe (Peripheral Component Interconnect Express) are applied to high-speed data transmission, providing raw ultrasound data. Characterization and verification results indicate that the system is ideal for challenging inspections in many industries.

Heterogeneous corrosion of carbon steel used for casing in deep geological radioactive waste repository in contact with claystone

The corrosion of C-steel in contact with the Cox claystone was studied under aerated conditions at 50°C, for 7 years, in a simplified laboratory experiment. A multi-scale and multi-technique approach, including SEM-EDX, Raman spectroscopy and STXM, was used to determine the nature and structure of the corrosion products and to better understand the mechanisms involved in the observed degradation. The effects of temperature, oxygen supply and the local influence of the composition and density of the claystone were examined here.

Carbon Steel Corrosion Induced by Sulfate-Reducing Bacteria: A Review of Electrochemical Mechanisms and Pathways in Biofilms

Microbial metal corrosion has become an important topic in metal research, which is one of the main causes of equipment damage, energy loss, and economic loss. At present, the research on microbial metal corrosion focuses on the characteristics of corrosion products, the environmental conditions affecting corrosion, and the measures and means of corrosion prevention, etc. In contrast, the main microbial taxa involved in metal corrosion, their specific role in the corrosion process, and the electron transfer pathway research are relatively small. This paper summarizes the mechanism of microbial carbon steel corrosion caused by SRB, including the cathodic depolarization theory, acid metabolite corrosion theory, and the biocatalytic cathodic sulfate reduction mechanism. Based on the reversible nature of electron transfer in biofilms and the fact that electrons must pass through the extracellular polymers layer between the solid electrode and the cell, this paper focuses on three types of electrochemical mechanisms and electron transfer modes of extracellular electron transfer occurring in microbial fuel cells, including direct-contact electron transfer, electron transfer by conductive bacterial hair proteins or nanowires, and electron shuttling mediated by the use of soluble electron mediators. Finally, a more complete pathway of electron transfer in microbial carbon steel corrosion due to SRB is presented: an electron goes from the metal anode, through the extracellular polymer layer, the extracellular membrane, the periplasm, and the intracellular membrane, to reach the cytoplasm for sulfate allosteric reduction. This article also focuses on a variety of complex components in the extracellular polymer layer, such as extracellular DNA, quinoline humic acid, iron sulfide (FeSX), Fe3+, etc., which may act as an extracellular electron donor to provide electrons for the SRB intracellular electron transfer chain; the bioinduced mineralization that occurs in the SRB biofilm can inhibit metal corrosion, and it can be used for the development of green corrosion inhibitors. This provides theoretical guidance for the diagnosis, prediction, and prevention of microbial metal corrosion.

Effect of electric arc surfacing on the structure and properties of coatings

Surfacing, like welding, is associated with heating metals in a wide range of temperatures and subsequent cooling of heated zones at different rates. This leads to complex structural and phase changes that are crucial for operational properties of the “protected material – coating” joint. The structure and properties of the alloyage zone of these two materials depend on the degree of penetration, nature of the intermediate layers that arise, and carbon diffusion in the boundary areas. When surfacing on low-carbon steel, depending on the composition of the deposited metal, the structures with a predominant amount of martensite or austenite can be obtained in the alloyage zone, depending on carbon content. The structure and mechanical properties of the bimetallic joint between carbon steel and stainless steel were studied depending on the modes of electric arc surfacing (submerged arc surfacing in one pass, in argon for one and two passes). It was established that the structural and phase composition of the deposited metal is austenite, finely dispersed carbides and a needle component. The structure of the layer deposited in argon in one pass is more homogeneous and does not contain defects. The microhardness increases smoothly along the depth of the deposited layer. As a result of surfacing in argon in two passes, the joint has a homogeneous microstructure, but a large number of microdefects are formed in the layer, which can further lead to the formation of a crack near the alloyage boundary. In submerged surfacing, the heating rate and specific heat input are insufficient, therefore, the surfacing bath is poorly mixed, which leads to a suboptimal structure and the formation of thermal stresses at the alloyage boundary and to the formation of a coating that is heterogeneous in structure and microhardness.

Cathodic Protection of Carbon Steel in Soil: A Study of Induced Passivation

Two-month experiments were carried out with carbon steel electrodes buried in an artificial sand wetted at 50–55% of saturation with a 0.07 mol L−1 Na2SO4·10H2O solution. Various protection potentials (corrected from the ohmic drop) were applied from −0.60 to −1.13 V/Cu-CuSO4. In each case, the behavior of the electrode protected by cathodic polarization was compared with that of an unprotected electrode. The electrochemical study was performed using voltammetry, linear polarization resistance measurements, and EIS. Surface characterization of the coupons was carried out using optical microscopy and X-ray diffraction. First, cathodic protection was observed to induce a spreading of the electrolyte on the metal surface because of electrocapillary effects. The active area, or more precisely the wet area, of the electrode increased, leading to a decrease in soil electrolyte resistance Rs measured using EIS. This phenomenon was experimentally confirmed via visual observations of the surface of the coupons at the end of the experiments. Secondly, cathodic protection induced a passivation of the steel surface. The passive state persisted for 35 to 85 h after cathodic protection was stopped and could be studied during various periods of interruption of the protection. In each case, the OCP of the previously polarized coupons reached high values, actually 200–250 mV higher than those measured for the unprotected coupons, and was associated with high polarization resistance Rp values (~40 kΩ cm2). Depassivation of the metal finally occurred, a phenomenon revealed by simultaneous important drops of both OCP and Rp.

Microstructure, hardness, and tribological properties of Ni-Co/ SiO2 nanocomposite coating produced through pulsed current electrodeposition

This study investigates the development of Ni-Co/SiO2 nanocomposite coatings on mild steel surface using pulsed-current electrodeposition method. The effects of incorporating SiO2 nanoparticle and varying its concentration on the coatings' microstructure, microhardness, wear resistance, and frictional properties were assessed using field-emission electron microscopy, X-ray diffraction, Vickers microhardness testing, and dry sliding wear tests. The results indicated that the coatings exhibited two-phases of Ni-Co solid solution (α) with a face-centered cubic (FCC) crystal structure and hexagonal Co, a refined crystallite size of approximately 31 nm for Ni-Co and about 25 nm for Ni-Co/SiO2, along with a colony-like morphology that did not show any preferred growth direction. The amount of Ni-Co solid solution increased with the addition of SiO2 nanoparticles. The composite coatings demonstrated enhanced microhardness of 581 HV, which is 52 % greater than that of the Ni-Co coating, as well as improved wear resistance and a reduced friction coefficient compared to the unreinforced alloy coating. However, higher SiO2 content adversely impacted the tribological properties due to nanoparticle agglomeration. Analysis of the worn surfaces revealed a transition from abrasive wear to oxidative wear with increasing applied force for the coatings.