Structural Carbon Steel Research Articles

Synthesis, Characterization and Theoretical Calculations of a Novel Organic Corrosion Inhibitor for Mild Steel

Abstract Q235 is a carbon structural steel sheet that is widely employed in the construction and engineering sectors due to its cost-effectiveness and durability. Here, A novel organic corrosion inhibitor for Q235 sheet based on furan-thiadiazole (5-amino-2-furyl-1, 3, 4-thiadiazole, AFTZ) has been designed, successfully synthesized and characterized in this work. Results of experimental data and theoretical calculations indicated that AFTZ has an excellent corrosion inhibition property for Q235 sheet in 1.0 mol/L H2SO4. The highest efficiency of corrosion inhibitor tested by weight loss experiment can reach 91.17% and electrochemical experiment was up to 95.85% when AFTZ increased to 2 mg/mL in H2SO4 solution. The morphological characteristics of Q235 sheets with or without corrosion inhibitor showed that the target inhibitor has good corrosion inhibition performance. Quantum computation using the DFT method of guassian09 software and FT-IR date attribute the excellent corrosion inhibition to the film-forming nature of AFTZ.

Impact toughness behaviour of A516 GR. 60 steel welded joints

Impact fracture behaviour of welded joints made of A516 Gr. 60 is analysed as a commonly used carbon structural steel for welded structures. Impact testing on Charpy instrumented pendulum is performed using specimens with a notch at positions: the base metal (BM), heat-affected-zone (HAZ), and weld metal (WM). The total impact energy is presented as a sum of energies for crack initiation and crack propagation to make the analysis more sophisticated and comprehensive. The effect of temperature up to -60 °C was also analysed to prove the A516 Gr. 60 steel usability at subzero conditions.

Study on the influence of high permeability magnetic iron on energy consumption reduction in high gradient magnetic separator

The green processing of weakly magnetic iron ore is inseparable from high-intensity and high-gradient magnetic separator (HGMS), which is one of the most energy-intensive magnetic separation equipment. Iron (Fe) armor serves as the key primary structure for enhancing magnetic field conduction efficiency within the magnetic system. The order of magnetic properties of commonly used magnetic yoke materials is: ordinary carbon structural steel < Q235 steel < DT4 electrical pure iron. But the utilization cost of DT4 electrical pure iron is the highest, especially the magnetic properties of DT4C super electrical pure iron are unstable and the yield is low. On the basis of ordinary pure iron materials, this article has developed a new type of 411 pure iron (411) upon controlling the levels of harmful elements, while increasing the concentration of beneficial elements.intensity Furthermore, through the utilization of magnetic field simulation software, the impact of 411 on the background magnetic field intensity of HGMS was analyzed. The results indicated that the newly developed 411 pure Fe exhibited a coercivity of 24.07 A/m, a saturation magnetization intensity of ∼ 1.69 T, a maximum relative magnetic permeability of 24.38 × 10-3H/m, demonstrating superior magnetic properties in comparison with Q235 and DT4C. When using 411 pure iron as the magnetic yoke material, the background magnetic field intensity of the HGMS can be increased by 6.85 % − 14.64 % compared with using DT4C super pure iron under the same excitation current conditions. The magnetic yoke with better magnetic conductivity will enhance the magnetic field utilization efficiency of the magnetic system, a reduce the excitation energy consumption, and improve the sorting performance of HGMS.

A new plastic global analysis approach for the fire design of steel and stainless steel structures

The new generation of structural codes for stainless steel allow carrying out global plastic analyses on certain types of stainless steel structures with plastic cross-sections at room temperature if the joints conforming the structure are classified as full-strength joints, a capability that has been long recognised for carbon steel structures. However, the requirements for the fire design of carbon and stainless steel structures in current and upcoming European design standards are still primarily based on the resistance of individual members, disregarding the redistribution of internal forces and strain hardening effects. Recent studies have proven that carbon and stainless steel frames with plastic cross-sections and full-strength joints are capable of redistributing internal forces at elevated temperatures, and failed describing global plastic collapse mechanisms under fire situation, suggesting that system effects are also relevant at elevated temperatures and could be taken into account for more efficient designs. On this basis, this paper develops an extensive numerical study focused on carbon and stainless steel frames under fire situation, and proposes a new methodology based on plastic global analysis to estimate the resistance of such structures under fire situation accounting for their redistribution capacity, improving the accuracy of the predicted fire time resistances significantly for the two materials.

ОПЕРАТИВНЫЙ КОНТРОЛЬ ВЕЛИЧИНЫ ИСТИННОГО СОПРОТИВЛЕНИЯ РАЗРЫВУ СТАЛЕЙ

The paper presents the method proposed by the authors for non-destructive determination of true tensile strength of steels by the parameters of elastic-plastic indentation of a spherical indenter. Acceptable accuracy of the method for engineering evaluation of the properties of carbon and alloy structural steels is shown.

STUDY OF THE INFLUENCE OF THE CHEMICAL COMPOSITION OF RAILWAY AXLE STEEL ON THE UNIFORMITY OF THE FINAL MICROSTRUCTURE

The relevance of the work. For modern railway transport, increasing the strength and operational reliability of rolling stock parts, in particular railway axles, is an urgent task. It is known that the inhomogeneity of the distribution of chemical elements in the structure of structural grade carbon steels is formed mainly during their crystallization and may subsequently affect the final structural state and set of properties. Purpose. Study of the influence of the chemical composition of steels for railway axles on the uniformity of the structure. Methodology. Experimental ingots of different chemical compositions with different amounts and ratios of the main chemical elements within the range of OS and EA1N were produced in laboratory conditions. The grain structure was studied on microsections after etching with nital. Chemical inhomogeneity (“traces” of the dendritic structure) − the distribution of chemical elements in the microstructure of cast samples was detected by etching in a hot solution of sodium picrate. Metallographic analysis was performed on a light (optical) microscope “Axiovert 200 M MAT” manufactured by “Carl Zeiss”. The results. The effect of changing the chemical composition of carbon steel, which is intended for the manufacture of railway axles, on the peculiarities of the formation of ferrite-pearlite heterogeneity and grain size is determined. It is shown that in samples of steels corresponding to the EA1N brand with a lower carbon content, the distribution of phases is uneven. The mechanism of formation of such a structure is explained from the point of view of two theories. In samples of steels with an average carbon content, which correspond to steel of the OS grade, the distribution of the pearlite and ferrite phases is more uniform, the relationship between the size and the degree of darkening of the pearlite areas with the order of the former dendritic branches has been established. Based on the results of the quantitative analysis of the final grain structure, it was established that OS steel with an average carbon content at different Mn/Si ratios has a more uniform grain structure. EA1N steel with a lower carbon content has a pronounced grain size, with an increase in the Mn/Si ratio, the largest maximum of the dependence of the distribution shifts to a larger grain size (smaller number). Practical results. Increasing the homogeneity of the final microstructure contributes to increasing the plasticity and viscosity of steel, which directly affects the reliability and durability of railway axles.

Exploring anti-corrosion properties and rheological behaviour of tannic acid and epoxidized soybean oil-based fully bio-based epoxy thermoset resins

This research explores the physicochemical attributes of a fully bio-epoxy thermoset aimed at serving as an anti-corrosion coating for safeguarding carbon steel structures in marine environments. Throughout this investigation, various epoxy thermosets formulations, based on epoxidized soybean oil (ESO) and tannic acid (TA), were synthesized by adjusting the initial ratios of epoxide:hydroxyl groups (epoxy:OH). These formulations were subsequently applied onto carbon steel substrates and subjected to thermal curing at moderate temperatures (170 °C) to evaluate their anti-corrosion effectiveness using electrochemical impedance spectroscopy (EIS). The examination of the total impedance values derived from EIS Bode diagrams (>106 Ω) revealed a notable anti-corrosion efficacy that endured over several months of immersion in 3.5 wt% NaCl solutions. In addition to electrochemical assessment, a rheological analysis was conducted to determine the optimal curing temperature for each formulation and to track the evolution of their mechanical properties throughout the curing process. Furthermore, the progression of corrosion at the coating-metal interphase was quantified using samples featuring artificially created notches to facilitate rapid water penetration, reaching the protected surface. Moreover, cross-cut and pull-off adhesion tests were conducted on coatings cured with various epoxide:hydroxyl ratios, yielding exceptional results on carbon steel substrates. Overall, a great potential for anti-corrosion protection has been demonstrated on the developed fully bio-based coatings with tuneable mechanical properties, regarding the initial component ratio, to reach the specific requirements for specific applications.

Research on the Macro-Cell Corrosion Behavior of Alloyed Corrosion-Resistant Steel for a Transmission Line Steel Structure under a Chloride Corrosion Environment

“The article investigates the macro-cell corrosion behavior and corrosion resistance when the alloyed steel and the carbon steel are used together because the traditional carbon steel is difficult to meet the corrosion resistance and durability of the steel structure of the transmission line in the marine environment.” In this paper, a new type of Cr-alloyed corrosion-resistant steel (00Cr10MoV) is used to partially replace carbon structural steel in order to meet the actual needs of corrosion resistance and service life improvement of steel structures for offshore transmission lines. It is important to systematically study the macro-cell corrosion behavior of combinations of the same type of steel and dissimilar steel, induced by the chloride concentration difference in simulated concrete solutions, and employ electrochemical testing methods to scientifically evaluate the corrosion resistance of steel after macro-cell corrosion. The aim is to study and evaluate the macro-cell corrosion behavior of alloyed corrosion-resistant steel and to lay a foundation for its combined use with carbon steel in a chloride corrosion environment to improve the overall corrosion resistance and service life. Under the same concentration difference, the macro-cell corrosion of the alloyed steel combination is milder compared with the carbon steel combination. The corrosion current of the alloyed steel combination at 29 times the concentration difference is only 1/10 of the carbon steel combination. Moreover, at 29 times the concentration difference, the macro-cell corrosion potential of dissimilar steel is only 1/6 of the combined potential of carbon steel combination under the same concentration difference, and the corrosion current is only 1/10 of that of the carbon steel combination.

Surface microstructuring of hot-rolled carbon structural steels under complex exposure to laser radiation

The purpose of the work was to study the effect of laser microstructuring modes of the cutting edge on changes in the structure and mechanical properties of the surface layer of parts made of hot-rolled structural carbon steels grades 20, 35, 45. Methods. Structural carbon steels of grades 20, 35, 45 were selected as objects of research. To study the effect of laser modification on changing the structure and mechanical properties of machine parts using laser cutting, special samples were made in the form of square plates (35×35 mm) with a thickness of 2 mm (St20 and St45) and 4 mm (St35). After laser cutting according to the modes, one of the sides of the sample was subjected to mechanical grinding in order to remove a layer with a modified structure of the material obtained during laser cutting. Next, laser microstructuring of the sample surfaces was performed using a continuous fiber laser. Metallographic and durometric studies were carried out to study the effect of laser microstructuring on changes in the structure and properties of the surface layer. Results. The regularities of the structure of the zone of laser action of structural carbon steels after laser microstructuring have been revealed, which consists of two layers: a non-etching (slightly etching) white layer, which is a finely dispersed martensite of a needle structure and immediately following it a zone of thermal influence, which, depending on the carbon content in the steel, has a different structure: ferrite-pearlite, martensitic, troostomartensitic, martensiticpearlitic. It has been established that laser microstructuring of a pre-polished surface in some cases leads to an increase in the values of microhardness and the length of the laser exposure zone, which may be associated with an increase in the absorption capacity of the material of the polished surface and, accordingly, a decrease in its reflectivity. Conclusion. The results obtained can be used in the creation of resource-saving material processing processes.

Impact of Boundary Conditions and Radius of Curvature on Vibro-Acoustic Behavior of Cold-Rolled Carbon Steel Structure

Impact of Boundary Conditions and Radius of Curvature on Vibro-Acoustic Behavior of Cold-Rolled Carbon Steel Structure

Effect of Process Parameters on the Microstructure and Wear Resistance of Fe3Al/Cr3C2 Composites

In this paper, a brake cylinder coating comprising a composite material of an Fe3Al and Cr3C2 mixed powder was prepared by adding laser cladding onto carbon structural steel. We studied the influence of process parameters on the microstructure and tribological properties of the cladding materials using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and 3D white light interferometer and wear tests. The influence of different processes on the morphology of the carbide strengthening phase was found to be relatively small with a Cr3C2 content of 15 wt.%. The carbides mainly exhibited a network structure in each group of cladding layers. The area of the network strengthening phase varied under different processes. Of the cladding layers formed with different processes, the scanning speed of the 0.003 m/s cladding layer had the lowest wear rate. When the laser power was too low or the powder feed rate was too high, unmelted Cr3C2 particles could be found in the cladding layer. During the wear process, the particles peeled off, causing severe abrasive wear. When the powder feeding rate was too low, more materials in the base material entered the cladding layer. This made the composition of the cladding layer similar to that of the grinding material, resulting in severe adhesive wear.

Gurson-Cohesive modeling (GCM) for 3D ductile fracture simulation

A Gurson-Cohesive Model (GCM) is proposed to investigate 3D ductile fracture accounting for the void growth, coalescence, and complete failure phenomena. The proposed model idealizes the ductile fracture process as continuum damage evolution, cohesive crack initiation, nonlinear softening along the crack surface, and complete failure. The Gurson model is employed to describe continuum damage with void growth, while the cohesive zone model is utilized to introduce discontinuous cracks and represent nonlinear softening behavior. The transition from the continuum damage to discontinuous crack is taken into account systematically using a porosity-based crack initiation criterion considering stress triaxiality. The computational results successfully reproduce the experimental results of fracture tests with 15–5 PH steel and structural carbon steel 20 within the unified modeling framework. Furthermore, strong and stable convergence of both global and local responses (e.g., load-displacement curve, area reduction, crack tip location) are demonstrated under the mesh refinement without the aid of any ad hoc characteristic length scale parameter in the simulations.

Tribological Behavior and Surface Analysis of Ni–P/BP Coatings

Abstract Nickel–phosphorus/black phosphorus (Ni–P/BP) coatings were deposited on ordinary carbon structural steel (Q235 steel) by electroless plating. The tribological behavior of the Ni–P/BP coatings and traditional nickel–phosphorus (Ni–P) coating was studied comparatively on a reciprocating tribometer. The Ni–P/BP coatings exhibited good tribological performances in the water environment. Compared with traditional Ni–P coating, the friction coefficient of Ni–P/BP20 coating in deionized water and Ni–P/BP30 coating in 3.5 wt% sodium chloride decreased by 31% and 30% at 4 N, respectively. The major wear mechanism of Ni–P/BP coatings was ascribed to slight abrasive wear. This was mainly due to the combination of the higher hardness of coatings, the interlayer slip of adsorbed black phosphorus nanosheets, and the development of oxide tribofilm at the sliding interfaces.

Erosion behaviour of Fe-Cr-C alloys: Cast alloy versus coating

Abstract: This research focuses on the erosion wear behaviour of two Fe-Cr-C alloys with similar chemical compositions obtained using different production methods. The first alloy belongs to the high chromium cast irons (HCCI). It was made by casting, after which the samples were heat treated by annealing. The second alloy in the form of the coating was applied by the plasma transferred arc (PTA) surface welding process at the substrate material (structural carbon steel). Damage to the components of industrial plants due to erosive and/or abrasive wear is a frequent cause of failure and outages of such systems. For this reason, and to bring the experimental research closer to real service conditions, an erosion test was performed at a gas blast sand facility with a high erodent speed of 90 m/s and a higher feed rate than standard erosion testing parameters recommended in ASTM G76 standard. Microstructural characterisation of all samples was done using a scanning electron microscope (SEM). The X-ray diffraction analysis (XRD) was used to identify the phases present. Similar erosion mechanisms were observed on all tested specimens, but coated samples (PTA alloy) had a lower mass loss during the erosion test compared to cast samples (HCCI alloy), i.e. they showed better erosion resistance.

Study of corrosion-resistant steels in hydrogen sulfide-containing environments of oil and gas fields

Hydrogen sulfide corrosion cracking of steel occurs in deposits containing corrosive components - hydrogen sulfide and carbon dioxide (carbon dioxide). The mechanism of corrosion cracking of steel in hydrogen sulfide-containing environments of corrosive oil and gas fields is considered, and factors influencing hydrogen sulfide cracking are identified. Increasing the performance properties of carbon, low-alloy, structural steels resistant to hydrogen sulfide and sulfide cracking was carried out on the basis of improving the composition of the components of chemical elements and the structural state through the choice of heat treatment methods depending on the acidity and temperature of the environment, partial pressures of carbon dioxide and hydrogen sulfide. Laboratory and production tests have shown the durability of the proposed compositions chemical elements of steels to hydrogen sulfide cracking, sulfide cracking and hydrogen swelling in deposits containing corrosive components was 70–80% compared to existing carbon structural steels.

ASSESSMENT OF INHIBITORS' PERFORMANCE ON CORROSION DEGRADATION OF CARBON STEEL IN FLOW ENVIRONMENTS USING ROTATING CYLINDER ELECTRODE (RCE)

This study investigates sweet corrosion mitigation methods focusing on the efficacy of inhibitors. Specifically, it examines the performance of two types of inhibitors: water-soluble and oil-soluble. Utilising a Rotating Cylinder Electrode (RCE) setup, turbulence is induced in saline solutions to assess the impact of inhibitors on the corrosion of carbon steel. Scanning Electron Microscopy (SEM) is employed to analyse corrosion degradation patterns and material damage mechanisms. Given the prevalent use of inhibitor injection in the oil sector, it is crucial to evaluate and compare the effectiveness of various inhibitors to recommend optimal options and further studies. The findings contribute to advancing corrosion mitigation strategies, providing insights into the performance of inhibitors in flow environments and aiding in the development of more effective corrosion control measures for carbon steel structures. The inhibitors under study are sourced from local oil company vendors. With a projected duration of six months and a total budget of KD 9850, this investigation aims to provide valuable insights into corrosion mitigation strategies

Research on the mechanical properties and fracture mechanism of ultrasonic vibration enhanced friction stir welded aluminum/steel joint

Friction stir welding (FSW) and ultrasonic vibration enhanced friction stir welding (UVeFSW) were used to connect 3 mm thick 2024-T3 Al alloy and Q235 carbon structural steel. The weld forming quality, mechanical properties, fracture location and interface behavior of the whole and layered joints were compared and analyzed, and the different mechanisms of the ultrasonic vibration to improve the tensile strength of the joint were summarized. As the results show, the ultrasonic vibration promoted the plastic flow ability of materials and improved the welding seam forming quality. Moreover, the ultrasonic vibration made the plastic deformation of the material in the nugget zone more uniform, which improved the strength of the nugget zone. In the middle layer of the joint, the ultrasonic vibration reduced the thickness of intermetallic compound layers (IMCLs), eliminated the laminated structure that harmed the connection quality of the joint, and formed a micromechanical interlocking structure in which IMCLs was inserted into the steel, which improved the interfacial bonding strength and improved the tensile strength by 11.1%. The ultrasonic vibration optimized the macro-mechanical interlocking structure in the joints of the lower layer, which enhanced its mechanical bonding ability with Al alloy.

Influence of Aerothermoacoustic Treatment on the Properties of High-Quality Carbon Structural Steel

Influence of Aerothermoacoustic Treatment on the Properties of High-Quality Carbon Structural Steel

Impact of Electric-Arc Welding on The Mechanical Properties of AISI 1055 Medium Carbon Steel with Varied Gauge Diameters

Purpose: This paper investigated through experimentation, the impact of electric-arc welding processes on the mechanical properties of AISI 1055 steel medium carbon steel material with varied gauge diameters.&#x0D; Design/Methodology/Approach: The study used experimental and analytical methods to investigate the impact of electric arc welding on the mechanical properties of AISI 1055 Medium Carbon Steel. The test samples were prepared based on the standards of the American Iron and Steel Institute (AISI), with varied gauge diameters. Standard tensile tests were performed on the samples before welding and after welding, using a computer-interfaced Universal Tensile Testing Machine. Data obtained from the study was analyzed using graphs, tables and charts. Finally, the sets of results for both welded and unwelded specimens were compared to determine the impact that welding has on welded medium carbon steel components and structures.&#x0D; Findings: The data recorded by the computer-interfaced tensile test machine was used to plot and display, the stress-stain graphs for the various sets of samples. The results showed that the welding processes adversely affected the Ultimate Tensile Strength (UTS), Yield Strength, Elastic Modulus and Impact Strength of the samples studied; since all the samples studied had their initial values dropped after undergoing welding and testing. However, the strain of the samples increased after welding.&#x0D; Research Limitation/Implication: Although there are other methods and techniques of welding metals, this study adopted electric arc welding to weld the samples used for the study due to resource constraints.&#x0D; Practical Implication: The findings of this study also bring to the fore, the need for industry regulators to promulgate standards to regulate the welding of medium carbon steel and by extension, other industrial materials to preserve the natural properties of the materials.&#x0D; Originality/Value: This study introduced an important perspective to the testing of engineering materials by varying the gauge diameters (a key determinant of the dimensional specifications of the specimen), to obtain a comprehensive insight into the impact of electric-arc welding on the mechanical properties of the material.

Effect of explosive welding on the interface characteristics of S32750/Q245R composite plate

ABSTRACT Super duplex stainless steel S32750 has excellent corrosion resistance. It is combined with carbon structural steel Q245R through explosive welding, not only with good mechanical properties but also with a satisfactory economic cost. In this paper, the characteristics of the bonding interface of S32750/Q245R explosive welding composite plate were analyzed. The interface of the composite plate exhibits a consistent wavy bonding interface with vortices. The adiabatic shear band was only observed on the S32750 plate side near the bonding interface, while defects such as pores, cracks, and inclusions were also detected at the bonding interface. The EBSD analysis revealed the presence of a layer of fine-grained grains close to the interface of the S32750 side, and the grains beyond this fine-grained layer were elongated and shaped like fibers. The largest plastic deformation occurs near the interface on the super duplex stainless steel side. The microhardness test results indicate that the highest hardness presents near the interface of the S32750/Q245R composite plate side, with the hardness being slightly higher at the wave waist than the wave peak and trough. The hardness of the composite plate showed a decreasing trend from the bonding interface to the plate edges on both sides.