Surface Modification Of Mild Steel Research Articles

Enhancing Mild Steel Surface Characteristics through Electrical Discharge Coating with Titanium Dioxide Suspension

In this research, surface modification of mild steel was carried out by using electric discharge coating (EDC) with titanium dioxide (TiO2) powder suspension. The concentrations of TiO2 powder were varied and their effect on the surface roughness and deposited element were investigated. The results showed that elements such as titanium, carbon, copper, oxygen, zinc and iron were successfully coated on the mild steel surface. Aside from that, the weight % of the titanium element increased with an increase of TiO2 powder concentration. The surface roughness was also reduced 62.9% by using 5 g/l TiO2 powder when compared to the pure kerosene oil.

Surface modification of mild steel to circumvent challenges in chemical vapour deposition of graphene coating for durable corrosion resistance

Graphene possesses unique combination of characteristics (i.e., inertness, impermeability and toughness) to qualify as ideal coating material for corrosion resistance, and graphene coatings on nickel and copper have been shown to provide excellent and durable corrosion resistances. However, growing graphene directly on mild steel by chemical vapour deposition (CVD), is prohibitively challenging due to high solubility of carbon in mild steel at high temperatures. The non-trivial challenge was circumvented through surface modification of steel by electroplating with Cu and Ni, accounting for the critical consideration, i.e., the inter-diffusivity of iron in nickel or copper. However, the key finding was that the undesirably high thicknesses of the electroplated Cu and Ni layers were detrimental, and optimization of their thicknesses was essential for successful deposition of the required quality graphene. The optimised thicknesses were derived on the basis of the fundamental diffusion calculations. The uniform multi-layered graphene coating on the suitably modified mild steel surface provided remarkable corrosion resistance in an aqueous chloride solution, and electrochemically validation of the corrosion durability for extended exposure (>1000 h) was characterised.

Surface modification of mild steel using 4-carboxyphenyl diazonium in sulfuric and hydrochloric acids. A corrosion study.

In this paper, the surface of mild steel is modified with 4-carboxyphenyl diazonium and subsequently, the corrosion behaviour of the modified surface is scrutinized in hydrochloric and sulfuric acid solutions. The diazonium salt was synthesized in situ either in 0.5 M HCl or 0.25 M H2SO4 through the reaction between 4-aminobenzoic acid and sodium nitrite. The surface of mild steel was modified with the obtained diazonium salt with or without the need for electrochemical assistance. Electrochemical impedance spectroscopy (EIS) measurements show that a spontaneously grafted mild steel surface has a better corrosion inhibition efficiency (86%) in 0.5 M HCl. Scanning electron microscopy reveals that the protective film formed on the surface of mild steel exposed to 0.5 M HCl containing the diazonium salt looks more consistent and uniform compared to the surface exposed to 0.25 M H2SO4. Optimized diazonium structure and the separation energy calculated using density functional theory correlate with the good corrosion inhibition obtained experimentally.

New developed for generating superhydrophobic surface modification on mild steel for corrosion protection

The synergism effect of sodium tartrate and Zn2+ binary inhibitor system on the corrosion inhibition efficiency of mild steel in an potable water medium containing was analyzed by means of gravimetric and electrochemical spectroscopic measurements. The effect of weight loss method and immersion time on the corrosion behavior of mild steel has also been studied. The scanning electron microscopic (SEM) images showed that the roughness and the deep cracks of the metal surface are reduced significantly by the inhibitor system. Results indicated that the formulation acted as anodic inhibitor. Adsorption of used inhibitor lead to a decrease in the double layer capacitance and an increase in the charge transfer resistance and confirm protective layer by SEM, EDX, AFM and FT-IR. Simple and novel binary inhibitors approach was developed for generating superhydrophobic surface modification of mild steel. Interestingly, Water droplets falling on the leaves bead up and roll off, mild steel immersed in potable water in the presence of binary inhibitor system (sodium tartrate and Zn2+) was attempted to create superhydrophobic surfaces. However, the water contact angle in presence of binary inhibitor system was found to be 152°±4°, whereas in the case of mild steel, it was 55°±2°. A detailed description of the surface-modified superhydrophobic in potable water on mild steel is presented in this article.

Evaluation of Bitter Kola Leaf Extract as an Anticorrosion Additive for Mild Steel in 1.2 M H2SO4 Electrolyte

ABSTRACT Plant-based material, namely bitter kola leaf, as an additive for surface modification of mild steel in H2SO4 solution was thoroughly scrutinized using electrochemical, theoretical and optimization techniques. The functional groups, of the biomolecules of the bitter kola leaf extract, were examined using Fourier transform infrared spectrometry (FTIR) and gas chroma-tography-mass spectrophotometry (GC-MS). For clarification purpose, scanning electron microscopy (SEM) was used to inspect the texture of the degraded and inhibited steel after 21 h of immersion. For the response surface methodology (RSM), central composite design of Design-Expert Software was used to optimize the inhibition efficiency as a function of acid concentration, inhibitor concentration, temperature and time. The optimum inhibition efficiency of 93 % was obtained at 0.9 g L-1 bitter kola leaf. The mutual correlation between the considered variables and expected response was adequately interpreted by a quadratic model. The fitness of the model was justified by the following standards which include P-value (<0.0001), adjusted R2 (0.9843), R2 (0.991), adequate precision (43.14) and coefficient of variation (2.59). Bitter kola leaf extract behaved as a mixed-type inhibitor and adequately satisfied Langmuir adsorption isotherm. Furthermore, the theoretical modelling revealed the most active molecule of bitter kola leaf responsible for the overall inhibition. The experimental and theoretical results are in agreement that bitter kola leaf extract is a viable corrosion inhibitor of mild steel in H2SO4 solution. Keywords: Acid corrosion, electrochemical study, green extract, mild steel, optimization study, theoretical modelling.

Surface modification of mild steel before acrylic resin coating by hybrid ZnO/GO nanostructures to improve the corrosion protection

The synergistic effect of ZnO and GO nanostructures on the surface modification of mild steel before the acrylic resin coating was studied. Firstly, the steel surface was pretreated in the presence of ultrasonic irradiation, and then ZnO nanostructures were synthesized by the cyclic voltammetry technique. GO nanosheets prepared by the modified hummer’s method were deposited on ZnO-containing surfaces using the electrophoretic deposition (EPD) technique. GO coatings with thicknesses of 2.84, 4.47 and 9.42μm were obtained by varying the EPD time, and the 4.47μm was found as the optimum value for the fabrication of hybrid ZnO/GO structures. All samples were then covered with a thin layer of acrylic resin (10μm) by the spin coating technique. The results indicated that the sample with underneath of hybrid ZnO/GO nanostructures shows significant improvement in anti-corrosion performance. In other words, Rp is increased from 150,000Ωcm2 (in the rein coated sample) to 380,000Ωcm2 (in the sample with hybrid nanostructures). The resulting surface has the potential to use as protective and glossy black coatings. The role of underneath nature, surface roughness, and molecular interactions between oxygen functional groups of ZnO, GO, resin, and the metal in the enhanced corrosion protection was illustrated.

Surface modification of mild steel by co-deposition using Zn-ZnO-Ant hill particulate composite coating in simulated sea water

Naval ships are constructed with mild steel. Corrosion is a major concern in a marine environment. This particular type of material degradation has recently received more attention by the marine industry. Effort is make my researchers to combat this problem. In this work, co-deposition of Zn-ZnO-Ant hill powder composite coating on mild steel was reported with the view to combat this problem. The Ant hill powder was varied from 0 to 25 g. A 10 mL of orange juice was used as an organic additive. The coating thickness, surface roughness, microstructure, hardness values, wear rate and potentiodynamic polarization in simulated sea water were determined. The addition of orange juice as an additive changed the morphological and texture of the coating, and the hardness values, wear and corrosion rate were enhanced. Maximum corrosion protection efficiency of 92.86% and 94.41% was obtained at Zn-ZnO-25gAnt hill and Zn-ZnO-25gAnt hill + orange juice, respectively. The work has established that Zn-ZnO-Ant hill powder composite coating on mild steel is promising.

Surface modification of mild steel: investigation of basic mechanical properties

The study reveals surface modification of mild steel carried out using friction surfacing process. Friction surfacing is a solid state coating process which enhances the properties of the substrate. The process involves deposition of aluminium-cadmium alloy on the surface of mild steel substrate. The aluminium-cadmium alloy was used in three different proportions namely sample 1 (Al-75%,Cd-25%), sample 2 (Al-80%,Cd-20%) and sample 3 (Al-85%,Cd-15%). Lathe machine was modified to enable the process parameters of friction surfacing. Hardness test, wear test, corrosion test, flexural strength and temperature profile measurement was carried out on the surface coating. There was considerable increase in hardness as the coating showed excellent resistance to corrosion, wear and flexural strength. The temperature profile was noted for all coated samples indicating the re-crystallisation temperature.

Surface modification of mild steel: investigation of basic mechanical properties

Surface modification of mild steel: investigation of basic mechanical properties

Surface modification of mild steel using a combination of laser and electrochemical processes

Traditional methods for achieving hierarchical surface structures include highly specified, deterministic approaches to create features to meet design intention. In this study microstructural alteration was undertaken using laser apparatus and secondary texturing was achieved via succeeding electrochemical processes. Electrochemical jet machining (EJM) was performed on mild steel subjected to laser pre-treatment using power densities of 4167 and 5556 W/cm2 with pulse durations from 0.3 - 1.5 seconds. Results show that in combination, laser pre-treatment and EJM can alter the exposed surface textures and chemistries. Here, machined surface roughness (Sa) was shown to increase from approximately 0.45 µm for untreated surfaces to approximately 18 µm for surfaces subjected to extreme laser pretreatments. After pre-treatments materials were characterised to appraise microstructural changes, shown to be martensite formation, reinforced by complementary simulation data, and significant increases in observable hardness from approximately 261 HV for the asreceived material to over 700 HV after pre-treatment. The greater hardness was retained after EJM. Exposed martensitic lath structures at machined surfaces are shown to be partially responsible for surface roughness increases. The surfaces were explored with energy dispersive X-ray spectroscopy (EDS) and Raman spectroscopy demonstrating changes in apparent surface chemistry. This analysis revealed increasing oxide formation at the surface of the pre-treated EJM surface, a further contributory factor to surface roughness increases. This new process chain will be of interest to manufacturers seeking to control surface morphology for applications including micro-injection mould/die manufacture. While demonstrated here for steel similar mechanisms are exploitable in other material systems. A new technique has been demonstrated, resulting from the models and processes presented to couple laser and electrolyte jet processing for complex surface preparation.

Anticorrosive behaviour of lumefantrine hydrophobic layer on mild steel surface

<span lang="EN-US">The surface modification of mild steel was achieved by chemical treatment in lumefantrine (LF) solution. The surface morphology and wettability of modified surface was analysed by 3D profilometer and contact angle goniometer. The corrosion inhibition performance of modified mild steel surface in 1.0 M HCl solution was investigated by potentiodynamic polarization and electrochemical impedance techniques.Electroche­mical measurements illustrate that the corrosion of mild steel in acidic chloride medium get substantially reduced by introducing LF film on its surface (94 % efficiency). Quantum chemical parameters were evaluated by ab initio method and they confer appropriate theoretical support to the experimental findings.</span>

Surface modification of mild steel by a self-assembled cetyl-trimethyl ammonium bromide (CTAB) monolayer: Evaluation of its corrosion protection property

Abstract The surface of mild steel was modified by generating cetyl-trimethyl ammonium bromide (CTAB) self-assembled monolayer (SAM) to enhance the corrosion resistance property. The experimental parameters (pH and time) for SAM generation were optimized. The modified surface was characterized by infrared reflection absorption spectroscopy (IRRAS) and contact angle measurements. The SAM generated in 1 mM solution of CTAB at pH 2.5 for 2 h showed a regimented monolayer. Polarization and electrochemical impedance spectroscopic (EIS) studies demonstrated a significant enhancement in the corrosion resistance property of the SAM protected steel in both 1 M HCl and 3.5% NaCl solution. The CTAB SAM surface substantially reduced the corrosion rate by approximately 4 times in 1 M HCl and 1.5 times in 3.5% NaCl media as compared to bare steel. Scanning electron microscopy images confirmed the formation of lesser amounts of corrosion products on the SAM protected surface.

Development and analysis of tribological behavior of microwave processed EWAC + 20% WC10Co2Ni composite cladding on mild steel substrate

The present work is based on the surface modification of mild steel by depositing composite cladding of EWAC+20% WC10Co2Ni powder through novel technology of hybrid microwave heating. Claddings of approximately 300μm thickness were developed in domestic microwave applicator at 2.45GHz frequency and 900W of power. Microstructural analysis and mechanical characterizations were carried out on the developed clads using relevant techniques of XRD, SEM, EDS, Vickers microhardness and wear tests. Pin on disk tribometer was used to evaluate the tribological properties (weight loss) of developed clads under the different loadings and sliding velocities at ambient temperature. Results revealed that clads are formed with good metallurgical bonding with melting and diffusion of substrate material. Developed clads showed the presence of hard carbides in the form of a skeleton like structure within a soft nickel matrix. The wear resistance of composite clads increased by approximately 128 times in comparison to mild steel and average Vickers microhardness of 980±52 HV has been reported by microwave processed clads.

Surface Modification of Mild Steel with Molybdenum Disulfide by Tungsten Inert Gas

Surface modification of mild steel was carried out with molybdenum disulfide powder using Tungsten Inert Gas (TIG) method. This paper presents the microstructure developed after the molybdenum disulfide coating on mild steel and also the effects of Tungsten Inert Gas method on the hardness of the mild steel. The microstructure of the molybdenum disulfide coating was studied by using Metallurgical Microscope fitted with Pixel Fox smart microscope digital camera and Rockwell Hardness Test was used to measure the hardness. A hard, wear resistant and metallurgically bonded surface coating was developed on the mild steel.

Surface Modification of Mild Steel with Thermally Cured Antibacterial Poly(vinylbenzyl chloride)–Polyaniline Bilayers for Effective Protection against Sulfate Reducing Bacteria Induced Corrosion

With the objective of developing anticorrosive conductive polymeric coatings to combat microbially induced corrosion (MIC), a facile and green synthesis approach based on a thermally induced reaction was described. Thermal curing of polyaniline (PANI) was carried out from the silanized mild steel (MS) surface containing reactive epoxy groups, followed by thermally induced N-alkylation of PANI by hydrophobic 4-vinylbenzyl chloride (VBzCl) to produce biocidal functionality. The so-synthesized MS coupons with hydrophobic poly(vinylbenzyl chloride) (PVBC)–quaternized PANI bilayer coatings were investigated for their anticorrosive and antibacterial properties toward biocorrosion induced by sulfate-reducing bacteria (SRB). Antibacterial assay results revealed an evident decrease in the bacterial attachment and the formation of biofilm. The QPANI–PVBC bilayer coatings showed a high corrosion resistance (inhibition efficiency >97%) and stability to resist SRB-induced corrosion. Thus, the QPANI–PVBC bilayer coated...

The effect of microstructure on high-stress abrasion resistance of Fe-Cr-C hardfacing deposits

Surface modification of mild steel was undertaken using two covered electrodes and two tubular electrodes. The two covered electrodes are DIN 8555: E6-UM-60 and E10-UM-60GR; however, the two tubular electrodes are E10-GF-60GR1 and E10-GF-60GR2. Chemical analysis for the weld metal and XRD of the flux covering for covered electrodes and flux core for tubular electrodes were conducted. The most important factor in determining the wear resistance is the microstructure of the deposit layers. In similar carbon equivalent electrodes E10-UM-60GR and E10-GF-60GR1, electrode E10-GF-60GR1 (tubular) shows larger carbides area fraction and better wear resistance than electrode E10-UM-60GR (covered). This could be attributed to a lower dilution associated with tubular electrode compared with covered electrode. The two tubular electrodes showed higher wear resistance than the covered electrodes which is mainly due to the larger Fe-Cr carbide precipitation area fraction.

Surface Modification Using Electric Discharge Machining (EDM) with Powder Addition

Powder mixed electrical discharge machining (PMEDM) is one of the recent innovations for the enhancement of the capabilities of EDM process. In this study, the effects of powder addition on the surface modification of mild steel were investigated. Copper tungsten electrode was used in the machining. Two different powders namely TiC and Al2O3 were used in the study with kerosene as the dielectric medium. The powder types and currents were manipulated to study their effects on the machined surface. The results show that increasing the current leads to increase in recast layer thickness, and the cracks. The Al2O3 powder gave higher layer thickness than TiC powder. TiC Powder addition also produced higher hardness, more tool material and carbon depositions on the work surface than Al2O3 powder.

Surface modification of mild steel with Boron Carbide reinforcement by electron beam melting

We investigated the effect of surface hardening and micro-structural modifications in Mild steel (MS) with the addition of Boron Carbide, melted by thermionic electron beam. Boron Carbide in the form of powder was added by making grooves in MS samples to trap the molten solution for interaction with solid particles. These samples were irradiated by 10 KeV electron beam with variable beam current (50–100 mA). XRD confirmed the addition of Boron Carbide in the matrix and SEM indicated micro-structural changes introduced by the electron beam. Micro-structural modification further revealed that ferrites have been transformed into dendrites and pearlites have been refined as a result of re-solidified melt. This significantly has enhanced the surface hardness greater than 6-times compared to as received Mild steal.

Surface Modification of Mild Steel by Orthophenylenediamine and Its Corrosion Study

Surface Modification of Mild Steel by Orthophenylenediamine and Its Corrosion Study

Microstructural surface modification of mild steel by TIG and plasma arcs

This letter addresses the microstructures of the fusion zone (FZ), fusion boundary region (FBR) and heat-affect zone (HAZ) of mild steel produced by TIG and plasma arcs, and the possibility of converting the mild steel surface-melting portion into stainless steel