Steel Surface Research Articles

Performance of Acetone Extract of Anthocleista grandiflora as a Potential Bioinhibitor on Corrosion Behavior of Carbon Steel in Seawater Environment

In this study, we evaluated the potential of Anthocleista grandiflora leaf (AGL) plant extract as an environmentally friendly and cost-effective corrosion inhibitor for carbon steel in seawater. We employed various experimental methods, including gravimetric analysis, potentiodynamic polarization, electrochemical impedance spectroscopy, scanning electron microscopy (SEM) and Fourier transform infrared spectrophotometry (FTIR). Our findings indicate that increasing the concentrations of the AGL extract results in higher charge transfer resistance (Rct ) and reduced double-layer capacitance (Cdl ), suggesting the effective adsorption of AGL extract on the surface of carbon steel. The inhibition efficiencies were notably high, 98.7%, 92.40%, and 90.7% determined with gravimetric analysis, potentiodynamic polarization, and electrochemical impedance spectroscopy, respectively. Polarization analysis revealed that the AGL extract acted as a mixed-type inhibitor. Moreover, the results obtained from different techniques exhibited a consistent agreement. The SEM images revealed that the surface layer formed by the AGL extract on the mild steel surface further devoids the surface from pitting as the extract concentration increases. Comparative analysis with similar bio-based inhibitors suggested that the tested AGL extract holds a significant promise as a corrosion inhibitor for carbon steel in seawater. Therefore, our findings support the recommendation of utilizing this AGL extract as an effective anti-corrosion agent in marine industries, owing to its green, low-cost, and efficient characteristics.

Fabrication and Properties of Superhydrophobic Colored Stainless Steel Surface for Decoration and Anti-Corrosion

A colored superhydrophobic surface on a stainless steel substrate was achieved by means of high temperature oxidation combined with subsequent spraying modification by superhydrophobic nano-silica film. Comprehensive characterizations of the surface were performed in terms of color, morphology, composition, wettability, and corrosion resistance by optical microscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), contact angle, potentiodynamic polarization, and electrochemical impedance spectroscopy measurement. At 400 °C, the surface was pale yellow, gradually turning yellow and then red as the temperature increased. At 700 °C and 800 °C, the surface colors were blue and dark brown, respectively. The samples with oxide films demonstrated lower contact angles, specifically 80.5° ± 2.5 at 400 °C, 79.1° ± 2.8 at 500 °C, and 75.6° ± 3.4 at 600 °C. The polarization resistance measured on the oxidized film formed at 600 °C exceeded 7.93 × 104 Ω·cm2. After spraying the treatment, these colorful surfaces exhibited superhydrophobicity, they were self-cleaning, and they satisfied anti-corrosion properties. The treatment performs as an excellent barrier and exhibits a high corrosion resistance of 4.68 × 106 Ω·cm2. The successful preparation of superhydrophobic colored surfaces offers the possibility of providing stainless steel with both decoration value and self-cleaning function simultaneously by our proposed chromium-free fabrication process.

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.

Molecular simulations of amine-based organic additives at a steel surface: Effect of the internal molecular structure on adsorption

Lubricating oils mitigate wear in gears and rolling bearings lengthening the lifespan of drivetrain units for electric vehicles. Amine-based organic additives from the lubricating oil contribute to alleviating wear by adsorbing on rubbing steel surfaces of mechanical contacts and forming anti-wear films. Cross-pin wear experiments suggest that additives with branches in polar heads improve wear protection, while remaining environmentally friendly. Experiments show a reasonable correlation with the energy of adsorption calculated from molecular dynamics simulations at large surface coverages. Whereas adsorption strengths and surface coverages are barely affected by the conformation of alkyl chains (cis/trans), they are affected by the length of branches in polar heads of additives. Results suggest better performances for branch lengths containing 3–4 C atoms.

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.

Study on the influence mechanism of austenitizing temperature on the surface of corrosion-resistant mold steel

Abstract The microstructure of 4Cr13 corrosion-resistant plastic mold steel was studied. The martensitic experimental steel obtained by different heat treatment processes was used as the object. The effect of austenitizing temperature on its corrosion behavior was studied by microstructure characterization and electrochemical test. The results show that the microstructure of the test steel is mainly composed of martensite laths. Under the same experimental conditions, the corrosion resistance of the test steel decreases with the increase of austenitizing temperature, and the corrosion products are mainly composed of iron-containing oxides. The austenitizing temperature of 1000°C improves the corrosion resistance of the material, because the precipitation of a large number of small-sized Cr-containing carbides hinders the further erosion of the material and improves the surface quality.

Frictional Axial Resistance of Clamped Split Pocket Mechanism Steel Structural Joint: An Experimental Study

The Clamped Split Pocket Mechanism (CSPM) prefabricated joint system was developed for a single-story steel instant house, designed to be compact and rapidly constructed without modifying the end of the beam and column element member. The CSPM bolted joint system was proposed as an optimal solution for post-disaster housing, especially after earthquakes. Despite its potential, the frictional tensile resistance behavior of the CSPM bolted joint system has not been previously studied, necessitating experimental investigation. This study examined the frictional tensile resistance behavior of the CSPM joint system by monitoring the effective friction coefficient under axial tension force. The experiments considered both the strong and weak axes of the joint and utilized two configuration types of specimens (L and T) with varying bolt pretensions of 2.5, 5, 7.5, and 10 kN. Results indicated that the effective friction coefficient of the CSPM bolted joint system ranged from 0.19 to 0.26, correlated to bolt pretension. Increased bolt pretension resulted in larger surface deformation of the split pocket, triggering a not uniform frictional tensile resistance across the steel surfaces of the split pocket joint. From this study, the achieved effective friction coefficients could guide the design of minimum pretension forces for clamps in prefabricated steel instant houses. Doi: 10.28991/CEJ-2024-010-09-07 Full Text: PDF

Features of Increasing the Wear Resistance of 90CrSi Tool Steel Surface under Various Electrophysical Parameters of Plasma Electrolytic Treatment

The paper investigates the feasibility of plasma electrolytic treatment (PET) of 90CrSi tool steel to enhance hardness and wear resistance. The influence of electrophysical parameters of PET (polarity of the active electrode, chemical-thermal treatment, and polishing modes) on the composition, structure, morphology, and tribological properties of the surface was studied. Tribological tests were carried out under dry friction conditions according to the shaft-bushing scheme with fixation of the friction coefficient and temperature in the friction contact zone, measurements of surface microgeometry parameters, morphological analysis of friction tracks, and weight wear. The formation of a surface hardened to 1110–1120 HV due to the formation of quenched martensite is shown. Features of nitrogen diffusion during anodic PET and cathodic PET were revealed, and diffusion coefficients were calculated. The wear resistance of the surface of 90CrSi steel increased by 5–9 times after anodic PET followed by polishing, by 16 times after cathodic PET, and up to 32 times after subsequent polishing. It is shown that in all cases, the violation of frictional bonds occurs through the plastic displacement of the material, and the wear mechanism is fatigue wear during dry friction and plastic contact.

Thermodynamic aspects of WO3 tungsten oxide reduction by carbon, silicon, aluminum and titanium

The development and research of new materials for machine parts of the mining and metallurgical complex by the method of surfacing with flux cored wire has a lot of attention nowadays. Flux cored wires are widely used for surfacing of steels with high wear resistance, in which reduced tungsten in the form of ferroalloys, ligatures and metal powder of various degrees of purity are used as fillers. However, due to the scarcity and high cost of tungsten, its rational use is an urgent task. For practical application, the technology of surfacing with tungsten-containing flux cored wire is of interest; using it the maximum extraction of tungsten into the deposited layer is achieved due to reduction processes in the arc. In order to increase the beneficial use of tungsten, the technologies of indirect alloying with tungsten during surfacing under the flux of flux cored wires, in which tungsten oxide is used as a filler on the one hand, and reducing agent – on the other, deserve consideration. It can be expected that during arc discharge, tungsten and (or) chemical compounds of tungsten with reducing agents can be formed during the surfacing process. This paper presents the results of a comparative analysis of the thermodynamic processes of tungsten oxide reduction by carbon, silicon, aluminum and titanium during arc discharge occurring during surfacing with flux cored wires under a layer of flux. The thermodynamic analysis of 41 reactions in standard states showed that the presence of reducing agents (carbon, silicon, aluminum, titanium) in the flux cored wire used for surfacing will contribute to the formation of silicides and tungsten carbides, and, possibly, tungsten itself. It was determined that the best state for the participation of tungsten oxide in reactions in the arc is WO3(g) gaseous state.

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.

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.

Experimental study on low-cycle fatigue performance of high-strength bolted shear connections

In strong earthquakes, low-cycle fatigue fractures may occur in the bolted connections of steel braced frames. Ensuring a high low-cycle fatigue life for high-strength bolted connections is of paramount significance in enhancing the overall safety and collapse resistance of steel structures. Despite substantial research on plate fatigue failure within bolted connections, there remains a research gap regarding low-cycle fatigue failure of high-strength bolts in these connections. This study aims to address the aforementioned shortcomings by conducting 34 sets of low-cycle fatigue tests on high-strength bolted connections. The test specimens all experienced low-cycle shear fatigue fracture at the threaded or unthreaded portion of the bolt shank as the dominant failure mode. Residual deformations were observed in the holes of connection plates. Based on the test data, ultimate shear capacity of a single shear connection is around 0.61Fy (tensile yield bearing capacity of bolt) when the shear force passes through the unthreaded portion and drops to 0.54Fy for the shear force at the thread. The untreated Q355 (minimum yield strength of 355 MPa) steel surface has an average anti-slip coefficient of around 0.37, while milling reduces it to approximately 0.30. The influence patterns of loading amplitude, bolt material, minimum plate thickness, bolt diameter, shear force position and connection type on low-cycle fatigue life are given by range analysis. Among them, variance analysis shows that loading amplitude and bolt material are the primary influencing factors. The correlation coefficient between loading amplitude and low-cycle fatigue life is −0.92, indicating a strong negative correlation. The degradation amount and rate of anti-slip capacity and shear capacity of bolted connections are also investigated. To propose reliable life prediction method, three models were used to establish the relationship between dimensionless shear deformation and low-cycle fatigue life of 10.9-grade high-strength bolted connections. It is not appropriate to use the fatigue categories defined in current standards to predict the low-cycle shear fatigue life of high-strength bolted connections.

Green chemistry approach to corrosion prevention: Saccocalyx satureioides as an effective inhibitor for C45 steel in acidic medium (HCl)

Carbon steel's corrosion in harsh, acidic environments presents significant challenges to industrial use. While traditional inhibitors are effective, they often raise environmental and sustainability concerns. This study explores the potential of Saccocalyx satureioides extract (S. Satureioides) as an environmentally Eco-friendly corrosion inhibitor for protecting carbon steel 45 in a highly corrosive 0.5 M HCl solution. The organic components of the sample were identified using phytochemical screening, LC-MS analysis, and ATR-FTIR spectroscopy. The main compounds detected were coumaric acid (68.10%), 4-methoxybenzoic acid (15.15%), and kaempferol (11.36%). Weight loss measurements demonstrated that the S. Satureioides extract had a highly effective anti-corrosion capability, achieving an inhibitory efficiency of around 96.93% at a concentration of 3 g.L-1 at a temperature of 25°C after 360 hours of immersion. This significantly reduced the corrosion rate from 0.1721 mg.cm−2.h−1 to 0.0053 mg.cm−2.h−1. The adsorption isotherms indicated that the adsorption of S. Satureioides molecules onto the steel surface followed the Langmuir model, exhibiting a high correlation coefficient of 0.9958. The negative value of the adsorption free energy ( = -17.162 kJ mol-1) indicates that the physisorption interactions occurred spontaneously. The SEM/EDX analysis revealed that the steel surface exhibited reduced damage due to the inhibitor's protective coating formation. This research not only significantly contributes to corrosion science filed but also provides crucial support for global efforts to promote sustainable industrial practices, with potential applications in various industries worldwide.

Effect of peening treatment on fatigue strength of welded joints of aged steel

This study experimentally investigates the effect of peening treatment on the fatigue strength of welded joints of aged steel. Fatigue tests were conducted on T-shaped fillet welded joints made from three different types of aged steel under three-point bending loading conditions. To reveal fatigue strength improvement mechanism, residual stress measurement, hardness measurement, and metallographic analysis were performed at the weld toe for both as-weld and peened specimens. Fractured surfaces were examined to identify crack initiation sites and propagation. The findings reveal that peening treatment introduces compressive residual stress on the peened surface of welded joints of aged steel equal to or higher than conventional steel welded joints. Higher improvement of hardness was observed in the near surface of the peened welded joints of aged steel, and the improvement continued up to around the zero crossing points of the residual stress distribution. Additionally, peening treatment might refine near-surface grains of aged steel welded toe similar to conventional steel. The fatigue strength improvement effect of the peening treatment was the same for aged steel as conventional one. Cracks were observed on the peened surface of the aged steel due to over-peening treatment. However, it doesn't affect the fatigue strength improvement of the welded joints of aged steel. In summary, it can be said that peening treatment can improve fatigue strength of welded joints of aged steel in the same manner of conventional steel.

Effect of WC content on the microstructure and properties of AlCoCrFeNi2.1 eutectic high entropy alloy coating prepared by ultra-high speed laser cladding technology

AlCoCrFeNi2.1 eutectic high entropy alloy coating with different WC content were prepared on 304 stainless steel surface by ultra-high speed laser cladding technology. Microstructure, phase distribution, Microhardness, friction, and wear properties were analyzed to investigate the influence mechanism of WC on the properties of alloy coatings. The results indicate that the addition of WC results in refined crystalline strengthening. The decomposition of WC leads to the formation of W2C and Cr23C6, which contribute to solid solution strengthening and second-phase strengthening. With increasing WC content, a noticeable improvement in microhardness and wear resistance properties is observed.

New triglycidyl ether triazine as a protective agent for metal: Comprehensive analysis

This study presents the synthesis and characterization of triglycidyl ether triazine (TGET), a novel epoxy resin, designed as a defensive agent for mild steel (C38) in a 1 M HCl environment. The corrosion inhibitory effectiveness of TGET was evaluated by various electrochemical methods and corroborated by surface analysis using surface and theoretical methods. The key findings demonstrate that the protection behavior of TGET rises with its concentration, achieving a maximum of 94.77 % at 10−3 mol/L, indicating a highly effective reduction in iron dissolution. Surface analysis confirmed the establishment of a defensive cover on the metal surface. The theoretical studies supported the experimental data, suggesting a strong adsorption of TGET molecules on the steel surface through chemical interaction, primarily via electron donation from the N and O atoms of the TGET to the metal surface. These results establish TGET as a highly effective corrosion inhibitor with potential applications in protecting steel structures in industrial environments characterized by acidic conditions.

Semiconductive Tendency of the Passive Film Formed on Super Austenitic Stainless Steel SR-50A in Acidic or Alkaline Chloride Solutions

Stainless steel is widely used in various industrial fields due to its excellent corrosion resistance and mechanical properties. The key to this corrosion resistance is the thin passive film that naturally forms on the metal surface. Passive films are characterized by oxide film theory and adsorption theory, each uniquely explaining the structure and mechanism of the protective film on the metal surface. Research on the semiconductive properties of passive films on stainless steel offers diverse viewpoints, classifying theories into the point defect model and the bipolar fixed charge-induced passivity. Specific changes in passive film attributes that lead to degradation, however, are not fully understood. In this study, we analyzed the inner and outer layers of the passive film on super austenitic stainless steel SR-50A under various conditions in acidic and alkaline chloride environments. The interpretations of these results were based on the point defect model and the bipolar model for the passivation mechanism, and correlations between p-type and n-type semiconductor properties and passivation behavior were examined. The surface of the stainless steel forms a passive film comprising two layers with p-type and n-type semiconductive properties, independent of the pH of the solutions. The corrosion resistance increases as the p-type and n-type semiconductive tendencies become more balanced, consequently enhancing the properties of the passive film.

Correction to: Fabrication of superhydrophobic, permeable, and anti-reflective porous steel surfaces using laser ablation and heat treatment

Correction to: Fabrication of superhydrophobic, permeable, and anti-reflective porous steel surfaces using laser ablation and heat treatment

Zn–Al with NO2− as a corrosion inhibitor epoxy-coated carbon steel under artificial atmospheric conditions

This study evaluated Zn–Al–NO2− layered double hydroxide as a corrosion inhibitor in a high-thickness epoxy resin coating (200 µm). The layered double hydroxide was tested in a NaCl solution, using electrochemical impedance spectroscopy. The formed oxides were analysed by X-ray diffraction and energy dispersive X-ray spectroscopy. The corrosion resistance of the epoxy coating (with and without layered double hydroxide) was analysed by electrochemical impedance spectroscopy after exposure to a NaCl solution, salt spray, or a weather-O-meter chamber in a simulated atmospheric environment. The electrochemical impedance spectroscopy measurements for the free layered double hydroxide in a NaCl solution revealed that layered double hydroxide prompted the formation of a compact, protective, and insoluble oxide layer on the carbon steel surface. The Cl− permeability through the epoxy resin film was 5.88 times lower for the film containing layered double hydroxide than for the control. The layered double hydroxide was added to the epoxy coating at a 5 wt-% to evaluate the behaviour of the coating in aggressive environments. The entry of aggressive ions was controlled by the ability of the layered double hydroxide to capture them and release the corrosion inhibitors. Thus, the layered double hydroxide worked as a trap for these aggressive ions and enhanced the performance of the coating. Therefore, a layered double hydroxide addition could benefit a high-thickness coating exposed to an aggressive environment and UV radiation.

Study on corrosion inhibition of carbon steel by imidazolylium-based ionic liquids in chlorine dioxide water disinfection

Chlorine dioxide (ClO2), recognized for its high efficiency, broad-spectrum capabilities, and safety, is extensively utilized in water disinfection processes. Possessing strong oxidizing properties, prolonged exposure to ClO2 can lead to irreversible corrosion of metals. To mitigate the ClO2-induced corrosion on steel, the corrosion inhibition performance and underlying mechanism of BMIMAc and BMIMBr on 20 steel and Q235 steel in ClO2 solutions ranging from 2.5 to 10 mg/L is systematically studied by static weightlessness experiments, potentiodynamic polarization curve experiments, SEM, EDS, DFT calculations, and MD simulation. The findings demonstrate that both ionic liquids significantly impede corrosion, where BMIMAc outperforms BMIMBr in terms of corrosion inhibition efficacy. These inhibitors exhibit effective adsorption onto the carbon steel surface, conforming to the Langmuir isotherm model. Both ionic liquids are cathodic inhibitors. They can adsorb on the metal surface in an approximately parallel manner and their imidazole ring can form a coordination bond with the metal, leading to the formation of an adsorbent membrane that prevents further contact of the metal with ClO2, thus reducing the degree of oxidation and retarding the corrosion process.