Interfacial reaction between AZ91D magnesium alloy melt and mild steel under high temperature

The metallurgical quality control of magnesium(Mg)and Mg alloys in melting process is required to ensure a satisfied mechanical and corrosion performance,while the typical used steel crucible introduces impurities and interfacial interaction during melting process.Therefore,a systematic study about impurities diffusion and interfacial interaction between molten Mg and steel is necessary.In the present study,the interfacial reaction between molten AZ91D Mg alloy and mild steel during melting process was investigated with the melting temperatures of 700℃,750℃ and 800℃.The results show that Al(Fe,Mn)intermetallic layer is the intermetallic primarily formed at the interfaces of AZ91D melt and mild steel.Meanwhile,Al_(8)(Mn,Fe)5is indexed between Al(Fe,Mn)and AZ91D.AlFe_(3)C appears between the mild steel and Al(Fe,Mn)at 700℃ and 750℃,but absent at 800℃ due to the increased solubility of carbon in Mg matrix.It is found that the growth of the intermetallic layer is controlled by diffusion mechanism,and Al and Mn are the dominant diffusing species in the whole interfacial reaction process.By measuring the thickness of different layers,the growth constant was calculated.It increases from 1.89(±0.03)×10^(-12)m^(2)·s^(-1)at 700℃ to 3.05(±0.05)×10^(-12)m^(2)·s^(-1)at 750℃,and 5.18(±0.05)×10^(-12)m^(2)·s^(-1)at 800℃.Meanwhile,the content of Fe is linearly increased in AZ91D with the increase of holding time at 700℃ and 750℃,while it shows a significantly increment after holding for 8 h at 800℃,indicating holding temperature is more crucial to determine the Fe content of AZ91D than holding time.

Enhanced adsorption of target branched compounds including antibiotic norfloxacin frameworks on mild steel surface for efficient protection: An experimental and molecular modelling study

In this study, an approach was proposed to employ new target branched compounds(TBCs) including multiple antibiotic norfloxacin frameworks for intensified adsorption films to achieve super protection of mild steel in HCl medium. Thus, the TBCs containing bis/tri norfloxacin skeletons were synthesized by multi-step preparation route. In addition, the reference linear compound(RLC) including a single norfloxacin part was also synthesized. The chemical structures of these compounds were confirmed by various means. It was demonstrated that the TBCs could form the tough adsorption films on the surface of mild steel, which could be processed mainly through chemisorption effect. The electrochemical analysis suggested that the TBCs displayed superior corrosion inhibition performance for low carbon steel in1.0 mol·L^(-1) HCl solution over the RLC(RLC, 87.80%;TBC1, 97.63%;TBC2, 98.35%), which was further understood by the molecular modelling. The isotherm adsorption plots were employed to analyze the spontaneous adsorption process of the TBCs on low carbon steel surface, and a prominent chemisorption could be inferred by the standard Gibbs free energy changes of the adsorption.

The Use of Models to Evaluate Corrosion Effects on Mild Steel Heat Exchanger in Water and Mono Ethanol Amine (MEA)

Heat exchanger is an important equipment used in process industries for cooling and heating purposes. Its design configuration which involves the flow of cold and hot fluids within the exchanger subjects it to corrosion attack. The article utilized the principle of mass and energy conservation in the development of weight and temperature models to study the effect of corrosion on mild steel coupon inside the exchanger containing water and Mono ethanol amine (MEA). The models developed were resolved analytically using Laplace Transform and simulated using Excel as simulation tool and data obtained from experiment in the laboratory to obtain profiles of weight loss and temperature as a function of time. The weight loss and performance of mild steel under various corrosive conditions were examined which indicates the effect of corrosion on the mild steel heat exchanger in water and MEA media. The result shows that water is more corrosive than MEA at higher temperatures and at lower temperatures of 35°C and 1 atm, MEA has inhibitive properties than water as indicated by the weight loss result with time. The comparative analysis between the results obtained from the model simulation and experimental results shows that the result obtained from the model is more reliable and demonstrated better performance characteristics as it clearly shows mild steel heat exchanger experiences more corrosive effect in water medium than MEA at higher temperatures. And at lower temperatures, MEA becomes more inhibitive and less corrosive than water. The model simulation results correlate with various literatures and hence, it is valid for future referencing.

Kinetics of Atmospheric Corrosion of Mild Steel in Marine and Rural Environments

In continuation of the extensive studies carried out to update the corrosion map of India, in this study, the degradation of mild steel by air pollutants was studied at 16 different locations from Nagore to Ammanichatram along the east coast of Tamilnadu, India over a period of two years. The weight loss study showed that the mild steel corrosion was more at Nagapattinam site, when compared to Ammanichatram and Maravakadu sites. A linear regression analysis of the experimental data was attempted to predict the mechanism of the corrosion. The composition of the corrosion products formed on the mild steel surfaces was identified by XRD technique. The corrosion rate values obtained are discussed in the light of the weathering parameters, atmospheric pollutants such as salt content ＆ SO2 levels in the atmosphere, corrosion products formed on the mild steel surfaces.

Adsorption isotherm mechanism of amino organic compounds as mild steel corrosion inhibitors by electrochemical measurement method

The inhibition ability of 4-amino-5-phenyl-4H-1, 2, 4-trizole-3-thiol （APTT）, ethylenediaminetetra-acetic acid （EDTA） and thiourea （TU） for mild steel corrosion in 1.0 moFL HC1 solution at 30 ℃ was investigated. Tafel polarization and electrochemical impedance spectroscopy （EIS） were used to investigate the influence of these organic compounds as corrosion inhibitors of mild steel in 1.0 mol/L HC1 solution at 30 ℃. The inhibition mechanism was discussed in terms of Langrnuir isotherm model. Results obtained from Tafel polarization and impedance measurements are in a good agreement. The inhibition efficiency increases with the increase of the inhibitor concentration. The adsorption of the inhibitors on the mild steel surface follows Langmuir adsorption isotherm and the free energy of adsorption AGads indicates that the adsorption of APTT, EDTA, and TU molecules is a spontaneous process and a typical chemisorption.

Analytical and experimental study on mild steel dampers with non-uniform vertical slits

This study proposes a novel mild steel damper with non-uniform vertical slits. The influence of different shapes of vertical slits of the core energy plate on the energy dissipation and buckling resistance capacities is analyzed. Based on the theoretical analysis, formulas of key parameters of the dampers, including the elastic lateral stiffness, shear bearing capacity and yield displacement, are derived. The effectiveness of the proposed damper is demonstrated through pseudo static tests on four 0.25-scale specimens. Performance of these dampers, i.e. cyclic deformation, stress distribution, energy dissipation capacity, etc., are presented and discussed. Using the numerical models of dampers calibrated through test data, earthquake time-history analyses were conducted, and it is observed that the dampers significantly reduce the seismic responses of the prototype frame and have a desirable energy dissipation capacity.

Combined electronic/atomic level computational, surface(SEM/EDS),chemical and electrochemical studies of the mild steel surface by quinoxalines derivatives anti-corrosion properties in 1 mol·L^(-1) HCl solution

This work is devoted to the study of the inhibition of corrosion of mild steel(MS)in molar hydrochloric acid(1 mol·L-1 HCl)by two named quinoxaline derivatives namely,2-(2,4-dichlorophenyl)-1,4-dihydroquinoxaline(HQ)and 2-(2,4-dichlorophenyl)-6-methyl-1,4-dihydroquinoxaline(CQ).The inhibitory efficacy of HQ and CQ compounds is first evaluated using the gravimetric method and using electrochemical techniques(stationary and transient techniques).The results showed that our compounds are efficient corrosion inhibitors and the inhibition rates(ηEIS%)reached up to 91%and 94.2%at 10-3 mol·L-1 for HQ and CQ,respectively.The mentioned molecules are classified as mixed-type inhibitors.The adsorption of these inhibitors on the surface of steel in hydrochloric HCl 1 mol·L-1 medium obeys the Langmuir adsorption isotherm.The results of the scanning electron microscope(SEM)showed the formation of a protective film on the surface of the steel in the presence of the inhibitors studied.Elementary analysis is obtained by energy dispersive X-ray spectroscopy(EDS).The inhibition property was further elucidated by theoretical approaches such as:Density Functional Theory(DFT),quantum chemical descriptors(QCD),local reactive indices,solvent effect,theoretical complexation,Molecular Dynamic(MD)simulation,effect of temperature on adsorption energy(Eads),Radial Distribution Function(RDF),and Mean Square Displacement(MSD).The results of these approaches support the experimental results.

Effect of Sulfate-reducing Bacteria on Corrosion Behavior of Mild Steel in Sea Mud

Microbiologically influenced corrosion （MIC） is very severe corrosion for constructions buried under sea mud environment. Therefore it is of great importance to carry out the investigation of the corrosion behavior of marine steel in sea mud. In this paper, the effect of sulfate-reducing bacteria （SRB） on corrosion behavior of mild steel in sea mud was studied by weight loss, dual-compartment cell, electronic probe microanalysis （EPMA）, transmission electron microscopy （TEM） combined with energy dispersive X-ray analysis （EDX） and electrochemical impedance spectroscopy （EIS）. The results showed that corrosion rate and galvanic current were influenced by the metabolic activity of SRB. In the environment of sea mud containing SRB, the original corrosion products, ferric （oxyhydr） oxide, transformed to iron sulfide. With the excess of the dissolved H2S, the composition of the protective layer formed of FeS transformed to FeS2 or other non-stoichiometric polysulphide, which changed the state of the former layer and accelerated the corrosion process.

Study on arc characteristics and behavior of metal transfer in pulse current flux-cored arc welding of mild steel

The variation in arc characteristics and behavior of metal transfer with the change in pulse parameters has been studied by high speed video camera during pulse current flux-cored arc weld deposition.A comparative study of similar nature has also been carried out during flux-cored arc weld deposition in globular and spray transfer modes.The effect of pulse parameters has been studied by considering their mean current and arc voltage.The arc characteristics studied by its root diameter,projected diameter and length,and the behavior of metal transfer noted by the metal transfer model and the droplet diameter have been found to vary significantly with the pulse parameters.The observation may help in understanding the arc characteristics with respect to the variation in pulse parameters which may be beneficial in using pulse current FCAW to produce desired weld quality.

ESTIMATE OF BURSTING PRESSURE OF MILD STEEL PRESSURE VESSEL AND PRESENTATION OF BURSTING FORMULA

In order to get more precise bursting pressure formula of mild steel, hundreds of bursting experiments of mild steel pressure vessels such as Q235（Gr.D） and 20R（1020） are done. Based on statistical data of bursting pressure and modification of Faupel formula, a more precise modified formula is given out according to the experimental data. It is proved to be more accurate after examining other bursting pressure value presented in many references. This bursting formula is very accurate in these experiments using pressure vessels with different diameter and shell thickness. Obviously, this modified bursting formula can be used in mild steel pressure vessels with different diameter and thickness of shell.

Study on deformation and microstructure characterizations of mild steel joints by continuous drive friction welding

Macro-deformation characteristics of continuous drive friction welded mild steel joints were examined by using one deformable workpiece （objective） and the other undeformable one （rigid）. The microstructure evolution and hardness change across the joint were studied. The results show that the axial shortening and radial increment of joints increase with increasing the frictiou time at l 200 rpm. The cementite particles of pearlites in the weld center are uniformly distributed on the ferrite matrix, while the cementites of the pearlite in the thermal-mechanically affected zone are broken and discontinuously dispersed in the pearlite. The hardness decreases rapidly from the weld center to the parent metal under the coupled effects of heat and deformation during the rapid heating and cooling processes.

Electrical-thermal interaction simulation for resistance spot welding nugget process of mild steel and stainless steel

A three dimensional finite difference electrical thermal model for resistance spot welding nugget process of mild steel and stainless steel is introduced. A simulation method of the interaction of electrical and thermal factors is presented. Meanwhile, calculation method of contact resistance and treatment method of heater structure is provided. The influence of the temperature dependent material properties and various cooling boundary conditions on welding process was also taken into account in the model. A method for improving the mild steel and stainless steel joint was analyzed in numerical simulation process. Experimental verification shows that the model prediction agrees well with the practice. The model provides a useful theoretic tool for the analysis of the process of resistance spot welding of mild steel and stainless steel.

Effect of electrochemical polishing time on surface topography of mild steel

The variation in altitude density function （ADF） of the surface topography of mild steel during electrochemical polishing （ECP） was investigated, and the mechanism of the variation of surface roughness with polishing time was analyzed. The results show that the variation trend of ADF with polishing time is flat-steep-flat; the variation of surface roughness results in the different distri- butions of surface current density, and there is a fine surface smoothness in the special period of ECP from 4 to 8 s.

Benevolent behavior of Kleinia grandiflora leaf extract as a green corrosion inhibitor for mild steel in sulfuric acid solution

The ethanolic extract of Kleinia grandiflora leaves was characterized and tested for its potential anticorrosion properties on mild steel in 1 M H2SO4 medium using mass-loss analysis, potentiodynamic polarization measurements, electrochemical impedance spectroscopy, Fourier-transform infrared spectroscopy, scanning electron microscopy, UV–visible spectroscopy, and X-ray diffraction analysis. The effect of temperature on the corrosion behavior of mild steel was studied in the range of 308 to 328 K. The inhibition efficiency was observed to increase with increasing concentration of the extract. Polarization curves revealed that the Kleinia grandiflora leaf extract is a mixed inhibitor. Impedance diagrams revealed that an increase of Kleinia grandiflora leaf extract concentration increased the charge transfer resistance and decreased the double-layer capacitance. The adsorption process obeys Langmuir＇s model, with a standard free energy of adsorption（ΔGads） of-18.62 k J/mol. The obtained results indicate that the Kleinia grandiflora leaf extract can serve as an effective inhibitor for the corrosion of mild steel in a sulfuric acid medium.

Measurement and analysis of polarization curves of mild steel in sodium carbonate/bicarbonate solution under erosion-corrosion conditions

The polarization curves of mild steel in de-aerated 0.5 mol NaHCO 3+0.5 mol Na 2CO 3 solution with and without erodent particles of 300 g/L of 100 μm alumina have been measured using a rotating cylinder electrode (RCE) apparatus over the range of rotation speeds from 0 to 4 000 r/min. The results show that the mild steel in the de-aerated slurry exhibits classical active/passive polarization behavior. The speed of cylinder rotation has a great effect in the presence of particles on the active dissolution current density. The erosion-corrosion process is severely erosion-dominated for the mild steel. However, the poor corrosion resistance of the mild steel in such turbulent slurries is also significant, especially at lower than 4 m/s.

Ethanol Extract of Vitex Doniana as a Green Corrosion Inhibitor for Mild Steel in Hydrochloric Acid Medium

Corrosion is a costly and complicated problem facing mild of Vitex doniana as a corrosion inhibitor for mild steel in HCI medium steel utility. This study investigated the use of ethanol extract Experimental methods used are gravimetric and thermometric The results showed that corrosion rate decreased as the concentration of ethanol extract of Vitex doniana increased and with decrease in temperature. Vitex doniana extract obeyed Langmuir and Tempkin adsorption isotherm. Physical adsorption was proposed from △G° and Ea. Inhibition efficiency （1%） and the degree of surface coverage （0） were calculated and all indicated that Vitex doniana was a good corrosion inhibitor.

Origanum majorana Extracts as Mild Steel Corrosion Green Inhibitors in Aqueous Chloride Medium

We optimized Origanum majorana (OM) extraction for mild steel corrosion inhibition in neutral 0.5 M chloride medium. The inhibition mechanism evolved in presence of the optimal extract was discussed when calculating the activation energy (Ea), the activation enthalpy (ΔaH) as well as the activation entropy (ΔaS). The OM extract molecules were investigated using the density functional theory (DFT) at B3LYP/6-31G(d,p) basis set level. 1-methyl-4-propan-2-ylcyclohexa-1,3-diene alpha-terpinene was predicted exhibiting the most inhibition capabilities.

Investigation of Aloe lateritia Gel as Corrosion Inhibitor for Mild Steel in 2 M HNO3 and 1 M H2SO4 Media

Corrsion inhibition of Aloe lateritia gel for Mild steel in 2 M HNO3 and 1 M H2SO4 solutions was investigated by potentiodynamic polarization, Scanning electron microscopy (SEM) and Foutier transform infrared (FT-IR). Inhibition efficiency increased with the increase of the concentration of the gel. The optimal concentration of the gel gives maximum inhibition efficiency of 77.4% and 70.3% in 1 M H2SO4 and 2 M HNO3 respectively. Polarization plots shows that, the gel works as a mixed type inhibitor altering both cathodic and anodic reaction. SEM proves the uniform and pitting corrosion at the surface of Mild steel in 1 M H2SO4 and 2 M HNO3 respectively. Using FT-IR potential function groups from pure gel and some stretch shift was observed from corrosion product and some stretch shift from corrosion products was observed.

Life Cycle Assessment of Household Water Tanks—A Study of LLDPE, Mild Steel and RCC Tanks

A case of household water tanks, 1000 L capacity, made of RCC, LLDPE and mild steel (stainless steel) was evaluated for life cycle analysis. The scope of the research comprised of the raw materials, energy inputs and corresponding emissions during all phases of product making such as extraction of raw material, it’s processing, followed by manufacturing and transport, as well as use and reuse of the product. Simapro 8 (System for Integrated environMental Assessment of PROducts), a modelling software, from Dutch PRé Consultants was used to conduct the life cycle analysis. Simapro 8 enables systematic and transparent modelling and analysis of complex life cycles based on the recommendations of the ISO 14040 series of standards. In the present study the most common method which is acceptable worldwide “Recipe Endpoint method” (ReCiPe) was employed. ReCiPe computes the impact categories and classifies them into two classes based on relevant arrays of characterization factors. Simapro addresses impact categories viz. ozone depletion, human toxicity, ionizing radiation, photochemical oxidant formation, particulate matter formation, terrestrial acidification, climate change, terrestrial ecotoxicity, agricultural land occupation, urban land occupation, natural land transformation, marine ecotoxicity, marine eutrophication, fresh water eutrophication, fresh water ecotoxicity, fossil fuel depletion, minerals depletion, fresh water depletion at the midpoint level. While at the Endpoint level, the impact categories are multiplied by corresponding damage factors and integrated to be represented as three Endpoint level categories, viz. human health, ecosystems and resource depletion. The three endpoint categories are normalized, weighted, and aggregated into a single score. LCA studies indicate that household water tanks of LLDPE have least environmental implications considering impacts on human health, ecosystems and resource depletion as compared to its counterparts viz. Household water tanks made up of mild steel and RCC. The sequence of the material with decreasing impacts is concrete tanks > mild steel tank > LLDPE tanks. The overall assessment is centred on the elements such as material inputs, energy inputs and environmental emissions.

Development of a Predictive Model to Improve the Hardness of Mild Steel Welded Joint

Structural integrity of weldment is greatly influenced by its process parameters and usually, it is expected for a welded joint to be stronger than its parent metal, but in actual fact, most failures occur at the welded joints and it is mostly due to poor combination of process parameters or inexperience of the welder. This poor combination leads to poor hardness exhibited at the welded joint. The aim of this study is to predict and improve the hardness of mild steel welded zone using the tungsten inert gas (TIG) welding process. Response Surface Methodology (RSM) was employed to analyze the welded response. 200 pieces of mild steel coupons measuring 27.5 × 10 × 10 mm were prepared and used for the experiment, the experiment was performed 20 times, using 5 specimens for each run, after which the hardness was measured and results analyzed respectively. The study produced eighteen (18) optimum results with the best selected to produce a material hardness of 299.269 N/mm2 with desirability of 95.6%, resulting from current of 120 amp, voltages of 20 and gas flow rate of 12 L/min.