Papers by Keyword: Mild Steel

Abstract: The corrosion inhibition on mild steel by eco-friendly paint produced from Mangifera indica leaves extract was carried out using the weight loss and potentiodynamic polarization methods. Central Composite Design (CCD) in Response Surface Methodology (RSM) was used for the design of experiment for the determination of corrosion inhibition efficiency, corrosion rate, and statistical analysis of the experimental results. Corrosion protection paint was formulated, and its efficacy was tested in a hydrochloric acid medium. The surface morphology of the mild steel sample was studied using the scanning electron microscopy (SEM). The corrosion inhibition efficiency of the paint for weight loss and potentiodynamic polarization methods is 83.68 and 99.49 %, respectively. The activation energy for corrosion process with coated mild steel is 26.47 J/mol K, which is higher than the value of 16.89 J/mol K obtained for uncoated mild steel, indicating that the adsorption process is physisorption. The enthalpy change is 23.96 kJ/mol. The positive value indicates that heat is absorbed from the environment. The entropy change is-180 J/mol K, implying that the activation energy complex is the rate determining step representing association rather than dissociation. Langmuir adsorption isotherm was found to be the best fit model. It was concluded from the study that the formulated paint has a high potential for commercialisation and industrial applications.

Abstract: This study evaluates and compares the corrosion resistance of zinc coatings deposited on mild steel using three different techniques: electroplating, TREFISSOUD Company hot-dip galvanization, and conventional hot-dip galvanization. Coated and uncoated samples were characterized by electrochemical polarization, microscopic analyses (optical microscopy and SEM), and X-ray diffraction (XRD). Electrochemical results demonstrated a significant decrease in corrosion current density (Icorr) for all zinc-coated specimens compared to bare steel, confirming the protective effect of the coatings. Among the coatings, hot-dip galvanization exhibited superior performance, with the TREFISSOUD Company method achieving the lowest corrosion current and the highest polarization resistance, indicating enhanced corrosion protection. Electroplated zinc, although thinner, provided adequate resistance in moderately aggressive environments. XRD analysis revealed zinc oxide (ZnO) and iron oxide (Fe₂O₃) as the main corrosion products. Their intensity was more pronounced in galvanized coatings than in electroplated zinc. Microscopic observations confirmed uniform and adherent coatings, with hot-dip galvanization producing thicker layers and stronger adhesion than electroplating. Overall, the findings demonstrate that hot-dip galvanization, particularly the TREFISSOUD Company method, provides the best long-term protection for mild steel exposed to harsh conditions. Electroplated zinc, while less durable, remains suitable for applications where a thinner, uniform coating is required. These results highlight the importance of selecting the coating method according to specific service conditions in industrial applications such as construction, pipelines, and marine environments. This study provides a new comparative analysis between conventional and TREFISSOUD company hot-dip galvanization methods, which has not been reported previously in the literature. The results highlight the distinctive performance of the TREFISSOUD Company process in improving coating uniformity, adhesion, and corrosion resistance. This novelty contributes to a better understanding of industrial zinc coating optimization for mild steel.

Abstract: In machining process, surface roughness and material removal rate have a vital importance since they affect mass production, consumption of energy, force, and tool life and product quality. In this study, Taguchi-Grey Relation Method (TGRM) is applied to AISI 1040 mild steels in the hardened form when machined with ceramic inserts using response surface methodology for multi-objective optimization. Grey-Relation Method and Pareto chart reveal that feed rate, depth of cut, speed besides square effect of speed/feed rate are effective parameters on the response. Among all eighteen experiments, trial twelfth provides the best multi-performance characteristics while the first experiment shows the worst performance. Optimal levels are determined at higher speed, higher feed rate associated with higher depth of cut. It is concluded that quadratic regression model and reduced quadratic regression model are developed. The correlation coefficients range from 98.3% to 96.89%, respectively. As a result, TGRM has an efficient to provide a good modelling in combination of surface roughness and metal removal rate.

Abstract: In this study, researchers investigated the effectiveness of silver nanoparticles (AgNPs) combined with powder extracts from Moringa oleifera (Malunggay) for inhibiting corrosion on A36 mild steel, a common material used in the oil and gas industry. The synthesis process involved mixing AgNPs with Moringa oleifera extracts at different concentrations in acidic conditions and varying temperatures. Characterization techniques such as UV-Vis Spectroscopy, FT-IR, and TEM were used to analyze the structural and functional properties of the resulting Moringa-AgNPs. The study aimed to evaluate how these nanoparticles affected the corrosion resistance of A36 steel under different conditions, including temperature and inhibitor concentration, by assessing parameters like weight loss and corrosion rate. SEM/EDS analysis provided further insights. Overall, the research suggests that incorporating Moringa-AgNPs could be a promising strategy to reduce corrosion rates in the oil and gas industry.

Abstract: This study investigates the influence of milling parameters on the material removal rate (MRR) of thick mild steel. The study employs a designed experiment to evaluate the influence of cutting speed, feed rate, and depth of cut on MRR. A total of nine milling experiments are conducted on mild steel using orthogonal array method. The study aims to identify the optimal process parameters for achieving a maximum MRR on mild steel workpieces. The value of signal to noise ratio (SNR) is used to evaluate the optimal values of milling parameters for thick mild steel. Higher-the-better type quality characteristic is used to evaluate the SNR of MRR. Further, MRR is analyzed using ANOVA method to elect the significant milling process parameters based on P-values and fisher coefficient. Depth of cut found the significant followed by feed rate and speed. The contribution of each milling process parameter is also evaluated. Depth of cut contribution is found 66% on MRR of thick mild steel

Abstract: Sustainable material processing is the current need of machine tool industries. This paper aims to design and experimentally study the material removal rate of mild steel during dry turning using a high-speed steel single point cutting tool and a conventional lathe machine. Twenty-seven turning operations are designed using an orthogonal array experimental design method. The speed, feed and depth of cut are selected as input parameters while material removal rate is considered as quality parameter. Input parameters are varied twenty-seven times during dry turning of mild steel workpieces. Effects of input parameters are investigated to discover which one has a significant effect on material removal rate and hence to determine the dry turning conditions for mild steel. Statistical test results revealed that the depth of cut is significant than feed and speed. The F-value obtained from ANOVA result and Pareto chart are verified that depth of cut is significant on material removal rate of mild steel during dry turning

Abstract: This study examined the corrosion inhibition characteristics of Launaea taraxacifolia on mild steel in 1M H₂SO₄ solution, considering the demand for environmentally benign and effective corrosion inhibitors in acid media. The work aimed at elucidating the adsorption behavior, inhibition mechanism, and thermodynamic properties of L. taraxacifolia. Gravimetric and potentiodynamic techniques were employed in assessing inhibitor performance for variations in inhibitor concentrations (0.3%–1.2% W/V), immersion time (10–60 minutes), and temperature (303K–323K). The results indicated that corrosion rates increased with temperature, showing that the inhibitory process is dependent on the adsorption of L. taraxacifolia onto the steel surface. Adsorption obeyed Freundlich and Temkin isotherms, and the calculated heat of adsorption was -11 kJ/mol, which indicated physical adsorption. The presence of key phytochemicals, aromatic compounds, and heteroatoms in the inhibitor played an important role in the process, making it a mixed-type inhibitor. The maximum inhibition efficiency of 97.78% was recorded at higher inhibitor concentrations and longer immersion times. The weight loss measurements were within the range of 0.001g to 0.038g across the temperatures. This study illustrates the potential of L. taraxacifolia as a green inhibitor, evidenced by its thermodynamic and kinetic properties. It concludes that L. taraxacifolia might serve as a good substitute for synthetic inhibitors, especially in those industries where environmental considerations are essential.

Abstract: This study investigates the effectiveness of carbon nanotubes (CNTs) in enhancing the surface hardness of mild steel through carburization. CNTs were synthesized via chemical vapor deposition at 700°C using iron nitrate and cobalt nitrate as precursors on CaCO₃ support. Acetylene was used as the carbon source and nitrogen as the inert gas. The as-synthesized CNTs were purified using a one-step nitric acid treatment. Characterization by SEM, TGA, and FTIR revealed CNT diameters of 42-52 nm and improved thermal stability after purification, with TGA showing mass losses of 78% for as-synthesized CNTs and 85% for purified CNTs. Low carbon steel (AISI 1018) samples were carburized with as-synthesized and purified CNTs at austenitic temperatures of 750°C and 800°C for period ranging from 10 to 50 minutes. The carburizing process involved heating at 10°C/minute, followed by a defined number of boost and diffusion steps. Surface hardness was evaluated using a Vickers FM 700 micro-hardness tester, and microstructure was checked with an Olympus SC50 optical microscope. Results show that the use of purified CNTs in the carburization displayed the highest surface hardness of 191.64 ± 4.16 GPa at 800°C for 50 minutes, representing a 32% increase over the untreated substrate (145.188 ± 2.66 GPa). As-synthesized CNTs yielded a hardness value of 177.88 ± 2.35 GPa under the same conditions. At 750°C, the percentage increase in hardness for as-synthesized CNTs and purified CNTs were 10.04% and 15.77%, respectively, compared to the untreated substrate. Higher carburization temperature and longer treatment time consistently increased the surface hardness. The use of purified CNTs resulted in an increase of 6.37% hardness when compared to that of the as-synthesized CNTs at 750°C. Microstructural changes in the steel samples confirmed improved surface hardness with both purified and unpurified CNTs, with purified CNTs showing superior performance. This study therefore provides a platform for the use of CNTs for enhancing surface hardness of steel for various industrial applications requiring enhanced mechanical properties and wear resistance in low carbon steels.

Abstract: In order to increase and extend the usage of mild steel in a range of applications, critical research needs are extremely interested in corrosion studies, including corrosion inhibitor performance. The goal of this study is to look at the corrosion-inhibiting capabilities of ammonium benzoate in a 0.5 M HCl solution for mild steel, with solanum tuberosum (potato) extract serving as a surfactant. Mild steel samples were cut into corrosion coupons and submerged in 0.5 M HCl media to investigate the inhibitory effects at room temperature for various concentrations of ammonium benzoate using polarisation and weight loss techniques. A scanning electron microscopy fitted with electron dispersion spectroscopy (SEM-EDS) was used to investigate the morphology of the corroded samples. The results obtained indicated that ammonium benzoate performed better when combined with solanum tuberosum (potato) extract as a surfactant that inhibits mild steel corrosion in 0.5 M HCl by lowering the rate of corrosion. As the concentration rises, ammonium benzoate becomes more effective. From the weight loss test and polarisation analysis, a maximum inhibition efficiency of 99.94% at the 1.0 M concentration of inhibitor was achieved. It was observed that the ammonium benzoate adsorption mechanism isotherm fit with the Langmuir absorption isotherm when it was adsorbed on mild steel. Furthermore, adding solanum tuberosum (potato) extract to the inhibitor significantly reduces the rate of mild steel corrosion in HCl solution. The SEM micrographs confirm the presence of an absorbed protective film layer on the mild steel surface.

Abstract: The widespread corrosion of critical oil and gas infrastructure requires development of innovative and environmentally sustainable solutions. This research considers the repurposing of hitherto un-useful expired drugs to meet this challenge and to do so in ways that also puts stop to the menacing and illegal circulation of expired pharmaceuticals in developing economies. The corrosion inhibitory potential of expired paracetamol was evaluated for mild steel in acidic environment. Electrochemical analysis revealed that the corrosion current decreased from for the mild steel immersed in the blank/uninhibited 0.5M HCl environment to in the case of the sample in the 8g/l environment. The concentration of dissolved ions of iron in the acidic environment also followed this trend supported by the results obtained from the gravimetric analysis. Optical microscopy showed gradual covering of the corroding surface by a layer of inhibitor film with increasing concentration of the additive in the acidic environment. The corrosion inhibition efficiency increased with increasing concentration of the expired drug, reaching a maximum of 73.24% for 8.0 mM of expired paracetamol directly dissolved in the acid. Expired paracetamol acted as a mixed-type inhibitor for mild steel in 0.5M HCl and the corrosion inhibition process was spontaneous. All analyses agreed that expired paracetamol drug is capable of inhibiting corrosion of mild steel in HCl and that the corrosion inhibition is achievable without prior pretreatment. The research is fundamental as it attempts to lay some groundwork for further research towards developing viable and marketable product from this category of materials.