Pitting corrosion resistance and bond strength of stainless steel overlay by friction surfacing on high strength low alloy steel

Surface modification is essential for improving the service properties of components. Cladding is one of the most widely employed methods of surface modification. Friction surfacing is a candidate process for depositing the corrosion resistant coatings. Being a solid state process, it offers several advantages over conventional fusion based surfacing process. The aim of this work is to identify the relationship between the input variables and the process response and develop the predictive models that can be used in the design of new friction surfacing applications. In the current work, austenitic stainless steel AISI 304 was friction surfaced on high strength low alloy steel substrate. Friction surfacing parameters,such as mechtrode rotational speed, feed rate of substrate and axial force on mechtrode, play a major role in determining the pitting corrosion resistance and bond strength of friction surfaced coatings. Friction surfaced coating and base metal were tested for pitting corrosion by potentiodynamic polarization technique. Coating microstructure was characterized using optical microscopy, scanning electron microscopy and X-ray diffraction. Coatings in the as deposited condition exhibited strain-induced martensite in austenitic matrix. Pitting resistance of surfaced coatings was found to be much lower than that of mechtrode material and superior to that of substrate. A central composite design with three factors(mechtrode rotational speed, substrate traverse speed, axial load on mechtrode) and five levels was chosen to minimize the number of experimental conditions. Response surface methodology was used to develop the model. In the present work, an attempt has been made to develop a mathematical model to predict the pitting corrosion resistance and bond strength by incorporating the friction surfacing process parameters.     

Microstructure and corrosion behaviour of gas tungsten arc welds of maraging steel

Superior properties of maraging steels make them suitable for the fabrication of components used for military applications like missile covering, rocket motor casing and ship hulls. Welding is the main process for fabrication of these components, while the maraging steels can be fusion welded using gas tungsten arc welding(GTAW) process. All these fabricated components require longer storage life and a major problem in welds is susceptible to stress corrosion cracking(SCC). The present study is aimed at studying the SCC behaviour of MDN 250(18% Ni) steel and its welds with respect to microstructural changes. In the present study, 5.2 mm thick sheets made of MDN 250 steel in the solution annealed condition was welded using GTAW process. Post-weld heat treatments of direct ageing(480 C for 3 h), solutionizing(815 C for 1 h) followed by ageing and homogenizing(1150 C for 1 h) followed by ageing were carried out. A mixture of martensite and austenite was observed in the microstructure of the fusion zone of solutionized and direct aged welds and only martensite in as-welded condition. Homogenization and ageing treatment have eliminated reverted austenite and elemental segregation. Homogenized welds also exhibited a marginal improvement in the corrosion resistance compared to those in the as-welded, solutionized and aged condition. Constant load SCC test data clearly revealed that the failure time of homogenized weld is much longer compared to other post weld treatments, and the homogenization treatment is recommended to improve the SCC life of GTA welds of MDN 250 Maraging steel.     

Effect of welding processes and consumables on fatigue crack growth behaviour of armour grade quenched and tempered steel joints

Quenched and Tempered (Q&T) steels are widely used in the construction of military vehicles due to its high strength to weight ratio and high hardness. These steels are prone to hydrogen induced cracking (HIC) in the heat affected zone (HAZ) after welding. The use of austenitic stainless steel (ASS) consumables to weld the above steel was the only available remedy because of higher solubility for hydrogen in austenitic phase. The use of stainless steel consumables for a non-stainless steel base metal is not economical. Hence, alternate consumables for welding Q&T steels and their vulnerability to HIC need to be explored. Recent studies proved that low hydrogen ferritic steel (LHF) consumables can be used to weld Q&T steels, which can give very low hydrogen levels in the weld deposits. The use of ASS and LHF consumables will lead to distinct microstructures in their respective welds. This microstructural heterogeneity will have a drastic influence in the fatigue crack growth resistance of armour grade Q&T steel welds. Hence, in this investigation an attempt has been made to study the influence of welding consumables and welding processes on fatigue crack growth behaviour of armour grade Q&T Steel joints. Shielded metal arc welding (SMAW) and Flux cored arc welding (FCAW) were used for fabrication of joints using ASS and LHF consumables. The joints fabricated by SMAW process using LHF consumable exhibited superior fatigue crack growth resistance than all other joints.     

不同腐蚀状态不锈钢管焊缝区 碱性腐蚀的电位噪声特征

利用电化学电位噪声方法检测了不同腐蚀状态304与316两种不镑钢管焊缝区试样在室温碱液中的腐蚀行为,并采用电化学噪声时域谱、频域谱进行了分析,结果表明:不同腐蚀状态焊缝试样的腐蚀电位及噪声时城谱特征不同,可利用电位噪声频城谱的高频斜率K值定性判定是否发生局部腐蚀,同时可根据频城谱中发生事件特殊频率fn区分材料的腐蚀状态...     

外加电位条件下7A52铝合金应力腐蚀开裂敏感性研究

摘要：采用电化学极化手段和慢应变速率拉伸试验,结合扫描电镜观察合金断口形貌,研究了外加电位对7A52铝合金应力腐蚀开裂敏感性的影响。研究结果表明：合金在3．5％NaCl溶液中的应力腐蚀开裂敏感性与外加电位有强烈的相关性,开裂敏感性在外加电位为一0．95V时最低,外加电位起到阴极保护的作用;在外加电位为一1V时有所升高,但仍然低于开路电位条件下的敏感性;在一1．1V时最高,应力腐蚀过程以氢脆为主;在一1．2V时又有所降低,阴极析出的氢以气态逸出而降低应力腐蚀开裂敏感性。     

基片方向对多弧离子镀ZrN涂层性能的影响

采用多弧离子镀在304不锈钢基体表面沉积ZrN涂层。利用X射线衍射仪、扫描电子显微镜、纳米压入仪、电化学分析仪等，比较了基片方向对涂层结构、形貌、成分、沉积速率、硬度以及耐腐蚀性的影响。结果表明：基片方向不同会引起晶体择优取向的改变；垂直于靶材的样品表面大颗粒相对较少，但沉积速率只有平行样品的40％-50％；在负偏压条件下，平行于靶材的样品涂层硬度更高，而垂直样品获得更好的耐腐蚀性。     

Feasibility of surface-coated friction stir welding tools to join AISI 304 grade austenitic stainless steel

An attempt is made to develop the tools that are capable enough to withstand the shear, impact and thermal forces that occur during friction stir welding of stainless steels. The atmospheric plasma spray and plasma transferred arc hardfacing processes are employed to deposit refractory ceramic based composite coatings on the Inconel 738 alloy. Five different combinations of self-fluxing alloy powder and 60% ceramic reinforcement particulate mixtures are used for coating. The best friction stir welding tool selected based on tool wear analysis is used to fabricate the austenitic stainless steel joints.     

不锈钢面板与铝面板泡沫铝夹芯梁的抗爆性能

为考查泡沫铝夹芯梁的抗爆性能及面板材料对其抗爆性能的影响，采用数值模拟方法分析了面板材料分别为工业纯铝与304号不锈钢，芯材为Alporas泡沫铝共同组成相同质量泡沫铝夹芯梁在不同爆炸荷载作用下的跨中位移与芯材压缩应变的差异。研究结果显示：在爆炸冲量分别为1．82，3．77，6．08，7．0kN·s的作用下，工业纯铝面板泡沫铝夹芯梁跨中位移分别为304号不锈钢面板泡沫铝夹芯梁跨中位移的68％，83％，84％及86％，较304号不锈钢面板泡沫铝夹芯梁具有更好地抵抗爆炸冲击波的能力，面板材料对泡沫铝夹芯梁的压缩应变影响较小。     

921A钢在海水中腐蚀的力学化学效应

为了研究弹性应力和弹塑性应变对921A船体钢在模拟海水中腐蚀行为的影响,采用自制的载荷-电化学实验装置对921A钢在载荷与腐蚀介质协同作用时的开路电位、动电位极化曲线和电化学阻抗谱等电化学性能进行了测试,并由电化学阻抗谱拟合得到的电荷传递电阻定义载荷下的腐蚀速率修正因子,将实验得到的腐蚀速率修正因子与理论值进行了对比。结果表明:弹性拉应力与弹性压应力对力学化学效应的影响具有对称性。力学化学效应随着弹性应力的增大而增大,随着弹塑性应变的增大先增大后减小。弹塑性应变对力学化学效应的影响远远大于弹性应力的影响。在研究范围内,弹塑性应变引起的腐蚀电位负移量最大为62.6 mV,相应的腐蚀速率修正因子高达4.113,而弹性应力引起的腐蚀电位负移量最大为24.5 mV,相应的腐蚀速率修正因子为1.746。由此可见,应力应变对921A钢在海水中腐蚀行为的影响不容忽视。     

Optimization of resistance spot brazing process parameters in AHSS and AISI 304 stainless steel joint using filler metal

The aim of this research study was to determine optimal resistance spot brazing parameters for joining between AHSS and AISI 304 stainless steel by using filler metal. The key parameters investigated in this study consist of the brazing current, electrode pressure and brazing time. The Taguchi method was applied to the design of experiments. Signal-to-Noise ratio was introduced in the study to identify optimal levels from the process where input parameters yield increased shear strength. Brazing was thus implemented with 5,000A brazing current, 0.70 MPa electrode pressure, and 1.50s brazing time. The maximum shear strength obtained was 54.31 N·mm⁻² in accordance with input parameter settings. In addition, Cu-rich phase and Ag_0.4Fe_0.6 intermetallic phases were found at the interface zone.     

铜包钢绞合导体与铜钢混绞导体的耐蚀性比较

通过电化学腐蚀原理的分析,认为被复线用铜包钢绞合导体是用铜钢混绞导体耐蚀性的3倍,有效提高了被复线的野外使用性能.与装备电缆通用的钢丝、铜丝混绞或混编导体或屏蔽层相比,铜包钢丝还兼有更好的耐蚀性、导电性、导磁性和力学性能,是一类优良的电磁屏蔽用导体材料,为装备线缆的设计采用和性能提高提供了防腐依据.     

低碳钢的点蚀诱发敏感性研究

选择 3种冶金因素有代表性的低碳钢 ,通过极化试验比较了它们之间的点蚀诱发敏感性 ,同时利用电子探针分析了不同夹杂物在诱发点蚀过程中的腐蚀特征 ,并利用Flade电位比较了不同钢之间的钝化膜稳定性的差异 .结果表明 :沸腾钢的点蚀诱发敏感性显著低于镇静钢 ,稀土处理镇静钢则介于两者之间 ;夹杂物是钢中主要点蚀诱发源 ,钢基体与夹杂物交界处的钝化膜保护作用最弱 ,点蚀均从该处诱发 ;同类夹杂物在不同类型钢中的点蚀诱发敏感性差异较大 ,同一钢中的不同类型夹杂物的点蚀诱发敏感性差异很小 ,硫化物夹杂较其它夹杂物的点蚀诱发敏感性稍强 .     

Effect of silicon carbide and wire-mesh reinforcements in dissimilar grade aluminium explosive clad composites

Aluminium composites are inevitable in the manufacture of aircraft structural elements owing to less weight, superior corrosion resistance and higher specific properties. These composites reduce the weight of the aircraft, improve the fuel efficiency and enhance the maintenance duration. This study proposes the development of dissimilar grade aluminium (aluminium 1100-aluminium 5052) composites with different reinforcement’s viz., stainless steel wire-mesh, silicon carbide (SiC) powders and SiC powder interspersed wire-mesh, by explosive cladding technique. Wire-mesh enhances the friction and restricts the movement of flyer plate to craft a defect free clad, while SiC particles form a band on the interface. Highest strength is obtained when SiC powder interspersed wire mesh is employed as reinforcement. The dissimilar aluminium explosive clad with SiC particle reinforcement results in lower strength, which is higher than that of the weaker parent alloy and that of the conventional dissimilar aluminium explosive clads without any reinforcement.     

Effect of hot-humid exposure on static strength of adhesive-bonded aluminum alloys

The effect of hot-humid exposure(i.e., 40 C and 98% R.H.) on the quasi-static strength of the adhesive-bonded aluminum alloys was studied. Test results show that the hot-humid exposure leads to the significant decrease in the joint strength and the change of the failure mode from a mixed cohesive and adhesive failure with cohesive failure being dominant to adhesive failure being dominant. Careful analyses of the results reveal that the physical bond is likely responsible for the bond adhesion between L adhesive and aluminum substrates. The reduction in joint strength and the change of the failure mode resulted from the degradation in bond adhesion, which was primarily attributed to the corrosion of aluminum substrate. In addition, the elevated temperature exposure significantly accelerated the corrosion reaction of aluminum, which accelerated the degradation in joint strength.     

Microstructure and pitting corrosion of shielded metal arc welded high nitrogen stainless steel

The present work is aimed at studying the microstructure and pitting corrosion behaviour of shielded metal arc welded high nitrogen steel made of Cromang-N electrode. Basis for selecting this electrode is to increase the solubility of nitrogen in weld metal due to high chromium and manganese content. Microscopic studies were carried out using optical microscopy(OM) and field emission scanning electron microscopy(FESEM). Energy back scattered diffraction(EBSD) method was used to determine the phase analysis, grain size and orientation image mapping. Potentio-dynamic polarization testing was carried out to study the pitting corrosion resistance in aerated 3.5% NaCl environment using a GillAC electrochemical system. The investigation results showed that the selected Cr-Mn-N type electrode resulted in a maximum reduction in delta-ferrite and improvement in pitting corrosion resistance of the weld zone was attributed to the coarse austenite grains owing to the reduction in active sites of the austenite/delta ferrite interface and the decrease in galvanic interaction between austenite and delta-ferrite.     

酸性条件下几种锅炉炉管钢腐蚀性能分析

研究了几种锅炉炉管钢在 p H=3的 H2 SO4 溶液中腐蚀速率的差异 .电化学测试结果表明 :炉管钢的腐蚀速率与钢中合金元素的种类和含量有一定关系 ;含铬、钼量较高的钢种腐蚀速率较低 .由此可见 ,铬元素是抑制炉管钢在酸性介质中发生腐蚀的最主要的合金元素 ,其他元素如钼、镍等对炉管钢的腐蚀性能也有重要影响     

Optimizing the defensive characteristics of mild steel via the electrodeposition of ZnSi3N4 reinforcing particles

The effect of ZnSi₃N₄ deposition prepared via direct electrolytic co-deposition on mild steel was studied as a result its inherent vulnerability to corrosion in an aggressive environment and failure on the application of load. The experiment was conducted varying the mass concentration of silicon nitride (Si₃N₄) between 7 and 13 g at cell voltage of 0.3 and 0.5 V, at constant temperature of 45 °C. The morphologies of the coated surfaces were characterized using high resolution Nikon Optical Microscope and Scanning Electron Microscope (SEM) revealing that the particles of the ZnSi₃N₄ were homogeneously dispersed. The corrosion behaviour was studied using potentiodynamic polarization technique in 3.65% NaCl solution and the microhardness was examined using Brinell hardness testing technique. The result of the corrosion experiment confirmed an improved corrosion resistance with a reduction in corrosion rate from 9.7425 mm/year to 0.10847 mm/year, maximum coating efficiency of 98.9%, maximum polarization resistance of 1555.3 Ω and a very low current density of 9.33 × 10⁻⁶ A/cm². The negative shift in the E_corr revealed the cathodic protective nature of the coating. The microhardness was also found to have increased from 137.9 HBN for the unmodified steel to a maximum value of 263.3 HBN for the 0.5Zn13Si₃N₄ coated steel representing 90.9% increment in hardness as a result of the matrix grain refining and dispersion-strengthening ability of the incorporated Si₃N₄ particles.     

Gas metal arc welding of high nitrogen stainless steel with Ar-N2-O2 ternary shielding gas

High nitrogen stainless steel with nitrogen content of 0.75％was welded by gas metal arc welding with Ar—N2-O2 ternary shielding gas. The effect of the ternary shielding gas on the retention and improvement of nitrogen content in the weld was identified. Surfacing test was conducted first to compare the ability of O2 and CO2 in prompting nitrogen dissolution. The nitrogen content of the surfacing metal with O2 is slightly higher than CO2. And then Ar—N2-O2 shielding gas was applied to weld high nitrogen stainless steel. After using N2-containing shielding gas, the nitrogen content of the weld was improved by 0.1 wt％. As N2 continued to increase, the increment of nitrogen content was not obvious, but the ferrite decreased from the top to the bottom. When the proportion of N2 reached 20％, a full austenitic weld was obtained and the tensile strength was improved by 8.7％. Combined with the results of surfacing test and welding test, it is concluded that the main effect of N2 is to inhibit the escape of nitrogen and suppress the ni-trogen diffusion from bottom to the top in the molten pool.     

活塞环表面CrTiAlN复合涂层的抗高温腐蚀性能研究

采用多弧离子镀技术,利用Cr靶和TiAl靶,在活塞环材料65 Mn钢基体上制备了CrTiAlN复合涂层,并对电镀Cr、CrN和CrTiAlN复合涂层在800℃下的抗高温腐蚀性能进行了比较分析,用扫描电镜、能谱仪和X射线衍射仪观察分析了样品表面高温腐蚀氧化膜。结果表明:CrTiAlN复合涂层具有优异的抗高温腐蚀性能,在800℃时仍具有良好的抗高温腐蚀性能,其氧化机理是O向涂层内部扩散氧化,在高温腐蚀过程中,CrTiAlN涂层中的Cr发生了选择性氧化,优先形成了Cr2O3,CrTiAlN涂层氧化层区域的结构由外至里组成顺序为Cr2O3、Al2O3+TiO2、(Cr,Ti,Al)N。涂层外层的Cr2O3氧化物有利于阻碍氧元素向涂层内部扩散,能够降低涂层的高温腐蚀速度。     

H2O2对镁合金稀土转化膜性能的影响

选择AZ91D镁合金为实验材料,利用扫描电镜和能谱分析、Tafel曲线和阻抗谱等分析手段,研究了H2O2的添加量对铈转化膜的微观形貌以及耐蚀性能的影响。结果表明：随H2O2添加量的增多,转化膜表面状态越不均匀,自腐蚀电位降低,转化膜电阻Rf变小,较为合适的H2O2添加量为5 mL/L。