A COMPARATIVE STUDY OF THE EFFECT OF SEAWATER CORROSION ON 0.34% AND 0.36% CARBON STEEL COMPOSITIONS

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A COMPARATIVE STUDY OF THE EFFECT OF SEAWATER CORROSION ON 0.34% AND 0.36% CARBON STEEL COMPOSITIONS Ajah U. C.*1, Nnam R. E.2, Onwuka I. N.3, Arinze C. V.3, Ezeali O. S.1 *1,1Department

of Civil Engineering Technology, Akanu Ibiam Federal Polytechnic Unwana.

2Department 3Department

of Food Technology, Akanu Ibiam Federal Polytechnic Unwana.

of Mechanical Engineering Technology, Akanu Ibiam Federal Polytechnic Unwana.

ABSTRACT In this research, the effect of seawater corrosion on 0.34% and 0.36% carbon steel compositions was investigated. 120mm of steel rod were used for each of 0.34% and 0.36%. Two samples of length 10mm and diameter 10mm were gotten from each steel rod. Also two samples of steel rod with length 50mm and diameter 10mm were also gotten from each of the steel rods of 0.34% and 0.36% composition. For each steel composition, one sample of length 10mm length and one specimen of 50mm length were heat treated. The heat treated sample of length 10mm and another one not treated with but of the same length and diameter were exposed to seawater to evaluate the effect of seawater corrosion on each of the steel rod compositions. The heat-treated specimen of 50mm length and one corresponding sample that was not heat treated for each steel composition was used for the micrography of this research. The result showed that the corrosion rate of 0.34%C changed from 0.21633mmpy to 0.15711mmpy on exposure to seawater. It also shows that the corrosion rate of 0.36%C changed from 0.17889mmpy to 0.00024519mmpy on exposure to the same seawater condition. The result showed that heat treatment improves the corrosion- resistant properties of both steel compositions more than that of the untreated carbon steel of same composition. The results also show that 0.36%C composition has a better corrosionresistant ability.

Keywords: corrosion, seawater, carbon steel, heat treatment; 0.34%C composition, 0.36%C composition.

I.

INTRODUCTION

One reason for the wide use of metallic materials in various engineering fields lies in the versatility of the mechanical properties they possess (Oluyemi et al 2011). Steel is an alloy of iron and carbon. Steel with low carbon content has the same properties as iron, soft but easily formed. As carbon content increases, the metal becomes harder and stronger but less ductile and more difficult to weld (Smith and Hashemi 2006; Daramola et al., 2010). Medium steel is steel with composition of carbon between 0.3 to 0.7%C and which are used in the reinforcement of building, manufacturing of food process equipment and production of machine parts such as nuts and bolts, shafts and gears (Ashby and Jones 1994). Carbon steel can be described as a steel in which the main interstitial alloying constituent is carbon and ranges from 0.12 – 2.0%. Medium carbon steels are the only types of plain carbon steels which can undergo both alloying and heat treatment processes to confer desirable properties on it. Each carbon steel composition has a unique micro-structure and property.

Carbon steel is by far the most important alloy used as structural members in engineering applications (Degarmo, 2003; Rajan, et al., 1989). The behavior of carbon steel is the fundamental parameter that determines the design and applicability of structural steel in engineering such as reinforcement members in structures. This is because they can also be easily bent or pre- stressed. They can also be used where small radii bends are necessary. As afore-mentioned, the mechanical properties of carbon steel like high tensile strength, yield strength, percentage elongation, ductility, hardness, wear resistance as well as its chemical properties such as corrosion resistance increases are improved significantly by heat treatment process and/or alloying (Daramola et al 2013; Larrabee, 1958; Afolabi et al 2011).

Heat treatment of carbon steels is one of the most important determining factors as to how carbon steels perform when used in different applications. Engineering materials, mostly steel, are heat treated under controlled sequence of heating and cooling to alter their physical and mechanical properties to meet www.irjmets.com

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desired engineering applications (Mahbobur Rahman et al., 2016; Awheme et al., 2018; Rajan et al., 1989).

Therefore, heat treatment is a process that involves controlled heating and cooling timed and applied to a metal or alloy in the solid state in a way that, will produce desired properties by changing their mechanical properties (Senthilkumar & Ajiboye 2012; Machado, 2006; Vijay Sharan Sony Ericsson 1990; ASTM 1991). It can also be used as a means to improve or increase the strength of materials by changing some certain manufacturability objectives especially when the materials might have been subjected to major stresses like forging and welding (Senthilkumar & Ajiboye 2012; Lu et al., 2017; Lo et al., 2009).

Thus, it can be said that heat treatment is a process in which a material is subjected to one or more temperature cycles to change the properties of the material. Basically, heat treatment helps to eliminating cold work, control dispersion strengthening and improve machinability. All basic heat-treating processes for steel, involve the transformation of austenite. By varying the manner in which, carbon steels are heated and cooled, different combinations of mechanical and chemical properties can be obtained (Degarmo et al., 2003; Digges et al 1966).

During heat treatment the micro-constituents of the metal is either completely or partially altered (Chen, et al., 2017; Jiang et al., 2013; Luo et al 2013; ). These changes in the micro-constituents of the metal may be in their nature, form, size and distribution in the metal piece (Clover et al., 2005; Igwenmezie & Ovril 2013). The theory of heat treatment is that when an alloy has been heated above a certain temperature, it undergoes a structural adjustment or stabilization when cooled to room temperature. The cooling rate plays an important role in this operation as the structural adjustment or modification is based on the cooling rate (Raji and Oluwole 2012; Calister 2001; Smith et al., 2006). These changes in their microstructure constituents control both the physical and mechanical properties of heat treated engineering materials (Budinski and Budinski, 1999; Qamar 2009; Onyekpe, 2002; Adnan, 2009). The material modification process modifies the behaviour of the steels in a beneficial manner to maximize service life i.e. stress relieving or strength properties (Raji and Oluwole, 2012; Smith, 2006; Ashby and Jones, 1994).

The importance of toughness for these applications is that they should resist sudden and unstable cracks which occur without any warning in brittle materials. So the minimization of distortion and obtaining tougher steel is only possible by heat treatment (DeGarmo et al., 1997). Studies have also shown that the failure of carbon steels can result from poor design, use of inferior materials, fabrication methods, manufacturing errors as a result of poor machining or failure from a phenomenon called fatigue (Knowles et al, 2013).

Carbon steels are the most commonly applied engineering materials for various purposes due to their mechanical strength, easy manufacture, weldability, formability and reasonable cost. Unfortunately, corrosion has proven to be a major threat to its favourable mechanical properties. In a more severe or aggressive environments, such as marine or seawater, carbon steel is not sufficient (Sundjono et al., 2017; Malik et al., 1999). Furthermore, seawater is a complex chemical system that is affected by various factors, including concentration and access of dissolved oxygen, salinity, concentration of minor ions, biological activity and pollutants (Bhosle, & Wagh, 1992). The corrosion of mild steel immersed in seawater is influenced by these factors. Consequently, seawater specimens have different corrosivity depending on the sampling location of the bulk seawater mass (Jones, 1992).

Corrosion of metals in seawater desalination system includes both general and localized corrosion. Both corrosions will bring great harm to the service life of seawater desalination equipment and safe operation of the system (Hou et al., 2018; Asphahani et al., 1989). Corrosion in the seawater leads to significant economic losses, such as loss of production, loss of product, loss of efficiency and product contamination.

Even more seriously, corrosion in the seawater leads to major catastrophic accidents, such as leakage of toxic substances, causing environmental pollution, endangering people's health, et al (Lee and Tuthill 1993).

As metal physical properties and chemical properties are not uniform, the potential is different on different parts of the metal surface, and local corrosion cell or micro cell is formed in the seawater (Audouard et al., 1995; Shone et al., 1988).

Carbon steel microstructure plays a significant role in terms of the corrosion rate and mechanism (Clover www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

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et al 2005; Oloruntoba et al., 2009; Aydoǧdu and Aydinol, 2006). Hurley and Scully (2006); Alo et al., (2017) also reported that corrosion of medium carbon steel and carbon steel in general is not only governed by the electrolytic conditions, but can also be influenced by its microstructure. It was observed that the distribution of cementite is responsible for the variation of the corrosion performance.

Igwenmezie and Ovril (2013), who investigated the effect of microstructure on the corrosion susceptibility of medium carbon steel (0.45%C) discovered that microstructures obtained by different heat treatment processes are sensitive to the environment and that the reason for the observable difference in corrosion rates could be attributed to precipitation of ferrite carbide phases, which led to setting up of microgalvanic cells within the microstructure with the carbide phase being the cathode and the ferrite the anode.

There are three major ways or techniques that corrosion can be measured. These methods include Weight loss, Electrical Resistance and Linear Polarisation Resistance methods (David, and Denise 2005; Atik et al 2003). For the sake of this research, the linear polarization resistance method was used. This method which is based on electrochemical principles of the materials- seawater and carbon steel is preferred because it is the only corrosion monitoring techniques that allows corrosion performance rates to be directly measured in real time. This attribute makes linear polarization resistance method superior to the other methods but it is only limited electrolytic ally conducting liquids.

Polarization resistance is particularly useful as a method to rapidly identify corrosion upsets and initiate remedial action, thereby prolonging plant life and reducing unscheduled shutdowns leading to downtime (Li, et al., 2004; Omotoyinbo et al., 2013). The technique has been used successfully for over thirty years in almost all types of water-based, corrosive environments like cooling water systems, secondary recovery system, amine sweetening, etc (Melchers and Jeffery, 2005).

II.

MATERIALS AND METHOD MATERIAL

The steel compositions used in this study are 0.34% carbon steel and 0.36% carbon steel details were obtained from Universal Steels Limited, Ikoyi, Lagos state. The chemical compositions for each of the carbon steel rod are outlined in tables 1 and 2 respectively of result and discussion. The seawater was obtained from Calabar Sea, Cross River State and the analysis of the seawater was done in Federal University of Technology Minna. The composition of the seawater used is shown in table 3.

METHODOLOGY A length of 120mm carbon steel rod each was cut from two original 1 meter carbon steel rod for 0.34%C and 0.36%C composition respectively. The two cut out samples were unribbed to a diameter of 10mm and cut into smaller sizes as follows: 0.34% C - 2 samples at 10mm in length each and 2 samples at 50mm in length each; 0.36% C – 2 samples at 10mm in length each and 2 samples at 50mm in length each. The unribbing and cuttings to different sizes were done in the Production Engineering workshop of the department of Mechanical Engineering Technology, Akanu Ibiam Federal Polytechnic Unwana. One sample each of length 10mm and 50mm were austenized at 860°C for 20mins for each of the carbon steel samples. The austenized samples were immediately quenched in water and after which tempered at 400°C for 15mins for both of 0.34%C and 0.36%C. The 10mm length of heat-treated and untreated samples of 0.34% and 0.36% respectively were exposed to seawater and the corrosion rate measured by Linear Polarization Resistance (LPR) method using a potentiostat. Also the 50mm length of heat-treated and untreated samples of 0.34% and 0.36% respectively were used to study the micro-structure of the carbon steel.

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RESULT AND DISCUSSION

Table 1: 0.34% Carbon Steel Chemical Composition Element

Content (Wt. %)

C

0.3490

Si

0.2080

Mn

0.8200

S

0.0535

P

0.0400

Cr

0.1390

Ni

0.0960

Cu

0.2800

Nb

0.0001

Al

0.0100

B

0.0001

W

0.0001

Mo

0.0001

V

0.0001

Ti

0.0050

Fe

97.9995 Table 2: 0.36% Carbon Steel chemical composition

Element

Content (Wt. %)

C

0.3585

Si

0.2190

Mn

0.7655

S

0.0670

P

0.0380

Cr

0.1180

Ni

0.0875

Cu

0.2590

Nb

0.0001

Al

0.0095

B

0.0010

W

0.0001

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Mo

0.0001

V

0.0001

Ti

0.0055

Fe

98.0715

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Table 3: Seawater Chemical Composition ����������

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đ?‘šđ?‘Źđ?‘şđ?‘źđ?‘łđ?‘ťđ?‘ş (đ?’Žđ?’ˆ/đ?’?)

pH

8.11

Phosphate

1166.67

Acidity (mg/l)

1866.7

Sulphate

280.559

Alkalinity (mg/l)

8660.0

Nitrate

0.2692

Hardness (mg/l)

1911.0

Chloride

2718.6

Calcium (mg/l)

720.14

Magnesium

398.85

Table 4: Showing the corrosion rates of the different samples as well as other relevant constants obtained from the experiment.

0.34% CONTROL CORROSION

0.34% HEAT TREATED

0.36% CONTROL

0.36% HEAT TREATED

0.21633

0.15711

0.17889

0.00024519

E (I = 0) (mV)

-661.203

-617.283

-656.054

-665.334

ICORR (ÂľA)

-18.643

-13.539

-15.416

-21.13 Ă— 10-3

βc (mV)

554.832

322.85

310.623

93.696

βa (mV)

84.72

113.331

79.761

84.463

FIT RANGE (mV)

-704.8 to -640

-640.04 to -599.6

-705.7 to -631.8

-693.4 to -640.4

CHI – SQUARE

5.1841

0.58578

0.089808

0.088771

POINTS IN FIT

54

28

53

46

RATE (mmpy)

Table 5: Corrosion-resistance performance SAMPLE

STATE

CORROSION RATE (mmpy)

0.34%C

Heat treated

0.15711

Control

0.21633

Heat treated

0.00024519

Control

0.17889

0.36%C

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0.34 CONTROL 0.34HT 0.36 HT

1E08

0.000001

0.000 1

0.0 1

i-

Figure 4.1: Plot of Corrosion Potential (Evs Ag/AgCl) against Current Density (i A/cm2) The TAFEL plot shown above is obtained from the values of the Corrosion Potential (Evs Ag/AgCl) and the Current Density (i A/cm2) in the appendix as gotten through the Linear Polarisation Resistance method of determining corrosion rates. The corrosion rate or current density (Icorr) is obtained from the graph by drawing perpendicular lines to the current density axis (x-axis) from the points of intersections of the curves.

Figure 4.2: 0.34%C (CONTROL). It shows a fine dispersion of cementite / carbide particles in the ferrite matrix.

Figure 4.3: 0.34%C (HEAT TREATED). It shows a decrease in the cementite particles in the ferrite matrix.

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Figure 4.4: 0.36%C (HEAT TREATED). It shows a fine dispersion of directionally aligned cementite in the ferrite matrix.

Figure 4.5: 0.36%C (CONTROL). It shows a more fine dispersion of cementite / carbide particles in the ferrite matrix.

NB: The darker patches displayed are cementite while the other light particles are the ferrite matrix.

IV.

DISCUSSION

From table 4, the value of corrosion rate obtained for the heat-treated sample of the 0.34% Carbon steel composition and 0.36% carbon steel composition respectively are lower than their corresponding samples that were not heat-treated. This shows that heat treatment has effect on seawater corrosion rate as the corrosion-resistant property of the steels was significantly improved through heat-treatment. This is in agreement with the assertion that heat treatment improves the mechanical properties of steel (Rajan, 1989; Joshua et al 2014; Lee, et al., 1999; Daramola et al., 2010). Figures 2, 3, 4 and 5, showed the micro-structure of heat treated and untreated steel samples for both 0.34% carbon steel and 0.36% carbon steel. The micrographs of figure 2 and 4 (0.34% and 0.36%carbon steel heat –untreated respectively) showed more concentration of the dark patches or cementite than that of the heat-treated samples as shown in figure 3 and 5 for 0.34% and 0.36% carbon steel respectively. According to Hurley and Scully (2006), the more the dark patches the more the corrosion. This is because the distribution of the cementite is responsible for the variation in the corrosion performance (Jousha et al 2014; Ismail, & Adan 2014; Lee & Su 1999; Paul 2010). In other words, the heat treatement improved the corrosion ability of each of the steel samples thereby making them less susceptible to seawater corrosion more than the untreated samples. Comparatively, the research showed that carbon steel of 0.36%C composition offered better resistance to corrosion than the 0.34%C composition when being subjected to seawater as shown from the values obtained in table 2 for both treated and untreated samples. On a general note, we see that heat-treatment improves corrosion resistance. This experiment goes further to prove that the effect of corrosion on different compositions of carbon steel varies when exposed to seawater condition.

V.

CONCLUSION

From the experiment, we can conclude that indeed heat treatment does improve the corrosion resistance of steels. The TAFEL plot shows a significant difference between the 0.36%C steel and other specimen, setting it apart as having the lower corrosion rate of 0.00024519mmpy. For the 0.34%C steel, the corrosion rate reduced by 0.05922mmpy when exposed to seawater while that for 0.36%C steel had a www.irjmets.com

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corrosion reduction rate of 0.178645mmpy when exposed to seawater. This result shows that 0.36%C steel is better in terms of corrosion resistance under seawater conditions than any of the other specimen used in this experiment. This option can be explored by technologists sourcing for materials to use for marine purposes especially under seawater conditions. Examples of industries that might be interested in such materials include the oil exploration industries, ship making industries, military technologist who specialize in building ships, submarines, etc.

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