Effect of Thermal Cycling on Corrosion Rate of Carbon Steel (0.4%C), Water Cooled

Abstract

The effect of thermal cycling was carried out on steel bars (0.4 %C). A single run was performed at a lower temperature of 320C and an upper temperature of 5000C cooled in water and seawater. For several numbers of cycles up to 30 cycles for an accurate determination of heating and cooling times. The effect of thermal cycling on the corrosion rate was evaluated. The effect of thermal cycling on the following properties was evaluated the corrosion rate. The comparison between the effect of thermal cycling on carbon steel (0.4% C) seawater cooled (previous results, sea-water cooled [1]) and the effect of thermal cycling on carbon steel (0.4 C %) (in this manuscript, water-cooled) has been studied. From the obtained test results (previous and in this paper, it was found that the type of corrosion is uniform, the corrosion rate of the first stage gradually increases with the number of thermal cycling up to 15 cycles, then it takes steady-state up to 30 cycles. It was found that the rate of corrosion (previous results, seawater cooled) is more than (the results in this paper, water-cooled).

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Engineering & Technology Review 1(1), 2020 ISSN 2693-115X
Effect of Thermal Cycling on Corrosion Rate
of Carbon Steel (0.4%C), Water Cooled
A. S. A. Elmaryami*
Salem Ahmed Salem
Ali Saleh Saad
Mokhtar Hussien Omar
Khaled Rafaa Ali
Department of Mechanical Engineering, Bright Star University, El-Brega - Libya
*Corresponding author: damer604@yahoo.com
https://sriopenjournals.com/index.php/engineering_technology_review/index
Doi: https://doi.org/10.47285/etr.v1i1.44
Citation: Elmaryami, A. S. A., Salem, A. S., Ali, S. S., Mokhtar, H. O. & Khaled, R. A. (2020). Effect of Thermal Cycling on
Corrosion Rate of Carbon Steel (0.4%C), Water Cooled, Engineering & Technology Review, 1(1),28-34.Doi:
https://doi.org/10.47285/etr.v1i1.44
Research Article
Abstract
The effect of thermal cycling was carried out on steel bars (0.4 %C). A single run was performed
at a lower temperature of 320C and an upper temperature of 5000C cooled in water and
seawater. For several numbers of cycles up to 30 cycles for an accurate determination of
heating and cooling times. The effect of thermal cycling on the corrosion rate was evaluated.
The effect of thermal cycling on the following properties was evaluated the corrosion rate. The
comparison between the effect of thermal cycling on carbon steel (0.4% C) seawater cooled
(previous results, sea-water cooled [1]) and the effect of thermal cycling on carbon steel (0.4 C
%) (in this manuscript, water-cooled) has been studied. From the obtained test results (previous
and in this paper, it was found that the type of corrosion is uniform, the corrosion rate of the first
stage gradually increases with the number of thermal cycling up to 15 cycles, then it takes
steady-state up to 30 cycles. It was found that the rate of corrosion (previous results, seawater
cooled) is more than (the results in this paper, water-cooled).
Keywords: Thermal Cycling, Corrosion Rate, Heat Treatment Hardening, Carbon Steel,
Sea water-cooled, water-cooled.
1.Introduction
Plain carbon steels are emerging as the backbone structural materials in high-
temperature applications such as spray towers turbine engines, missiles, etc. Carbon steels
have many advantages, high strength, and ductile materials and very easy to alloyed with
other elements, etc. On the other hand, its disadvantages are the high ability to corrosion. So,
a lot of researches has been studied corrosion mechanisms through which a better
understanding is obtained of the causes of corrosion and the available means for preventing
or minimizing resulting damage. Many factors have a great influence on corrosion

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rate, environments, metallurgical factors, the effect of stress. A tendency of new cast
austenitic-ferritic steels to stress corrosion cracking have been investigated in different
aggressive environments to determine the regions of their most efficient application studied
byHalynaChumalo [2]. While C.P.Atkins and J.D. Scantlebury et. al. [3] studied the activity
coefficient of sodium chloride in a simulated pore solution environment. S.H.Zhang, S.B. Lyon,
et. al. [4] investigated the retention of passivity on iron after several months’ atmospheric
exposure.
Shin-ichiKomazaki et. al. [5] using six different plates of steel. Slow strain rate tensile test and
thermal disruption spectroscopic analysis were applied to specimens subjected to wet-dry
cyclic corrosion tests in a NaCl solution. Hideki Katayama, et al [6] was conducted the
corrosion simulation in a chamber to carbon steels in an atmospheric environment by
controlling the environmental factors such as temperature, relative humidity, and the
temperature of carbon steels. Akira Tahara and Tadashi Shinohara, et al [7]. They found that
there are two kinds of corrosion patterns were distinguished, uniform corrosion and local
corrosion and the addition of Cu, Ni, and Cr changed the form of the corroded surface from
the uniform corrosion to the combined pattern (uniform corrosion + local corrosion) While
M.Yamashita, et al., [8] studied the initial rust formation process on carbon steel under Na2SO4
and NaCl solution films with wet/dry cycles using synchrotron radiation X-rays. Robert E.
Melchers, et. al. [9] reported that the corrosion loss vs. time behavior is initially highly non-linear
and then almost linear until corrosion product formation begins to control the rate of corrosion.
On the other hand, mathematical modeling was carried out by Hiroshi Kihira, et. al. [10] to
corrosion prediction for weathering steels.
2.Iron-Carbon Equilibrium Diagram
A study of the constitution and structure of all steels and irons must first start with the Iron-
Carbon Equilibrium Diagram, the Iron- Carbon Constitutional Diagram should extend from 100
percent Iron to 100 percent cementite (6.67C%) [11-15], the plain carbon steels (0.4%C), water-
cooled were used, shown in Fig.2.1.
3.Experimental Work
3.1Materials
In this work hypo-eutectoid carbon steel (0 .4% C) has been used as their chemical
composition are given in Table 1.
Table I. Chemical composition of the used sample [1]
Carbon, C
0.40 %
Iron, Fe
98.51 - 98.98 %
Manganese, Mn
0.60 - 0.90 %
Phosphorous, P
≤ 0.040 %
Sulfur, S
≤ 0.050 %
3.2Thermal cycled experiments
Thermal cycled experiments were conducted:
To study the effect of thermal cycling [10, 20, and 30 times] on the corrosion rate, water-
cooled.

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The thermal cycling was carried out in the Material Science Laboratory at The Bright Star
University, the details of the furnace are: [Gallenhamp, Cat. No. (FSW - 670 - 010 J), APP. No.
(7B9714 B)].England, S302AU. For this furnace, the heating and cooling rate was recorded as
shown in Fig.3.1 andFig.3.2 respectively [1].
Fig.2.1. Iron-Carbon Equilibrium Diagram
Fig.3.1. The furnace heating rate [1]
After (10
Thermal Cycling.)
After
(30
Ther
mal
Cyclin
g)
After (20
Thermal Cycling.)
0.4 %C

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Repeated (10, 20
and 30 times
Fig.3.2. The furnace cooling rate [1].
The samples were divided into three groups, and each group was subjected to different
numbers of thermal cycling (10, 20, and 30 cycles). All samples were subjected to the same
heating cycle, in which the samples were heated below A1 to 500oC and held in the furnace
for 15 min. Three samples of each heating cycle were cooled in water. The total time of a
single cycle was 40 min, as shown in Figs.3.3.
Fig.3.3. T.T. Diagram shows the [10, 20, and 30 cycled cooled in water].
3.3Corrosion Testing
Thousands of corrosion tests are made every year. The value and reliability of the data
obtained depend on the details involved. Unfortunately, many tests are not conducted or
reported properly, and the information obtained is misleading. Corrosion rate has been
measured by using the weight loss method for thus a [(Bulgur) calvarias (Varese) DEC.MIN.24-1-
2003 N0 205295] were used. The difference between the weighted sample after and before

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subjecting it to thermal cycling then removal the corroded layer by a piece of wood (softer
than steel).
This loss of weight (ΔW) is considered as weights of corroded materials were:
Losses of corrosion % = ΔW / WO * 100
Where ΔW: losses of weight (mgr) due to thermal cycling.
WO: original weight (gram).
4.Results and Discussions
4.1The effect of thermal cycling on corrosion rate water-cooled
The samples subjected to a number of thermal cycling 10, 20, and 30 cycles then exposure to
corrosion attack for (one week about 168 hr). We used water as a cooling media, Fig.4.1 shows
the effect of thermal cycling on the corrosion rate. The increase in thermal cycling leads to an
increase in the corrosion rate for carbon steel. This increase can be divided into two stages:
In the first stage, the corrosion rate increases gradually with increasing thermal cycling up to 10
cycles. Above that (more than 10 cycles) the corrosion rate increasing slowly until 30 cycles.
This behavior can be attributed to the increase in the number of residual stresses, this amount
of residual stress increases with increasing cycles up to (10 cycles), and then there is slowly
increasing in residual stresses after that. The lead to introduce residual stresses which have a
strong influence on corrosion rate.
Based on the above results, it can be safely concluded that thermal cycling introduced
residual stresses which lead to an increase in the corrosion rate. Stages by increasing the
number of cycles corrosion rate increases through two depending on the amount of thermal
cycling.
Fig.4.1. The effect of (10, 20, and 30 thermal cyclings on corrosion rate, water-cooled.
The comparison between the effect of thermal cycling sea water cooled (previous results [1])
and the effect of thermal cycling water-cooled (in this manuscript) shown in Fig. 4.2.

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Fig.4.2. The effect of (10, 20, and 30 thermal cyclings on corrosion rate, water, and sea water-
cooled.
5.Conclusion
The results of this investigation show that:
Thermal cycling causes a uniform corrosion attack for steel bars (0.4 C%).
The corrosion rate of the first stage gradually increases with the number of thermal cycling
up to 15 cycles, then it takes steady-state up to 30 cycles.
The rate of corrosion (previous results, seawater cooled) more than (corrosion's results in this
paper, water-cooled).
From the obtained test results (previous and in this paper, it was found that: the type of
corrosion is uniform attack; corrosion rate of the first stage gradually increases with the number
of thermal cycling up to 15 cycles, then it takes steady-state up to 30 cycles.
It was found that the rate of corrosion of previous results, (seawater cooled) is more than
corrosion's results in this paper, (water-cooled).
For future papers, the cooling media and thermal cycling should be changed.
Acknowledgment: The authors wish to gratefully acknowledge the Bright Star University, El-
Brega - Libya, especially Dr. Ahmed Elbarsha, Dr. Rahel Guma Rahel, Mr. Alzaroug, Mr. Osama
Dawood, Dr. Abdul-Hakheem Altarhouni and Dr. Thaw Sassi for supporting this Manuscript.
Conflict of Interest: The authors declare no conflict of interest.
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