International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (E-ISSN 2250-2459, Scopus Indexed, ISO 9001:2008 Certified Journal, Volume 12, Issue 09, September 2022)
Manuscript Received: 14 July 2022, Received in Revised form: 27 August 2022, Accepted: 01 September 2022 DOI: 10.46338/ijetae0922_16

The Effect of Cooling Media on the Corrosion Behavior of Mild

Steel after Heat Treatment
L Lebea1, M Pita2
1
Department of Mechanical Engineering University of South Africa, Johannesburg, South Africa
Abstract— When creating structural molds and automobile The effects of heat treatment on hot corrosion behavior
parts, mild steel is employed in a number of technical of mild steel was previously investigated [6], [8]. However,
applications. However, the material experiences corrosion due to the material's rate of corrosion, it is extremely
when it is exposed to the environment and this leads to large vulnerable to corrosion in the majority of settings [9].
economic impacts for applications using the metal. This
Corrosion is an unwelcome natural occurrence that happens
research work discusses the effect of cooling media (water, air
and oil) on the corrosion assessment of mild steel after heat when metals are exposed to their environment [10]. This
treatment. The temperature for the polarization experiments presented a significant obstacle to the widespread use of
was 260C, and the immersion periods ranged from one day (24 metallic materials in the industry [11], since mild steel is
hours) to twelve days (288 hours). It was discovered that when the most adaptable, affordable, and often utilized
the open circuit potential (OCP) measurement was carried out engineering material, many different sectors have
in the mild steel samples before heat treatment, the value discovered extensive uses for it [12]. The characterisation
initially changed to 0.0192 V, this then moved towards the of corrosion tests, according to the authors [3], [4], is an
negative to a value of -0.3716 V. The results show that in experimental method for accelerating corrosion's natural
samples heat treated at 5000C, the efficiency is lower than
course. Even though extensive research has been done on
when the temperature is increased to 9000C, where an
improvement in efficiency is observed. experimental investigations of corrosion [7], [8], corrosion
assessment after heat treatment has not yet received much
Keywords— polarisation, corrosion, microstructures, heat attention. Steel material offers excellent corrosion and
treatment, immersion creep resistance, with better ductility, formability, high
thermal expansion, and heat capacity and lower thermal
I. INTRODUCTION conductivity [8]. As such, in this study the heat treatment
Due to the numerous technical characteristics that make was carried out to enhance the corrosion resistance of the
mild steel a suitable choice, its continuous usage in major mild steel. Although the material may not always fail
industrial activities is rapidly growing [1]. Mild steel is by owing to corrosion, it is sometimes discovered to fail
far the most widely used, affordable, and practical metal in because of accelerated processes such wear and fretting
the world [2]. Engineering item frequently experience that cause tribocorrosion [15].
quick deterioration and catastrophic failure due to The highest rate of corrosion progression in saltwater
corrosion-related accidents, which has a significant occurs at room temperature of 18 °C, according to
negative economic impact [3]. Generally, mild steel pipe is experimental research to identify the corrosion progression
coated with other metals such as copper, to protect itself characteristics of steels in relation to freshwater and sea-
from corrosion [7]. However, in the current study heat water [16]. The capacity of materials to prevent breakage,
treatment was conducted to evaluate the corrosion early degradation, repair, and replacement of damaged
resistance of mild steel. In order to change a metal's components has also been linked to the significance of
physical and mechanical characteristics without affecting material corrosion resistance [17]. The authors of this study
the product's form, it must be carefully heated and cooled. [18], [19], also noted that when the concentration of the
Heat treatment has been said to improve a material's NaCl solution grew, the rate of corrosion increased.
mechanical qualities in the past [4]. Numerous heat Additionally, the rate of corrosion growth reduced as the
treatment techniques have been demonstrated to concentration of chloride ions rose [20]. Heat treatment is
significantly affect the microstructure and mechanical an easy way to change the mechanical characteristics of
characteristics of steel, according to certain research [5]. mild steel to meet specific design goals [21].

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (E-ISSN 2250-2459, Scopus Indexed, ISO 9001:2008 Certified Journal, Volume 12, Issue 09, September 2022)
Therefore, the present effort will look at how cooling 2.3. Linear Polarisation Resistance
medium affect mild steel's corrosion resistance following Polarisation testing was performed using an Autolab
heat treatment. The study's findings will be put into potentiostat and Nova 2.1 software. Three electrodes were
practice in the University of South Africa's Mechanical attached to the equipment as part of the system. The
Engineering lab, where students make hand tools for working electrodes were mild steel samples. The samples
various design projects. were connected to the apparatus and placed in beakers,
each with 100 ml of electrolyte solution. The scan rate was
II. MATERIALS AND METHODS 0.005 m/s, and the potentiodynamic polarisation versus
2.1. Sample Preparation open circuit potential (OCP) curves were produced. The
The mild steel samples used in this investigation were 70 working electrodes were immersed in the electrolyte
x 10 x 10 cm in length. Distilled water was used to clean solution (3.65 percent NaCl solution) for 1800.85 seconds
the samples. The weight of each specimen was recorded to achieve the steady-state potential, and the results were
and indicated. To act as the corrosive medium, a 3.65 recorded. Tafel plots were used to measure the polarisation
percent NaCl solution was created. For all corrosion potential (Ecorr) and current density (jcorr).
experiments, solutions (100 mL in each beaker) were 2.4. Weight Loss Experiment (Immersion Test)
produced. The polarisation and immersion experiments The 70 x 10 x 10 cm mild steel samples were produced,
were performed at 26 degrees Celsius. washed with distilled water, and given time to thoroughly
dry. In beakers with tap water, the pre-cleaned and weighed
samples were suspended. The samples were subsequently
heated to corresponding temperatures of 500°C and 900°C.
The experiments were carried out while completely
submerged in the solution. The duration of the immersion
ranged from one day (24 hours) to 12 days (288 hours).
Every 24 hours, the samples were taken out of the test
solutions, cleaned properly, dried, and reweighed. It was
Figure 1: Fabricated hand tools waiting for heat treatment [A] assumed that the weight loss was the difference between
Toolmake rs ,[B] Combination calliper and ,[C] Oddleg calliper. the samples' weight at a certain time and their starting
Figure 1 represent various hand tools design fabricated weight. The following equation (equation 1) was applied to
by the students using hand in which heat treatment will be obtain the corrosion rate (R) values:
implemented based on the outcome of the study. In this
study, the best heating treatment temperature and cooling (1)
media will be selected that has shown adequate corrosion
where W stands for weight loss in milligrams, D for
resistance.
density in grams per cubic centimeter, A for area in square
2.2. Heat Treatment and Cooling Experimentation centimeters, and T for exposure period in hours. The
The heat treatment procedure was performed using two following relationship equation (equation 2) was used to
(2) different temperatures namely 500 0C, and 900 0C in a obtain the percentage of solution efficiency:
marble furnace. The samples were placed inside the furnace
for one (1) hour, carefully removed and placed in a cooling (2)
media. For each temperature, three samples were utilized
and heated for one hour. After one hour, the samples were where W1 represents weight loss without solutions, and
removed from the furnace and cooled in three different W2 represents weight loss with solutions. Throughout the
cooling media, which were a container with tap water, a trial, the efficiency % was computed every 24 hours.
container with Castrol GTX 20W-50 oil, and by ambient
air.

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 International Journal of Emerging Technology and Advanced Engineering
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III. RESULTS AND DISCUSSION 3.1.2 Open Circuit Potential (OCP) Measurement
3.1 Linear Polarisation (5000c and 9000c)
The potentiodynamic polarization data of mild steel When the cell has no current or potential, OCP is the
immersion in 3.65 percent NaCl solution, at 500°C and working electrode's potential in relation to the baseline
900°C, are shown in Table 1 for comparison. In Figures electrode [22]. Polarization is the result of variations in
2A–2C, the comparable polarization curve is displayed. open circuit potential. This is caused by the passage of
Tafel extrapolation of the current-potential line was used to current via the contact between the electrode and the
generate the jcorr. The Tafel curve was also used to get the electrolyte [23]. Open circuit potential (OCP) vs. time
values for the corrosion rate (Cr) and polarization potential curve of mild steel heat-treated at 5000C and 900 0C and
(Pr). chilled in various mediums is shown in Figure 2. The
Table 1: steady-state potential for the samples at each temperature
Polarisation data for mild steel before and after heat treatment at moves in a more negative direction, according to the
5000C – 9000C and performe d at various cooling media. examination of the OCP vs. time curve (Figure 2). The
Ecorr jcorr Ecorr jcorr OCP took place between 0.5617 and 1800.56 seconds.
Cooling (V) (A/cm²) icorr (A) (V) (A/cm²) icorr (A)
media 5000 C 5000 C 5000 C 9000 C 9000 C 9000 C
0
Water at 500 C
Parent -0.7684 0.0010193 0.001019 -0.7684 0.0010193 0.001019 0,0 0
Air at 500 C
0
Oil at 500 C
air -0.9868 0.0079222 0.007922 -0.9625 0.0033952 0.003395 0
Water at 900 C
oil -0.9453 0.0016616 0.001662 -1.0281 0.0078812 0.007881 0
Air at 900 C
-0,2 0
water -1.0257 0.0055594 0.005559 -0.8595 0.0065631 0.006563 Oil 900 C
Parent sample
Potential (V)

3.1.1 Polarisation Data -0,4

The density of the corrosion current is inversely
proportional to the corrosion rate [10], [11]. The corrosion
-0,6
potential values (Ecorr) match the corrosion current
density, as indicated in Table 1. It was also noticed that the
parent sample had the lowest corrosion rate of all the -0,8
samples, at 11.844 mm/year. The effect of heat treatment
on cooling media was observed, and it was found that
heating the mild steels to 5000C and cooling them in an air -1,0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
exhibit saw a maximum corrosion rate of 92.054 mm/year,
Time (s)
while heating the mild steels to 900 0C saw the corrosion
rate decrease to 39.452 mm/year. The polarisation of air Figure 2: Evolution of OCP: Potential vs. exposure time for mild steel.
The heat treatment was performed at 5000 C and 9000C.
media was 75.787 Ω in mild steel heated to 5000C and this
increased with the temperature, where mild steel heated to The OCP values in oil media at 500 0C were -0.8347 V
9000C saw an increased polarisation of 37%. Furthermore, and -0.9152 V, and when the temperature increased to
the samples heated to 5000C and cooled in oil media had 9000C, the OCP was reported to be lower with values
significantly low corrosion rates with the value of 19.308 between -0.3812 V and -0.5582 V. It was noticed that when
mm/year, and when the temperature rose to 900 0C there the samples were heat treated to 500 0C and cooled in water,
was a 79% increase in the corrosion rates. In oil media, the the OCP was between -0.3662 V and -0.5145 V. When the
polarisation was higher during the 500 0C heat cycle with temperature in the water-cooling media was increased to
190.07 Ω which resulted in a decrease in polarisation when 9000C, the OCP was observed to be between -0.2355 V and
the temperature increased to 900 0C with 91.579 Ω. It was -0.4579 V. Furthermore, when air was considered as the
also observed that when water is used as the cooling media, cooling media the OCP was between -0.4564 V and -
at 5000C the corrosion rate is 64.6 mm/year and increases 0.5292 V at 5000C and between -0.2973 V and -0.4639 V
by 16% at a temperature of 900 0C. at 9000C. It was discovered that when the OCP was carried
out in the sample before heat treatment, the values changed
to a range between 0.0192 V and -0.3716 V.

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 International Journal of Emerging Technology and Advanced Engineering
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3.1.3 Potentiodynamic Polarization (PDP) The corrosion potential of water at 5000C was 0.9961 V,
Measurement (5000c and 9000c) which is 1.5% higher than in air cooling media and 41%
The PDP test is carried out in a manner that causes the higher than in oil cooling media (Figure 3 [A and B]). It
test sample's potential to rise gradually [24], [25]. This was further noticed that water performed better at 900 0C
results in an oxidation or reduction process on the test with 1.0527 V, which is 0.6% higher than in air cooling
material's surface, which generates electricity. The jcorr media and 10.5% higher than in oil cooling media. It was
was obtained via Tafel extrapolation of the current- discovered that at 900 0C, the percentage difference was
potential line. By using Tafel slope extrapolation, the smaller as compared to the difference at 500 0C, which
polarization curve was utilized to assess the corrosion demonstrates great potential for heating samples to 900 0C.
behavior of the heat-treated samples (Figure 3 [A and B]). From Figure 3 [A and B], it can be concluded that the
corrosion current densities at 5000C in water and air
1,5
0
cooling are passive. When the temperature was increased to
1,0
Heat treatment at 500 C
Water 9000C, it was noticed that samples cooled in oil media are
0,5
Air
Oil
passive, this indicates that water- and air-cooled samples
0,0
Parent heated under 5000C have better corrosion resistance. This
was also observed in samples heated to 900 0C, where oil
Potential (V)

-0,5
cooled samples showed better corrosion resistance as
-1,0
compared to other samples. According to a prior research,
-1,5 less stress corrosion took place inside the samples during
-2,0 the annealing and normalizing operations than it did during
-2,5
the quenching process [26].
-6 -5 -4
Current density
-3 -2
3.2 Immersion Test
For the duration of twelve days, an experimental
[A] immersion technique was used to compile a database on
corrosion development. Corrosion was assessed as a
1,5
percentage of the average mass loss of the specimens every
0
Heat treatment at 900 C
1,0
Water
24 hours in order to create the graphical model. Equations 1
0,5
Air
Oil
and 2 were used to determine the specimens' corrosion
Parent progress rates and efficiency. Figures 4 to 6 compare the
0,0
weight loss and corrosion rates over time for cooling
Potential (V)

-0,5
medium made of water, oil, and air.
-1,0
3.2.1 Corrosion Rate, Weight Loss And Efficiency
-1,5
The corrosion rate in the water solution was reported to
-2,0
be 0.3 mm/year within 24 hours at 500 0C, and when the
-2,5 temperature increased to 9000C, the rate was 0.39 mm/year
-6 -5 -4 -3 -2
Current density (Figure 4). It was further noticed that there was a gradual
decrease in the rate. During day 12 the rate was 8% at
[B] 5000C and 8.5% when the heat treatment increased to
Figure 3: Tafel polarisation graphs of mild steel samples, [A] heat 9000C. Weight loss was measured just after 24 hours and
treated at 5000 C, [B] heat treated at 9000C. The samples are cooled in was 0.0003 g, after 12 days the weight loss had increased
diferent cooling medias .
by 1.5% at 500 0C and 0.46% at 9000C.

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Air as a cooling media was considered and the results
0,024 0 0,024

0,4
Weight loss (water) at 500 C
0,4
follow in Figure 6. During the first 24 hours it was
0
Corrosion rate (water) at 500 C
observed that a corrosion rate of 0.35 mm/year in 500 0C
Corrosion rate (water) at 500 C

0
Weight loss (g) (water) at 500 C
0

Weight loss (g) (water) at 900 C

Weight loss (water) at 900 C
0

Corrosion rate (water) at 900 C

heat treated samples could be reached. Corrosion was

0
0
Corrosion rate (water) at 900 C
0,3
0,016 0,016
0,3 shown to occur at a rate of 0.36 mm/year when the heating
temperature was raised to 900 0C, which is somewhat
greater than that of samples heated to 500 0C (see Figure 6).
0,2 0,2
The samples heated to 500 0C showed a corrosion rate of
0,008 0,008 0.029 mm/year after 288 hours, and to 900 0C the corrosion
0,1 0,1 rate was 0.03 mm/year. The weight loss of the samples at
5000C was observed to be 0.00004 g, this decreased by
0.38% after 288 hours. When the temperature increased to
0,0 0,000
0 48 96 144 192 240 288 336
0,000 0,0
9000C, it was noticed that the weight loss of 0.0083 g
Exposure time (h)
observed within 24 hours, gradually increased to 0.028 g.
Figure 4: Corrosion rate vs. exposure time, and weight loss vs.
exposure time in mild steel samples cooled in water. The heat
treatment was performed at 5000 C and 9000C.

The corrosion rate in oil cooling media was observed to

be 0.36 mm/year during 24 hours with the samples heat
treated at 5000C, the rate gradually decreased by 8.3% after
288 hours (Figure 5). When the temperature increased to
9000C, the corrosion rate was at its highest with 0.45
mm/year which gradually decreased by 8.2% after 288
hours. The weight loss of the samples cooled in oil was
observed to be 0.0003 g during 24 hours with samples that
were heat treated at 5000C, the loss increased by 1.35%
when the samples were heat treated to 900 0C. The
observations of this study exhibit similar results to those
previously reported [12], [27].
0,025 0,025 0,5
0
Weight loss (Oil) at 500 C
0
Corrosion rate (Oil) at 500 C
0,4 0
Weight loss (Oil) at 900 C
0
Corrosion rate (Oil) at 900 C
0,020 0,020 0,4
Figure 6: Corrosion rate vs. exposure time, and weight loss vs.
Weight loss (g) (Oil) at 500 C
Corrosion rate (Oil) at 500 C

Weight loss (g) (Oil) at 900 C

Corrosion rate (Oil) at 900 C

exposure time in mild steel samples cooled in air. The heat treatment
0
0

0
0

0,3
was performe d at 5000 C and 9000 C.
0,015 0,015 0,3

The efficiency of the cooling media at temperatures of

0,2
0,010 0,010 0,2
5000C and 900 0C was observed and the study found that
efficiency was lower in samples heat treated at 500 0C, and
0,1
when the temperature increased to 900 0C efficiency
0,005 0,005 0,1
improved (Figure 7). This shows that heat treatment at
higher temperatures will result in desired corrosion
0,0 0,000 0,000 0,0 properties. In the current investigation, it was shown that
0 48 96 144 192 240 288
Exposure time (h) the weight loss of the mild steel sample reduced over time.
Figure 5: Corrosion rate vs. exposure time, and weight loss vs. It has previously been reported that the rate of mild steel
exposure time in mild steel samples cooled in oil. The heat treatment corrosion reduces with an increase in time [12], [28].
was performe d at 5000 C and 9000 C.

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In addition, the development of spheroidal graphite Acknowledgments
particles with a strong two-phase with martensite has been The authors thank the University of South Africa for its
reported to cause the corrosion rate to rise with the financial assistance.
quenching process following heat treatment [27].
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