Art:10.1007/s11665 008 9336 Z PDF
Art:10.1007/s11665 008 9336 Z PDF
Art:10.1007/s11665 008 9336 Z PDF
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Keywords
1. Introduction
High strength reinforcing steel bars (rebar) (yield stress:
420 MPa min), produced by in-line quenching thermomechanical treatment (TMT) process, are the backbone for general
construction, and are used in combination with cement concrete
for reinforced cement concrete (RCC) structures (Ref 1). The
properties of these rebars are usually modied by alloying with
suitable elements for use in specic areas such as seismic prone
zones, and corrosive environments: coastal, marine, and
industrial. When used in marine, and regions with high
humidity content, the rebars should have good corrosion
resistance properties. In seismic zones, the specic ultimate
tensile to yield stress (UTS/YS) ratio should be maintained
close to 1.25 as specied by ASTM A 706:2006 (Gr. 60).
The TMT process for rebars involves rolling billets in a
continuous mill comprising roughing, intermediate, and nishing stands. The nish rolling temperature of billets is maintained relatively on higher side (about 1000 C). After the
Eq 1
Fe ! Fe2 2e
Eq 3
Eq 4
Eq 5
Eq 6
Eq 7
Eq 8
3. Results
3.1 Visual Examination
The surface of as-rolled TMT rebar (Fig. 2) did not show
any pits or groves. However, the surface of the corroded rebars
was irregular with corrosion products lling the valleys
between the transverse ribs. The corrosion products (rust) were
Fig. 1
Fig. 3
Appearance of rust developed on (a) C-Mn rebar and (b) alloy rebar: (A) goethite, (B) akaganeite, (C) lepidocrocite, and (D) magnetite
Fig. 4
Appearance of the surface of rebars after removal of corrosion product: (a) C-Mn rebar and (b) alloy rebar
Table 1 Chemical composition (wt.%) of experimental reinforcing steels along with as-specied composition
in the standard
Steel
C-Mn
Cu-P-Cr
ASTM A 706 Gr. 60
Mn
Si
Cu
Cr
N, ppm
0.19
0.14
0.30 max
1.14
0.75
1.50 max
0.01
0.04
0.50 max
0.020
0.028
0.04 max
0.018
0.107
0.035 max
Trace
0.33
Trace
0.13
63
81
of varying color and hue (Fig. 3). The dark brown corrosion
products are presumed to be a-FeOOH (goethite) (A) and
b-FeOOH (akaganeite) (B); the orange colored rust is
c-FeOOH (lepidocrocite) (C); and the blackish regions are
Fe3O4 (magnetite) (D) (Ref 8). The comparative appearance of
the surface of rebars after the removal of rust is shown in
Fig. 4. The surface of C-Mn TMT rebar showed several pits
and a few longitudinal channels up to 1.5 mm deep running
across the helical transverse ribs (Fig. 4a), whereas the surface
of Cu-P-Cr alloyed rebar was relatively free from pits and
channels (Fig. 4b).
Steel
C-Mn
Cu-P-Cr
ASTM A 706
Gr. 60
Bar diameter: 32 mm
3.4 Macrostructure
519
512
420-540
636
640
550 min
1.22
1.25
1.25 min
21
20
12 min
Fig. 6 Microstructure of (a) C-Mn rebar and (b) alloy rebar: PF, polygonal ferrite; NPF, non-polygonal ferrite; P, pearlite; B, bainite; Fe3C,
cementite
kW
Atd
4. Discussion
The build-up of rust or iron oxide proceeds by anodic and
cathodic reactions on iron and steel substrate that involves
transfer of charge. Though there are 16 types of known
iron oxides (Ref 8), only goehite (a-FeOOH), akaganeite
(b-FeOOH), lepidocrocite (c-FeOOH), and magnetite (Fe3O4)
were found in the corrosion products of the investigated
reinforcing steels. a-FeOOH or goethite structure consists of
hexagonal close packed array of anions (O2- and OH-) stacked
along [010] direction with Fe3+ ions located in half of the
available interstices. c-FeOOH or lepidocrocite structure consists of arrays of cubic close packed anions arranged along
[150] direction with Fe3+ ions in octahedral interstices. In
b-FeOOH or akaganeite structure, anions are arranged in a
body centered cubic array with Fe3+ ions in octahedral
interstices. In Fe3O4 or magnetite, 32 oxygen ions are arranged
in [111] direction of face-centered cubic unit cell with Fe3+ ions
occupying both tetrahedral and octahedral sites. In these oxides,
cations other than Fe can also occupy the vacant sites of the
arrays of anions (oxygen) subject to the condition involving
similarity of the ionic radii, and the valency of cations.
When alloying elements are used, they increase the driving
electromotive force required for corrosion to occur due to poor
electron transfer behavior of the barrier at metal/environment
interface. Phosphorus, chromium, and copper are alloying
elements in the present alloyed TMT rebar. Sulfur is an
impurity element (Ref 9). Nitrogen is also an impurity but due
to its relatively low concentration (81 ppm) it is not detrimental
to the rebar steel. The alloy design ensured low carbon and
sulfur. Carbon is detrimental since it forms pearlite in as-rolled
steel, making the steel vulnerable to micro-galvanic corrosion.
Carbon also reduces the breakdown potential (Ref 10) (Table 5)
of passive lm on steel. A negative breakdown potential is
liable to favor diffusion of chloride ions to the steel substrate.
In a TMT rebar, tempered martensite formed from higher
carbon steel is likely to corrode faster than that of low carbon
steel tempered martensite in chloride environment. This is
because the Ms temperature of steel with lower carbon is at a
Area, cm2
Initial
weight, g
Final
weight, g
Corrosion
rate, mpy
68.2
68.8
431.0
435.8
419.6
429.2
34.0
19.5
Steel
C-Mn
Cu-P-Cr
Free corrosion
potential
(mV versus SCE)
Corrosion
current, lA
Corrosion
rate, mpy
-560.2
-410.9
169.2
93.8
3.849
2.162
higher level, and the driving force necessary for the transformation to martensite in low carbon steel is smaller. Consequently, the density of mobile dislocations present in low carbon
tempered martensite will be smaller (Ref 11). Manganese is a
substitutional solid solution strengthener, increases hardenability, and forms MnS inclusions. Elongated MnS inclusions are
detrimental particularly when they lie close to the surface.
Higher amount of manganese in alloy rebar could favor bainitic
transformation in the core affecting the ductility of rebar.
Copper has a benecial effect in increasing the corrosion
resistance of steel due to the formation of a very thin oxide lm
on the steel surface (Ref 12, 13). Phosphorus has been used in
alloy rebar in relatively higher amount (0.11 wt.%) similar to a
weathering steel (P0.08-0.15 wt.%). The solubility of phosphorus in a-iron at room temperature is low (Ref 14). In a
phosphorus bearing steel with 0.11 wt.% phosphorus, the atoms
of phosphorus are in substitutional solid solution of a-iron,
causing the strengthening effect of ferrite in the TMT rebar.
Phosphorus also increases the hardenability of steel. Phosphorus is generally perceived as an embrittling element in steel due
to its segregation tendency to grain boundaries. The segregation
of phosphorus lowers the fracture toughness of steel. In
structural steel, interstitial carbon diffuses to the ferrite grain
boundaries in preference to phosphorus since the Gibbs free
energy for grain boundary segregation of carbon in ferrite is
lower (-72 kJ/mol) than Gibbs free energy for grain boundary
segregation of phosphorus in ferrite (-49 kJ/mol), and the
grain boundary embrittlement tendency in phosphorus steel is
minimized (Ref 15). Though the highest segregation occurs at
550-600 C, special measures were taken to eliminate this by
control of rolling and in-line quenching parameters of TMT
rebar. Presence of phosphorus in steel increases its corrosion
resistance in coastal region (Ref 16) and is very effective when
added with small amount of copper (Table 6). It makes the
surface rust layer impervious, dense, and adherent compared to
the rust layer on C-Mn steel which is relatively, porous, loose,
and often ridden with ssures. It has been observed in
weathering steel that the rust layer has an amorphous structure
(Ref 17), with the presence of Cu, P, Ni, and Cr in it (Ref 12).
This layer is also non-porous and adherent.
Quantum mechanical calculations by Briant and Messmer
(Ref 18) have shown that phosphorus is more electronegative
with respect to iron and draws charge off the host metal on to
itself as shown schematically in Fig. 8. According to the
electronegativity scale of Pauling (Ref 19), chromium is more
electronegative with respect to iron, as a result of which
chromium atoms draw charge from iron (Fig. 8). The implication of this is that the availability of charge (electrons in 3d
orbital of iron) for anodic reaction is greatly reduced, and
corrosion is hindered.
Table 6 Effect of alloying elements on the corrosion resistance of unalloyed steel in seawater (Ref 16)
Element
P
Cu
Cr
Al
Ni, Si, Mo, Co
C
Mn
S
Remarks
Signicant inuence
Low inuence
Adverse inuence
5. Conclusions
The results of investigation of a Cu-P-Cr alloyed and a
C-Mn steel TMT rebar can be summarized as follows.
1. Both the rebars exhibited composite macro and microstructures comprising tempered martensitic rim followed
by an intermediate bainitic region. However, the core of
Cu-P-Cr alloyed rebar revealed mixed ferrite-pearlite
structure with some bainite in contrast to the predominantly ferrite-pearlite core of C-Mn rebar.
2. The tensile properties of both reinforcing steels conformed to ASTM A 706 specications. The UTS/YS
ratio of Cu-P-Cr alloyed rebar conformed to the specied
value (1.25) as per the standard.
3. The corrosion resistance index of Cu-P-Cr alloyed reinforcing steel was 1.7 with respect to C-Mn steel as determined by both salt fog and potentiodynamic polarization
tests. The rust formed on the Cu-P-Cr rebar was found to
be adherent and of multiple colors.
4. A schematic charge transfer mechanism has been proposed to explain the role of alloying elements like Cu,
Cr, and P on the formation of protective rust layer on
alloyed TMT rebar.
5. The Cu-P-Cr alloyed reinforcing steel exhibited a good
balance of strength, UTS/YS ratio, ductility, and corrosion resistance.
Acknowledgments
The authors thank the management of Steel Authority of India
Limited, Bhilai Steel Plant, and R & D Center for Iron and Steel,
Ranchi, India, for support. The authors also express their gratitude
to Mr. Dhritiman Panigrahi, undergraduate student of Mechanical
Engineering at Manipal Academy of Higher Education, Manipal,
Karnataka, India, for preparation of drawings, and Mr. Sabyasachi
Mahapatra, Lecturer in Physics, St. Pauls Cathedral Mission
College, Kolkata, India, for discussion.
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