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Materials Today: Proceedings 5 (2018) 6855–6861 www.materialstoday.com/proceedings

IMME17

Hot workability and corrosion behavior of EN31 grade steel

Sudhakar.Ia*, Jagadeesh.Na, RaviKumar.Na , V.S.N. Venkata Ramanab*
a
Department of Mechanical Engineering Department, MVGRCE(A), Vizianagaram, A.P., India.
b
Department of Mechanical Engineering Department, GITAM University, Visakhapatanam, A.P., India.

Abstract

In the recent years across the globe, there is a remarkable shift in paradigm of manufacturing agricultural tools and accessories
for farming in agricultural sectors. Most often, high carbon steels are usually used for making agricultural tools. In the present
investigation, one of the used farming accessories was cut and accessed for compositional identification using spectrometer and
based on its composition report, stock material (EN31 grade steel) was procured. Most of the agricultural tools especially ploughs
are conventionally made using open die forging in rural areas to have intended properties. But morphological variation like size
of the grain boundaries, carbide free zones, carbide rich zones and composition across the grain boundaries accompanied by
forging, causes pitting corrosion. Hence the present investigation aims to study the effect of hot working at different temperatures
while processing the selected EN31 grade steel on pitting potential and identifying the most suitable temperature for hot
deformation and high corrosion resistance. All the processed steels exhibited both superior hardness and corrosion resistance
compared to the base metal. Forged steel at 800°C has shown maximum corrosion resistance compared to steels forged at other
temperatures and it may be attributed to the extent of dissolution of the carbides and uniform distribution of carbide particles in
the parent matrix which act as insulator to the path of galvanic cell formation between cathodic of intermetallic particles and
anodic cells i.e. parent microstructure. Even though the extent of deformation rate is found to be maximum while forging at
850°C, it has been restricted because of premature appearance of cracks, hence hot forging of base metal at 800°C is
recommendable one.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and
Manufacturing Engineering (IMME17).

Keywords: EN31; deformation; corrosion resistance; forging

* Corresponding author.
E-mail address: sudhakar@mvgrce.edu.in

2214-7853 © 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and Manufacturing Engineering
(IMME17).
6856 Sudhakar et al., / Materials Today: Proceedings 5 (2018) 6855–6861

1. Introduction

Having poor hardness and wear resistance in many environmental conditions opens a scope for lot of researchers
to surface engineer the austenitic steels, but these steels always impose a challenge by losing its inherent corrosion
resistance phenomena. Thus number of attempts were made to surface engineer the austenitic steel with an objective
of improving both wear and corrosion resistance. It was observed that the effect of super solidus sintering and
intermetallic(Ni3Al, Fe3Al) additions on the sintered austenitic (316L) stainless steels has resulted in significant
improvement of densification, wear resistance, corrosion resistance, strength and ductility[1]. Similarly, plasma
sprayed ceramic coatings of alumina powders with γ- and α-forms on stainless steel substrate exhibited higher wear
and corrosion resistance critical plasma spray parameters 825 W/nLpm [2]. Pitting corrosion resistance of shielded
metal arc welded high nitrogen stainless steel (HNS) has improved in the fusion zone compared to base metal(HNS)
and is 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 [3]. Studies on 2205 duplex
stainless steel with an objective of increasing corrosion resistance and hardness revealed that by plasma nitro-
carburizing at 400 0C exhibited the highest corrosion resistance with a significant raise in surface hardness and at
higher temperatures, the treated base metal showed poor corrosion resistance [4]. Film thickness of 500–600 nm of
aluminium oxide deposited by metal–organic chemical vapour deposition on 304L steel is found to be optimum on
providing maximum corrosion resistance. It has also observed that grain size variation has no considerable effect on
pitting potential of 304L austenitic stainless steel owing to improved passivity of film on grain boundaries which are
the credible sites of pit generation and coherent twin boundaries were found to be resistant to intergranular corrosion
(IGC) [5-7]. Pitting corrosion resistance of ultrapure 429 ferritic stainless steels is improved because of appearance
of Al2O3 inclusions with small size and decreased content of MnS which improves pitting corrosion resistance [8].
The microstructural changes on the surface of the AISI 420 martensitic stainless steel brought by high current pulsed
electron Beam (HCPEB) treatment increased the corrosion resistance which is attributed to an increase in Cr content
together with a very limited amount of surface craters [9]. Laser shock peening is found to be an effective means to
improve abrasion and corrosion properties of a seawater desalination pump parts made of duplex stainless steel [10].
Similarly, depending on the urgency of enhancing the corrosion resistance of different steels, number of efforts were
made by different researchers to modify the surface morphology of substrates. Corrosion studies on surface
engineered mild steel with alumina coated with sol –gel technique, plasma assisted multi-layered TiN and CrN , arc
ion plated TiN and using an aqueous extract of allamanda blanchetii and piper nigrum L with different surface
modifications techniques revealed an improvement in corrosion resistance of base i.e. mild steel [11-16]. Al–Zn–Si–
RE epoxy coatings with various levels of ZrO2 nanoparticles and organic coating in combination with sacrificial
metal zinc alloys using electron-beam plasma-assisted physical vapour deposition and arc spraying resulted in
improvement of corrosion resistance owing to their dense non-columnar structure and formation of corrosion
products deposited in the defects, which hindered corrosion rate [17-19]. Sudhakar et.al., investigated effect of
different heat treatments on pitting resistance of EN24 and EN8 grade steel and obtained that annealing was more
effective one compared to normalizing and quenching[20]. Wear resistance of laser surface engineered AISI H13
tool steel showed a significant improvement as compared to that in hardened and tempered condition. Due to an
increased hardness, surface melting shows superior resistance to wear and a marginal improvement in corrosion
resistance was also recorded in laser surface engineered samples due to microstructural/compositional
homogenization introduced by laser surface engineering [21]. Similar works on improvement of corrosion resistance
of high carbon steel such as high speed steel using surface modification techniques like cathodic arc deposition,
reactive triode ion plating, intermediate plasma etching with different coatings material Cr-N, TiN, Zr-N, NbN was
resulted in better corrosion resistance [22-24]. From the above discussion, it is well understood that ample number of
investigations were carried on enhancing the corrosion resistance of stainless steel compared to that by taking mild
steel and high carbon steel as substrates. Thus, the present investigation deals with studying the effect of hot forming
on high strength low alloy steel (EN31) which is widely used in agriculture due to easy availability, good weldability
and formability on corrosion resistance.
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2. Material and methods

Samples are cut from rolled received EN31 grade steel (composition is given in Table 1) plate and went
through shot blasting before undergone for high vapour oxy fuel spraying using copper and tungsten powder for
modification of base metal.
Table 1 Composition of EN 31 grade steel

Element % Element %
(in weight) (in weight)
C 1.23 S 0.01
Si 0.2 P 0.025
Mn 1.07 Fe Rest

As most of conventional agricultural tools are produced using open die forging, the present investigation aimed at
finding out suitable temperature limits for forming of selected base metal i.e. EN31 grade steel. Thus temperature
limits for hot working were ascertained using Iron-Iron Carbide equilibrium diagram. The cut-off specimens were
heated for selected open die forging temperature of 750°C, 800°C and 850°C respectively using muffle type furnace
with an arrangement of automatic cut off and regulator for setting the temperature limit. Depending on size of
specimens suitable soaking time was allowed. The upper limit of forming was restricted as conventional practices in
rural areas never exceed 850°C.

2.1 Metallography
Optical microscopy: Specimens were cut from both base metal and formed material subjected to standard
metallographic practice to obtain scratch free surface. Metallographic examination was carried out to understand the
grain morphology and to analyse the variation in grain size compared to that of base metal. Nital (95% Ethyl
alcohol and 5% Nitric acid) was used as etchant to reveal the microstructure. Polished and etched samples were
examined by metallurgical microscope (make: Olympus) at 100x magnification.

Scanning electron microscopy (SEM): Cracks produced during hot forging test were analysed in JEOL-JSM 840 A
scanning electron microscope (SEM). The focus is mainly to observe the mode of cracks involved during forging. It
was also used to understand the morphological variation in forged base.

2.2 Hardness testing:

Rockwell hardness testing machine was chosen for finding the hardness of both base metal and deformed
base metal. Constant load of 150 kgf was maintained during evaluation of hardness and sufficient dwell period about
15 seconds was allowed. Reported hardness data was based on the average of 5 readings and obtained one was
rounded off to nearest whole number. Indentations were made on flat surface of both base and deformed material.

2.3 Corrosion test:

Software based Gill AC electrochemical system was used to conduct potentiodynamic polarization tests to
study the pitting corrosion behaviour of the base metal and deformed base as per ASTM G106 standards. All
experiments were conducted in aerated 3.5% NaCl solutions with pH adjusted to 10 by adding potassium hydroxide.
The potential scan was carried out at 0.166 mvs-1 with the initial potential of –0.25V (OC) SCE to the final pitting
potential. The breakage of the passive film was denoted by Epit value and hence the corrosion current increases
drastically with the applied voltage after Epit. The potential at which current increased drastically was considered to
be the critical pitting corrosion Epit. Specimens exhibiting relatively more positive potential (or less negative
potentials) were considered to have better pitting corrosion resistance. The exposure area for these experiments was
1cm2. Fig.1 shows the experimental set up for corrosion test to find the pitting potential of both surface and
processed surface composites. Attempts were made to find the effect of deformed base on corrosion behaviour.
Fig1. shows the specimens which were firmly fixed with the help of lids to expose aerated solution.
6858 Sudhakar et al., / Materials Today: Proceedings 5 (2018) 6855–6861

Fig.1 Corrosion test rig along with auxiliary and reference electrodes for evaluating pitting potential of both base and deformed base.

3. Results and discussion

3.1 Microstructure:
Optical micrograph of base metal consists of carbides along with pearlite. The extent of reduction in grain
size of deformed base at different temperatures is prominently evident from the Fig. 2.

Fig.2 Optical microstructures of (a) Base metal (b) deformed at 7500 C (c) deformed at 8000C and (d) deformed at 8500 C.

It has been noticed that the extent of plastic deformation is maximum for base material at higher temperature of
forging and also there is pre-inception of cracks during forging at 8500 C which is clearly visible from the clustering
of carbide along grain boundary as shown in Fig.3. This premature generation of cracks during forging at 8500C is
further being supported by scanning electron micrograph as depicted in Fig. 3(b) which shows the presence of
dimples that are clearly indicates the ductile mode of failure.
 Sudhakar et al., / Materials Today: Proceedings 5 (2018) 6855–6861 6859

Fig. 3 (a) clustering of carbide along the grain boundary (b) Ductile mode of failure.

3.2 Hardness testing:

The results of hardness test at various temperature has been shown in in Fig.4.

Fig.4 hardness of base metal under different condition.

During forging of base metal irrespective of forging temperatures, significant amount of plastic
deformation has been observed. It may be due to free dislocation movement in crystallographic planes which has
undergone either by slip or twin mechanism. It can also be seen that there is considerable improvement in hardness
of forged base metal at 750° C compared to base material. Significant morphological modifications like
microstructural refinement, homogenization and densification achieved during forging led to yield higher hardness
in open die forging of base material at different temperature. It can be also well validated from distribution of
carbide particles as observed from the microstructure (Fig.3(b)).The applied mechanical load is responsible for
change in the dimension of carbide particles earlier present in base metal. Furthermore, during deformation
regardless of carbide particles, grains break into smaller size and a large number of high angle boundaries are
produced. Mechanical rupture of inherent grain boundaries during forging are also attributed to form high angle
boundaries. These high angle and low angle boundaries during forging impedes the free movement of dislocations
6860 Sudhakar et al., / Materials Today: Proceedings 5 (2018) 6855–6861

on a common slip plane during passing from one grain to the next across the grain boundary. Hence dislocations are
stopped by grain boundaries and pile up against them resulting in increase in strength and hardness of forged base
material.The extent of plastic flow of base material is high at 800° C compared to 750° C, which is well validated
from obtained hardness results. The extent of intermittent heating for carrying out forging is more at 750° C
compared to 800° C. Even though deformation at 850° C is high, the clustering of carbide particles along the grain
boundaries has resulted in early inception of cracks as witnessed from Fig. 3(b). Thus open die forging at 800°C is
the most recommended one for open die forging.

3.3 Corrosion testing:

Pitting corrosion occurs from Refinement of inherent grain boundaries, presence of cavities in surface, grain
orientation and deformed structure are the root cause of occurrence of pitting corrosion. Fig.5 shows the results of
potentiodynamic polarization test.

Fig.5 Potentiodynamic curves of base metal and forfes steels st different temperatures

In base metal, formation of galvanic cells between the strengthening carbide particles and the parent matrix favour
the corrosion rate. In contradictory to forged samples exhibits better corrosion resistance which is attributed to the
redistribution of carbide particles during open die forging causing reduction in the number of sites available for
galvanic coupling. Hence, there is an increase in corrosion resistance of base metal forged at 750° C as seen from
obtained results.
Among all the samples, sample forged at 8000C shows resulted in better corrosion resistance compared to other
samples. It may be accounted to intergranular corrosion and formation of stress cell. It can be well noticed the extent
of microstructural refinement is high in the sample forged at 8500C. The available large grain boundaries have
higher energy than the centre of grain itself. Thus, the grain boundary has higher potential than the rest of the crystal
and grain boundaries are becoming the source of anodic and grain centres serve as cathode and under the influence
of corrosive environment galvanic cell is formed causing corrosion of grain boundary. It can be further supported by
 Sudhakar et al., / Materials Today: Proceedings 5 (2018) 6855–6861 6861

abnormalities of structure and composition which favour anodic attack along grain boundary. Fine grained forged
material have higher corrosion rate because of much more availability of grain boundary area.
In addition to above, stress corrosion takes place in forged sample having internal i.e. residual stresses. Internal
stresses attain high potential and behave as anode. The atoms remain in lowest energy position where internal
stresses are not there, hence this stress free area serves as cathode and in presence of corrosive environment favors
the formation of galvanic cell. The highly deformed areas act as favourable sites for anode and thus corrosion takes
place at anode which is well supported from the obtained pitting potential results.

4. Conclusions

1) Open die forging of chosen steel can be considered as one of the forming processes because of least economy.
Forging of selected steel at temperature 8000C is recommended.
2)Even though significant rate of deformation witnessed during forging at 8500 C, it has not considered as suitable
temperature of forming because of pre- inception of cracks which are accounted due to clustering of carbides along
the grain boundaries.
3) All the forged base steel exhibited better strength and hardness because of impediment of dislocations movement
due to formation of low and high angle boundaries during forming.
4) Forged samples exhibits better corrosion resistance compared to base metal because of redistribution of carbide
particles during open die forging causing reduction in the number of sites available for galvanic coupling.
5) Among all the samples, sample forged at 8000 C shows better corrosion resistance compared to other samples. It
may be accounted to intergranular corrosion and formation of stress cell.
6) As the present investigation aims at studying the effect corrosion behaviour in the light of forming, thus forging at
8000 C is strongly recommended from both the considerations of forging temperature limit and offering better
corrosion resistance.

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