Cyclic quenching and tempering (QT) heat–treatment processes have the potential to improve the mechanical properties of steel due to the formation of fine grain size microstructure. This work aims to investigate the mechanical and corrosion properties of experimental medium carbon low alloy steel under cyclic heat–treatment processes. Cyclic single quenching and tempering (SQT), double quenching and tempering (DQT), and triple quenching and tempering (TQT) heat–treatment processes were carried out on the medium carbon low alloy steel. X–ray diffraction analysis validated the formation of fine ε–carbide (Fe_2.4C) after intermediate low–temperature tempering in DQT and TQT heat–treatments. These fine carbides provided preferential nucleation sites for the formation of new austenitic grain, resulting in a refined microstructure composed of supersaturated (carbon) lath martensite (α′) and retained austenite (γ). The DQT and TQT heat–treatments improved 19% tensile strength, 100% elongation, and 95% impact absorption energy in comparison to SQT heat–treatment. DQT and TQT heat–treatments also transformed the brittle behavior of SQT steel into a ductile behavior. It was also revealed by the small number and size of dimples along with a large number of short tear ridges in fractographs. Morphology of corrosion products of heat–treated experimental steel was also studied in a 5% NaCl solution. The SQT heat–treated sample showed porous morphology of corrosion products, while the TQT sample showed morphology with less porosity on the surface. The DQT sample showed solid corrosion morphology with little porosity. As the grain size went on decreasing in the cyclic heat–treatments the corrosion rate was also dropped.

The quenched–partitioned–tempered (QPT) steel is one of the novel steel in third–generation advanced high strength steels. Herein, an attempt has been made to investigate the microstructure, mechanical, and electrochemical properties of QPT steel as a function of tempering time. Microstructural analysis reveals that a high volume fraction of martensite with low fractions of retained austenite and bainite were achieved after 30 sec of tempering. Mechanical tests validated that this triplex composite microstructure resulted in an 18% improvement in Vickers hardness, 73% in tensile strength (Rm) with little reduction of 12% elongation (ƐT) in comparison to non–heat treated steel sample. Tempering for 90 sec increased the volume fractions of stable retained austenite, bainite and decreased the fractions of martensite by carbon diffusion to austenite. Further increase in tempering time stabilized retained austenite at an expense of bainite and martensite phases, resulting in reduced hardness and improved strength and elongation. Electrochemical analysis of the QPT heat–treated samples performed in 3.5% NaCl solution showed that the high corrosion rate was yielded from the steel sample tempered for 30 sec, while other samples tempered for 90 to 150 sec showed much lower corrosion rate than non–heat–treated steel sample.

The thermo-mechanical treatments and cyclic annealing processes have the potential of optimizing the corrosion performance of carbon steels in corrosive environments. Herein, an attempt has been made to optimize the corrosion performance of AISI 1345 steel in hydrochloric acid by thermo-mechanical cyclic annealing treatments. AISI 1345 steel was produced and cast in the laboratory and subjected to three types of thermo-mechanical cyclic annealing treatments (TMCA). The first TMCA treatment comprised hot rolling at 1050 °C followed by oil quenching and single austenitizing at 900 °C followed by furnace cooling (TMSA). The second and the third TMCA treatments involved similar hot rolling processes with double austenitizing and furnace cooling (TMDA) and triple austenitizing and furnace cooling (TMTA) processes. Microstructure analysis showed that dual-phase (retained austenite + pearlite) microstructure was achieved after all TMCA treatments with an exception of secondary phase particles precipitation after TMSA treatment. Maximum fractions of retained austenite and minimum fractions of pearlite were achieved after TMTA treatment. Highly refined microstructure of size 26.7 µm was achieved after TMDA treatment whereas; TMSA treatment offered coarse grained microstructure of size 254 µm. Electrochemical analysis was performed in 5 vol% HCl solution using Tafel scan technique. Results revealed that both TMDA and TMTA treatments caused three-fold reduction in corrosion rates (3.025, 2.771 mpy) compared to non-treated steel sample. After 168 h of immersion corrosion analysis in 5 vol% HCl solution, the surface of TMTA treated sample was observed to be partially covered with a very thin, crack-free oxide layer exhibiting minimum oxygen (8.16%) percentage. These features indicated that the TMTA treated sample underwent a very low-intensity minor corrosion attack of HCl solution and exhibited the best immersion corrosion performance among all samples. Electrochemical and immersion corrosion analysis results were in good agreement.

Nickel–chrome coatings are widely used to improve surface properties and service life of engineering components made from different ferrous and non–ferrous alloys. Herein, an attempt has been made to investigate the impact of various voltages ranging from 26–30 V and spray–off distances ranging from 100–300 mm of electric-arc spray technique on the surface properties of Ni–Cr coating developed on 304L stainless steel. Thickness, porosity, surface morphology, surface roughness, and hardness of Ni–Cr coatings were determined to study the impact of deposition parameters. Coating deposition at 26 V exhibited the lowest porosity and the highest percentage of Cr nodules among all samples. The comparison study showed that coating deposit developed at 26 V and 100 mm spray–off distance has a maximum thickness, followed by coating developed at 30 V and 100 mm spray–off distance. This indicated that coating deposit developed at 100 mm spray–off distance results in thicker coatings. Maximum hardness was achieved at 30 V and 300 mm spray–off distance. The shorter spray–off distance revealed that coatings tend to be thicker and harder resulting in longer coating life.