Nitrogen uptake of nickel free austenitic stainless steel powder during heat treatment—an XPS study

In austenitic stainless steel nitrogen stabilizes the austenitic phase, improves the mechanical properties and increases the corrosion resistance. Nitrogen alloying enables to produce austenitic steels without the element nickel which is high priced and classified as allergy inducing. A novel production route is nitrogen alloying of CrMn‐prealloyed steel powder via the gas phase. This is beneficial as the nitrogen content can be adjusted above the amount that is reached during conventional casting. A problem which has to be overcome is the oxide layer present on the powder surface which impedes both the sintering process and the uptake of nitrogen. This study focuses on whether heat treatment under pure nitrogen is an appropriate procedure to enable sintering and nitrogen uptake by reduction of surface oxides. X‐ray photoelectron spectroscopy (XPS) in combination with scanning electron microscopy (SEM) and energy dispersive X‐ray spectrometry (EDS) are used to investigate the surface of powdered FeMn19Cr17C0.4N heat treated under nitrogen atmosphere. The analyses showed reduction of iron oxides already at 500 °C leading to oxide‐free metallic surface zones. Mn and Cr oxides are reduced at higher temperatures. Distinct nitrogen uptake was registered, and successful subsequent sintering was reached. Copyright © 2014 John Wiley & Sons, Ltd.     

Effect of atomization on surface oxide composition in 316L stainless steel powders for additive manufacturing

The initial oxide state of powder is essential to the robust additive manufacturing of metal components using powder bed fusion processes. However, the variation of the powder surface oxide composition as a function of the atomizing medium is not clear. This work summarizes a detailed surface characterization of three 316L powders, produced using water atomization (WA), vacuum melting inert gas atomization (VIGA), and nitrogen atomization (GA). X-ray photoelectron spectroscopy (XPS) and scanning electron microscopy analyses were combined to characterize the surface state of the powders. The results showed that the surface oxides consisted of a thin (~4 nm) iron oxide (Fe₂O₃) layer with particulate oxide phases rich in Cr, Mn, and Si, with a varying composition. XPS analysis combined with depth-profiling showed that the VIGA powder had the lowest surface coverage of particulate compounds, followed by the GA powder, whereas the WA powder had the largest fraction of particulate surface oxides. The composition of the oxides was evaluated based on the XPS analysis of the oxide standards. Effects of Ar sputtering on the peak positions of the oxide standards were evaluated with the aim of providing an accurate analysis of the oxide characteristics at different etch depths.     

XPS study of carboxylic acid layers on oxidized metals with reference to particulate materials

Low‐molecular‐weight organic additives such as stearic acid are commonly used as surface additives in powder injection moulding (PIM). It is therefore important to know how the additives interact with the surface of the powder used. In this study, such interactions are studied by means of controlled adsorption of carboxylic acids on the oxides of interest. The oxides are prepared by oxidation of flat samples of Fe, Cr, Mn and Si. Surface chemical characterization is done by means of XPS, the main approach on flat samples being a comparison of angle‐resolved analysis and the use of the Tougaard nanostructure analysis technique. Taking advantage of this comparison, the Tougaard method is then applied in the evaluation of XPS analyses of stainless‐steel powder with adsorbed stearic acid. In addition, time‐of‐flight SIMS analysis is used to verify the adsorption of stearic acid on the powder surface. It is shown that Tougaard nanostructure analysis can be used for determining the thickness of an organic layer on particulate material. The layer thickness of adsorbed stearic acid was estimated to be ～20 Å, corresponding to monolayer adsorption. Time‐of‐flight SIMS analysis verified the adsorption of stearic acid on the powder surface. From the XPS analysis of flat samples it was determined that the use of the metal/oxide universal cross‐section in Tougaard nanostructure analysis best described the increased background due to adsorption of carboxylic acids, and that information about molecular orientation could be gained. Copyright © 2003 John Wiley & Sons, Ltd.     

Application of thermal analysis techniques to study the oxidation/reduction phenomena during sintering of steels containing oxygen-sensitive alloying elements

For the consolidation of steel parts manufactured by powder metallurgy (PM) techniques, removal of the surface oxides covering metallic powder particles is a necessary prerequisite. In PM steels with conventional compositions, reduction of the oxides is easily achieved in traditional sintering furnaces. However, processing steels containing alloying elements with a high oxygen affinity represents a big challenge that requires a deeper understanding of the chemical processes occurring during sintering. In the present work, thermogravimetry analysis coupled with mass spectrometry is used to describe the oxidation/reduction phenomena that take place when sintering steel powders and how these processes are modified by the addition of admixed particles containing oxygen-sensitive elements. Carbothermal reduction processes are studied using pure oxides (Fe₂O₃, MnO₂, Cr₂O₃ and SiO₂) as well as water-atomized Fe powders mixed with small amounts—4 mass/%—of Cr, Mn and Si powders or Fe–Mn–Si–(Cr) master alloy powders. The results show that there is an oxygen transfer from the base iron particles to the oxidation-sensitive elements—“internal getter effect”—taking place mostly through the gas phase. Different alloying elements (Cr, Mn, Si) show different temperature ranges of susceptibility to oxidation. Combination of these oxygen-sensitive alloying elements in the form of a master alloy powder reduces their sensitivity to oxidation. Also, the use of master alloys promotes the concentration of the oxides on the surface of the alloying particles and not in the grain boundaries of the surrounding iron particles—as occurs when using Mn carriers—which should have a beneficial impact on the final mechanical performance.     

Investigation of surface and thermogravimetric characteristics of carbon-coated iron nanopowder

Demand for high-density press and sinter components is increasing day by day. Of the different ways to improve the sinter density, the addition of nanopowder to the conventional micrometer-sized metal powder is an effective solution. The present investigation is aimed at studying the surface chemistry of iron nanopowder coated with graphitic carbon, which is intended to be mixed with the conventional iron powder. For this purpose, iron nanopowder in the size range of 30 nm to submicron (less than 1 micron) was investigated using thermogravimetry at different temperatures: 400°C, 600°C, 800°C, 1000°C, and 1350°C. The X-ray photoelectron spectroscopy (XPS), Auger electron spectroscopy (AES), and high-resolution scanning electron microscopy (HR-SEM) were used for characterizing the powder as well as samples sintered at different temperatures. The presence of iron, oxygen, carbon, chromium, and zinc were observed on the surface of the nanopowder. Iron was present in oxide state, although a small metallic iron peak at 707 eV was also observed in the XPS spectra obtained from the surface indicating the oxide scale to be maximum of about 5 nm in thickness. For the sample treated at 600°C, presence of manganese was observed on the surface. Thermogravimetry results showed a two-step mass loss with a total mass loss of 4 wt.% when heated to 1350°C where the first step corresponds to the surface oxide reduction.     

不同温度下生成的过渡金属表面氧化物的热稳定性研究

不久前本文作者等首次观察到金属钴表面氧化物的热稳定性与其氧化温度密切相关。研究对象包括多晶钴片和蒸镀的钴薄膜。它们无论是被纯氧氧化或是被空气氧化,其结果相同:室温表面氧化钴在真空中300℃加热时很容易被还原成金属钴,而对250℃形成的表面氧化钴作同样的真空热处理则不能被还原成金属钴,鉴于该现象在多相催化、金属氧化和腐蚀,电子学表面器件等研究领域中的意义,本文用X射线光电子能谱(XPS)等方法研究     

Surface chemistry and diffusion of trace and alloying elements during in vacuum thermal deoxidation of stainless steel

Removal of the native surface oxide from steel is an important initial step during vacuum brazing. Trace and alloying elements in steel, such as Mn, Si, and Ni, can diffuse to the surface and influence the deoxidation process. The detailed surface chemical composition and grain morphology of the common stainless-steel grade 316L is imaged and spectroscopically analyzed at several stages of in-vacuum annealing from room temperature up to 850°C. Measurements are performed using synchrotron-based X-ray photoemission and low-energy electron microscopy (XPEEM/LEEM). The initial native Cr surface oxide is amorphous and unaffected by the underlying Fe grain morphology. After annealing to ~700°C, the grain morphology is seen at the surface, persisting also after the complete oxygen removal at 850°C. The surface concentration of first Mn and then Si increases significantly when annealing to 500°C and 700°C, respectively, while Ni and Cr concentrations do not change. Mn and Si are not located only in grain boundaries or clusters but are distributed across over the surface. Both Mn and Si appear as oxides, while Cr oxide becomes metallic Cr. Annealing from 500°C up to 850°C leads to the removal of first the Mn and then Si oxides from the surface, while Cr and Fe are completely reduced to metals. Deoxidation of Cr occurs faster at the grain boundaries, and the final Cr metal surface content varies between the grains. The findings are summarized in a general qualitative model, relevant for austenite steels.     

XPS and ToF‐SIMS characterization of a Finemet surface: effect of heating

X‐ray photoelectron spectroscopy (XPS) and time‐of‐flight secondary ion mass spectrometry (ToF‐SIMS) were used to study the surface composition and electronic structure of Finemet, Fe₇₃Si_15.8B_7.2Cu₁Nb₃, in the original amorphous state and after gradual heating in vacuum to a temperature of 400 °C and cooling back to room temperature. It was found that relaxation processes occurring during heat treatment well below the crystallization onset caused the physico‐chemical state of Finemet surface to change irreversibly. In the relaxed alloy, the surface originally covered with the native air‐formed oxide was significantly enriched with elemental iron and depleted of other alloy constituents compared with the original state. Yet in the as‐quenched state, clustering of copper atoms on the Finemet surface was detected which was enhanced by heating. The thermal treatment resulted in the selective reduction of iron oxides and caused noticeable changes in the valence band structure and the Fe L₃VV Auger spectrum associated with atomic redistribution. Copyright © 2009 John Wiley & Sons, Ltd.     

Surface chemical and geometrical properties of pure copper powder intended for binder jetting and sintering

One novel important application of sinter-based additive manufacturing involving binder jetting is copper-based products. Three different variants of nominally pure copper powder having particle size distributions with D90 < 16, 22, or 31 μm were investigated in this study. The packing behavior and the flow properties using dynamic test and shear cell, as well as specific surface area were evaluated. The analyses employed illustrate the multidimensional complexity. Because different measurements capture different aspect of the powder, it is imperative to apply a characterization approach involving different methods. Surface chemical analysis by means of X-ray photoelectron spectroscopy (XPS) showed that all powder variants were covered by Cu₂O, CuO, and Cu (OH)₂, with Cu₂O being dominant in all cases. The finest powder with D90 < 16 μm tended to have higher relative amount of copper in divalent state. The average apparent oxide thickness estimated by XPS depth profiling showed that the two coarser variants had similar overall average oxide thickness, whereas the finest one possessed smaller oxide thickness. The surface chemistry of the powder grades is found to be related to their rheological behavior in dynamic condition. Considering the specific surface areas in combination with the average oxide thicknesses, the amount of surface bound oxygen was estimated to be about ~220 ppm for all three variants. Specific concerns need to be taken during the sintering of powder to keep oxygen level below that of electrolytic pitch copper (400 ppm).     

Surface chemical analysis of copper powder used in additive manufacturing

Additive manufacturing (AM) has during years gained significant interest owing to its endless component design possibilities. One of the most popular AM techniques is laser powder bed fusion (LPBF), which selectively melts metal powder layer-by-layer in a chamber with protective argon atmosphere. This technique is attractive for realizing Cu-based products in which the high electrical conductivity of Cu is combined with component design possibilities. The successful use of Cu powder not only poses challenges owing to the high reflectivity and thermal conductivity of Cu but also involves the important concern of controlling the powder surface chemistry since the powder surface constitutes the main source of oxygen. It is of crucial importance to control the oxygen level in order to maintain good electrical conductivity and brazing ability of the AM-fabricated Cu-part. In LPBF, fine spherical powder with size of 10–60 μm is used, providing significant specific surface area, and this powder is also usually recycled several times, and hence, the role of powder surface chemistry is evident. Two kinds of copper powder with purities 99.70 and 99.95 wt% were analysed in both virgin and in used conditions after numerous printing cycles using LPBF. The powder was analysed by X-ray photoelectron spectroscopy (XPS) and scanning electron microscopy (SEM). A clear difference between the two powder grades in terms of surface chemistry was observed. The oxide thickness and bulk oxygen content increased for both powder grades after recycling. The surface oxides under different conditions are identified and the effect of powder purity on the oxide formed is discussed.     

SIMS/XPS characterization of surface layers formed in 3 mass% Si‐steel by annealing in oxygen at low partial pressure

Selective oxidation in silicon steel shows several interesting phenomena, such as the formation of an internal oxidation zone that depends on the oxidation conditions and the steel composition. In this work, SIMS and XPS were used for characterizing the formation processes of surface layers formed during selective oxidation of a typical silicon steel. The starting material is a secondary‐recrystallized 3 mass% Si‐steel sheet with a surface orientation of (011). Sample sheets were annealed at a temperature of 948–1023 K under an atmosphere with a low partial pressure of oxygen. The SIMS depth profiles show that the internal oxidation zone thickens and an iron‐rich layer that formed on the internal oxidation zone expands as the annealing temperature increases. Manganese and chromium levels increase outside the internal oxidation zone, whereas tin exists in the internal oxidation zone. The XPS results of the sample surface show that silicon and manganese levels increase on the sample surface to form oxides, and the chemical composition and state of these elements depend on the annealing temperature. In addition, tin increases on the surface of a relatively thick iron‐rich layer that formed on the internal oxidation layer. These experimental results are discussed on the basis of the thermodynamic characteristics of the elements. Copyright © 2003 John Wiley & Sons, Ltd.     

The effect of calcination on morphology of phosphate coating and microstructure of sintered iron phosphated powder

Carbonyl iron powder was coated with phosphate layer using phosphating precipitation method. The phosphated powder was dried at 60 °C for 2 h in air and heat treated by calcination at 400 and 800 °C for 3 h in air. Cylindrical specimens density of ~6.5 g.cm^?3 based on iron phosphated powder calcined at 400 °C were sintered at 820, 900, 1110 °C in N₂ + 10%H₂ atmosphere and 1240 °C in vacuum for 30 min. The morphology and phase composition of the phosphate coating and sintered compacts were studied by scanning electron microscopy, atomic force microscopy (AFM) and X‐ray diffraction (XRD) analysis. Gelatinous morphology of dried phosphate coating (thickness of ~100 nm) containing nanoparticles of iron oxyhydroxides and hydrated iron phosphate was observed. From XRD, diffractogram indicated the presence of goethite α‐FeOOH, lepidocrocite γ‐FeOOH and ludlamite Fe₃(PO₄)₂.4H₂O. The calcined phosphate coating (thickness of ~ 400 nm) contained non‐homogeneous consistency of α‐Fe₂O₃ layer on iron particles, an inter‐layer of amorphous FePO₄ and Fe₃O₄ top layer. The transformation to crystalline FePO₄ structure occurred during calcination at 800 °C with the presence of α‐Fe₂O₃ forming a light top zone (rough morphology). The microstructure of compacts sintered in solid state at temperatures up to 900 °C has retained composite network character. A fundamental change in microstructure due to the liquid phase sintering occurred after sintering at temperatures of 1100 and 1240 °C. It was confirmed that the microstructure complex consists of spheroidized α‐Fe and α‐Fe₂O₃ phases surrounded by solidified liquid phase consisting various phosphate compounds. Copyright © 2013 John Wiley & Sons, Ltd.     

Influence of soaking duration on the selective oxidation and galvanizability of a high‐strength dual phase steel

High‐strength dual phase steels readily exhibit bad galvanizability and coating defects because of selective oxides formed on steel surface during the annealing process prior to galvanizing. To investigate selective oxidation of alloying elements and their effects on glavanizability, a high‐strength dual phase steel was annealed with soaking duration for 45, 90, and 120 s, respectively, and then galvanized using a hot‐dip simulator. Field‐emission scanning electron microscopy characterization revealed that when dual phase steel was soaked for 45 s, selective oxides mainly precipitated along grain boundaries, while only a few of the oxides formed on grains. With soaking duration increased, oxides were so dense that nearly all steel surface was covered, leaving little bare area of the steel surface. Further XPS analysis showed that selective oxides mainly consisted of MnO and Cr₂O₃. In addition, the chemical nature of oxides did not change at all although soaking duration prolonged. Scanning Auger microprobe depth profiles presented that Mn had a much higher tendency to segregate than Cr and Mo. Oxygen penetration depth to subsurface was promoted as soaking duration increased. The formation of interfacial inhibition layer was founded to be greatly influenced by the density and size of surface oxides. The widely spaced small oxides had virtually no adverse effect on wettability because of aluminothermic reduction of oxides by the bath dissolved Al. As the oxides became dense and considerably big, the grains of the inhibition layer in some certain zones became coarse and the galvanizability tended to deteriorate. Copyright © 2011 John Wiley & Sons, Ltd.     

Iron(III) Oxide Graphite Composite Electrodes: Application to the Electroanalytical Detection of Hydrazine and Hydrogen Peroxide

Composite electrodes based on iron(III) oxide, Fe₂O₃, carbon powder and epoxy resin have been prepared and characterized using electrochemical methods and X‐ray photoelectron spectroscopy (XPS). Initially composite electrodes were made by mixing micron sized carbon powder surface with iron(III) oxide. However, the voltammetric responses were unsatisfactory. Therefore, a new type of composite electrodes was made using carbon powder modified with iron(III) oxide via a wet impregnation procedure. This technique involves saturation of the carbon powder with iron(III) nitrate followed by thermal treatment at ca. 623 K forming iron(III) oxide on the surface of the carbon powder.     

Infrared study of the thermal transformation of goethite to magnetite in alkali-iodide disks

Synthetic and natural goethites (0.5–1.5 mg) were heated up to 600°C in alkali-halide disks (400 mg). The thermal transformations occurring at different temperatures are found to depend on the preparation of the disks. For mixtures of alkali-halides and goethite not ground during the preparation of the disks, heating at >200°C resulted in protohematite, which persisted up to 600°C. However, disks which were subjected to repeated grinding—pressing cycles before thermal treatments gave rise to protohematite at >200°C, which on further heating at >300°C was transformed to a transitional iron oxide. In CsI disks, the transitional oxide derived from synthetic goethite can be further transformed to maghemite at 500°C; however, almost no maghemite could be obtained from natural goethite. At 600°C, both the transitional oxide and the maghemite resulting from the synthetic goethite in CsI disks were reduced to magnetite. On the other hand, in KI disks, transitional oxides obtained from both synthetic and natural goethites were reduced to magnetite upon re-pressing and gradual heating of the disks at 600°C. In KI disks, magnetite can be formed only if the reduction temperature is reached gradually, whereas in CsI disks magnetite is formed upon direct heating of the disks to 600°C. The iron oxides referred to above, including the transitional oxides resulting from thermal treatments, were studied by IR absorption spectroscopy.     

X-ray photoelectron and scanning Auger electron spectroscopy study of electrodeposited ZnCr coatings on steel

Zn–Cr alloyed coatings electrochemically deposited are of high interest for leading steel manufacturing companies because of their novel properties and high corrosion resistance compared with conventional Zn coatings on steel. For tuning and optimizing the properties of the electrodeposited Zn–Cr coatings, a broad range of the deposition conditions must be studied. For this reason, two different types of material were investigated in this study, one with a low electrolyte temperature and one with an elevated electrolyte pH, compared with the standard values. Because different corrosion performance and delamination behaviour of the layers were observed for the two types, advanced surface analysis was conducted to understand the origin of this behaviour and to discover differences in the formation of the coatings. The topmost surface, the shallow subsurface region, and the whole bulk down to the coating–steel interface surface were analysed in detail by X-ray photoelectron spectroscopy (XPS) and high-resolution scanning Auger electron spectroscopy to determine the elemental and the chemical composition. For better understanding of the resulting layer structure, multiple reference samples and materials were measured and their Auger and XPS spectra were fitted to the experimental data. The results showed that one coating type is composed of metallic Zn and Cr, with oxide residing only on the surface and interface, whereas the other type contains significant amounts of Zn and Cr oxides throughout the whole coating thickness.     

The preparation and selected properties of Mg-doped p-type iron oxide as a photocathode for the photoelectrolysis of water using visible light

Stable Mg-doped iron oxides that exhibit p-type character have been synthesized. These have been utilized in the form of sintered polycrystalline disks for the photodissociation of water. We report the influence of sintering temperature, surface oxygen deficiency, Mg-doping level, and solution chemistry on the photoactivity of the Mg-doped iron oxide photocathodes.     

The influence of alkali‐degreasing on the chemical composition of hot‐dip galvanized steel surfaces

The influence of dipping temperature and time on the surface chemistry of hot‐dipped galvanized steel sheets during the alkaline degreasing process is investigated. The surface chemistry was monitored with scanning Auger electron spectroscopy (AES), X‐ray photoelectron spectroscopy (XPS), and time‐of‐flight secondary ion mass spectroscopy (ToF‐SIMS). The results show high Al concentrations on the untreated surfaces, which are significantly reduced during alkaline degreasing. The same conclusions could be drawn for the carbon compounds that accumulate on the surface during storage. The measurements reveal a gradual reduction in surface Al as the alkali solution temperature and/or degreasing time are increased. When degreasing was conducted at 70 °C for 30 s the surface was practically free from Al, which was present only in small islands. Furthermore, the experiments showed that the thickness of the oxide film covering the surfaces before and after alkaline degreasing is approximately 20 Å. The main constituents of the film varied from ZnAl hydroxide/oxide to Zn hydroxide/oxide, before and after degreasing, respectively. Copyright © 2006 John Wiley & Sons, Ltd.     

Direct growth of aligned multiwalled carbon nanotubes on treated stainless steel substrates

Growth of aligned carbon nanotubes (CNTs) on electrically conductive substrates is promising for many applications; however, the lack of complete understanding of the substrate effects on CNT growth poses a lot of technical challenges. Here, we report the direct growth of aligned multiwalled nanotubes (MWNTs) on chemically treated stainless steel (Type 304) using a chemical vapor deposition (CVD) process. A detailed X-ray photoelectron spectroscopy (XPS) analysis has been carried out for the various treated samples in order to better understand the correlation between the surface properties of the substrates and the MWNT growth. The XPS studies revealed that the CNTs prefer to grow on the enriched surface of iron oxides obtained by the chemical treatment rather than on the passive chromium oxide films present on the surface of the as-received stainless steel substrates. The density and alignment of the MWNTs could therefore be controlled by tuning the ratio of the iron oxides to chromium oxides through the chemical treatment on the stainless steel surfaces. On the basis of this method, selective growth of CNT patterns on stainless steel has also been demonstrated.     

Formation of Al‐enriched surface layers through reaction at the Mg‐substrate/Al‐powder interface

Al‐enriched surface layers containing a Mg₁₇Al₁₂ intermetallic phase and a solid solution of Al in Mg were fabricated by heating Mg specimens in contact with Al powder in a vacuum furnace. The layer formation process proceeded through partial melting at the Mg‐substrate/Al‐powder interface. The test results suggest that a good contact between the Al powder and the Mg substrate is required during heat treatment. In this study, a pressure of 1 MPa was applied to improve the contact of the Al powder with the Mg specimen. When the powder was pressed down during heating, it was possible to reduce the process temperature from 450 °C to 440 °C. The layers produced at 440 °C in a short heating time (40 min) were thick, continuous and uniform. The microhardness of the Al‐enriched layers was much higher than that of the Mg substrate. The results of the electrochemical corrosion tests indicated that the Mg specimens with an Al‐enriched surface layer had better corrosion resistance than the bare Mg. Copyright © 2014 John Wiley & Sons, Ltd.