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<p>The rapid carburization of mild steel is demonstrated via the electrochemical deposition of solid carbon, followed by thermochemical iron-carbon (Fe-C) reaction using a molten lithium-potassium carbonate (LiKCO<sub>3</sub>) salt electrolyte and carbon dioxide as the carbon source. Depth-dependent microstructural and compositional changes in the steel are shown to be controlled by the applied cell voltage and reaction temperatures. Reaction temperatures above the Fe-C eutectoid temperature promote faster carburization due to carbon dissolution into austenite. The carbon deposition rate is regulated by the applied cell voltage: At − 2.4&#xa0;V, carbon deposition occurs much faster than its diffusion into the steel, resulting in the accumulation of a carbon-rich layer exceeding 1&#xa0;mm, which does not diffuse into the steel. In contrast, at − 1.8&#xa0;V, all deposited carbon effectively diffuses into the steel, leaving a minimal external deposit. In both cases, carbon ingress forms a carbide-rich surface layer and precipitates additional carbides along the grain boundaries within the steel electrode. This method offers a potential approach to increase the carbon content of mild or low-carbon steel feedstocks, such as scrap or direct reduced iron, for industrial applications.</p>

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Electro-carburization of mild steel through two-step reaction in molten-salt electrolyte

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年3月19日

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  • Samuel Pennell,
  • Ivy Wu,
  • Haley Hoover,
  • Oluwatamilore Olushina,
  • Judith Vidal,
  • Bryan Webler,
  • Robert Bell,
  • Kerry Rippy

摘要

The rapid carburization of mild steel is demonstrated via the electrochemical deposition of solid carbon, followed by thermochemical iron-carbon (Fe-C) reaction using a molten lithium-potassium carbonate (LiKCO3) salt electrolyte and carbon dioxide as the carbon source. Depth-dependent microstructural and compositional changes in the steel are shown to be controlled by the applied cell voltage and reaction temperatures. Reaction temperatures above the Fe-C eutectoid temperature promote faster carburization due to carbon dissolution into austenite. The carbon deposition rate is regulated by the applied cell voltage: At − 2.4 V, carbon deposition occurs much faster than its diffusion into the steel, resulting in the accumulation of a carbon-rich layer exceeding 1 mm, which does not diffuse into the steel. In contrast, at − 1.8 V, all deposited carbon effectively diffuses into the steel, leaving a minimal external deposit. In both cases, carbon ingress forms a carbide-rich surface layer and precipitates additional carbides along the grain boundaries within the steel electrode. This method offers a potential approach to increase the carbon content of mild or low-carbon steel feedstocks, such as scrap or direct reduced iron, for industrial applications.