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Development and characterization of repeating macro and micro geometric surface features on plain carbon steel using chemical etching

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This paper investigates the use of chemical etching to develop repeating macro and micro geometric surface features on plain carbon steel. Important properties can be imparted in a material by the use of these surface features or textures leading to enhanced corrosion resistance in plain carbon steels. Maskant perforated with pinholes combined with standard chemical etching methods was used to create repeating features on the sample’s surface. Surface characterization was carried out using optical materials analysis microscopy and dynamic-mode imaging using an Atomic Force Microscope. Surface profiles were evaluated based on their center-to-center distance, surface topography and average surface roughness. Comparison with control sample revealed the effects of chemical etching in terms of changes in the average surface roughness and surface topography. Limitations were observed in the control of etchant flow to sample’s surface. However, the results were significant in refinement of the chemical etching methodology for this application.