7 8 November 2005, Srni - Czech Republic

CAUSES OF DEGRADATION PROCESSES IN HIGH-SPEED STEELS

A. K Keywords: High-speed steel, degradation processes, structure

Introduction
Progressive development of contemporary tool steels has its roots in requirements for enhanced properties of tools. Alloyed steels have thus replaced the original carbon steels. The era of steel tools has culminated in development of high-speed steels. Those are the most frequently used materials for production of high-performance and heavy-duty tools for machine cutting of metals. Application of these steels is justified by their typical properties, which include, for instance, high resistance to tempering, retention of high hardness at elevated temperatures, high wearresistance and adequate toughness. High-speed steels comprise the tungsten-alloyed and tungsten-molybdenum-alloyed steels, as well as the high-performance cobalt-alloyed steels. Attention will be paid both to fundamental technological procedures, which control the quality of steels, and to the cobalt containing high-speed steels. Owing to presence of cobalt, which causes higher sensitivity to transformation temperatures, these steels are even more complicated to manfuacture and process than the other grades of high-speed steels. That is why observance of proper technological procedures is very important, as there is greater occurrence of rejects here[KOUTSK 1969].

1. PROPERTIES OF HIGH-SPEED STEELS

1.1. Parameters of the Raw Product Required properties of high-speed steels can only be achieved by satisfying the following conditions. Appropriate parameters of the raw product rank among the most important, yet often disregarded ones. These parameters are controlled both by the metallurgical process and subsequent mechanical working. Forging and rolling of ingots of tool steels are performed to achieve the proper shape and dimension of products, refine the grain and modify the steel microstructure, which entails crushing the carbide network along the austenite grain boundaries. Forging in one direction leads to carbide banding (Fig. 1), in which case anisotropy impairs mechanical properties of the product. Often, this occurs in sculptured tools, which then fail in brittle manner under load. Banding also results in presence of large volume fraction of retained austenite (Fig. 2), which impairs resulting properties of material [PIBIL 1985]. Carbide banding may cause formation of coarse grains of different sizes in some regions, which may initiate a heterogeneous brittle fracture. If carbide banding is to be avoided, sufficient number of upsetting operations must be included in the forging procedure alongside the drawing out operation. Steel manufacturers do not observe this rule in their pursuit of cost and time savings. Such type of banding cannot be eliminated by any of the subsequent processing operations. This is why it is classified as an irreparable defect.

Fig. 1 Carbide banding as Fig. 2 Preserved martensite and retained a proof of insufficient forging reduction. austenite.

Carbide banding may be identified in the plant conditions by means of measurement of hardness in transversal and longitudinal directions of the product. However, the most accurate results will be obtained through metallographic observation in said directions. In such case, banding may be assessed both qualitatively and quantitatively. Another possible cause of heterogeneity of distribution of carbide phases may be an inadequate metallurgical process, which leads to formation of carbide segregates (Fig. 3). These are considered as irreparable defects and often result in early production failure of the tool during heat treatment procedure. Heterogeneity of carbide distribution, as described above, may be effectively, though expensively, avoided by using steel produced by powder metallurgy process (Fig. 4). This guarantees uniform distribution of small and globular carbide particles.

Fig. 3 Carbide segregates

Fig. 4 Steel produced by powder metallurgy

As a rule of thumb, raw products of diameters exceeding 150 mm, regardless of their prior forging reduction values, exhibit such degree of heterogeneity of carbide distribution, which poses serious risk of failure. Anisotropy must be accounted for in smaller tools as well. The position of the tool with respect to the axis of the raw product must be selected carefully. If there is misalignment, the carbide bands intersect the tool cutting edge (which is most severely loaded part of the tool) and initiate failure. Carbides may also affect the finish grinding process, as they may separate from matrix during this process (Fig. 5). That may lead to undesired changes in tool geometry and aggravate its surface properties.

1.2. Heat Treatment of High-Speed Steels Frequent sources of defects in highspeed steels are inadequate heat treatment procedures. Departure from conditions of optimum technological process (involving heating rate, temperature, soaking time, cooling rate, number of tempering treatments) may lead to irreversible damage to the steel. Heat treatment of a high-speed steel is a specialized and demanding operation. Achieving superior cutting efficiency of tools requires very high quenching temperatures of 1150 to 1300C [WALLA 1952]. Reducing thermal stresses by stepwise heating is necessary due to low thermal conductivity, which is a consequence of high alloy content. Quenching temperature controls the course of processes in the material. Lower quenching temperature leads to insufficient dissolution of carbides and consequently low secondary Fig. 5 Failed cohesion between carbides and tempered martensite matrix hardness and lowered resistance to tempering (i.e. lowered thermal stability). However, the resulting volume fraction of retained austenite is low, while the hardness upon quenching is high. The potential of high-speed steels is not fully utilized with this type of quenching but it is often used in sculptured tools or tools, where high toughness is specified. Subsequent tempering must be performed at lowered temperatures, typically below 200C. Raising quenching temperature leads to dissolution of greater fraction of carbides. Quenched steel thus contains more retained austenite and shows lower hardness. Tempering at higher temperatures causes decomposition of retained austenite and precipitation of fine carbide particles. Decomposition of retained austenite continues during cooling from tempering temperature. This is the reason for multiple tempering operations. Raising quenching temperature involves greater risk of cracking and distortion upon quenching. When maximum quenching temperatures are exceeded, grain boundary carbides, which had been pinning the boundaries, begin to dissolve rapidly. This leads to grain coarsening and decrease of toughness of steel [4]. A case study describing application of incorrect quenching temperature follows.

2. CASE STUDY
2.1. Structural Inhomogeneity Hobbing cutter made of Czech Standard CSN 19856 (DIN S 6-5-2-5) steel has experienced an in-service sudden fracture. Observation of the fracture surface revealed that the fracture was brittle and intercrystalline. In order to identify the cause of the fracture, metallographic analysis was conducted, which also provided information on prior technological processing and deviations from appropriate procedures. In recent years, engineering companies began to utilize their older stocks of materials. This led to occurrence of many rejects due to confusion of material grades. Hence, analysis of chemical composition may reveal the defect origin, which proved true in this case. The actual material used was CSN 19802 (DIN S 12-1-2). However, this materials confusion had not been the main cause of failure.

The photographs (Fig. 6) suggest that the failure was related to carbide network along the prior austenite grain boundaries. Resulting deterioration of properties of grain boundaries led to initiation of a brittle intercrystalline fracture. The carbide network shows signs of deformation in both directions. However, the strain had not been sufficient to crush this brittle phase and generate the uniform microstructure, which is required in high-speed steels. Primary carbides in ledeburite cannot be eliminated by any type of subsequent heat treatments. At the same time, a properly processed semiproduct with uniform microstructure, and sufficient prior forging reduction, may form ledeburite network along grain boundaries again, if it is exposed to excessively high quenching temperature. If that had been the case, though, the carbide network would not have been affected by prior deformation and it would exhibit uniform shape.

a) b) Fig. 6 Microstructure of tempered CSN 19802 high-speed steel containing ledeburite network affected by strain at levels insufficient for breaking this phase. a) transversal direction, b) longitudinal direction

2.2. Deviation from Appropriate Heat Treatment Process The following study concerns sudden failure of hobbing cutter teeth, which had been made of DIN 1 3247 steel. This steels most close match in terms of chemical composition and mechanical properties is the Czech Standard steel 19850 [5]. It is not an exactly identical material but the experience related to this steel will be used for analysis of errors in the heat treatment procedure. Rockwell hardness HRC of the faces of the hobbing cutter was measured 10 times on each face. Measurement locations between inner and outer diameters of the tool (five measurements) have been selected so as to highlight possible inhomogeneity of material related with the tool shape. Lateral distribution of hardness on the tool face was determined through 5 more measurements along the line perpendicular to that of the previous measurements. However, no such inhomogeneity was found. Average value of hardness at the inner diameter of tool was 650,5 HRC, slightly increasing towards the outer diameter, where it reached 66,50,5 HRC. The other face of the cutter exhibited somewhat lower average hardness of 631 HRC and 64 1 HRC at the inner and outer diameter, respectively. For this reason, metallographic observation of both surfaces has been carried out. Upon revelation of microstructure by means of Vilella-Bain etchant, large amount of carbide phase along prior austenite grain boundaries was observed in analysed sections. Prior austenite grain size was determined according to Czech Standard CSN 420462. According to this standard, the grain size value corresponds to 5 (i.e. nominal number of 256 grains per mm2) [KRAUSS 1989]. Both faces of the tool have exhibited grain size within the adequate interval (Fig. 7). Measured grain size exceeds the value, which is typically found in high-

speed steels. This is a proof that the proper quenching temperature was exceeded. As literature [KRAUSS 1989]does not state hardening temperature for this steel, the magnitude of excess cannot be determined. Similar Czech Standard CSN 19850 (ASTM M36) steels prescribed quenching temperature is 1190-1220C [WALLA 1952]. Since the cobaltcontaining steels are generally sensitive to quenching temperature, it is necessary to strictly comply with the temperature specifications. When the required temperature is exceeded by as little as 10C, these high speed steels show undesirable change in austenite grain size and precipitation of carbides along grain boundaries [KOUTSK 1969].

Fig. 7 Microstructure of specimen taken from the front side of the tool

Fig. 8 Presence of sharp-edged carbides in ledeburite along the prior austenite grain boundaries proves that proper quenching temperature has been considerably exceeded

As there was difference in measured HRC hardness values, metallographic analysis has been performed on both faces of the tool. Ledeburite (Fig. 8) was found in the microstructure of the front face, which had shown slightly higher hardness. Carbide formation was due to temperature considerably higher than the proper quenching temperature (by tens of C). This polished section contains large regions of martensite. The martesite fraction is slightly higher in the vicinity of the inner diameter of tool. Substantially lower martensite volume fraction than in the previous section has been observed on the rear face of the cutter. Very low martensite volume fraction was encountered near the inner diameter of tool, contrary to the outer diameter region. However, both are much lower than the amount of martensite in the front face of the tool. No ledeburite has been found in the rear face of tool. Carbide phase along the prior austenite grain boundary has been found in both specimens (both faces of the tool). Being a rather continuous sharp-edged network, it causes substantial deterioration of material toughness. Heterogeneity of phase composition, i.e. presence of ledeburite and untransformed martensite, leads to decrease in toughness as well. Volume fraction of retained austenite is adequate to applied heat treatment procedure. The fraction has been estimated as lower than 3 per cent. With regard to applied 6 tempering cycles, the amount of retained austenite may be considered as final. Unusually large number of tempering procedures has been probably selected in order to reduce hardness of the material. However, desired mechanical properties cannot be achieved by this operation because of unfavourable distribution of carbides along prior austenite grain boundaries.

3. CONCLUSIONS
Presented case studies covered the most frequent causes of failures of cutting tools. This type of tool degradation may be prevented by means of preliminary testing of chemical composition and applied

forging reduction of the semi-product and by precise compliance with prescribed heat treatment procedure. Where larger and expensive batches of tools are processed, it is possible to apply identical heat treatment procedure to attached reference specimens made of identical material. Subsequent evaluation of these may reveal flaws in the processed tools and their distribution may be stopped. This paper is sponsored by the GAR of the Czech Republic under project 106/03/P092.

Reference;
KOUTSK, J, JANDO, F..: Materilov vady ocelovch nstroj. Praha, 1969. PIBIL, E.: Nstrojov oceli POLDI a jejich pouit. Kladno, 1985. WALLA, V.: Nstrojov oceli, Praha, 1952. KRAUSS, G.: STEELS Heat Treatment and Processing Principles, ASM International,1989. K Antonn, Doc. Dr. Ing. University of West Bohemia in Pilsen Univerzitn 22, Plze, 306 14, Czech Republic Tel.:+420 737 163433, e-mail: kriz@kmm.zcu.cz