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Documente Profesional
Documente Cultură
Lecturer:
Myrna Ariati, Dr. Ir., M.S.
Preface
Heat and Surface Treatment is one of spesific knowledge in the stream of
Metallurgy and Materials Engineering. It covers basic equilibrium diagram,
phase equilibrium and transformation that correlates to most of metallurgical
and material processing, microscopic phenomenon and mechanism which
control behaviour of materials. It also covers effect of various heating and
cooling of metals to the microstructure and mechanical properties of metals.
It lays foundation for further subjects related to manufacturing and
processing, because it studies how phase change, what affects the change
and how an engineer manipulate the change to obtain the optimum
properties of the materials.
This guidebook is intended to provide guidelines for students taking this
subject. This guidebook gives comprehensive information of the subject ,
therefore it is expected that students understand the learning objectives
and should be able to prepare themselves prior to each topic.
Any
comments and correction to this guidebook is thankfully accepted.
Table of Content
Preface
Table of Content
Chapter 1. General Information
1
Chapter 2. Learning Objectives
3
Chapter 3. Outlines of Subject
4
Chapter 4: Teaching Methods and Learning Activities
9
Chapter 5: Exercises and Assignments
11
Chapter 6. Assessment
17
References
20
General Information
Chapter
1. Subject
2. Subject Code
MMS 310807
3. Semester
4. Credit
3 SKS
5. Year
2011/2012
6. Type of Subject
7. Prerequisite
Metallurgy 2.
8. Relationship between this subject and other subjects in Metallurgy and
Materials Engineering
10.
Heat Treatment and Surface Engineering covers heating and cooling a solid
metal or alloy in such a way so as to obtain specific conditions or properties.
It studies the characteristics of each phase or microstructure of metal, such
as its hardness, ductility, toughness, etc. It also studies how to obtain a
certain microstructure of metals by some variation of heating and cooling
rate and temperature. It based on foundation of phase equilibrium and
phase transformation knowledge , giving a thorough understanding of how
to heat treat parts without sacrificing wear, and learn how to minimize the
loss from cracking or distortion . It also covers how to give heating and
cooling the materials to change the phase, effect of the change and how an
engineer manipulate the change to obtain the optimum properties of the
materials.
Learning activities will be conducted through various method, which consists of:
interactive lecture, question-based learning, discussion, and unguided structured
assignments. Assessment will be made continuously through a set of exercises,
discussion,presentation, mid semester exam and final exam.
This guide book will help students prepare for learning activities throughout the
semester for this subject. Preparation may include reading, preparation of
worksheet and practice. Achievement of students will entirely be due to their
activities and preparation. Construction of knowledge will be made through
exercises, and questions available in this book. Students are expected to do the
exercises, and they may move to further stage as they ready for that. Overall,
students are expected to be active learners by acquiring knowledge through
thinking and exercising. Students may also use this guidebook to self-assess their
achievement.
Learning Objectives
Chapter
1. Students are expected to understand the basic principles of heat treatment process, based on binary
equilibrium transformation and non equilibrium transformation.
2. If a complex binary phase diagram is provided, the students are able to define all important
points,phases and its presentage in every condition.
3. If a binary phase diagram is provided, students are able to predict the phase transformation during
equilibrium cooling.
4. Students understand the details in the binary Fe-Fe3C diagram and are able to determine the phase
transformation during equilibrium cooling.
5. Students understand diffusion of atoms that mainly controls phase transformation and If a diffusionrelated case is given, the students are able to calculate the processing parameter needed for desired
properties.
6. Students understand and can explain about anneal , recrystallization, hardening, tempering,
secondary hardening, precipitation hardening, austermpering,and martempering process
7. Students understand and can explain about hardenability of steel,effect of alloying elements
Outline of Subject
Chapter
Support
ive
Learnin
g
Objectiv
e
1,2 ,3
Topic
1. Basic Concept of
Heat and Surface
Treatment, its
application in
manufacturing
process
Fe-Fe3C Phase
Diagram
,4
2.
3, 4. Heat Treatment by
Diffusion Process
5, 6 Non Diffusion
Heat Treatment.
Sub-topic
Referenc
e
[1]
Chap.1
[2]
Chap.1, 5,
8
[3] Chap.
12, 13
[1]
Chap.2
7,8 Hardenability
[1]
Chap.3
Midterm
[1]
Chap.5
11.Special Heat
Treatment for Ferrous
and non-Ferrous
material
12, 13 Surface
Heat Treatment
Austempering, Martempering,
Marquenching
PWHT.
Exercises
Hardening and tempering of tools
steels; heat treatment of HSLA
steels; Heat Treatment of cast Iron ,
Principles of heat treating of
nonferrous alloys; heat treatment for
aluminum, copper, and nickel base
alloys; precipitation hardening;
solution treatment, quenching,
aging, overaging. exercises
Carburizing,nitriding,nitrocarburizing
,Boronizing,Chromating,PVD,CVD,ex
ercises
Types of heat-treating furnaces; salt
bath heat-treating equipment;
fluidized-bed heat-treating
equipment; heat treating in vacuum
furnaces and auxiliary equipment
Dimensional changes during
hardening, tempering; case
hardening,nitriding; examples of
dimensional changes; and designing
for heat treatment.
10,11
14 . Heat Treatment
Atmosphere and
Problems and
methods to
overcome
11
Learning Activities
Wee
k
2.
1
3.
4.
1.
2. Fe-Fe3C Phase
Diagram
Refere
nce
Learning
Method
Media
Assessment
[1]
Chap.1,
2
Interactiv
e lecture
LCD,
Laptop
Question in
class,
[2]
Chap.3,4
Interactive
lecture
LCD,
Laptop
Question in class
Assignment 1, 2
5.
3, 4
3. Heat Treatment
by Diffusion
Process
4.
Non
Diffusion
Heat
Treatment.
5.
Hardenability
5,6
7,8
2.3 Diffusion,
2.4. Lever Rule,Practical ,
2.5 TTT and CCT diagrams.
2.6 Effect of Alloying element to FeFe3C diagram and heat treatment
behaviour
3.1 Effect of various heating and cooling
rate;
3.2.Full annealing, stress relief,
homogenization, normalizing,
spheroidization, recrystallization,
3.3.Effect of temperature to grain growth,
exercises
4.1.Steel Hardening mechanism,
4.2. Effect of preheating, tempering
process, double tempering, tempering
embrittlement, Retained austenite,
subzero treatment. Multi-alloyed steels
and carbide stabilizer;
4.3. Effect of temperature on martensite
formation, formation of pearlite and
bainite during isothermal transformation,
4.4. Effect of heating media, rate of
heating, hardening temperature, holding
time, methods of cooling, and quenching
media
5.1. The Grossmann hardenability
test and calculation of Divalues;
5.2. The Jominy end-quench
hardenability test and practical
applications of Jominy curves.
5.3. Applications of hardenability;
and the influence of the depth
of hardening on the stress
pattern.
MID SEMESTER EXAM
[3] Chap.
6,7
Interactive
lecture
LCD,
Laptop
Question in class,
Assignment 3,
Assignment 4
[1] Chap
6,72
Interactive
lecture
LCD,
Laptop
Question in class,
Assignment 5
Chapter 3
Interactive
lecture
LCD,
Laptop
Question in class,
Assignment 5
Week
10
12, 13
6.
Special
Heat
Treatme
nt
7.
Special
Heat
Treatme
nt for
Ferrous
and nonFerrous
material
Learning
Method
Media
Assessment
[1]
Chap.6,7
Interactive
lecture
LCD,
Laptop
Question in class,
Assignment 6
[1]
Chap.10,
11,12
Interactive
lecture
LCD,
Laptop
Question in class,
Ass Exercises;
An alysis of
improper Heat
Treatment
ignment 7
8. Surface
Heat
Treatment
8.1.Carburizing,nitriding,nitroca
rburizing,Boronizing,Chromatin
g,
8.2. PVD,CVD,exercises
[1]
Chap.8,9
Interactive
lecture
LCD,
Laptop
Question in class,
Assignment 8
10.If a microstructure of
material is given, the
students are able to predict
history of heat treatment of
the materials and the
equipment or furnace have
been used in heat treatment.
11.
If a case of heat
treatment failure, students
are able to analyze the
possible reason of the
failure and how to avoid it.
9.. Heat
Treatment
Atmosphere
and Problems
and methods
to overcome
9.1.Types of heat-treating
furnaces; salt bath heattreating equipment;
fluidized-bed heattreating equipment; heat
treating in vacuum
furnaces and auxiliary
equipment
9.2. Dimensional changes during
hardening, tempering; case
hardening,nitriding;
9.3. Examples of dimensional
changes; problems during Heat
[1]
Chap.4,14
Interactive
lecture
LCD,
Laptop
Question in class,
Assignment 9
.
Student Guide Book
t
Reference
14
FINAL EXAM
Week
1, 2
3,4
5,6
7,8
Subtopic
General introduction to Heat Treatment
and Surface Engineering;Phase
diagrams and Transformation
Fe-Fe3C phase diagram, Steel
microstructure
characteristics,Transformation of Carbon
Steel in continous cooling condition,
Diffusion, Lever Rule,Practical , TTT and
CCT diagrams. Effect of Alloying
element to Fe-Fe3C diagram and hat
treatment behaviour
Heat Treatment by Diffusion Process ;
effect of various heating and cooling
rate; full annealing, stress relief,
homogenization, normalizing,
spheroidization,
recrystallization,effect of
temperature to grain growth.
Non Diffusion Heat Treatment;Steel
Hardening mechanism,effect of
preheating, tempering process,
tempering embrittlement. Retained
austenite, subzero treatment, double
tempering, multi-alloyed steels and
carbide stabilizer; effect of temperature
on martensite formation, effect on the
formation of pearlite and bainite during
isothermal transformation.
Effect of heating media, rate of heating,
hardening temperature, holding time,
various quenching media,
The Grossmann hardenability test and
calculation of Di-values; The Jominy endquench hardenability test and practical
applications of Jominy curves.
applications of hardenability; and the
influence of the depth of hardening on
the stress pattern.
MIDSEMESTER EXAM
Assignment
Group
Individual
Assignment
Assignment
Assignment 1,
due date: Week 2
in class
Assignment 2,
due date: Week 3
in class
Assignment 3,
due date: Week 4
in class
Assignment 4,
due date: Week 5
in class
Assignment 5,
due date: Week 6
in class
10
11
Week
12
13
14
15
16
Assignment 6,
due date: Week 9
in class
Assignment 7,
due date: Week
13 in class
Assignment
Assignment 8,
due date: Week
15 in class
1.
2. Dari dua paduan non-ferrous dengan komposisi yang tampak pada diagram fasa di
bawah, terangkan:
a. Jenis larutan padat yang terbentuk (interstisi/substitusi), jelaskan jawaban saudara
b. Mekanisme penguatan yang tepat untuk masing-masing paduan di bawah,
terangkan mengapa demikian.
c. Terangkan mekanisme penguatan denga Precipitation Hardening (pengerasan
endapan), skets siklus panas yang harus dilakukan.
d. Skets dan jelaskan singkat endapam koheren , semi koheren dan in-koheren, dan
bagaimana efek penguatannya (25)
3. Pada laku panas permukaan terangkan perbedaan prinsip, struktur yang didapat dan pengaruhnya terhadap
sifat akhir material, antara :
Proses
Material
dasar
(25)
Prinsip dasar
Proses
Struktur Mikro
Permukaan dan
kekerasan perm
dicapai
Nitriding
Karburisasi
Flame
Hardening
Induction
Hardening
Struktur Mikro
Bagian inti
Temperatur
Proses
4. A. Rantai sepeda motor yang menggunakan material baja 1050 dipersyaratkan memiliki
kekerasan permukaan yang cukup tinggi (hampir 50 HRC) , namun dibutuhkan memiliki
keuletan yang memadai agar tidak cepat patah. Buat flowchart proses perlakuan panas /
permukaan yang harus dilakukan untuk tercapainya persyaratan tersebut. Apakah struktur
mikro yang dihasilkan dari perlakuan panas/permukaan yang anda rekomendasikan.
b. Apa perbedaan mendasar antara perlakuan permukaan PVD dan CVD dibandingkan
dengan proses termokimia? Apa akibatnya terhadap sifat mekanis permukaan material?
5.. a. Dies (cetakan) untuk proses stamping body otomotive terbuat dari besi tuang nodular cor.
Untuk meningkatkan kekerasan permukaan cetakan yang bersentuhan dengan logam cair,
perlakuan panas apa yang dapat meningkatkan kekerasan besi tuang nodular? Mengapa
demikian?
b. Buat siklus perlakuan panas untuk mendapatkan besi tuang putih, dan skets struktur mikro
yang terbentuk, serta sifat besi tuang type ini
c. Buat siklus perlakuan panas untuk mendapatkan Malleable cast Iron, dan skets struktur
mikronya., serta sifat besi tuang tersebut.
d. Jika material dies adalah baja perkakas H13 (0.35 C, 5.00 Cr. 1.50 MO. 1 .OO V), Perlakuan
panas/permukaan apa yang harus dilakukan agar dies kuat terhadap temperatur dan gesekan dengan plat
logam yang dibentuk(25).
6. Apakah.
a. Austempered ductile iron dan terangkan struktur dan silat yang didapat pada bahan tersebut.
b. Red Hardness, terangkan singkat
c. Secondary hardening pada tool steel, struktur dan sifat yang didapat pada kondisi tersebut..
d. Perbedaan dan persamaan proses Thermal spray dan Proses PVD, ditinjau dari prinsip dasar
proses, dan hasil yan diperoleh dari proses ini.(25).
a. Suatu baja karbon sederhana didinginkan perlahan dari daerah austenit ke suhu yang
memiliki 9,1% berfasa ferit proeutektoid.. Hitung % karbon pada baja tersebut, dengan
sumsi tak ada perubahan struktur pada pendinginan di bawah temperatur eutektoid.
b. Terangkan tahapan proses anil rekristalisasi, apa tujuannya dan tunjukkan pada gambar di
atas rentang temperatur prosesnya.
c. Suatu produk casting dengan cetakan pasir memiliki struktur butir yang tidak seragam
akibat laju pendinginan yang berbeda antara bagian tepi dan tengah. Terangkan
perlakuan panas yang dapat diterapkan untuk mendapatkan struktur yang homogen, dan
tunjukkan rentang temperatur laku panas pada gambar di atas.
d. Terangkan tujuan anil normalisasi pada baja karbon, tunjukkan rentang temperatur laku
panasnya pada gambar di atas dan apa tujuannya.(30 point)
2. Pada gambar isothermal Transformation berikut dari baja paduan AISI 4130 di bawah
tentukan struktur mikro akhir berikut prosentasenya dari sampel yang berukuran diameter 2,5
cm dan panjang 5 cm (ukuran sampel kecil), yang telah mengalami perlakuan sebagai berikut
di bawah ini. Pada setiap perlakuan diasumsikan sampel mulai perlakuan pada suhu 800oC dan
telah ditahan pada temperatur ini cukup lama untuk mendapatkan fasa austenit yang homogen;
a. Didinginkan cepat ke 250oC, tahan 10 s, diquench ke suhu ruang.
Student Guide Book
t
.
3. a. Skets dan terangkan siklus pemanasan dan pendinginan proses pengerasan pada baja
karbon.dan transformasi kristal pada fasa yang terjadi
b. 2 jenis baja 0,5 dan 1 %C akan dikeraskan untuk mencapai kekerasan minimal 50HRC.
Tunjukkan pada FeC diagram pada soal 1 rentang temperatur austenisasi pada
pengerasan.masing-masing baja tersebut , terangkan alasan saudara dalam menentukan
temperatur tersebut.
c. Apa Tujuan Proses temper pada baja?
d. Skets aliran proses sub-zero treatment pada sketsa soal nomor 3 a.
e. Bagaimana pengaruh penambahan unsur Cr,V,Mo terhadap diagram CCT baja 4130 di
atas dan bagaimana pengaruhnya terhadap diagran Fe-C di atas, diketahui sbb(40 point)
5. Baja AISI 4140 (C=0,4%,Mn=0,85%, Cr=0,95,Mo=0,2%) dan baja AISI 8620 ( C=0,20 , Mn=0,8, Ni=0,55,
Cr=0,50, Mo = 0,20) akan dibuat cetakan untuk die casting setebal 8 cm. Karakter yang harus dimiliki oleh
dies tersebut adalah bagian permukaannya kekerasannya amat tinggi sekitar 55 HRC, sedangkan bagian
intinya hanya 25 HRC. Material di austenisasi sekitar 850o sekitar 1,5 jam dan dicelup dengan oli dengan
kecepatan pengadukan tinggi.Butir austenit diketahui sebesar 7 ASTM.
a) Tentukan apakah kedua bahan ini sesuai untuk digunakan. untuk aplikasi tersebut di atas.(Dg Grossman)
b.) Jika ketebalan pengerasan minimal yang diinginkan adalah 30 mm dari permukaan, apakah kedua bahan
ini sesuai untuk digunakan dalam aplikasi di atas? Terangkan jawaban saudara.(40)