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Article history: Deep cryogenic treatment (DCT) is a one time permanent process, carried out on steel com-
Received 28 June 2006 ponents in such a way that the material is slowly cooled down to the cryogenic temperature,
Received in revised form after which it is held at that temperature for a specied period of time and is heated back to
27 April 2007 room temperature at a slow rate followed by low temperature tempering. The main advan-
Accepted 3 May 2007 tage of DCT is to enhance the wear resistance. The various levels of DCT process parameters
have their own inuence upon the wear resistance of the material. In this study, the Taguchi
method has been used to optimize the process parameters of DCT for a commercial piston
Keywords: ring, made up of 18% Cr martensitic stainless steel (SR34) to obtain maximum wear resis-
Wear resistance tance. The DCT parameters considered for optimization are: the cooling rate, the soaking
Piston ring temperature, the soaking time, the tempering temperature and the tempering time. In this
Taguchi optimization regard, two iterations of Taguchi design have been used to arrive at the optimum DCT param-
Cryogenic treatment eters. During the rst iteration, L16 215 orthogonal array (OA) was used to conduct the Taguchi
ANOVA experiment so as to study the signicance of these factors and the effect of their possible
two-factor interactions. In the second iteration, L9 34 OA was used to conduct the Taguchi
experiment to arrive at the optimal levels. Wear test was conducted on a reciprocatory fric-
tion and wear monitor (RFWM) by weight loss method, as per ASTM standards G-181 and
G-133. The relative importance of the controlling parameters of DCT and their interactions
for enhancing the wear resistance was evaluated in terms of their percentage contributions
using analysis of variance (ANOVA). The optimum levels of the signicant DCT parameters
for SR34 steel ring were arrived based on the maximum S/N ratio. A conrmation test was
conducted subsequently, and the results were found to be within the condence interval.
2007 Elsevier B.V. All rights reserved.
Corresponding author. Tel.: +91 94442 10306/44 22203262; fax: +91 44 24420593.
E-mail addresses: jdarwa@yahoo.com (J.D. Darwin), mohanlal@annauniv.edu (D. Mohan Lal), nagarajan@annauniv.edu (G. Nagarajan).
1
Tel.: +91 44 22203262.
0924-0136/$ see front matter 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.05.005
242 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 5 ( 2 0 0 8 ) 241247
Table 2 Possible interactions of factors in DOE 1 Table 4 Factor and level descriptions for DOE 2
Interactions Factors Levels
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2
3 1 1 1 2 2 2 2 1 1 1 1 2 2 2 2
4 1 1 1 2 2 2 2 2 2 2 2 1 1 1 1
5 1 2 2 1 1 2 2 1 1 2 2 1 1 2 2
6 1 2 2 1 1 2 2 2 2 1 1 2 2 1 1
7 1 2 2 2 2 1 1 1 1 2 2 2 2 1 1
8 1 2 2 2 2 1 1 2 2 1 1 1 1 2 2
9 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
10 2 1 2 1 2 1 2 2 1 2 1 2 1 2 1
11 2 1 2 2 1 2 1 1 2 1 2 2 1 2 1
12 2 1 2 2 1 2 1 2 1 2 1 1 2 1 2
13 2 2 1 1 2 2 1 1 2 2 1 1 2 2 1
14 2 2 1 1 2 2 1 2 1 1 2 2 1 1 2
15 2 2 1 2 1 1 2 1 2 2 1 2 1 1 2
16 2 2 1 2 1 1 2 2 1 1 2 1 2 2 1
244 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 5 ( 2 0 0 8 ) 241247
3. Experimental procedure
Table 7 Experimental results for DOE 1 Table 9 Initial ANOVA for DOE 1
Exp. no. Wear loss (mg) S/N ratio Source SS d.f. Variance F
Fig. 5 Plot of response data of S/N ratio for main factors of Fig. 6 Plot of response data of S/N ratio for main factors of
DOE 1. DOE 2.
Table 11 Interaction breakup of A B and B C second iteration its contribution was 24% to the wear resis-
tance. The reason is that, the third level, considered for this
Interaction B1 B2
factor in the second iteration (36 h), has more signicance on
A1 11.82 9.67 the wear resistance. The optimum level for the soaking period
A2 11.97 10.33 was thus arrived as 36 h. The long soak is because of the pres-
ence of more chromium in the material, which needs more
Interaction C1 C2
time to form carbides. The third signicant factor is the cool-
B1 12.11 11.69 ing rate. On comparing the two iterations, it is observed that
B2 10.66 9.34 very low cooling rate and a higher cooling rate result in low
wear resistance, because, very low cooling rate will not enter-
of the corresponding factors are same as the optimum levels tain martensitic transformation and the high cooling rate will
obtained individually. make the material brittle because of thermal shock. The opti-
For the DOE 2, only the signicant factorssoaking tem- mum rate of cooling is 1 C/min. The fourth signicant factor,
perature, soaking period, cooling rate and the tempering tempering temperature shows only little signicance. The per-
temperature, were taken for analysis. The ANOVA for the DOE centage contribution of tempering temperature over the wear
2 is shown in Table 12. The results show that the signicance resistance is only around 2%. However the optimum level of
of the factors prevails in the following order of importance: tempering temperature is 250 C. This is again due to the rea-
(1) soaking temperature; (2) soaking period; (3) cooling rate; son that Chromium carbide needs a higher temperature for
(4) tempering temperature. The response data of S/N ratio precipitation. Though the tempering time is insignicant, in
for main factors of DOE 2 are plotted in Fig. 6. Considering order to complete the DCT process, the standard 1 h period is
maximum value of S/N ratio, the optimum levels of the signif- taken.
icant parameters are as follows: soaking temperature, 184 C;
soaking period, 36 h; cooling rate, 1 C/min; tempering temper- 5. Conrmation experiment
ature, 250 C.
Comparing the two iterations, in the DOE 1 and DOE 2, it
The predicted optimum wear loss of the SR34 material is cal-
can be observed that the most signicant factor is soaking
culated as 2.26 mg. The condence interval for the predicted
temperature. But in the DOE 1, the percentage contribution
value is calculated as 0.102 (95% condence), using the for-
of soaking temperature to the wear resistance was 71.4% and
mula
in DOE 2 it was 60.6%. This may be because of the reason
that in the rst iteration, the difference in levels of the soak- F;1;ve Vep
CI =
ing temperature was high and in the second iteration it was neff
low. But in both the cases, the optimum level of the soaking The specication for control limits is
temperature is 184 C. The next signicant factor is soak-
ing period. In the rst iteration it contributed 14%, and in the 2.26 CI < e < 2.26 + CI, 2.158 < e < 2.362