MSM: Chapter 5, Iron Carbon Systems

Chapter 5: Iron Carbon Systems

Steels and cast irons are among the most extensively used range of engineering materials in the world today. They are essentially iron-carbon alloys and hence of all binary alloys systems, the one that is most important is the Iron-Carbon.

Cooling curve for pure iron:

Liquid 1538 Fe (BCC)

Temperature, oC

1394

Fe (FCC) Non-Magnetic

912 770

Fe (BCC) Non-Magnetic Fe (BCC) Magnetic

Time Fig 5.1 Cooling curve for pure iron

Iron in the pure form, usually known as ingot-iron, basically consists of: Carbon 0.012% Manganese Sulphur 0.017% 0.025%

Phosphorous 0.005% Silicon traces

Vijay G. S., Faculty, Dept. of Mech. & Mfg., MIT, Manipal

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MSM: Chapter 5, Iron Carbon Systems

Typical mechanical properties of Ingot-Iron: Tensile strength Elongation in 2 inches Rockwell B hardness 40000 psi (275 MPa) 40% 30

Iron is allotropic metal, which means that it can exist in more than one type of lattice structure depending upon temperature. A study of cooling curve of pure iron shows that it can exist in more than one allotropic form. When iron solidifies first, at 1538oC, it is in the BCC form called Delta Iron. Further cooling at 1394oC, a phase change occurs and atoms re-arrange themselves into FCC form called as Gamma Iron, which is non-magnetic. When the temperature reaches 912oC, another phase change occurs and atoms begin to re-arrange themselves into form called as Alpha Iron, which is non-magnetic. Finally at 768oC, the -iron becomes magnetic

without a change in the crystal lattice structure. Initially, non-magnetic -iron was called -iron until subsequent x-rays studies showed no change in lattice structure at 768oC. This magnetic transformation does not change the heat treatment of iron-carbon alloys. Hence it will be neglected in the study. All the allotropic changes give off heat (exothermic) when iron is cooled and absorb heat (endothermic) when iron is heated.

The Iron-Carbon Equilibrium Diagram: The left vertical axis represents 100% iron and shows all the allotropic changes of pure iron with temperature. The temperature at which allotropic changes occur in iron changes when it is alloyed with different amounts of carbon.

Vijay G. S., Faculty, Dept. of Mech. & Mfg., MIT, Manipal

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MSM: Chapter 5, Iron Carbon Systems

1600 1538A 1500 1400 1394 N 1300

+ L B 1495oC

+ L Fe3C + L

Temperature, o C

1200 C 1100 1000 912 900 800 + 700 H 600 500 400 300 1148oC 2%

E 4.33%

+ Fe3C

J 0.8 %

727oC

+ Fe3C

3 Carbon % (by weight)

6.67

STEELS

CAST IRONS Hypo Eutectic Hyper Eutectic

Hypo Eutectoid Steels

Hyper Eutectoid

Cast Irons

Cast Irons

Fig Steels 5.2 Iron Iron Carbide Equilibrium Diagram

Vijay G. S., Faculty, Dept. of Mech. & Mfg., MIT, Manipal

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MSM: Chapter 5, Iron Carbon Systems

The right vertical axis does not represent 100% carbon but instead represents only 6.67% C by weight. This is because only a maximum of 6.67% C can be added to molten iron at which it becomes saturated. Any further addition of carbon will not dissolve in iron but rather floats or gets blown away owing to its very low density. Iron when contains exactly 6.67% C by weight forms an intermediate phase called Cementite or Iron Carbide (Fe3C). Hence, the Iron-Carbon equilibrium diagram is actually called as the Iron Iron Carbide Equilibrium Diagram with pure iron and pure Fe3C (Iron Carbide) forming the extremities. Actually, the phase Fe3C (Iron Carbide) is called meta stable state because it decomposes with passage of time. Here, the equilibrium phase diagram for iron and carbon assumes that Fe3C is stable with respect to time. Hence, it is not a true equilibrium diagram. The diagram shows 3 horizontal lines (isotherms) which represent 3 invariant reactions. (a) The first isotherm at 1493oC indicates the peritectic reaction. This region where the peritectic reaction takes place is called the Delta region. (b) The second isotherm at 1148oC indicates the eutectic reaction. This region where the eutectic reaction takes place is called the Eutectic region. (c) The third isotherm at 727oC indicates the eutectoid reaction. This region where the eutectoid reaction takes place is called the Eutectoid region. The invariant reactions in the Fe-Fe3C diagram:

(a) The Delta Region: The first horizontal line MB at 1495oC indicates the Peritectic reaction. This region is called as the delta region because of the solid solution . The point P is known as the peritectic point at 1495oC & 0.18%C.

Vijay G. S., Faculty, Dept. of Mech. & Mfg., MIT, Manipal

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MSM: Chapter 5, Iron Carbon Systems

The peritectic reaction may be written as:

1538oC cooling

A L+ M P
0.5% C

Liquid +

heatin g

(Austenite)

1495oC

B L+

The maximum solubility of carbon in bcc Fe is 0.1% (point M) while in fcc Fe, the solubility is much greater.

1395oC N

Fig. 5.3 The Delta region

0.18% C 0.1% C

The presence of carbon influences the allotropic change. As carbon is added to iron, the allotropic change increases from 1394oC to 1495oC at 0.1%C. On cooling, the portion NM represents the beginning of the crystal structure change from bcc Fe to fcc Fe for alloys containing less than 0.1%C. The portion MP represents the beginning of this crystal structure change by means of a peritectic reaction for alloys between 0.1 and 0.18% C. For alloys containing less than 0.18% C, on cooling, the end of the crystal structure change is given by the line NP. The portion PB represents the beginning and ending of the crystal structure change by means of peritectic reaction. That is, for alloys between 0.18%C and 0.5% C, the allotropic change begins and ends at constant temperature. For alloys containing more than 0.5%C, the liquid will solidify to austenite ( ) directly, i.e., there is no allotropic change.

Vijay G. S., Faculty, Dept. of Mech. & Mfg., MIT, Manipal

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MSM: Chapter 5, Iron Carbon Systems

(b) The Eutectic Region:

L+ 2%C 1148oC C E 4.33%C

L + Fe3C D

+ Fe3C Fig. 5.4 The Eutectic Region

The Eutectic reaction takes place at 1148oC. The Eutectic point E is at 1148oC and at 4.33% C. whenever an alloy crosses the line line CED, and Eutectic reaction takes place, giving rise to a fine mixture of Austenite + Cementite ( + Fe3C). This eutectic mixture is commonly called a Ledeburite. This reaction can be expressed as:

Liquid (L)

cooling heatin g

Austenite ( ) + Cementite (Fe3C)

Eutectic mixture (Ledeburite)

Since austenite ( ) is not stable at room temperature, its microstructure cannot be seen for slow cooling. However, it has to under go another reaction (Eutectoid reaction).

(c) The Eutectoid Reaction: A small solid solution region to the left of the line GH, which represents -Fe (Ferrite), is a solid solution with small amounts of carbon dissolved in BCC Fe. At 912oC, the FCC -Fe changes to BCC -Fe. Line HJK represents the Eutectoid reaction taking place at 727oC. The Eutectoid point is J which has 0.8%C & 727oC.

Vijay G. S., Faculty, Dept. of Mech. & Mfg., MIT, Manipal

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MSM: Chapter 5, Iron Carbon Systems

Whenever an alloy crosses the line HJK, the Eutectoid reaction takes place giving rise to the fine Eutectoid mixture of Ferrite + Cementite ( + Fe3C) commonly known as Pearlite. This reaction can be expressed as:
0.8% C +Fe3 C 912oC + H

+Fe3 C J 727oC K

Fig. 5.5 The Eutectoid Region

Austenite ( )

cooling heatin g

Ferrite ( ) + Cementite (Fe3C)

Eutectoid mixture (Pearlite)

Vijay G. S., Faculty, Dept. of Mech. & Mfg., MIT, Manipal

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