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Through:
Change in Microstructure
He
at
in
g
Temperature
Holding
(soak)
Co
o
Time
lin
Industry
331
332
34
Steel Mills
Iron and Steel Foundries
Metal Fabrication
Machinery and
Electrical/Electronic Equipment
Transportation Equipment
Commercial Heat Treating
Steel Service Centers
35 & 36
37
3398
5051
Arvind Thekdi - E3M, Inc.
Sales
Ferrous Metals
Steel
Cast Iron
Alloys
Stainless Steel
Tool Steel
Non-ferrous
Metals
Aluminum
Copper
Brass
Titanium
Cleaning
Pre-wash with coalescer
De-phosphate system
Spray rinse
Tempering
Surface coating
Unloading
Arvind Thekdi - E3M, Inc.
Sales
Heating
Preheating
Heating
Soak & diffusion
Pre-cooling
Quenching (Cooling)
Post-wash
Vacuum Furnace
Induction Equipment
Arvind Thekdi - E3M, Inc.
Sales
4560
Induction
Carbottom
100
150
150
Vertical Pit
60
13425
Box
100
7700
Salt Bath
Vacuum
Lead pot (cont.)
Rolelr hearth
Barre-roller
Cont. stripline
Cont. induction
200
Conveyor
4395
Car Bottom
6000
Pusher
Pusher
Fluidized bed
Salt-bath
3195
Conveyor
4890
Bell, hood, tip-up
50
330
5
55
130
4765
Vertical Pit
2510
Vacuum
Electric beam
Flame heads
Vacuum
Operated at vacuum or sub-atmospheric
pressure.
May involve high pressure gas cooling using
special gases.
Includes ion or plasma processing
equipment.
Muffle
Indirect Heating
(Radiant Tubes or Electrical Resistance)
Reactive
To Add Non-metallic (i.e., Carbon, Oxygen,
Nitrogen) or Metallic (i.e., Chromium, Boron,
Vanadium) Elements to the Base Metal.
Purging
To Remove Air or Flammable Gases From Furnaces
or Vessels.
Nitrogen
Mixture of N2 and
small amount of CO
Reactive
Exothermic gases
Mixture (or
individual) of gases:
Hydrogen, CO, CH4,
Nitrogen and other
hydrocarbons
Dissociated Ammonia
(H2 + N2)
Source of Atmospheres
Requirement:
Use of Atmospheres in a
Plant
Requirement:
ANNEALING
Annealing, involves heating to a predetermined
temperature, holding at this temperature, and finally
cooling at a very slow rate.
The temperature, to which steel is heated, and the
holding time are determined by various factors such
as the chemical composition of steel, size and shape
of steel component and final properties desired.
Purpose of Annealing
i. Relieve internal stresses developed during
solidification, machining, forging, rolling, or
welding;
ii. Improve or restore ductility & toughness;
iii. Enhance machinability
iv. Eliminate chemical non-uniformity;
v. Refine grain size; and
vi. Reduce the gaseous contents in steel.
CLASSIFICATION
1. Heat treatment
temperature
Full annealing
Partial annealing
Sub-critical
annealing
2. Phase
transformation
First-order
annealing
Second-order
annealing
3. Specific
purpose
Full annealing
Isothermal
annealing
Diffusion
annealing
Partial annealing
Recrystallization
annealing
Spheroidisation
annealing
2.2 The second-order annealing differs from the former in the sense
that the end results in the former are essentially due to phase
transformation which takes place during the treatment.
Advantages:
Improved machinability.
Homogeneous structure and better surface finish.
Time required for complete cycle is comparably less.
The process is of great use for alloy steels as the steels
have to be cooled slowly.
Limitation:
Process:
Steel is heated sufficiently above the upper critical temperature (say,
1000-2000oC), and held at this temperature for 10-20 hours,
followed by slow cooling.
Segregated zones are eliminated, and a chemically homogeneous
steel is obtained by this treatment as a result of diffusion.
Heating to such a high temp. results in considerable coarsening of
austenitic grains & heavy scale formation. The coarse austenite thus
obtained further transforms to coarse pearlite on cooling, which is
not a desirable structure as mechanical properties are impaired.
3.5 Recrystallization
Annealing
The process consists of heating steel above
the recrystallization temperature, holding at
this temperature and cooling thereafter.
It is used to treat work-hardened parts made
out of low-Carbon steels (< 0.25% Carbon).
This allows the parts to be soft enough to
undergo further cold working without
fracturing.
To restore ductility
To refine coarse grains
To improve electrical and magnetic
properties in grain-oriented Si steels.
Spheroidising Process:
Heat the part to a temperature just below the FerriteAustenite line, line A1 or below the AusteniteCementite line, essentially below the 727 C (1340
F) line. Hold the temperature for a prolonged time
and follow by fairly slow cooling. Or
Cycle multiple times between temperatures slightly
above and slightly below the 727 C (1340 F) line,
say for example between 700 and 750 C (1292 1382 F), and slow cool. Or
For tool and alloy steels heat to 750 to 800 C (13821472 F) and hold for several hours followed by slow
cooling.
minimum hardness
maximum ductility
maximum machinability
maximum softness
TEMPERING
Martensite is a very strong phase, but it is normally
very brittle so it is necessary to modify the
mechanical properties by heat, treatment in the
range 150700C.
Essentially, martensite is a highly Supersaturated
solid solution of carbon in iron which, during
tempering, rejects carbon in the form of finely divided
carbide phases.
The end result of tempering is a fine dispersion of
carbides in an -iron matrix which often bears little
structural similarity to the original as-quenched
martensite.
NORMALIZING
The normalizing of steel is carried out by
heating above the UCT (Upper Critical
Temperature) to single phase austenitic
region to get homogeneous austenite,
soaking there for some time and then
cooling it in air to room temperature.
The austenitising temperature range are:
For hypoeutectoid steels and eutectoid steel
Ac3 + (40-60oC)
For hypereutectoid steels
Acm + (30-50oC)
AIMs OF NORMALIZING
NORMALIZING
VS
ANNEALING
Comparison of temperature
ranges in annealing and
normalizing
HARDENING
It is the process of heating the steel to
proper austenitizing temperature , soaking at
this temperature to get a fine grained and
homogeneous austenite , and then cooling
the steel at a rate faster than its critical
cooling rate.
OBJECTIVES OF HARDENING
The aims of hardening are:
1. Main aim of hardening is to induce high hardness. The
cutting ability of a tool is proportional to its hardness.
2. Many machine parts and all tools are hardened to induce
high wear resistance higher is the hardness , higher is the
wear and the abrasion resistance .For example ,gears, shaft.
3. The main objective of hardening machine components made
of structural steel sis to develop high yield strength with
good toughness and ductility to bear high working stresses.
PROCESS OF QUENCHING
When a heated steel object (say at 840C) is plunged into a
stationary bath of cold it has three stages as:
Stage A -vapour-blanket stage:
PROCESS OF QUENCHING
PROCESS OF QUENCHING
Stage B-Intermittent contact stage (Liquid-boiling stage):
Heat is removed in the form of heat of vaporization in this
stage as is indicated by the steep slope of the cooling curve.
During this stage, the vapour-blanket is broken intermittently
allowing the coolant to come in contact with the hot surface
at one instant, but soon being pushed away by violent
boiling action of vapour bubble.
The rapid cooling in this stage soon brings the metal surface
below the boiling point of the coolant.
PROCESS OF
QUENCHING
QUENCHING MEDIUMS
As the aim is to get martensite, the coolant should have
quenching power to cool austenite to let it transform to martensite.
The following factors effect the quenching power of the coolant :
The cooling rate decreases as the temperature of water and brine
increases, i.e., it increases stage A, i.e., helps in persistence of
the vapour blanket stage.
The increased temperature brings it closer to its boiling point, and
thus, requires less heat to form vapour, specially above 60C.
Good range of temperature for water as coolant is 20-40C.
Oils in general, show increased cooling rates with the rise of
temperature, with optimum cooling rates in range 5080C.
QUENCHING MEDIUMS
In oils, the increase of temperature increases the persistence of vapourblanket, but this resulting decrease in the cooling rate is more than
compensated by the decrease of viscosity (with the rise in temperature)
to result in increase of rate of heat removal through the oil.
If the boiling point of a coolant is low, vapours form easily to increase
the A stage of cooling. t is better to use a coolant with higher boiling
point. A coolant with low specific heat gets heated up at a faster rate to
form vapours easily.
A coolant with low latent heat of vapourisation changes into vapour
easily to promote A stage, i.e., decreases the cooling rate.
A coolant with high thermal conductivity increases the cooling rate.
Coolants with low viscoity provide faster cooling rates and decrease the
A stage.
QUENCHING MEDIUMS
A coolant should be able to Provide rate of cooling fast
enough to avoid transformation of austenite to pearlite and
bainite . Plain carbon steel invariably require ooling in water
or brine. Whereby alloy steels are quenched normally in oils.
But milder the cooling medium , lesser the internal stresses
developed , and thus lesser the danger of distortion , or
cracks . An ideal quenching medium is one which is able to
provide very fast cooling rate near the nose of the curve ( 650
-550C)and at the same time it should provide very
considerable slower rate if cooling within the range of
martensitic transformation( 300 - 200C) to minimize internal
stresses .
WATER
The oldest and still the most popular quenching medium, water meets the
requirements of low cost ,general easy availability, easy handling and safety.
The cooling characteristics change more than oil with the rise of temperature,
specially there is a rapid fall in cooling capacity as the temperature rises
above 60C, because of easy formation of vapour-blanket.
The optimum cooling pover is when water is 2O-4OC.
Thc cooling power of water is between brine and oils.
Water provides high cooling power to avoid the transformation of austenite to
pearlite/bainite, but the major draw back is that it also provides high cooling
rate in the the temperature range of martensite formation.
At this stage, the steel is simultaneously under the influence of structural
stresses (non-uniform change in structure) and thermal stresses which
increase the risk of crack formation.
BRINE
Sodium chloride aqueous solutions of about 10% by weight are widely
used and are called brines.
The cooling power is between 10% NaOH aqueous solution and water.
These are corrosive to appliances.
The greater cooling efficiency of brines, or other aqueous solutions is
based as :
In brine heating of the solution at the steel surface causes the
deposition of crystal of the salt on hot steel surface .
This layer of solid crystals disrupts with mild explosive violence, und
throws off a cloud of crystals. This action destroys the vapour-film from
the surface, and thus permits direct contact of the coolant with the
steel surface with an accompanying rapid removal of heat.
Brines are used where cooling rates faster than water arc requited.
OILS
Oils have cooling power between water at 40C to water at 90C.
In oil-quench, considerable variation can be obtained by the use of animal,
vegetable, or mineral oil, or their blends.
Oils should be used at 50- 80C when these are more fluid, i.e less
VISCOUS, which increases the cooling power.
As the oils used generally have high boiling points, moderate increase of
temperature of oil does not very much increase the vapour blanket stage.
However, oils in contrast to water, or brine, have much lower quenching
power .
Its this relatively slow cooling rate in the range of martensitic formation is
atlvantageous as it helps in minimsing the danger to crack formation.
Oils with high viscosity are less volatile, and thus have decreased vapourblanket stage (increase thecooling rate). As lesser volatile matter is lost,
their cooling power is not affected much with use.
POLYMER QUENCHANTS
polymer quenchants cool rapidly the heated steel to Ms
temperature, and then rather slowly when martensite is
forming .
Polymer quenchants are water-soluble organic
chemicals of high ,molecular weights, and are generally
polyalkylene glycol-based, or polyvinyl pyrolidenebased.
Widely different cooling rates can be obtained by varying
the concentration of Organic additives in water; higher
the additions, slower is the cooling rate of solution.
There are little dangers of distortions and cracks.
SALT BATHS
It is an ideal quenching medium for a steel of
not very large section but with good
hardenabilty.
Addition of O.3-O.5% water almost doubles
the cooling capacity. Normally holding time is
2-4 minutes/cm of section thickness.
Salt baths used for austenitising keep the
steel clean.
RETAINED AUSTENITE
Martensitic transfomiation is essentially an athermal transformation.
Austenite begins to transform to martensite at Ms, and the amount of
martensite formed increases as the temperature decreases to complete at
Mf temperature.
Less than 1 % of austenite may not transform because of unfavourable
stress conditions.
The Ms and Mf temperatures are lowered as the amounts of carbon content
and alloying elements(except cobalt and aluminium) increase in the steel.
In a quenched steel, the amount of martensite formed depends on the
location of Ms and Mf and the temperature of the coolant (which is normally
room temperature. As long as room temperature lies between Ms and Mf
temperatures, austenite does not transform completely to martensite as it
has not been cooled below Mf temperature.
This untransformed austenite is retained austenite.
DISADVANTAGES
1) The presence of soft austenite decreases the
hardness of hardened steels.
2) As retained austenite may transform to lower
bainite, or martensite later in service ,increase in
dimensions of the part occurs.
3) This creates problems in precision gauges or
dies.
4) Stresses may develop in the part itself as well as
in adjacent pans. Grinding-cracks are mainly due
to retained austenite transforming to martensite.
5) Austenite is non-magnetic, decreases the
magnetic properties of the steels.
DEFECTS IN HARDENING
The main defects produced during hardening are:
1. Mechanical properties not up to specifications:
The common defect in hardened tools, or component is too low a
hardness.
One or more of the followings could be the cause of such a
defect.
Insufficient fast cooling due to overheated or even polluted
coolant could be responsible for a defect.
The presence of scale, or oil, etc. on the surface also decreases
the cooling rate.
Circulation of coolant, or agitation of component may also result
in such defect.
DEFECTS IN HARDENING
A shorter austenitising time can also cause such a defect. Lower
austenitising temperature can also result in such a defect.
Decarburisation can also result in low surface hardness. If too
high temperature had been used, which produces larger amount
of retained austenite can result in low surface hardness.
2. Soft Spots:
Soft areas on the hardened surface are called soft spots.
The adhering scale, or decarburisation of some areas or
prolonged vapour-blanket stage due to overheated coolant or
insufficient agitation or circulation of coolant, or rough surface
could cause presence of soft spots surface.
Stages of Tempering
Stages of Tempering
On reheating as-quenched martensite, the tempering
takes place in four distinct but overlapping stages:
Stage 1, up to 250C precipitation of E-iron carbide;
partial loss of tetragonality in martensite.
Stage 2, between 200 and 300C decomposition of
retained austenite .
Stage 3, between 200 and 350C replacement of
&iron carbide by cementite; martensite loses
tetragonality.
Stage 4, above 350C cementite coarsens and
spheroidizes; recrystallization of ferrite.
Tempering stage 1
Martensite formed in medium and high carbon steels
(0.31.5 wt% C) is not stable at room temperature
because interstitial carbon atoms can diffuse in the
tetragonal martensite lattice at this temperature.
This instability increases between room temperature
and 250C, when -iron carbide precipitates in the
martensite (Fig. 9.2).
This carbide has a close-packed hexagonal structure,
and precipitates as narrow laths or rodlets on cube
planes of the matrix with a well-defined
orientation relationship .
Tempering stage 1
At the end of stage 1 the martensite still possesses a tetragonality,
indicating a carbon content of around
0.25 wt%.
It follows that steels with lower carbon contents are unlikely to
precipitate -carhide.
This stage of tempering possess an activation energy of between
60 and 80 kJ mo1, which is in the right range for diffusion of carbon
in martensite. The activation energy has been shown to increase
linearly with the carbon concentration between 0.2 and 1.5 wt% C.
This would be expected as increasing the carbon concentration also
increases the occupancy of the preferred
interstitial sites, i.e. the octahedral interstices at the mid-points of
cell edges, and centres of cell faces, thus reducing the mobility of C
atoms.
Tempering stage 2
During stage 2. austenite retained during quenching is
decomposed usually in the temperature range 230300C.
In martensitiC plain carbon steels below 0.5
carbon. the retained austenite is often below 2%, rising
to around 6 % at 0.8 wt C and over 30 % at 1.25 wt C.
The little available evidence suggests that in the range
230-300C, retained austenite decomposes to bainitic
ferrte and cementite, but no detailed comparison
between this phase and lower bainite has yet been
made.
Tempering stage 3
During the third stage of tempering, cementite flrst
appears in the microstructure as a Widmanstatten
distribution of plates which have a well-defined
orientation relationship with the matrix which has now
lost its tetragonality and become ferrite.
This reaction commences as low as 100C and is fully
developed at 300C, with particles up to 200 nm long
and 15 nm in thickness.
Similar structures are often observed in lower carbon
steels as quenched, as a result of the formation of
Fe3C during the quench.
Tempering stage 3
During tempering, the most likely sites for the
nucleation of the cementite are the -iron carbide
irterfaces with the matrix (Fig 9.2) and as the Fe3C
particles grow, the -iron carbide particles gradually
disappear.
The twins occurring in the higher carbon martensites
are also site for the nucleation and growth of
cementite which tends to grow along
the twin boundaries forming colonies of similarly
oriented lath shaped particles (Fig. 9.3) which can
be readily ditinguished from the normal
Widmanstatten habit.
Tempering stage 3
A third site for the nucleation of cementite is the grain
boundary regions (Fig, 9.4)of both the interlath boundaries
of martensite and
the original austenite grain b0unjaries.
The cementite can form as very thin films which are
difficult to detect but which gradually
sp1eroidise to give rise to welI-defined particles of Fe3C in
the grain boundary regions.
There is some evidence to show that these.
boundary cementite films can adversely affect
ductility.However it can be modified by addition of
alloying elements.
Tempering stage 3
During the third stage of tempering , the
tetragonality of thc matrix disappears and it
is then, essentially, ferrite, not
supersaturated with
respect to carbon.
Subsequent changes in the morpriology of
cementite particles occur by process where
the smaller particles dissolve in the matrix
providing carbon for the selective growth of
the larger particles.
Tempering stage 3
During the third stage of tempering ,
the tetragonality of thc matrix
disappears and it is then, essentially,
ferrite, not supersaturated with
respect to carbon.
Subsequent changes in the morpriology
of
cementite particles occur by process
where the smaller particles dissolve in
the matrix providing carbon for the
Tempering stage 4
It is useful to define a fourth stage of tempering in which the
cementite particles undergo a coarsening process and
essentially lose their crystallographic morphology, becoming
spheroidized.
It commences between 300 and 400C, while
spheroidizatiun takes place increasingly up to 700C.
At the higher end of this range of tempera.
ture the martensite lath boundaries are replaced by more
equi-axid frrite grain boundaries by a process which is best
described as recrystallization.
The final result is an equi-axed array of ferrite
grains with coarse spheroidized particles of Fe3C (Fig. 9.5),
partly, but not exclusively, by the grain boundaries.
Tempering stage 4
The spherodisation of the Fe3C is encouraged by the resulting
decrease in surface energy.
The particles which preferentially grew and spheroidize are
located mainly at interlath boundaries and prior
austenite boundaries, although some particles remain in the
matrix.
The boundary sites are preferred because of the greater ease of
diffusion in these regions. Also, the growth of cementite into
ferrite is associated with a decrease in density so vacancies are
required to accommodate the growing cementite.
Vacancies will diffuse away from cementite particles which are
redissolving in the ferrite and towards cementite particles which
are growing, so that the rate controlling process is likely to be
the diffusion of vacancies.
Tempering stage 4
The original martensite lath boundaries remain stable up to
about 600C, but in the range 350600C. there is
considerable rearrangement of the dislocations within the laths
and at those lath boundaries which are essentially low angle
boundaries.
This leads to a marked reduction in the dislocation density and
to lath-shaped ferritic grains closely related to the packets of
similarly oriented laths in the original
martensite.
This process, which is essentially one of recovery, is
replaced between 600 and 700C by recrystallization which
results in the formation of equi-axed ferrite grains with
spheroidal Fe3C particles in the boundaries and within the
grains.
Tempering stage 4
This process occurs most readily in carbon
steels.
At higher carbon content, the increased
density of cementite particles is much
more effective in pinning the ferrite
boundaries, so recrystallisation is much
more sluggish.
The final process is the continued
coarsening of the cementite particles and
gradual ferrite grain growth.
where:
T is the absolute temperature and
t the tempering time in hours,
while k is a constant which is about 20 for
alloy steels, usually referred to as the
Holloman-Jaffe parameter.
Martempering
Interrupted quench from the
A1
CASE HARDENING
Low carbon steels cannot be hardened
by heating due to the small amounts of
carbon present.
Case hardening seeks to give a hard
outer skin over a softer core on the
metal.
The addition of carbon to the outer skin
is known as carburising.
CARBURIZING
The highest hardness of a steel is obtained when its carbon
content ishigh, around 0.8 weight % C (Figure 1). Steels with
such high carbon content are hard, but also brittle, and
therefore cannot be used in machine parts such as gears,
sleeves and shafts that are exposed to dynamic bending and
tensile stresses during operation. A carbon content as high as
1% C also makes the steel difficult to machine by cutting
operations such as turning or drilling. These shortcomings can
be eliminated by using a low carbon content steel to machine a
part to its final form and dimensions prior to carburizing and
hardening. The low carbon content in the steel ensures good
machinability before carburizing. After carburizing and
quenching the part will have a hard case but a softer core that
will assure wear and fatigue resistance. The martensitic case
attains a hardness corresponding to its carbon content. The
case is typically 0.11.5 mm (0.004- 0.060 inches) thick. The
core of the part maintains its low carbon concentration and
corresponding lower hardness.
PROPERTIES OF CARBURISED
STEEL
The gas-carburized (carbonitrided) part can
be said to consist of a composite material,
where the carburized surface is hard but
the unaffected core is softer and ductile.
Compressive residual stresses are formed
in the surface layer upon quenching from
the carburizing temperature. The
combination of high hardness and
compressive stresses results in high fatigue
strength, wear resistance, and toughness.
CHEMISTRY OF CASE
HARDENING
Carburizing Atmospheres
Endogas
A carburizing atmosphere can be achieved
by means of incomplete combustion of
propane or methane with air in accordance
with one of the reactions:
C3H 8 + 7.2 air 5.7 N2 + 3CO + 4H2
CH4 + 2.4 air 1.9 N2 + CO + 2H2
The mixing and combustion of fuel and air
takes place in special endothermicgas
generators
Nitrogen/Methanol Atmospheres
Introducing nitrogen and methanol directly into the
furnace chamber is a common way of creating the
furnace atmosphere. Upon entering the furnace,
methanol cracks to form carbon monoxide and
hydrogen in accordance with the following reaction:
CH 3 OH CO + 2H 2
complete cracking of methanol into CO and H 2 only
occurs if the temperature is above 700-800C (12921472F),which is why methanol should not be
introduced into a furnace at a lower temperature. The
cracking of methanol into CO and H2 requires energy.
This energy is taken from the area surrounding the
point of methanol injection. There must therefore be
sufficient heat flux towards the injection point to
DIFFERENT TYPES
OFCARBURISING
Solid or pack carburising
Liquid carburising
Gas carburising
Pack carburising
The component is packed
surrounded by a carbon-rich
compound and placed in
the furnace at 900 degrees.
Over a period of time
carbon will diffuse into the
surface of the metal.
The longer left in the
furnace, the greater the
depth of hard carbon skin.
Grain refining is necessary
in order to prevent
cracking.
Highly
Highly energy
Less-pollution
selective
efficiency
process
Practical Problems
Lack of systematic heating time and temperature distribution control inside WP.
Nonlinear effect of material properties.
Lack phase transformation data inside WP for hardness and residual stress determination.
Evaluate combination effect of AC power density, frequency and gap on final hardness pattern.
Trial and error, cost and design period.
Fast quenching
process transforms
austenite to
martensite phase
Martensite
content determines
the hardness
Martensitic
structure is the
most hardest
microstructure
workpiece
Inductor/coil
Heating
process
Joule heat
by
eddy
current
Electromagneti
c field
Induction
coil
High
freq. AC
power
WP
Coil
Input AC power
to coil
Calculation of
magnetic vector potential (A)
Calculation of
magnetic flux density (B)
Calculation of
magnetic field intensity (H)
Calculation of
electric field intensity (E)
Calculation of
electric field density (D)
0 I
4
B=A
dl
r
(Gauss Law for
magnetic field)
H=B/
QN
B
t
(Faradays Law)
QW
QN
QE t
QC
D=E
QE
QS
D
J
t
Calculation of
Inducting heat (Qinduction)
Qinduction = E J = J2/
(Amperes
Circuital Law)
QB
QR+ QCV
(Outside)
QS
Calculation of
current density (J)
Output:
Heat generation Qinduction in WP
(a) WP geometry
Heat conduction
c
c
T
k 2T Qinduction
t
T
k 2T Qinduction A F T 4 Tair4 A h T Tair
t
Heat radiation
Heat convection
concave
convex
Geometry Model
conductivity
WP relative
permeability
Electrical
Resistivity
Specific
heat
Emissivity
Convection
coefficient
t=4s
t=2s
Summary
A finite element method based modeling system is developed to
analyze the coupled electromagnetic/thermal process in induction
heating and implemented in ANSYS package, with following
capabilities.
Provide electrical and magnetic field strength distribution.
Provide instantaneous temperature field data in workpiece.
Provide Temperature history at any location in heating process.
Provide guidance for inductor/coil design based on adjustment of
Quenching of carburized
parts
Carburized parts are usually quenched
from the austenitic condition to produce
a hard case with a martensitic structure,
as shown
Tempering of carburized
parts
Nitriding
Nitriding
Introduction
Benefits of Nitriding
Types of Nitriding
Future of Nitriding
Process Determination
CVD Reaction
Deposition Process
Diffusion Depth
Process Results
Nitriding
Principal Reasons for Nitriding are:
Benefits
Nitriding
Background
Nitriding
Process methods for nitriding
include:
Gas
Liquid
Plasma
Bright
Pack
***Lots of more nitriding methods for
specific applications***
http://www.nitriding.co.uk/np01.htm
Gas Nitriding
Gas methods:
Case-Hardening Process
Nitrogen Introduction
Surface of a Solid Ferrous Alloy
Suitable Temperature
Between 495 and 565C (for Steels)
Nitrogenous Gas
Ammonia
Liquid Nitriding
Liquid nitriding:
Thermo-chemical Diffusion Treatment
Hardening Components With
Repeatability.
Salt Bath, at Less Critical
Temperatures.
Preserves Dimensional Stability
Corrosion Protection
Exhibit Long-Term Resistance to Wear,
Seizure, Scuffing, Adhesion and
Plasma Nitriding
Vacuum Chamber
Pressure = 0.64 Pa
Se
p
U
t- Pre-Heat Cycle
Surface Cleaning
Ion Bombardment
Control Gas Flow
N, H, CH4
o
r
P
s
Ionization by Voltage
s
e
c
Blue-Violet Glow
Wear Resistant Layer
http://www.milwaukeegear.com/nitrid.htm
Mechanism of Nitriding
Fe- N equilibrium diagram can be used to study
nitriding process.
The solubility limit of nitrogen in iron is temperature
dependent, and at 450 C the iron-base alloy will
absorb up to 5.7 to 6.1% of N.
Beyond this, the surface phase formation on alloy
steels tends to be predominantly -phase.
This is strongly influenced by the C-content of the
steel; the greater the carbon content, the more
potential for the phase to form
As the temperature is further increased to the
gamma prime (-nitride) phase temperature at 490
C , the window or limit of solubility begins to
decrease at a temperature of approximately 680 C.
http://www.northeastcoating.com/
Problem Statement
Gas Nitriding
How do the variables of nitriding steel affect
the process and the mechanical properties of
the surface?
The following variables were investigated:
Time
Temperature
Gas Velocity
Develop Process Model
CVD Equations
Calculations
CVD Process
Calculations
CVD Reaction
Calculations
CVD Process
Surface
The FollowingComposition
Variables Were Used
in The Calculation of C surface
Calculations
(T)
(T)
D(T)
(T,v)
hmass(T,v)
Calculations
Case Depth
Calculations
Case Depth
Calculations
Case Depth
CONCLUSION
Time Effects
Increase Diffusion Depth
Temperature Effects
Surface Composition
Deposition Efficiency
Diffusion Rate
Diffusion Depth
Gas Velocity Effects
Surface Composition
Replenishes Nitrogen Gas
Minimizes Stagnant Layer Thickness
CONCLUSION
Microstructural Effects
on
C
Processing Temperature
Surface Microstructure
Mechanical Property Effects
Improves
Surface Hardness
Wear Resistance
Corrosion Resistance
Fatigue Life
Yield Strength
Lowers
Ductility
Fracture Toughness
d
e
u
tin
Disadvantages
It is an expensive process.
Much more time is required to develop
the requisite case depth (due to low
temp)
Expensive gas ammonia is used in
nitriding.
Expensive alloy steels can only be
nitrided and are used.
Nitriding is more expensive than
carburising and carbonitriding
Carbonitriding of Steels
Carbonitriding is a modified form of carburizing and is not a
form of nitriding. The modification in carbonitriding consists
of adding ammonia (NH3) to the carburizing gas so that
nitrogen diffuses in the steel case along with carbon.
Carbonitriding is usually carried out at a lower temperature
and for a shorter time than gas carburizing, and so a thinner
case is usually produced than by carburizing. Carbonitriding
is principally used to produce a hard, wear-resistant case in
steels, normally from 0.075 to 0.75 mm thick. Nitrogen
increases the hardenability of steel, and so a carbonitrided
case has higher hardenability than a carburized case on the
same steel. Also, since nitrogen is an austenite stabilizer,
high nitrogen levels can result in retained austenite,
particularly in alloy steels. Maximum hardness and less
distortion can be attained by carbonitriding since less
drastic oil quenching than for carburizing can be used.
Laser Hardening
Introduction
LASER beams are invisible electromagnetic
radiation in infra-red portion of spectrum.
Used for surface hardening of ferrous material
Laser used for hardening:
YAG- Solid state type
CO2 Gas type
Hardening Mechanism-Hypoeutectoid
Consider the microstructure of a hypoeutectoid
steel containing 0.35% carbon. It consists of
pearlite colonies surrounded by proeutectoid
ferrite.
On heating,
Pearlite Austenite (dissolution of the cementite),
Growth of the Austenite transformation front into
regions of high carbon concentration, at a rate
controlled by carbon diffusion between the lamellae.
Ferrite transforms by nucleation and growth of austenite
at internal ferrite grain boundaries, (rate controlled by
carbon diffusion
Turbine blades
Cutting edges and edges of dies for sheet metal forming
Cam followers, Gear teeth and Shafts
Rim geometries, e.g. Piston rings
Plastic injection moulds at highly loaded areas on the surface
Cylinder liners in diesel engines
Heavy duty and ball bearing steels
Tool steels
Disadvantages
High initial cost
Laser use 10% of the input energy
Depth of case is very limited
Working cost is high
Difficult to surface harden high alloy
steel
Extra care is needed to avoid fusion
TOOL STEELS
INTRODUCTION
TOOL STEEL are high quality steels made to
controlled chemical composition and processed to
develop properties useful for working and shaping
of other materials.
The Carbon content in them is between 0.1 -1.6% .
Tool steel also contain alloying elements like,
Chromium, Molybdenum and Vanadium.
Tool steel offers better durability, strength,
corrosion resistance and temperature stability,
as compared to the Construction & Engg. Steel.
These are used in applications such as Blanking,
die forging, forming, extrusion and plastic molding
OBJECTIVES OF HEAT
TREATMENT OF TOOL STEELS
To obtain a desired microstructure and
properties suitable for machining or cold
deformation.
To release residual stresses accumulated
during previous thermal and mechanical
treatments.
To homogenize the microstructure with
globular carbides by a spheroidization
treatment.
To dissolve by a normalizing treatment the
intergranular carbides that are detrimental
CHARACTERISTICS OF TOOL
STEELS
Require special heat treatment
process.
Higher cost than alloy steels.
Better hardenability than most carbon
and alloy steels.
Higher heat resistance.
Easies to heat treat.
The
TYPES
SHOCKRESISTING
TOOL STEELS
COLDWORKED
TOOL STEELS
HOTWORKED
TOOL STEELS
HIGH-SPEED
TOOL STEELS
WATERHARDENED
TOOL STEELS
Oil-hardened
Air-hardened
High Carbon, High
Chromium
SHOCKRESISTING
TOOL STEELS
COLDWORKED
TOOL STEELS
HOTWORKED
TOOL STEELS
HIGH-SPEED
TOOL STEELS
WATERHARDENED
TOOL STEELS
Chromium-based
Tungsten-based
Molybdenumbased
SHOCKRESISTING
TOOL STEELS
COLDWORKED
TOOL STEELS
HOTWORKED
TOOL STEELS
Tungsten-based
HIGH-SPEED
TOOL STEELS
WATERHARDENED
TOOL STEELS
Molybdenum-based
HEAT TREATMENT PROCEDURE (in general) : Annealing : Slow & uniform heating in the
range of 790-800C followed by furnace cooling
at rate of 8-15C/hr.
Stress relieving : Heat to 650- 675C and
furnace cooling.
Hardening :
Preheating warming to about 650C &
holding for 20 minutes/ 25mm.
Austenitizing heating to 900-950C &
holding again for 20minutes/25mm.
Applications:
Chisels
Pneumatic chisels
Punches
Shear blades
GOLD SET
Scarring Tools
MAGNETIC NUT
River sets
SETTER
Driver bits.
SWANSTORM
DISC CUTTER
ROTARY
PIPE
CUTTER
CHROMIUM BASED
Contains Chromium (>=3.25%), and small amounts of
Vanadium, Tungsten and Molybdenum.
These are characterized by high red hardness & high
hardenability.
Oil quenching is reqd. when dimensional stability is not
of prime importance. Tempering temperature for these
steels varies from 550-675C.
Applications:
Hot dies for extrusion, forging, mandrels,
punches.
Highly stressed structural parts of supersonic
aircrafts.
Hot work steels.
TUNGSTEN BASED
Contains tungsten (=9.00%) & Chromium (2.0
-12.0%), and low Carbon %.
These are characterized by resistance to high
temperature softening.
Tempering temperature for these steels varies
from 550-675C.
Applications:
Punches .
Mandrels .
Extrusion dies for Brass, Steel & Nickel alloys.
MOLYBDENUM BASED
Contains Molybdenum (8.00%) &
Chromium (4.0 -12.0%), and some
tungsten and Vanadium.
These are characterized by high toughness
& high heat check resistance.
Tempering temperature for these steels
varies from 550-650C.
Microstructure of
H-13 TOOL STEEL
(1000x)
Microstructure of
Annealed H-13 TOOL
STEEL
Applications:
Mandrel for tube rolling by Pilger rolls .
Blanking & piercing dies, Coining dies,
Microstructure of
As-Tempered COLD
WORK TOOL STEEL
(1000x)
EXPANSION
REAMERS
COINING
DIES
Temperature
(C)
2
minutes
(1200C)
4-5
hrs
(850
C)
20
minutes
Tempering
1
(1 hr)
Tim
e
Tempering
2
(1 hr)
Microstructure of
oil- quenched HSS
(500x)
Microstructure of
oil- quenched
18-4-1 type HSS
MILL
CUTTERS
Applications :
DRILL ROD OF
W1 TOOL STEEL
WATCH
MAKERS
TOOLS
Nb(CN) dynamic
precipitation ~
900 C
%Mn precipitation
(shift PTT curve
Ps : Precipitation
start
Pf : Precipitation
finish
Ti(CN)
dynamic
precipitation ~
1025 C Norecrystallization
temperature (Tnr)
Nb(CN))
%Mn precipitation
(shift PTT curve
HSLA steel Nb)
(Norecrystallization
temperature; Tnr)
Controlled Rolling
Controlled hot rolling is done to obtain ultra fine grains of ferrite and
precipitation hardening.
Fine austenite grains or very thin unrecrystallized grains of austenite
before transition is a prerequisite to obtain fine ferrite grains.
Presence of TiN and Nb(C,N) during hot rolling of austenite at high
temperatures does some refinement.
This demands heavy deformation and low finishing temperatures below
950 0C so that austenite is unable to recrystallize.
Heavy reductions (more than 50 %) is done during the finishing stages in
no- recrystallization range of austenite to obtain, thin, elongated and
flattened austenite grains.
Normally finishing temperature is above the transition temperature
and nature of transformation is changed by using water sprays during
rolling to enhance cooling rate.
The subcritical transformation produces still finer ferrite grains and this
may produce widmanstatten ferrite with still higher dislocation density.
Controlled rolling/Thermo-mechanical
processing (TMCP)
1. Outline process
SRT ~ 1200-1250 C
FT ~ 1000 C
Roughing rolling
Hold/Delay
normalizing ~ 920 C
Austenite-elongated grain
(pancake structure)
Controlled rolling/Thermo-mechanical
processing (TMCP)
2. Slab Reheating
Importance of slab reheating stage
- control amount of micro-alloying element taken
into solution
- starting grain size
Re-solution temperature of micro-alloy
precipitates
- VC: complete solution ~ 920 C (normalizing
temp.)
- VN: at somewhat higher temperature
- Nb(CN), AlN and TiN: around 1150-1300 C
- TiN (most stable compound) little dissolution at
normal slab reheating temperature (SRT)
Controlled rolling/Thermo-mechanical
processing (TMCP)
2. Slab Reheating
Un-dissolved fine carbo-nitride (CN) particles
- maintain fine austenite grain size at slab
reheating stage
Micro-alloying elements taken into solution
(which can be influence in later stage in process)
- control of recrystallization
- precipitation strengthening
Multiple micro-alloy additions for above dual
requirements
Controlled rolling/Thermo-mechanical
processing (TMCP)
3. Rolling
Controlled rolling/Thermo-mechanical
processing (TMCP)
3. Rolling
Controlled rolling/Thermo-mechanical
processing (TMCP)
3. Rolling
Controlled rolling/Thermo-mechanical
processing (TMCP)
4. Transformation to ferrite
Controlled rolling/Thermo-mechanical
processing (TMCP)
Controlled rolling/Thermo-mechanical
processing (TMCP)
Precipitation Hardening
Precipitate strengthening occur by those particles that form :In austenite at low temperatures at low temperatures.
At the interface at low temperatures.
In ferrite during further cooling.
Main contribution to precipitation strengthening is due to precipitation of carbide
Ti, V which occurs during transformation of austenite to ferrite progressively at
boundaries called interphase precipitation.
It occurs on a very fine scale between 850 650 0C with size about 5 nm.
Solid solution strengthening due to presence of elements like Mn, Si, and even u
N takes place.
The most effective factor is the ultra fine ferrite grain size as ferrite size is 5-10
plates though a size of 1-2 has been obtained under laboratory conditions.
ron-Carbon phase diagram with thermal treatment for dual phase steel
Advantages of DP steels
Low cost of manufacturing.
Excellent formability.
High strength (500-700 MN/m2).
Low yield stress (300-350 MPa).
Rapid rate of work hardening.
No yield point elongation.
A high strain rate sensitivity (the faster it is crushed the more
energy it absorbs).
.
Maraging steels
Maraging steels, a portmanteau of martensitic and aging, are iron alloys,
are a special class of low carbon ultra high strength steels which derive
their strength not from carbon, but from precipitation of inter metallic
compounds.
The maraging steels offer a good combination of strength and ductility
with a yield strength as high as 400 MPa and an elongation of 6 %.
These are essentially high alloy steels with C < 0.03 %, upto 25 % Ni, 710 % Co, 3-5 % Mo,1.75 % Ti & 0.2 % Al.
Presence of Ni in large amount is necessary to form ductile and soft
martensite based on Fe-Ni system.
The soft ductile and tough martensite is strengthened by precipitation
hardening resulting in a fine dispersion of Ni3(X,Y) intermetallic phases
along dislocations left by martensitic transformation, where X and Y
aresoluteelements added for such precipitation.
Maraging steels have good weldability and can be cold rolled to 80-90 %
before aging.
Maraging steels also have good machinability and undergo little
dimensional changes onheat treatment.
Due to the higher cost maraging steels are mainly used for rocket
casings and other aerospace applications.
They are suitable for engine components, such as crankshafts and gears,
Maraging steels
A series of iron base alloys capable of attaining
yield strengths upto 300,000 psi.
in combination with excellent fracture toughness.
Low carbon (0.03%),
18-25 % Nickel and other hardening elements.
Yield strength: The stress at which a material exhibits a
specified deviation from proportionality of stress and
strain.
Fracture toughness:resistance to crack propagation.
Maraging steels
As annealed, these steels are martensitic.
They achieve high strength on being aged in the
annealed or martensitic condition.
Maraging steels
There are two groups, based on hardening element
used.
1.The 18% nickel grades use cobalt molybdenum
additions
2.The 20% nickel grades use titanium-aluminiumcolumbium additions.
Maraging steels
1 hr
150
0
18% Nickel
Heated to 1500 deg F , held for
1 hour .
3 hrs
900
Ms
300
100
300
300300
300
300
28
RC
52 RC
Deg F
Hardness of 52 RC can be
Maraging steels
18% Nickel
The interest is in achieving high strength at room
temperature.
Simple heat treatment carried out at moderate
temperature is enough to achieve good properties.
Section size, heating and cooling rates are not
important.
Very low in carbon content and so no problem of
decarburization.
Protective atmosphere is not required.
Low aging temperatures means less distortion.
Maraging steels
Effect of additives on maraging
strength development
Solution treated 110,000 psi
After maraging 300,000 psi
52
7Co+Mo
Co
Iron nickel martensite 25Rc
Mo
Co
A weak response to maraging is
seen after addition of 7% cobalt.
Co
Rockwell C
24
2
%Mo or %Co
Solution
treated
6
8
Maraging steels
25%Nickel
Largely austenitic after annealing.
The conversion to martensite is done by ausaging or
cold working.
Ausaging-conditioning treatment at 1300 deg F.
Reduces the stability of austenite by causing nickel
titanium compounds to precipitate from the austenitic
solid solution.
It raises the Ms temperature so that martensite will
start forming at room temperature.
Cold worked to 25% to start the transformation to
martensite and is completed by refrigeration at
minus100 deg F.
Maraging steels
20% Nickel
Lower alloy content
Freedom from cobalt and molybdenum. Useful in
certain environments and applications.
Compared to the 25% grade, this does not require a
conditioning treatment to become martensite.
Ms temperature is above room temperature.
Disadvantages:
Lower in
toughness, resistance to stress corrosion cracking and
in dimensional stability during heat treatment.
Maraging steels
Applications for maraging steels
Hulls for hydrospace vehicles
Pressure vehicles
Motor cases for missiles
Mortar and rifle tubing
Hot extrusion dies
Low temperature structural parts
Cold headed bolts
(Complex shapes that need to be strong after shaping)
TAINLESS
TEELS
WHAT IS STAINLESS
STEEL
a minimum 12% Cr
IMPORTANCE
Stainless steel are versatile for the following
properties
Good corrosion and oxidation resistance
Characteristics
As austenitic steels have FCC structure
non
magnetic in nature
tough at low
temperatures as no ductile brittle transition good
ductility with elongation about 50%
Excellent corrosion resistance in organic acid , industrial
& marine environment
Excellent formability, fabricability, cleanability and
hygiene characteristics
Cr/Ni austenitic steels are resistant to high temperature
oxidation
Excellent weldability since single phase materials
Austenitic steels do not have 475o C embrittlement but
show reduced ductility and toughness due to formation of
brittle intermettalic compounds called sigma phase.
Sigma phase increaseswith increase in chromium amount
& presence of Mo, Ti & Si. Manganese helps reduce the
Cold work
Work hardening rate is high due to low stacking fault energy of
0.002 J/m2
Upon cold working by 60% increases yield strength from 240
Mpa to 1035 Mpa & tensile strength of 585 Mpa gets doubled
Loss of strength at temperatures above 600 OC & also in HAZ of
a weld
Microstructure of austenitic
steels
Limitations
There are two limitations of austenitic stainless steel
Cracking due to stress corrosion
Intergranular corrosion
Stress corrosion
Austenitic stainless steel is prone to stress corrosion
cracking in the presence of chloride ions even
present in ppm levels
Failure can occur due to the presence of small
stresses or even residual stresses
Fracture ids transgranular with little or no plastic
deformation
Can reduced inhigh nickel (>30%Ni) austenitic steels
or reduce the stress or eliminate chloride ions
Chromium depletion as a
function of distance from
various types
of grain boundaries in type 304
stainless steel. Courtesy of M.G.
Burke, Westinghouse Electric
Corp., Pittsburgh
Solution Annealing
main objective of this treatment is to dissolve the phases that
have precipitated during the thermo mechanical processing of
the material, especially the chromium-rich carbides of the
M23C6-type where M =Cr, Fe, Mo
lower temperature limit for solution annealing should be over
900 oC
Carbides should be completely dissolved but they dissolve
slowly. Grain growth limits the maximum solution-annealing
temperature
abnormal grain growth, also known as secondary
recrystallization, must be avoided
Cooling from heat treatment temperatures should be sufficiently
fast to avoid chromium carbide precipitation. On the other hand,
too fast cooling rates cause component distortions
During solidificationor welding, the formation of d-ferritemay
occur, whichmay be difficult to eliminate completely during the
thermomechanical treatment and itmay be present before the
Stabilize Annealing
Stabilize annealing is used for stabilized austenitic stainless
steels in order to assure maximum intergranular corrosion
resistance
After the solution-annealing treatment, only part of the carbon
is bound in the form of primary phases, such as carbides, MC,
carbo-nitrides, M(C,N), nitrides MN, or carbo-sulfides M4C2S2,
where M=Ti, Nb, or V. The remaining carbon stays in solid
solution and may precipitate as secondary carbides MC or
M23C6 at lower temperatures, since the carbon solubility in
austenite under 900 oC is very low
exposing the steel, after solution annealing, to temperatures in
the 845 to 955 oC temperature range for up to 5 h (depending
on component size), favors MC precipitationin detriment to
M23C6. Furnace atmosphere control, avoiding carburizing or
excessively oxidizing conditions, should be employed and the
sulfur content in oil- or gas-fired furnaces should be kept at low
levels.
Bright Annealing
Martensite Formation
Austenite in stainless steel is generally not a stable
phase.
In the solution-annealed condition, the Ms temperature
is normally below room temperature. For the majority
of these steels, the Md temperature (the temperature
below which martensite will form under deformation) is
above room temperature.
Two kinds of martensite can occur in stainless steels:
(bcc, ferromagnetic) and (hcp,nonferromagnetic).
The transformation of austenite to martensite can be
also induced in austenitic stainless steels by cathodic
charging with hydrogen.
Typical lattice parameters are
=0.2872nm &
a =0.2532nm C =0.4114nm
Engineering stress-strain
curves for type 304 stainless
steels at
various temperatures
Basic Properties
Moderate to good corrosion resistance increases with Cr
content
Not hardenable by heat treatment and always used in the
annealed condition
Magnetic in nature
Formability not as good as the austenitic stainless steel
Moderate ductility - not easy to deep draw 20%
elongation
Low impact strength - brittle at low temperatures
Poor weld ductility due to grain growth in HAZ
Moderate strength
These steels work harden less
Yield strength is 275-415 Mpa ,tensile strength is 500600Mpa &yield elongation is 30%
Intermetallic Phases
Various phases found are SIGMA Phase ,CHI phase &
LAVES Phase
Various intermetallic phases form by the arrangement of
iron, chromium, molybdenum, and other transition metal
atoms into crystal structures that accommodate atomic
size and electronic differences that limit the lowtemperature solid solubility of alloying elements in the
bcc ferritic structure
The formation of the intermetallic phases follows C
curve kinetics, which are influenced by alloy composition
The C curves are useful in that they define temperature
ranges that can be used to dissolve the intermetallic
phases and through which specimens must be rapidly
cooled to avoid reprecipitation of the phases. The C
curves also identify operating temperatures that should
be avoided for application of ferritic stainless steels.
SIGMA ()-PHASE
Treischke and Tamman studied the FeCr system and
proposed the existence of an intermetallic
compound containing Cr in the 30 to 50 wt% range.
In 1927, Bain and Griffiths studied the FeCrNi
system and observed a hard and fragile phase,
which they called constituent B, from brittle. In 1936,
Jett and Foote called it sigma()phase and in 1951,
Bergmann and Shoemaker determined through
crystallography its structure in the FeCr system.
The precipitation of sigma phase in stainless steels
can occur in the austenitic, ferritic, and ferritic
austenitic phases with duplex structure types. The
precipitation of this FeCrMo intermetallic, of
tetragonal structure with 30 atoms per unit cell,
Austenite
Ferrite
No - Sigma Phase
Formation
1000C
Phase
Cooling Curve
Time
600C
1000C
Phase
600C
Cooling Curve
Time
Sigma Phase
Sigma Phase
Cr
Fe
Mo
Chi Phase
Chi (x) phase was identified, for the first time, by Andrews in
1949 in residues extracted from the CrNiMo steel. Later,
Kasper synthetically produced the chi (x) phase with the
Fe36Cr12Mo10 composition and studied its crystal structure in
detail.
Chi ( x) phase, for example, may occur also in austenitic,
ferritic, and duplex (ferritic austenitic) stainless steels and its
precipitation is associated with negative effects on properties.
While sigma phase is present in the binary FeCr system, chi
phase appears only in the FeCrMo ternary and in the FeCr
NiMo and FeCrNiTi quaternary systems. Still in comparison
with the sigma phase, chi ( x) phase is richer in molybdenum
and poorer in chromium.
The occurrence of (x)-phase in ferritic stainless steels is
conditioned to a minimum in the molybdenum content
Effect of molybdenum on the sigma (s)- and chi (x)-phase formation in the Fe28 wt% Cr
Mo system
Basic Properties
Less resistant to corrosion in comparison to the other
grades of steel
Can be hardened by heat treatment
High strength & hardness levels can be achieved
Poor weldability
Magnetic in nature
Yield strength of 550-1860Mpa
Poor machinability
As Cr content increases hardenability increases
Have improved toughness
Basic Properties
Stronger than austenitic steels due to
two phase structure
presence of delta ferrite causes grain refinement causing
strengthening
refinement in grain structure due to thermo-mechanical
treatment
Good corrosion resistance
Freedom from transgranular stress corrosion cracking
Good weldability but micro duplex structure destroyed in HAZ
which decreases strength as well as stress corrosion resistance
Duplex steels have ductile brittle transition temperature due
the presence of ferrite
Suffer from embrittlement effect
Duplex Applications
Pharmaceutical industry
On/offshore industry
FERRITIC
AUSTENITIC
DUPLEX
Solidification of DSS
Austenite
Embrittlement Effects
Duplex stainless steels are susceptible to three types
of embrittlement :
1. Embrittlement caused by the presence of a
carbide network, particularly in the austenite, in alloys
with higher carbon content
2. Embrittlement caused by precipitation of the phase, 475 oC embrittlement of ferrite
3. Embrittlement caused by precipitation of the phase, particularly in the ferrite
In the case of duplex steels with higher carbon content, the first
phase that solidifies is also ferrite. The residual liquid enriched in
carbon solidifies forming austenite and a chromiumrich M23C6type carbide network. This carbide network within the austenite
leads to an improved wear resistance. During cooling, austenite
islands can also form in the ferrite grains.Some secondary carbide
may also precipitate in austenite in the solid state. With the
application of mechanical stresses, these carbides initiate
fractures and cracks that propagate along the carbide network
950C
Sigma
Phase
nose
+N
600 C
Time
Phase Imbalance
High ferrite (> 70%):
low ductility
loss of corrosion
resistance
H2 cracking susceptibility
High austenite (> 80%):
low SCC resistance
low strength
Avoid imbalance
Chrome Nitrides
Result from rapid cooling
Can result in excessive ferrite content and
chromium nitrides
Which will reduce pitting resistance
Chromium Nitrides
Types of steels
martensitic ,semi-austenitic & austenitic
Martensitic alloys
Predominantly austenitic structure at annealing
temperature of around 1040-1065 0C. Upon cooling to room
temperature austenite changes to martensite
Austenitic alloys
Retain their austenite structure after annealing & hardening
by ageing. Precipitate hardening phase is soluble. Hardness
is lower than the other two & remain non magnetic
http://www.superior-ny.com/mk41.htm
Mechanical properties as a function of tempering temperature of type 410 stainless steel. Data on left is for
specimens austenitized at 925 C (1697 F) and data on right is for specimens austenitized at 1010 C (1850
F). All specimens oil quenched between 65 and 95 C (149 and 203 F), stress relieved at 175 C (347 F), and
tempered for 2 h
Austenite
Substitutional
Elements
Cr
Ni
Mo
Fe
Sulphur - S
Phosphorus - P
Stress [MPa]
800
austenite
600
duplex
ferrite
400
200
0,0
0,2
0,4
Strain
0,6
0,8
Strength at
temperature
Impact Resistance
Objective
The objective of this lecture is to describe the
relationship between precipitation and
hardness as an example of a key
microstructure-property relationship.
442
443
Al-Cu ppt
structures
GP zone structure
445
Al-Cu microstructures
This tableau shows which of the different
ppt types are associated with which part
of the hardening curve.
GP zones
446
448
449
Al-Ag: example 2
The age hardening curve has the same
double peak as for the Al-Cu series, but
the separation is more pronounced.
Shewmon
450
Al-Ag, contd.
GP zones are spherical (Ag atom is larger than Al).
g is hcp with OR (0001)g//(111)a and [1120]g //[110]a;
heterogeneously nucleated on the stacking faults of
dislocations which provide sites of local hexagonal packing.
g is also hcp with the same OR; forms plate-like precipitates. A
cellular mechanism can also occur.
Shewmon
451
Shewmon
452
PRECIPITATION HARDENING
Particles impede dislocations.
Ex: Al-Cu system
700
T(C)
Procedure:
--Pt A: solution heat treat
(get solid solution)
--Pt B: quench to room temp.
--Pt C: reheat to nucleate
small crystals within
crystals.
Other precipitation
systems:
Cu-Be
Cu-Sn
Mg-Al
600
500
400
+L
(Al)
+L
300
0 B 10
CuAl2
20
30
40
50
wt% Cu
composition range
needed for precipitation hardening
Adapted from Fig. 11.24, Callister 7e. (Fig. 11.24 adapted from
J.L. Murray, International Metals Review 30, p.5, 1985.)
Temp.
Pt A (soln heat treat)
Pt C (precipitate
Pt B
Time
453
Solution Treat
Age
Quench
F11_22_PG403
f11_22_pg403
F11_23_PG404
f11_23_pg404
400
300
200
100
204C
fe
pr wer
ov ecip lar
era ita ge
ge tes
d
%EL (2 in sample)
no
sol n-eq
id uil
sol .
ut
ion
ma
pr ny s
eci m
pit all
ag ates
ed
TS peaks with
precipitation time.
Increasing T accelerates
process.
149C
1min
1h 1day 1mo 1yr
precipitation heat treat time
30
20
10
0
204C
149C
1min
1h 1day 1mo 1yr
precipitation heat treat time
457
Adapted from Fig. 11.27 (a) and (b), Callister 7e. (Fig. 11.27 adapted from Metals Handbook:
Properties and Selection: Nonferrous Alloys and Pure Metals, Vol. 2, 9th ed., H. Baker (Managing
Ed.), American Society for Metals, 1979. p. 41.)
F11_27_PG406
f11_27_pg406
F11_25_PG405
f11_25_pg405
462
Breaking Angle: fc
Courtney
Gb c
cos
L 2
Strong Obstacles: ~ 0
463 ~ 180
Weak Obstacles:
Hardness -microstructure
relationships
In order to understand the relationship between
microstructure and hardness, we need to delve into the
subject of hardening mechanisms.
The central concept is that the strength of a ductile
material is governed by dislocation flow past obstacles.
Therefore strength can be designed by controlling the
density and nature of the obstacles to dislocation motion.
Most technological (metallic) alloys rely on precipitation
hardening in one form or another to achieve high
strengths. Ceramics, on the other hand, are intrinsically
harder and therefore the main objective of strengthening
is to increase their fracture toughness and thereby
increase their (reliable) load carrying capacity. The
objective of this discussion is therefore to bring your
attention to a number of ways in which we can
understand and predict the contributions to strength
of
464
different types of obstacle.
Strengthening Methods
Microstructural Feature:
strength dependence.
Dislocations: strain/work hardening
(discussed in 301): (dislocation spacing)1/2.
Internal Boundaries: grain boundaries can
have a strong strengthening effect, i.e. the
Hall-Petch effect (discussed in 301): (grain
size)-1/2.
Dislocation Boundaries (low angle
boundaries): (subgrain size)-1.
Second Phase Particles: particle spacing.
Solutes: (concentration)1/2.
465
Mechanisms of particle
strengthening
Dislocations
A re-statement of the governing equation
for strength controlled by obstacle
spacing:
M 0 Gb /
Parameter
<M>
G
b
Description
flowstress
Comments
Experimentallyaccessiblethroughmechanical
tests
AverageTaylorfactor
Magnitude~3fortensionorcompression;
dependsonthenatureofthedeformation,the
textureandthecrystalstructure,e.g.<M>~1.73
fortorsion(cubicmetals)
Athermalstress
Contributionsfromgrainsizehardening,
solutes,etc.
Geometricalfactor
Thistermaccountsforbothgeometricalfactors,
andforthermalactivation
ShearModulus
Mustchooseappropriateshearmodulusforthe
slipplaneused;
Temperaturedependent
Burgersvector
Derivedfromtheforceonadislocation(Peach
KoehlerEq.)
dislocationdensity
Equivalenttothereciprocalofameanobstacle
spacing;dependsonworkhardening
obstaclespacing
Givenanumberdensityofparticles,themean
467
spacing,=N1/2
Courtney
468
Dislocation Boundaries
At large strains and higher temperatures, low angle
boundaries appear as a subgrain network forms. We
distinguish this microstructural feature from the first
two categories because the [lattice] misorientations
are much smaller (2-5) than grain boundaries
(15+) and they are distinct from statistically stored
dislocations. This strengthening method is most
important at high temperatures where other
microstructural features such as solutes are weak.
The contribution to the flow strength is typically
found to be proportional to (grain size)-1; this is in
contrast to the 1/d dependence of the Hall-Patch
effect.
469
Solutes
Solutes in a crystal act as obstacles to
dislocation motion through their elastic
and/or chemical interactions with
dislocations. Most solutes are weak
hardeners except for the
(technologically) important class of
interstitial solutes that induce anisotropic
distortions of the lattice, e.g. tetragonal
distortions of C in Fe.
470
Substitutional solutes
Most Solutes have only a rather weak effect on strength. In
other words, even if you put several per cent of a soluble
atom into another element, you will not see a dramatic
increase in flow stress. These remarks can be quantified by
going back to the Orowan equation, i.e. the force balance
between the forward motion and the resisting force:
tcrss = b/l.
For substitutional solutes, the numerator in the RHS, i.e. the
reaction force from the solute atoms is of order Gb2/120,
which is a small number. This is so because the small
differences in size between solute and matrix atoms results
in a small interaction energy with dislocations. Thus they
are weak obstacles and dislocations remain nearly straight
when interacting with solutes (weak obstacles,
7slides
471
before this).
Interstitial solutes
Interstitials in bcc, however, can exert forces on the
order of Gb2/5 to Gb2/10, which are large values. In
this case, the dislocations bow out significantly
between the atoms, and the breaking angle deviates
significantly from 180. In this case, the concentration
dependence is easy to obtain. The spacing between
interstitials is inversely proportional to the (square root
of the) concentration, and so we can insert a spacing
into the standard (Orowan bowing) formula to get the
following, where A is a constant of order unity:
t = AGb(c/b) = AGc.
472
4r
1 VV( )
L3
; L3
;
( )
3
VV
4r 1 VV( ) 4r1 f 4r
()
3 VV
3f
3f
474
Coherency hardening
Differences in density between the particle and the matrix give
rise to elastic stresses in the vicinity of the particle. This has
been analyzed on the basis of the elastic stresses that exist in
the matrix adjacent to a particle that has a different lattice
parameter than the matrix. Ignoring differences in modulus for
now, and setting a parameter, e, that approximates a strain to
characterize the magnitude of the effect. For
e = (aparticle amatrix )/ amatrix
t = 7|e|3/2 G(rf/b)1/2
This mechanism applies to the early stages of precipitation,
e.g. strengthening by GP zones.
475
Chemical hardening
Cutting through a particle with a dislocation displaces one half
relative to the other by b, thereby creating new interfacial energy
of 2rbg, where g is the interfacial energy between the matrix
and the particle. The distance over which this energy has to be
created occurs at the entry and exit points and so the
characteristic distance is of order b. Thus the force is dE/dx, or,
F = 2rbg/2b = rg
476
t = fg/2b.
A more realistic approach produces the following relationship.
t = 2G{g/Gr}3/2(fr/b)1/2
Courtney defines a chemical hardening parameter, ech = g/Gr,
related to the interfacial energy, modulus and particle size. This
parameter is precisely analogous to the same parameter used,
e.g. in APB hardening. Chemical hardening applies only in the
early stages of precipitation.
477
Order Hardening
The hardening depends on the product of the antiphaseboundary energy (APBE) and the area swept by a dislocation in
a particle. Thus the increase in flow stress is given by:
t = f{APBE}/2b
In general, low values of the APBE not only predict small
increments in hardness, but also the result that the dislocations
can move through the particles independently of one another.
A more detailed analysis, not presented here, shows a square
root dependence on volume fraction, with particle size,
Modulus hardening
The line length in the particle is 2r and the change in tension is
(Gparticle-Gmatrix)b2/2, assuming the same Burgers vector in matrix
and particle. Multiplying the two together and dividing by the
distance, i.e. the radius, we get:
F= b2(Gparticle-Gmatrix) = Gb2e,
where e = (Gparticle-Gmatrix)/Gmatrix, a measure similar to that used in
solution hardening.
More realistic estimates of modulus hardening lead to the
following formula:
t = 10-2 G e3/2 {fr/b}
Think of modulus hardening as being caused by a temporary
increase in dislocation line energy while it resides within a
particle.
479
Hardenability--Steels
flat ground
Rockwell C
hardness tests
Hardness, HRC
T(C)
600
0%
100%
400
200
M(start)
A M
0.1
10
t e ar
rli Pe
lite ea +
ar P i t e
Pe ine ens
F
t
ar ite
M en s
t
ar
M
0 M(finish)
100
1000
lite
Time (s)
Hardenability vs Alloy
Composition
10
60
4340
80 %M
50
40
4140
8640
40
20
10
"Alloy Steels"
(4140, 4340, 5140,
8640)
--contain Ni, Cr, Mo
(0.2 to 2wt%)
--these elements
shift the "nose".
--martensite is
easier to form.
100
Hardness, HRC
5140
0 10 20 30 40 50
Distance from quenched end (mm)
800
T(C)
600
400
200
0 -1
10
10
TE
shift from
A to B due
to alloying
M(start)
M(90%)
(Quenchedinwater)
(Quenchedinoil)
(Quenchedinwater)
(Quenchedinoil)