Modeling the Heat Treatment Response of P/M Components

Research Team
Makhlouf M. Makhlouf, Professor Richard D. Sisson, Jr., Professor Jiankun Yuan, Research Associate Virendra S. Werke, PhD Student

Focus Group Members

Sim Narasimhan Bill Jandeska Sylvain St-Laurent Lorenz Sigl (co-chair) Jean Lynn (chair) Hoeganaes General Motors Quebec Metal Powders, Ltd. Sinterstahl G.m.b.H. DaimlerChrysler Corperation

Introduction
P/M components experience considerable changes during heat treatment that include changes in mechanical properties, in dimensions, in magnitude and sense of residual stresses, and in metallurgical phase composition. Since the quality assurances criteria that heat-treated P/M components must meet include prescribed minimum mechanical properties and compliance with dimensional tolerances, it is necessary for P/M producers to be able to accurately predict these changes in order to take appropriate measures to prevent their harmful effects and insure the production of good quality parts. Satisfactory response to heat treatment is often gauged by the ability of the component to be heat treated to a desired microstructure, hardness and strength level without undergoing cracking, distortion or excessive dimensional changes. In addition to the completely reversible changes caused by thermal expansion and contraction, metallic components experience other permanent dimensional changes during heat treatment. These permanent changes can be classified into three groups based on their origin: (1) Dimensional changes with mechanical origins, these include dimensional changes caused by stresses developed by external forces, dimensional changes arising from thermally induced stresses, and dimensional changes caused by relaxation of residual stresses. (2) Dimensional changes with metallurgical origins, these include dimensional changes caused by recrystallization, solution and precipitation of alloying elements, and phase transformations. (3) Dimensional changes due to quenching, these are dimensional changes that occur during quenching or that result from stresses induced by quenching. Residual stresses often adversely affect the mechanical properties of P/M components. They are caused by differing rates of cooling during quenching and depend on the
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differential rate of cooling, section thickness, and material strength. Decreasing the severity of the quench results in a lower level of residual stresses but with a correspondingly reduced material strength of solution heat-treated materials. Residual stresses may also arise from phase transformations during heat treatment that result in differential volumetric changes in the material.

Objective
The main objective of this project is to develop and verify a computer simulation software and strategy that enables the prediction of the effects of heat treatment on powder metallurgy components. The simulation will accurately predict dimensional change and distortion, residual stresses, type and quantity of metallurgical phases in the microstructure, and hardness.

Research Plan
Commercially available software will be chosen for the project. At this time, Dante, which is a finite element based CAE tool for analyzing metal heat treatment processes and marketed by DCT, Inc. is the software of choice. This software can perform all the required simulations, but its materials properties database was not designed for P/M. Consequently, Phase I of the project will focus on assessing the capabilities of Dante and the possibility of adapting it to the specifics of powder metallurgy. Once, this is accomplished, Phase II of the project will commence and will focus on using the modified software to predict the heat treatment response of powder metallurgy components. The predicted responses will be compared to experimentally measured responses and a modeling/prediction strategy will be formulated and recommendations will be made to the consortium members. In the early phases of the project, the heated part will be a simple right cylinder. At later phases of the project production parts chosen by the focus group may be modeled.

Methodology
The project will be divided into two phases as follows: PHASE I: ASSESSMENT OF DANTES CAPABILITIES AND THE POTENTIAL OF ADAPTING IT TO P/M COMPONENTS Task 1: Assessment of Dantes ability to predict heat treatment response in fully dense components. Subtask1.1: Computer simulations Dante will be used to numerically simulate the heating and quenching processes on a 3D fully dense circular cylinder made from 5160 carbon steel for which a comprehensive material properties data set is available.

Input to Dante will include the 3D geometry model and finite element grid, material properties, and heat treatment schedule. Output from Dante will include (1) Resultant volume fraction of metallurgical phases. (2) Hardness distribution after heat treatment. (3) Dimensional changes and distortion. (4) Magnitude and sense of residual stresses. Subtask 1.2: Experiments and measurements Dantes predictions will be verified by comparing them to measurements of corresponding parameters for specimens obtained using processing conditions similar to those used in the simulations. Measurement of dimensional changes and distortion A Starrett coordinate measuring machine will be used to measure the dimensional changes and distortion caused by the heat treatment process. Sufficient measurements will be made to obtain accurate representation of the part before and after heat treatment. Coordinate measuring machines are a fast, accurate and more convenient alternative to conventional methods for measuring complex parts. Measurement of residual stresses The standard x-ray diffraction method for measuring residual stress in metallic components will be used. Line shifts due to a uniform strain in the component is measured and then the stress in the component is determined either by a calculation involving the elastic constants of the material or by a calibration procedure involving measurement of the strain produced by known stresses. Measurement of volume fraction of metallurgical phases Standard metallographic sample preparation techniques will be used to prepare specimens from the heat-treated components. Samples will be prepared from three different crosssections of the cylinder that are equally spaced along the length of the cylinder. Optical and scanning electron microscopy together with automated image analysis and energy disperssive x-rays will be used to characterize and quantify the various phases in the specimens. Measurement of hardness Standard Rockwell hardness and microhardness measurements will be performed on the heat-treated cylinders. Measurements will be performed across three different crosssections of the cylinder that are equally spaced along the length of the cylinder. Task 2: Adapt Dante to P/M components Once Dantes predictions are validated for fully dense components, the software will be used to model the heat treatment response of 5160 carbon steel P/M components that have low green density. In this case, a critical input to the model is material properties that accurately reflect the properties of porous 5160 carbon steel. Development of this

database will be a major focus of this Task. The team at WPI will work with the software producers to develop a reliable properties database for porous P/M processed 5160 and 8620 steels and 601AB aluminum alloy. PHASE II: MODELING THE EFFECT OF VARIOUS PROCESS PARAMETERS ON THE HEAT TREATMENT RESPONSE OF P/M PARTS Task 1: Computer simulations Computer simulation of the heat treatment response of cylinders made from 5160 and 8620 steels as well as 601AB alloy will be performed as described in subtasks 1.1 to 1.3. Subtask 1.1: Computer simulation of the heat treatment response of 5160 steel Dante will be used to predict the heat treatment response, i.e., distortion, residual stress, hardness, and microstructure evolution in a 5160 carbon steel cylinder for combinations of the following conditions: Green density: (1) Low density, (2) full density, and (3) highly variable density across the length of the cylindrical component. Heating method: (1) Conventional heating, and (2) induction heating. Severity of quench: (1) Moderate quench (e.g., in oil), and (2) severe quench (e.g., in water). Subtask 1.2: Computer simulation of the heat treatment response of 8620 steel Dante will be used to predict the heat treatment response, i.e., distortion, residual stress, hardness, and microstructures evolution in a 8620 steel cylinder for combinations of the following conditions: Green density: (1) Low density, (2) full density, and (3) highly variable density across the length of the cylindrical component. Heating method: (1) Carburizing atmosphere in a conventional furnace, and (2) noncarburizing atmosphere in a conventional furnace. Severity of quench: (1) Moderate quench (e.g., in oil), and (2) severe quench (e.g., in water). Subtask 1.3: Computer simulation of the heat treatment response of 601AB aluminum alloy Dante will be used to predict the heat treatment response, i.e., distortion, residual stress, hardness, and microstructures evolution in an aluminum 601AB alloy cylinder for combinations of the following conditions: Green density: (1) Low density, (2) full density, and (3) highly variable density across the length of the cylindrical component. Heating method: (1) Conventional heating, and (2) induction heating. Severity of quench: (1) Moderate quench (e.g., in oil), and (2) severe quench (e.g., in water).

TASK 2: Experiments and measurements Software predictions obtained in Subtasks 1.1 1.3 will be verified by comparing them to measurements of corresponding parameters for specimens obtained using processing conditions similar to those used in the simulations. The measurements are outlined in Subtasks 2.1 to 2.3. Subtask 2.1: Measurement of the heat treatment response of 5160 steel Software predictions for 5160 steel will be verified by comparing them to measurements of corresponding parameters for 5160 steel specimens obtained using processing conditions similar to those used in the simulations. Measurement of dimensional changes and distortion A Starrett coordinate measuring machine will be used to measure the dimensional changes and distortion caused by the heat treatment process. Sufficient measurements will be made to get accurate representation of the part before and after heat treatment. Measurement of residual stresses The standard x-ray diffraction method for measuring residual stress in metallic components will be used. Line shifts due to a uniform strain in the component is measured and then the stress in the component is determined either by a calculation involving the elastic constants of the material or by a calibration procedure involving measurement of the strain produced by known stresses. Measurement of volume fraction of metallurgical phases Standard metallographic sample preparation techniques will be used to prepare specimens from the heat-treated cylinders. Samples will be prepared from three different crosssections of the cylinder that are equally spaced along the length of the cylinder. Optical and scanning electron microscopy together with automated image analysis and energy disperssive x-rays will be used to characterize and quantify the various phases in the specimens. Measurement of hardness Standard Rockwell hardness and microhardness measurements will be performed on the heat-treated cylinders. Measurements will be performed across three different crosssections of the cylinder that are equally spaced along the length of the cylinder. Subtask 2.2: Measurement of the heat treatment response of 8620 steel Software predictions for 8620 steel will be verified by comparing them to measurements of corresponding parameters for 8620 steel specimens obtained using processing conditions similar to those used in the simulations. Measurement of dimensional changes and distortion A Starrett coordinate measuring machine will be used to measure the dimensional changes and distortion caused by the heat treatment process. Sufficient measurements will be made to get accurate representation of the part before and after heat treatment.

Measurement of residual stresses The standard x-ray diffraction method for measuring residual stress in metallic components will be used. Line shifts due to a uniform strain in the component is measured and then the stress in the component is determined either by a calculation involving the elastic constants of the material or by a calibration procedure involving measurement of the strain produced by known stresses. Measurement of volume fraction of metallurgical phases Standard metallographic sample preparation techniques will be used to prepare specimens from the heat-treated cylinders. Samples will be prepared from three different crosssections of the cylinder that are equally spaced along the length of the cylinder. Optical and scanning electron microscopy together with automated image analysis and energy disperssive x-rays will be used to characterize and quantify the various phases in the specimens. Measurement of hardness Standard Rockwell hardness and microhardness measurements will be performed on the heat-treated cylinders. Measurements will be performed across three different crosssections of the cylinder that are equally spaced along the length of the cylinder. Subtask 2.3: Measurement of the heat treatment response of 601AB aluminum alloy Software predictions for 601AB aluminum alloy will be verified by comparing them to measurements of corresponding parameters for 601AB aluminum alloy specimens obtained using processing conditions similar to those used in the simulations. Measurement of dimensional changes and distortion A Starrett coordinate measuring machine will be used to measure the dimensional changes and distortion caused by the heat treatment process. Sufficient measurements will be made to get accurate representation of the part before and after heat treatment. Measurement of residual stresses The standard x-ray diffraction method for measuring residual stress in metallic components will be used. Line shifts due to a uniform strain in the component is measured and then the stress in the component is determined either by a calculation involving the elastic constants of the material or by a calibration procedure involving measurement of the strain produced by known stresses. Measurement of volume fraction of metallurgical phases Standard metallographic sample preparation techniques will be used to prepare specimens from the heat-treated cylinders. Samples will be prepared from three different crosssections of the cylinder that are equally spaced along the length of the cylinder. Optical and scanning electron microscopy together with automated image analysis and energy disperssive x-rays will be used to characterize and quantify the various phases in the specimens.

Measurement of hardness Standard Rockwell hardness and microhardness measurements will be performed on the heat-treated cylinders. Measurements will be performed across three different crosssections of the cylinder that are equally spaced along the length of the cylinder. Deliverables The main deliverable from the project will be a verified predictive strategy and software that enable a complete assessment of the response of powder metallurgy components to heat treatment. The characteristics predicted by the software will include part distortion, residual stresses, microstructure evolution, and hardness. An additional deliverable from the project will be documentation of the effect of processing conditions, including green density, heating method, and severity of quench on the response of 5160 steel, 8620 steel, and 601AB aluminum alloy P/M parts to heat treatment. Schedule