Evaluation of Heat Transfer Coefficient During Quenching of Steels - Hala - Thesis PDF

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Evaluation
of Heat Transfer Coefficient
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during Quenching of
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Steels
A thesis
Submitted to the Department of Electromechanical Engineering/

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University of Technology in a partial fulfilment of the requirements for the
!degree of Doctor of philosophy in Mechanical Engineering
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"#$#!%#$&#'!"#(#'!
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September 2009
Failure is the opportunity to begin again more intelligently.

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Henry Ford
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To my family
With my all respect, appreciation, and love.
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Hala!
Acknowledgement
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Contents
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1 INTRODUCTION AND LITERATURE REVIEW
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3 NEURAL NETWORK MODEL FOR PREDICTION OF THERMAL

CONDUCTIVITY OF STEELS
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6 CONCLUSION AND FUTURE WORK

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REFERENCES
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Chapter 1
Introduction and Literature review
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)(:?&$*2#$+! 8/%8$/',$(! %.! ('$$0! /$?&,/$(! )22&/)'$! +)')! %.! '#$! 5%&*+)/6!
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2#)/)2'$/,@$!'#$!(&/.)2$!#$)'!'/)*(.$/!2%$..,2,$*'!DBU=!BEF;!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
Figure 1-1: Coupling effect between cooling rate, phase

transformation and stresses, and their influence on material
properties.
1: Temperature dependent phase transformations.
2: Thermal stress.
3: Latent heat.
4: Heat of deformation.
5: Transformation strain.
6: Stress-induced transformation.
!
!
!
!
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%0+!)88/%)2#!,*!+$'$/3,*,*-!'#$!?&$*2#!.)2'%/!AGVC;!

1.2
Literature review
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./%3! )*! %57$2'! +&/,*-! '#$! ?&$*2#,*-! 8/%2$((! )*+! '%! 8/%+&2$! '#$! +$(,/$+!
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3,*,3,@$!+,('%/',%*!+&$!'%!'#$!+$9$0%83$*'!%.!/$(,+&)0!('/$(($(!56!8/%3%',*-!
'#$!&*,.%/3,'6!%.!2%%0,*-!%9$/!'#$!(&/.)2$!%.!'#$!2%38%*$*';!"#$!3$2#)*,2)0!
8/%8$/',$(! %5'),*$+! )/$! (,-*,.,2)*'06! )..$2'$+! 56! '#$! 2%%0,*-! /)'$(! )''),*$+!
+&/,*-!?&$*2#,*-!DBL:BNF;!
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)88/%8/,)'$! ?&$*2#,*-! 3$+,&3! .%/! '#$! #$)'! '/$)'3$*'! %.! ('$$0! 8)/'(;! "#$!
'$2#*,?&$!$9)0&)'$(!'#$!2%%0,*-!8%1$/!%.!?&$*2#,*-!3$+,)!56!3$)(&/,*-!'#$!
'#$/3)0!/$(8%*($!%.!)!8/%5$=!(&,')506!,*('/&3$*'$+!1,'#!'#$/3%2%&80$(!1#,2#!
)/$! &($+! 0)'$/! '%! $(',3)'$! ?&$*2#! ($9$/,'6! )*+! ?&$*2#! .)2'%/;! "#$! 3%('!
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'#$/3%2%&80$! ,(! &(&)006! 0%2)'$+! )'! '#$! -$%3$'/,2! 2$*'/$! %.! '#$! 8/%5$;! X/%5$(!
1,'#! 3&0',80$! '#$/3%2%&80$(! $35$++$+! )/$! )0(%! &($+! ,*! %/+$/! '%! 3$)(&/$!
'#$/3)0!-/)+,$*'(!DBM:SBF;!
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$Q#,5,'!)*6!8#)($!'/)*(.%/3)',%*!+&/,*-!?&$*2#,*-=!(&2#!)(!I*2%*$0!LRR!DBP=!
SS:SEF=!(,09$/!DBP=!SS=!SKF!%/!URE!('),*0$((!('$$0!DSL:SMF=!'%!)00%1!'#$!/$(&0'(!'%!
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#)(! )! #,-#! ($*(,',9,'6! )*+! $Q2$00$*'! /$8/%+&2,5,0,'6! %.! /$(&0'(;! <%1$9$/=! ,'(!
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8/%5$;!W0(%=!'#$!(&/.)2$!2%*+,',%*!%.!'#,(!IY>!8/%5$!,(!*%'!(')50$!+&/,*-!,*,',)0!
#$)',*-=!1#,0$!'#)'!%.!'#$!(,09$/!8/%5$!,(!)01)6(!(')50$;!"#$!I*2%*$0!8/%5$!#)(!
)! '#$/3)0! 2%*+&2',9,'6! 1#,2#! ,(! 3&2#! 20%($/! '%! '#)'! %.! ('$$0! '#)*! ,(! '#$! 2)($!
1,'#!(,09$/;!I'!)0(%!+%$(!*%'!$Q#,5,'!)*6!8#)($!'/)*(.%/3)',%*(!DBP=!SS:SEF;!!
!
Table 1-1: Comparison of probe specifications standards.
Variable
Probe
ISO
AFNOR
9950:1995(E)
NFT-60778
(International)
(France)
JIS K 2242
ZBE 45003-88
(Japan)
(China)
Proposed
ASTM
(United State)
Y,09$/=!
Y,09$/=!
PP;PPP[!
PP;PP[!
8&/$!
8&/$!
BS;K!! !LR!
BL!! !EN!
BR!! UR!
BR!! UR!
BS;K!! LR!
NKR\!K!
NRR\!K!
NBR\!K!
NBR\!K!
NKR\!K!
I*2%*$0!LRR!
Y,09$/=!PP;PL[!
8&/$!
I*2%*$0!LRR!
Probe
dimensions,
Diameter !
Length, mm
Probe
quenching
temperature, C
!
!
!
!
!
!
!
!
!
!
!
Figure
1-2: JIS Silver
probe [18].
Figure 1-3: Inconel 600

probe [18].
])'$(! )*+! "%''$*! DUKF! #)9$! &($+! )*! )0&3,*,&3! 8/%5$! 1,'#! 3&0',80$!
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!
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M;L!23!
! R;U!23!
!
BK;S!23!
!
!
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U;N!23!
Figure 1-4: Multiple thermocouples

! probe [18].
Figure 1-5: Hines-Mueller type

304 stainless steel probe [18].
1.2.1!!!!!Calculation of heat transfer coefficient

!
G&$*2#,*-! )! #%'! %57$2'! ,*'%! )! 0,?&,+! 3$+,&3! ,*9%09$(! )! 2%380$Q! #$)'!
'/)*(.$/!8/%2$((;!<$)'!$Q'/)2',%*!./%3!'#$!(&/.)2$!%.!'#$!%57$2'!%22&/(!'#/%&-#!
($9$/)0!+,..$/$*':#$)'!'/)*(.$/!3$2#)*,(3(!)*+!,*!+,(',*2'!'$38$/)'&/$!/)*-$(;!
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/$?&,/$(!)22&/)'$!+)')!%.!'#$!5%&*+)/6!2%*+,',%*(H!'#$!#$)'!'/)*(.$/!2%$..,2,$*'!
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10
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U;!
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!
!
!
!
!
!
!
!
Figure 1-6: Heat-transfer coefficients as a function of temperature
during
quenching of cylindrical probe with 30!90 mm dimensions [18].
!
11
!
!
!
!
!
!
!
!
!
!
Figure 1-7: Effect of quenchant composition on the heat-transfer

coefficients [18].
a-NaCl
b-NaOH
!
!
!
!
!
!
!
!
!
Figure 1-8: Heat-transfer coefficients as a function of temperature

during quenching in various viscosity oil quenching [18]:
a- 113.9!106 m2 s-1
b- 68.3!106 m2 s-1
c- 31.1!106 m2 s-1
d- 22.9!106 m2 s-1
12
!
!
!
!
!
!
!
!
!
Figure 1-9: Cooling rates as a function of temperature obtained

using silver ball with 20 mm diameter quenched in a different
temperatures still water [1].
!
!
^)*6!'$2#*,?&$(!#)9$!5$$*!+$9$0%8$+!.%/!'#$!,*9$/($!)*)06(,(!3$'#%+!
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13
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2%$..,2,$*'!%*!'#$!2)02&0)'$+!3)/'$*(,'$!'/)*(.%/3)',%*!)*+!'#$!8)/'!+,('%/',%*!
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V&*)')*,! et al.! DSSF! '/,$+! '%! 20)/,.6! '#$! $..$2'! %.! '#$! (#)8$=! (,@$! )*+!
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g*',0! *%1! 8/%5$(! +,3$*(,%*(! %.! 0$((! '#)*! BR! 33! )/$! *%'! %.'$*! &($+!
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)!.&00!8/$+,2',9$!?&$*2#!(,3&0)',%*!'%%0;!
1.2.2!!!!!Quench factor analysis
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14
4,*$',2!8/%8$/',$(!,(!2)00$+!'#$!?&$*2#!.)2'%/!)*+!1)(!+$(2/,5$+!%/,-,*)006!56!
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+$9$0%8$+!'%!?&)*',')',9$06!8/$+,2'!8/%8$/',$(!DKLF;!!
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15
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3$)(&/$+!DBM=!KKF;

1.3
16
Objective of the study
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B; "%! ,*9$(',-)'$! )*+! &*+$/(')*+! '#$! /%0$! %.! '#$! ?&$*2#)*'! '68$! )*+!
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#$)':'/)*(.$/!2%$..,2,$*'!.%/!('$$0(!)(!)!.&*2',%*!%.!(&/.)2$!'$38$/)'&/$=!
&(,*-!3$)(&/$+!'$38$/)'&/$!8/%.,0$(;!
U; "%!,*9$(',-)'$!'#$!$..$2'!%.!?&$*2#,*-!8)/)3$'$/(!%*!'#$!?&$*2#!.)2'%/!
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2%*+&2',9,'6;!
1.4
Research work layout

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17
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18
'$2#*,?&$! +$(2/,5$+! ,*! 2#)8'$/! E! )*+! '%! )(($((! '#$! )880,2)5,0,'6! %.! '#$!
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Chapter 2
Theoretical background
2.1 Quenching and quenching stages

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2 Theoretical background
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20
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2.1.1
Stage-A Heat Removal
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21
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*&+(,-%.)&/01'%31$"&/#23%9:7%JJ=>%
2.1.2
Stage-B Heat Removal
%%%%%%%%%%%?"1%"#@"12'%$(()#/@%-&'12%($$,-%#/%2'&@1%K%(-%'"1%/,$)1&'1%.(#)#/@%2'&@1>%
F2% '"1% 2'11)% $(()27% '"1% -&'1% (5% /,$)1&'#(/% &/4% @-(!'"% (5% '"1% *&+(,-% .,..)12%
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%
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!
2.1.3
22
Stage-C Heat Removal
!!!!!!!!!!!"#$%&! '! ()*+,*&-! #.&! /++,()%! +0! #.&! ,(12(3! $)3! 4&%()-! 5.&)! #.&!
#&67&8$#28&! +0! #.&! -#&&,! -280$/&! 8&$/.&-! $! 7+()#! 5.&8&! ,(12(3! /+)*&/#(+)! (-!
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8$#&!+0!/++,()%!$%$()!3&/8&$-&-:!>.&!/++,()%!8$#&-!()!#.(-!-#$%&!$8&!3&7&)3&)#!
+)!#.&!*(-/+-(#=!+0!#.&!12&)/.$)#:!?,,!+#.&8!0$/#+8-!4&()%!&12$,<!/++,()%!8$#&-!
3&/8&$-&!5(#.!()/8&$-()%!*(-/+-(#=:!
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/++,()%!8$#&-!#+!$*+(3!#.&!7&$8,(#&!#8$)-0+86$#(+)!8&%(+)!$)3!6()(6$,!'!-#$%&!
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.$77&)! ()! #.&! #&67&8$#28&-! 5.&8&! #.&! 6$8#&)-(#&! -#82/#28&! /$)! 0+86&3! BCD<!
EDF:!
!
Figure 2-1:!Cooling curve and cooling rate curve at the centre of a 25 mm

diameter probe quenched with 95 C water flowing at 0.25 m sec-1 [17].
!
2.2
23
Cooling curve analysis
!!!!!!!!!!"#$!%&'(!)'$*)+!,-.!&*!-//)0-($+.!1$'/023245!(#$!/&%6+$7!%$/#-42'%!
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"#$!%-72%)%!/&&+245!0-($!C%-7DB!
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<=?!=LA:!
2.2.1
Effect of quenching parameters on cooling curve
!!!!!!!!!!M-02&)'! *-/(&0'! 24! -112(2&4! (&! ,&0K! 62$/$! /&4*25)0-(2&4! %-.! -**$/(! (#$!
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!
2.2.1.1
24
Quenchant type
!!!!!!!!!!"#$!%&'%()$!(*!+#$!,&$-.#/-+!0)!+(!.(-+'(1!#$/+!+'/-)*$'!*'(2!+#$!#(+!
2$+/1! 3('4! %0$.$5! "#$! +6%$! (*! ,&$-.#/-+! &)$7! #/)! /! 7'/2/+0.! $**$.+! (-!
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;/)$7! %(162$')@! (01! /-7! )/1+)5! A$'6! )1(3! .((10-8! ./-! ;$! (;+/0-$7! 0-! /0'@!
0-$'+!8/)!/+2()%#$'$)!('!:/.&&2!BC@!CDE5!
2.2.1.2
Quenchant temperature
!!!!!!!!!!"#$! +$2%$'/+&'$! (*! +#$! ,&$-.#/-+! (;:0(&)16! /**$.+)! 0+)! /;010+6! +(!
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+#$! +$2%$'/+&'$! 0-.'$/)$75! "#$! '$7&.$7! (01! :0).()0+6! (**)$+)! /-6! '$7&.$7!
,&$-.#0-8!/;010+6!./&)$7!;6!+#$!+$2%$'/+&'$!'0)$5!
!!!!!!!!!!I-.'$/)0-8! +#$! +$2%$'/+&'$! (*! +#$! 3('4! %0$.$! #/)! '$1/+0:$16! 10++1$!
$**$.+!(-!0+)!/;010+6!+(!+'/-)*$'!#$/+!+(!+#$!,&$-.#0-8!2$70&2!;$./&)$!(*!+#$!
1/'8$! +$2%$'/+&'$! 70**$'$-.$! 30+#! +#$! ,&$-.#0-8! 2$70&25! "#$! 2()+!
-(+0.$/;1$!.#/-8$!0-!/;010+6!+(!+'/-)*$'!#$/+!%'(;/;16!.(2$)!*'(2!+#$!2('$!
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0-.'$/)$! ('! 7$.'$/)$! +#$! #$/+! +'/-)*$'! ./%/;010+6@! 7$%$-70-8! (-! +#$!
+#0.4-$))!(*!+#$!(F07$!7$:$1(%$7!BCD@!KLE5!
!
!
2.2.1.3
25
Quenchant agitation
!!!!!!!!!!"#$%&%$'(! ')! *')+,-! +$)+./&%$'(! '*! %0,! 1.,(+0&(%! 0&2! &! -)&3&%$+!
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&(-!2'/$-2!*)'3!%0,!2.)*&+,!'*!%0,!%,2%!6$,+,!')!%0'2,!2.26,(-,-!&%!%0,!,-#,!'*!
%0,! 7&6'.)! 8/&(9,%:! %0.2! 6)'-.+$(#! *&2%,)! 0,&%! %)&(2*,)! $(! 2%&#,! =4! "#$%&%$'(!
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&#$%&%$(#!%0,!*/.$-!?@:!ABC4!
!
2.2.2
Estimating as quenched hardness of steel from cooling curve
!!!!!!!!!!D.,(+0!*&+%')!&(&/;2$2!6,)3$%2!%0,!-$),+%!+')),/&%$'(!'*!%0,!20&6,!'*!%0,!
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$(%,),2%4!
!!!!!!!!!!E0,! 9,;! *'.(-&%$'(&/! 6)$(+$6/,! '*! 1.,(+0! *&+%')! &(&/;2$2 $2! %0,! .2,! '*!
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&7,)&#,!1.,(+0,2!)&%,!&66)'&+0!$2!%&9,(4!E0,!.2,!'*!$2'%0,)3&/!-&%&!%'!3&9,!
!
26
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27
!!!!!!!!"#$!"""!%&'()'*!+,-.&./.!,0!/1,!23+4)5$.!)$6)$.$-/&-(!/#$!&-&/&'/&,-!,0!
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!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!9H7C;!
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!!!!!!!!
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9H7H;!
!
!
!
!
28
!!
!
!
!
!
!
!
!
!!!!!!!!!
!!!!!!!!!!!! Figure 2-2: Calculation of quench factor from cooling curve
and C-Curve for Fe-0.16 C-0.16 Si-0.67 Mn wt% steel.
!
!
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/)%*012! +.%(&8$! 2$%*+0.! *#+%;.$226! )7+*)*+0.6! ).8! 2&1/)%$! /+.+2#! $//$%*2! 0.!
%00(+.7! 1)*$! )2! <$((! )2! *#$! *1).2/01')*+0.! 1)*$! 0/! *#$! )((04:! "#$! %)(%&()*+0.!
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!!!!!!!!!!"#$!-&$.%#!/)%*01!%).!9$!&2$8!*0!$2*+')*$!*#$!)2>-&$.%#$8!#)18.$22!+.!
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!!!!!!!!!!!!!!!!!!!!!!!!G=:HI!
!
29
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,-)! :2$-+#*-;! <,%*,=5$.?! ,-)! ,554"! $0(*%*+,5! (%$)*+'*4-.! '4! =$! 0,)$! ,=42'!
#,%)-$..!,-)!.'%$-;'#!*-!.($+*3*+!,5546.!,-)!.($+*3*+!54+,'*4-.!*-!(,%'./!I-+$!,!
:2$-+#! 3,+'4%! *.! $.',=5*.#$)! '#,'! "*55! (%4<*)$! '#$! %$:2*%$)! #,%)-$..! ,-)!
.'%$-;'#/! J! :2$-+#! .#425)! =$! .$5$+'$)! ,-)! 2.$)! *-! .2+#! ,! ",6! '#,'! '#$%0,5!
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!
!
30
2.3 Quenching as a heat transfer process

2.3.1
Unsteady state heat transfer
!!!!!!!!!!"#$!#$%&!&'%()*$'!+)!,()&$%-.!/#$(!%!&$01$'%&,'$!%&!%(.!2+3$(!456%&+5(!
+(!%!).)&$0!6#%(2$)!/+&#!&+0$7!
!!!!!!!!!"#$! 1#$(50$(5(! 5*! ,()&$%-.! )&%&$! #$%&! &'%()*$'! 566,')! 5*&$(! +(!
+(-,)&'+%4! 1'56$))$)8! ),6#! %)! 9,$(6#+(2!5*! 0$&%4)7! :(! &#$)$! %114+6%&+5()8! #$%&!
&'%()*$'!+)!%!-.(%0+68!&+0$!-$1$(-$(&!1'56$))7!!
!!!!!!!!!"#$! ,()&$%-.! 1'5;4$0)! %'$! *5'0,4%&$-! %665'-+(2! &5! !" #$%&! 5'! !"
'()*+(,$*-'" ).)*-%" !/!#.)()7! <5(3$6&+3$! #$%&! &'%()*$'! &#'5,2#! ;5,(-%'+$)! +)!
+015'&%(&! +(! &#$! *5'0,4%&+5(! %(-! )54,&+5(! 5*! 65(-,6&+5(! 1'5;4$0)7! "#$!
-+0$()+5(4$))! *5'0! 5*! &#$! ;5,(-%'.! 65(-+&+5(! .+$4-)! &#$! =+5&!
(,0;$'8/#+6#! +)! &#$! '%&+5! 5*! &#$! $>&$'(%4! 65(-,6&%(6$! &5! +(&$'(%4!
65(-,6&%(6$!?@AB7!!

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0"G!#$%&!&'%()*$'!65$**+6+$(&!H!I!0JD!K<!JL7!
"#$'0%4!65(-,6&+3+&.!5*!&#$!9,$(6#$-!1%'&!H!I!0JL!K<!JL7!
<#%'%6&$'+)&+6!4$(2&#!*5'!&#$!1%'&!H!07!
!!M,'*%6$!%'$%!5*!&#$!1%'&!;$+(2!9,$(6#$-!H!0D7!
"!N54,0$!5*!&#$!1%'&!H!0O7!
!!!!!!!!!!I#$(! &#$! +(&$'(%4! '$)+)&%(6$! +)! ($24+2+;4$! C5'! /#$(! &#$! $>&$'(%4!
65(-,6&%(6$!+)!4%'2$F8!1"2" !!!%(-! !P!&#+)!6%)$!65''$)15(-)!&5!%!)0%44!
3" 5'! 4%'2$! 1! 8! %(-! 1$'0+&)! &#$! 50+))+5(! 5*! &#$! )1%&+%4! &$01$'%&,'$! 3%'+%&+5(!
31
!"#!"$%&'()*#+,-+,."+/-($%*#0+.*1&$2+,.&3+'-$%&,&-$4+,.(3+&,+)"*%3+,-+!"#$%&'("
)*)+'%"!,!#*)-)."
++++++++++5."$+ ,."+ &$,"#$*)+ *$%+ "6,"#$*)+ #"3&3,*$'"3+ 7-#+ '-$%(',*$'"8+ *#"+
'-9!*#*/)":+ ,."+ 2"$"#*)+ /-($%*#0+ '-$%&,&-$+ '*$$-,+ /"+ 3&9!)&;&"%+ *$%+ ,."+
!#-/)"9+ 9(3,+ /"+ 3-)1"%+ &$+ ,"#93+ -;+ ,.&3+ '-$%&,&-$<+ =.&3+ '*3"+ #">(&#"3+ +/'"
(-)+0-1$+'(")*)+'%"!&&02!3/."
++++++++++=."+ '*)'()*,&-$+ -;+ ."*,+ ,#*$3;"#+ '-";;&'&"$,3+ ,.#-(2.+ ,."+ (3"+ -;+ ,."+
)(9!"%+3(9+9-%")+9*?"+&,+!-33&/)"+,-+"3,&9*,"+,."+*9-($,+-;+,&9"+*+303,"9+
,*?"3+,-+#"*'.+3,"*%0+3,*,"+'-$%&,&-$3+@AB:+CDE<+
2.3.2
Heat transfer during quenching
++++++++++F"*,+ #"9-1*)+ ;#-9+ !*#,3+ %(#&$2+ >("$'.&$2+ '*$+ /"+ 9*,."9*,&'*))0+

%"3'#&/"%+&$+,"#93+-;+,."+";;"',&1"+&$,"#;*'"+."*,+,#*$3;"#+'-";;&'&"$,<+
++++++++++G+ >("$'.*$,+ 9(3,+ &9!*#,+ *+ 3(;;&'&"$,)0+ .&2.+ &$,"#;*'"+ ."*,+ ,#*$3;"#+
'-";;&'&"$,+ ,-+ !#-%('"+ *+ '--)&$2+ #*,"+ ,.*,+ H&))+ 9&$&9&I"+ ,#*$3;-#9*,&-$+ -;+
*(3,"$&,"+ ,-+ ;"##&,"+ -#+ !"*#)&,"+ *$%+ 0&")%+ ,."+ %"3&#"%+ *9-($,+ -;+ 9*#,"$3&,"+ -#+
/*&$&,"<+
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H."#"K+
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4+N+O*#,+*#"*<+
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32
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!"#$%"%012(30.%0)")%.&%(')+(%/"
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)$%" -%0)(%" 3," -68204(2-'8" )%*)" &(35%*" 92)$" &'()2-+8'(" 42.%0*230*/" #$%" -338207"
(')%" -'0" 5%" 4%)%(.20%4" 31%(" '" &'()2-+8'(" )%.&%(')+(%" ('07%" ,(3." )$%" -338207"
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20)%(%*)/"
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2*" )$')" )$%*%" 1'8+%*" -'0" 5%" +*%4" 92)$" -30,24%0-%" 20" ,202)%" %8%.%0)" 3(" ,202)%"
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83-')230*/"
"
2.3.3
Determination of heat transfer coefficient using inverse method
""""""""""?0")$%"0+.%(2-'8"*2.+8')230"3,"=+%0-$207"&(3-%**:")$%")%.&%(')+(%",2%84"
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;039" )$%" 1'(23+*" -3%,,2-2%0)*:" )$%" 53+04'(6" -3042)230*:" '04" )$%" 202)2'8"
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56" ;0390" 53+04'(6" -3042)230*/" #$%" *+(,'-%" $%')" )('0*,%(" -3%,,2-2%0)" 2*" )$%"
!
33
!"#$%&!'"($)*$%+",*-)(.%/"*-&$&"*%)*-%01.%')()!1$1(%2"(%'("/1##%#&!,3)$&"*%
4567%89:;%
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-1$1(!&*1-%&#%,*)$$)&*)+31%+.%-&(1/$%1C'1(&!1*$#7%)*-%/"*/3,#&"*#%/"*/1(*&*A%
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@=1% +",*-)(.% /"*-&$&"*#% "2% =1)$% $()*#21(% )(1% #",A=$% &*% $=1% &*?1(#1% !1$="-%
4DE:;% @=1%'("/1##% 1221/$#% /)*% +1% -1$1(!&*1-% +.% $=1% $1!'1()$,(1% /=)*A1#% )$% )%
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$=1%/",'31-%1221/$#%+1$>11*%'=)#1%$()*#2"(!)$&"*%)*-%$1!'1()$,(1%45E7%D9:;
2.3.3.1
Lumped Capacitance Models
%%%%%%%%%%%<*% )% G,1*/=&*A% '("/1##% =1)$% $()*#21(% &#% )% -.*)!&/7% $&!1% -1'1*-1*$%

'("/1##;%I=1*%$=1%$=1(!)3%'("'1($&1#%"2%$=1%+"-.%,*-1(%&*?1#$&A)$&"*%)*-%$=1%
$=1(!)3%/"*-&$&"*#%"2%&$#%#,(2)/1%)(1%#,/=%$=)$%$=1%$1!'1()$,(1%&*#&-1%$=1%+"-.%
?)(&1#%,*&2"(!3.%&*%$&!1%)*-%$=1%+"-.%&#%)$%)*.%!"!1*$%)3!"#$%&#"$=1(!)37%$=1%
3,!'1-%/)')/&$)*/1%!1$="-%&*%$=&#%/)#1%&#%)%/"*?1*&1*$7%#&!'31%)*-%)//,()$1%
$""3%"2%$=1(!)3%)*)3.#&#;%<2%$=1%')($%&#%&!!1(#1-%)$%!"#"$%&*%)%/""3&*A%23,&-%>&$=%
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34
!!!!!!!!!!"#$%! &'! %($)'*#((#+! &)'&+#! %,#! -.+/! -/! 0.)+10%&.)! $)+! -/! 0.)2#0%&.)!
*(.3!%,#!-.+/!%.!%,#!'1((.1)+&)4!*51&+!(#'#(2.&(6!7*!%,#!%,#(3$5!(#'&'%$)0#!.*!
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&)'%$)%$)#.1'! %#38#($%1(#! *&#5+! &)'&+#! %,#! -.+/! &'! 1)&*.(3>! $)+! %,#! &)%#()$5!
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%$A#'!%,#!8$(%&015$(!*.(3!BC;>!C<>!CCDE!
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35
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2.3.3.2
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!<=->?@!
Applicability of lumped capacity analysis
!!!!!!!!!!".#! &'(30! 0:! (.#! 34(#&4'6! <5047)5(31#@! &#939('45#! (0! (.#! #A(#&4'6!
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2.4
36
Material physical properties
!!!!!!!!!!"#$%! $%&'()*! +#,-.+$/0/$1! !"#! ),-! 23&+/4/+! %&)$! ! #! 0)*.&2! #4! $%&!
()$&'/)*! ,&&-! $#! 5&! &63'&22&-! )2! )! 4.,+$/#,! #4! $&(3&')$.'&! -.'/,7! $%&!
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2.4.1
Specific heat capacity
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37
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############## ##############?<4@<E#
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Figure 2-3: Evolution of equilibrium phase fraction using MTDATA

calculation for Fe- 0.16 C- 0.16 Si- 0.67 Mn wt% steel. Only ferrite,
austenite, cementite were allowed to exist.
!
38
Figure 2-4: Calculated specific heat capacity of Fe- 0.16 C- 0.16 Si-0.67
Mn wt% steel as a function of temperature using MTDATA.
2.4.2
Thermal conductivity
!!!!!!!!!!"#$%&'(!)*+,-)./0/.1!/2!'!3-+)./*+!*3!.#$!)*&4*2/./*+!'+,!.#$!2.%-).-%$!
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39
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Figure
2-5: Calculated thermal conductivity for Fe- 0.16 C- 0.16 Si!!
0.67 Mn wt% steel as a function of temperature using the thermal
conductivity neural network model.
2.5
Theoretical and experimental investigation
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40
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2.6 Mathematical description of quenching process
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!
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Program transient
temperature
!
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Input & Initialization

"!#$%&'(!)*!#)+',-!
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Temperature Profile
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END
Figure 2-8: Temperature profile program flowchart.
Yes
Chapter 3
Neural Network Model for Prediction of
Thermal Conductivity of Steels
!
3.1
Introduction
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Neural Network Model for Prediction of Thermal Conductivity of Steels
57
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3.2
Modelling Complex Properties

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3.3
58
Thermal conductivity
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3.3.1
59
Thermal conductivity and electrical resistivity

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3.3.2
Effect of temperature
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3.3.3
60
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3.4
62
Bayesian Neural Networks

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a
b
c
Figure 3-1: Variation of thermal conductivities of iron

and steels with temperature [88].
a-Iron.
c- Alloy steels.
b- Carbon steel.
d- High alloy steels.
((((((((((((((((((((((((((((((((((((((((((((((((((((((
8
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3-2: An example of three layer neural network with four inputs
and five hidden units.
64
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3.4.1
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3.4.2
Noise and uncertainties

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68
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!
Figure 3-3: Variations in the test and training errors as a function of
model complexity, for noisy data in a case where y should vary with x3.
The filled points were used to create the models (training data), and the
circles constitute the test data [102].
(a) A linear function which is too simple.
(b) A cubic polynomial with optimum representation of both the training
and test data.
(c) A fifth order polynomial which generalizes poorly.
(d) Schematic illustration of the variation in the test and training errors
as a function of the model complexity.
69
!
!
Figure 3-4: Schematic illustration of the uncertainty in defining a

fitting function in regions where data are sparse (B) or where there is
scatter (A).The thinner lines represent error bounds due to
uncertainties in determining the weights [102].
3.5
Procedures
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71
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&
Table 3-1: Summary of the database of steel thermal conductivities,
&
all elements
are in wt%.
Input
Minimum Maximum
Average
Standard
Deviation
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HHD&
F0"2$*'+-+'7&O&M&.PA&QPA&&
AB9C&&
>H9>A&&
HH9EC&&
AA9?>&&
&
&
!
!
!
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!
!
!
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!
!
!
!
!
!
!
!
!
Figure 3-5: Distribution of data.
72
73
!
!
!
!
!
!
!
!
!
! Figure 3-6: Significance of each input in each sub-model used to build
!
! the committee model, T is the temperature.
"#$%&%&'!()!*+,-.(/01*!2%34!,03200&!5!$&/!67!4%//0&!+&%3*!$&/!+*%&'!8!
/%))0#0&3!#$&/(.!*00/*!#0*+130/!%&!579!*+,-.(/01*!*+::0**)+11;!3#$%&0/!)#(.!
667! /%))0#0&3! %&%3%$1! :(&/%3%(&*<! "0*3%&'! 0$:4! ()! 340*0! .(/01*! :$=$,%1%3%0*! 3(!
=#0/%:3!340!+&*00&!30*3%&'!*03!$11(20/!$!#$&>%&'!,;!340!1('!=#0/%:3%?0!0##(#<!@!
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#01$3%(&*4%=!%*!?0#;!*%.=10E!)(#!0A$.=10!1%&0$#!34#(+'4(+3!340!#$&'0!()!%&=+3E!
(#! 34$3! 340#0! %*! $! 1(2! :(##01$3%(&! ,03200&! 340*0! %&=+3*! $&/! 340! 340#.$1!
:(&/+:3%?%3;<!K3!$1*(!.%'43!,0!340!:$*0!34$3!340*0!010.0&3*!4$?0!,00&!:(+&30/!
)(#!34#(+'4!340!LB0L!%&=+3<!F$#,(&!4$*!4%'40#!*%'&%)%:$&3!34$&!340*0!010.0&3*<!
M%))0#0&3! *+,C.(/01*! $**%'&0/! /%))0#0&3! *%'&%)%:$&:0*! 3(! N&E! G%E! N(E! O! $&/!
F(! 24%:4! *(.03%.0*! 4$/! *%'&%)%:$&:0! *%.%1$#! 3(! :$#,(&! $&/! *(.03%.0*! 4$/!
74
!"#$%& '%($)*+,& -%./%#"*0#%& "12& *)%& +0.& 34& *)%& %!%.%1*+& 56%7& '%#%& #380+*!9&
/%#:%(;%2&*3&8%&+($1(4(:"1*&(1/0*+,&
&
3.6
Model predictions
6($0#%& <=>& +)3'+& "& :3./"#(+31& 8%*'%%1& *)%& /#%2(:*%2& *)%#."!&
:3120:*(;(*9&0+(1$&1%0#"!&1%*'3#?&.32%!&"12&*)%&*"#$%*&2"*"&4#3.&*)%&*%+*&+%*,&
-)%#%& (+& $332& "$#%%.%1*& 8%*'%%1& *)%.@& ')(:)& (12(:"*%+& 3/*(.0.&
/%#43#."1:%&43#&*)%&.32%!,&
6($0#%&<=A&+)3'+&*)%&(14!0%1:%&34&(1:#%"+(1$&*%./%#"*0#%&31&*)%&*)%#."!&
:3120:*(;(*9& 34& (#31& "12& 2(44%#%1*& +*%%!& :3./3+(*(31+,& B":)& :3./3+(*(31& )"+&
2(44%#%1*&*)%#."!&:3120:*(;(*9&;"!0%&"*&#33.&*%./%#"*0#%,&C+&*)%&*%./%#"*0#%&
(+& (1:#%"+%2@& /)3131& +:"**%#(1$& +*"#*+& *3& 23.(1"*%& "12& *)%& .%"1& 4#%%& /"*)&
#%20:%+&'(*)&(1:#%"+(1$&*%./%#"*0#%@&"12&"*&)($)&*%./%#"*0#%+&5"0+*%1(*%&/)"+%&
4(%!27& *)%& *)%#."!& :3120:*(;(*9& (+& .0:)& !%++& 2%/%12%1*& 31& *)%& /0#(*9& 34& *)%&
+"./!%&8%:"0+%&"!!&*)%&%!%.%1*+&$3&*3&*)%&+3!0*(31@&*)%&;"!0%+&:31;%#$%,&
6($0#%+&4#3.&<=D&*3&<=<E&+)3'&*)"*&*)%#."!&:3120:*(;(*9&2%:#%"+%+&43#&
%":)& %!%.%1*& "+& "!!39(1$& (1:#%"+%+@& "+& %F/%:*%2& 4#3.& %G0"*(31& <,E,& -)%&
."H3#(*9& 34& *)%& %!%.%1*+&2%:#%"+%& *)%& *)%#."!& :3120:*(;(*9&')%1&"22%2&83*)&
*3& /0#%& (#31& "12& I,J& :"#831& +*%%!,& -)%& %44%:*& (+& .3#%& /#31301:%2& "*& !3'%#&
*%./%#"*0#%+,& K"1"2(0.& "12& :3//%#& "#%& 83*)& %F:%/*(31+@& (*& (+& !(?%!9& *)%&
%F/!"1"*(31& (+& *)"*& *)%+%& %!%.%1*+& "#%& 13*& $%1%#"!!9& (1& +3!(2& +3!0*(31,&
K"1"2(0.&'(!!&#%.3;%&:"#831&4#3.&+3!0*(31&*3&43#.&:"#8(2%+@&"12&:3//%#&'(!!&
43#.& :3//%#& /#%:(/(*"*%+@& ')(:)& )";%& .0:)& )($)%#& :3120:*(;(*9& *)"1& (#31,&
L(.(!"#!9&*(*"1(0.&:"1&8%&+%%1&*3&)";%&"1&%44%:*&(1&*)%&I,J&:"#831&+*%%!&5')%#%&
-(M& '(!!& 43#.7& 80*& (1*%#%+*(1$!9& 13*& (1& *)%& /0#%& (#31,& B44%:*& 34& (1:#%"+%2&
:3120:*(;(*9& 43#& ;"1"2(0.& "22(*(31& *3& /0#%& (#31& 54($0#%& <=J>7& (+& /#38"8!9& "1&
75
!"#$%!&#' ()' #*$' +,-$./' 0$&!12$' #*$' +!3,"(#4' ,%' -!#!' !"$' %,"' 2#$$.2' 5&,)#!()()6'
&!"0,)78'
Figure 3-7: Comparison of predicted against the measured

thermal conductivity for the final committee.
Figure 3-8: predicted influence of temperature on the thermal

conductivity of iron and different compositions steels.
!
!
!
!
!
!
!
!
!
!
!Figure 3-9: Predicted influence of carbon addition to pure iron
at different test temperatures.
!
!
!
!
!
!
Figure 3-10: Predicted influence of carbon addition to 0.1C-1.5Mn

steel at different test temperatures.
76
3
!!
77
Figure 3-11: Predicted influence manganese addition to pure

iron at different test temperatures.
Figure 3-12: Predicted influence of manganese addition to 0.1C-1.5Mn

3
!
Figure 3-13: Predicted influence of nickel addition to pure iron

Figure 3-14: Predicted influence of nickel addition to 0.1C1.5Mn steel at different test temperatures.
78
3
!
79
Figure 3-15: Predicted influence of molybdenum addition to

pure iron at different test temperatures.
Figure 3-16: Predicted influence of molybdenum addition to 0.1C-1.5Mn

Figure 3-17: Predicted influence of vanadium addition to pure

Figure 3-18: Predicted influence of vanadium addition to 0.1C-1.5Mn

80
81
Figure 3-19: Predicted influence of chromium addition to pure

Figure 3-20: Predicted influence of chromium addition to 0.1C-1.5Mn

Figure 3-21: Predicted influence of copper addition to pure iron

Figure 3-22: Predicted influence of copper addition to 0.1C-1.5Mn

82
Figure 3-23: Predicted influence of niobium addition to pure

Figure 3-24: Predicted influence of niobium addition to 0.1C-1.5Mn

83
Figure 3-25: Predicted influence of aluminum addition to pure

Figure 3-26: Predicted influence of aluminum addition to 0.1C1.5Mn steel at different test temperatures.
84
Figure 3-27: Predicted influence of silicon addition to pure iron

Figure 3-28: Predicted influence of silicon addition to 0.1C1.5Mn steel at different test temperatures.
85
Figure 3-29: Predicted influence of tungsten addition to pure

Figure 3-30: Predicted influence of tungsten addition to 0.1C-1.5Mn

86
Figure 3-31: Predicted influence of titanium addition to pure

Figure 3-32: Predicted influence of titanium addition to 0.1C1.5Mn steel at different test temperatures.
87
Figure 3-33: Predicted influence of cobalt addition to pure iron

Figure 3-34: Predicted influence of cobalt addition to 0.1C1.5Mn steel at different test temperatures.
88
3.7
89
Predictive ability
!"#$ %#&#'()$ *#'+,'-(&.#$ ,+$ /"#$ -,0#)$ .(&$ 1#$ /#2/#0$ 13$ *'#04./4&%$ ,&$
5&2##&$ 0(/(6$ !"#$ -,0#)$ 42$ +,5&0$ /,$ 1#$ (1)#$ /,$ %#&#'()47#$ 25++4.4#&/)3$ /,$
'#*',05.#$ /"#$ 1(24.$ /'#&0$ 4&$ /"#$ 0(/(8$ (&0$ 1#$ .(*(1)#$ ,+$ -(94&%$ 52#+5)$
*'#04./4,&2$,+$5&2##&$.,-*,24/4,&2$:+4%5'#2$;<;=$/,$;<>?@8$/"#2#$A#'#$%',5*#0$
4&/,$ /",2#$ A4/"4&$ /"#$ '(&%#$ ,+$ 0(/($ 52#0$ +,'$ /'(4&4&%$ (&0$ /",2#$ ,5/240#$ /"#$
'(&%#$ (&0$ /"42$ 0,#2$ &,/$ &#.#22('4)3$ .)(224+3$ /"#-$ (2$ 4&/#'*,)(/4,&$ (&0$
#B/'(*,)(/4,&$ 1#.(52#$ 4/$ 42$ *,2241)#$ /,$ "(C#$ /"#$ #)#-#&/2$ 4&$ 04++#'#&/$
.,-14&(/4,&28$A"4."$A#'#$&,/$*'#2#&/$4&$/"#$0(/(1(2#6$$$
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3.7.1
Unseen data within the range of model

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5&2##&$ 0(/($ %4C#&$ 13$ F,)-(&$ GH?I8$ ,&)3$ /"#$ %'(0#2$ ,+$ 2/##)2$ A#'#$ %4C#&$ 13$
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2",A&$4&$/(1)#$;<L6$
!"#$ *'#04./4,&2$ .,-*('#$ +(C,'(1)3$ A4/"$ /"#$ '#+#'#&.#$ 1,,9$ 0(/(8$ (2$
2",A&$4&$/"#$+4%5'#28$(&0$()2,$A4/"$/"#$#B*#./#0$/#-*#'(/5'#$0#*#&0#&.#$+',-$
+4%5'#$ ;<M8$ '#*',05.4&%$ /"#$ .,''#./$ 0#*#&0#&.#$ 5*,&$ /#-*#'(/5'#$ +,'$ /"#$
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/"(/$ -,0#)$ .(&$ *'#04./$ /"#$ .,''#./$ /#-*#'(/5'#$ 0#*#&0#&.#$ +,'$ /"#2#$ /3*4.()$
.,-*,24/4,&2$,+$2/##)6$$
N&,/"#'$.,-*('42,&$+,'$/"#$*'#04./4,&$,+$/"#$-,0#)$A(2$(%(4&2/$0(/($+,'$
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90
!"#$%&'&%()*+',+-)',&)&..".)/0.1)"2)',&)#"3&%4)&5&-)',"67,)',&)&80!')50.+0'+"-)
01) 0) 26-!'+"-) "2) '&#$&.0'6.&) .&$".'&3) +1) -"') #0'!,&34) $0.'+!6%0.%() 2".) ',&)
2&..+'+!)1'&&%9):,&)3+22&.&-!&)+-)',&)$.&3+!'+"-)2".)',&)2&..+'+!)1'&&%)+1)1+#+%0.)'")
',&)&8$&.+#&-'0%)3+22&.&-!&).&$".'&3)+-)50.+"61)$0$&.19)
:0/%&);<=)1,"*1)',0')',&)$&.!&+5&3)&..".)"2)',&)#"3&%4)*,+!,).&$.&1&-'1)
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+3&0%)!01&)',&)'*")50%6&1)1,"6%3)/&)&?60%9):,&)#"3&%)"5&.&1'+#0'&3)',&)&..".)
2".)6-1&&-)30'04)/6')',&)20!')',0')',&)#"3&%)+-3+!0'&3)',&)6-!&.'0+-'()+1)0)61&26%)
*0.-+-79)
)
)
) Table 3-3: Compositions for the steels used to test predictive capability.
Steel
Fe-18Cr-8Ni
Mn
Mo V
Cr
Cu Al Nb Si
Ti
Co
D9>@)) D9;@) B))
D))
D))
>B))
D))
D)) D))
D))
D))
D))
D))
Fe-0.5C
D9@)) D9@)) D))
D))
D))
D))
D))
D)) D))
D9C@)) D))
D))
D))
Fe-1C
>))
D9@)) D))
D))
D))
D))
D))
D)) D))
D9C@)) D))
D))
D))
Fe-1.5C
>9@)) D9@)) D))
D))
D))
D))
D))
D)) D))
D9C@)) D))
D))
D))
Ferritic steel
D9C)
>)
D9@ >C)
D)
D)
D)
D9C@) D9@) D)
D)
>;9@ D)
D)
D)
D9E@) D)
D9C)
Austenitic steel D9D=) C)
Ni
D9@)
>@9@ C)
D)
D9C@ D)
)
)
)
)
)
)
Table 3-4: The prediction ability of the model against the unseen data.
Data set
)
)
)
Perceived error Root mean squared error
Unseen data within the range of model.
@9@)
A9>)
Data beyond range of model.
BC9;)
@D9B)
Figure 3-35: Prediction for an 18-chromium 8-nickel stainless

!
steel.
!
!
!
!
!
!
!
!
!
!
!
Figure 3-36: Prediction for 0.5wt% Carbon steel.
91
Figure 3-37: Prediction for a 1wt% carbon steel.
Figure 3-38: Prediction for a 1.5wt% Carbon steel.
92
Figure 3-39: Prediction for austenitic stainless steel.
Figure 3-40: Prediction for ferritic stainless steel.
93
94
Summary
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Chapter 4
Experimental work
4.1
Introduction
A calculation of the heat transfer coefficient needs accurate data for the
temperature history within the sample. In this chapter, the design of the probe
and the quenching system used to generate the necessary data (cooling curves)
for steels is described. Experimental details such as the preparation of the
probe and the method for analysing the collected data are also described.
Figure 4-1 shows the details of the experimental work as a flow chart,
showing the factors considered in the design of the experiments and
summarising the test conditions.
4.2
Quenching system design

Previous researchers have utilised a multitude of probe techniques to
predict the heat transfer coefficient (as discussed in chapter 1), but probe
dimensions of less than 10 mm are not often used because of the difficulty of
temperature control during the transfer from the furnace to the quench bath.
4 Experimental work
Figure 4-1: Flow chart details for the experimental work.
96
4 Experimental work
97
Figure 4-2: The Quenching system.
In this work, a controlled quenching system was designed to ensure that

the probe is not excessively cooled in air during the transfer from the furnace
to the quenchant tank. Figure 4-2 illustrates the experimental arrangement.
The system consists of a data- acquisition system, a small axial furnace,
0.25 litre beaker for the quenchant and a K-type thermocouple inserted in to
the geometric centre of the probe where it is held in place by a 35 cm steel
tube. This allowed temperature data to be taken at the geometric centre of the
probe. The tube also acts to guide the movement of the probe as it is dropped,
and increases the probe transfer speed from inside the furnace to the
quenchant tank using gravity.
4 Experimental work
98
All components were held in place by a stand to guide the probe as it is

traversed from the middle of the furnace to the middle of the quench tank, as
shown in figure 4-2.
4.2.1
The furnace
Carbolite axial furnace with maximum operating temperature 1000C,
inside diameter is 2.5 cm, and heated length 13 cm is placed in the frame as
shown in figure 4-2 to allow the probe to transfer from the furnace to the
quench tank.
4.2.2
Quench tank
A 0.25 litre glass beaker is used as a quench tank. This size of beaker is
enough to keep the quenchant temperature with no significant change during

the quenching process.
4.2.3
The thermocouple
A 1 mm diameter, 1 m long K-type inconel 600 sheathed thermocouple
is used for time-temperature data recording. The thermocouple is inserted to

the geometric centre of the probe through a side hole at the upper end (figure
4-3). And a screw is used to fix it in position.
The response time of the thermocouple used is sufficiently short in
order to register the change during quenching of the probe.
4 Experimental work
Figure 4-3: The arrangement of probe, thermocouple and

guide shaft. The 1 mm shielded thermocouple passes through
centre of guide shaft and into the probe.
99
4 Experimental work
4.2.4
100
Data acquisition system

National instruments SCXI-1000-1328 data acquisition system with a
Virtual bench-logger software and computer was used to collect the timetemperature data from the thermocouple inside the probe during the quenching
process.
The thermocouple is connected to the connector box which is connected
to the computer via National Instrument DAG card- 6036E. The connector can
accommodate a maximum of 4 thermocouple connections. Data were
collected every 0.001 s.
4.2.5
The probe
4.2.5.1
Probe materials
The probe was made from different alloy steels (table 4-1) in order to
characterise its cooling rates and the heat transfer coefficients and to ensure
that the coupling of heat flow and structural transformations can be obtained.
Table 4-1: Chemical composition in wt%.

Steel
Si
Mn
Ni
Mo
Cr
Al
Co
Cu
Pb
Ti
Sb
0.16
0.16
0.67
0.08
0.02
0.06
0.15
1.19
1.5
0.08
0.31
1.19
0.02
0.136
0.78
1.6
2.02
0.25
1.01
1.37
3.87
0.55
0.22
0.77
0.15
0.05
0.2
0.001
0.54
0.2
0.74
0.17
0.05
0.2
0.001
0.16
0.22
0.3
2.93
0.389
1.47
0.28
0.01
0.004
0.001
0.003
0.001
0.013
0.011
4 Experimental work
4.2.5.2
101
Probe dimensions
The probe was designed using the lumped heat capacity method (as
discussed in chapter 2) to be able to justify an assumption of uniform probe
temperature during the cooling process. The dimensional quantity plays an
important role in assessing the applicability of the lumped capacitance
method. Essentially, with !"##$%&, the results are expected to yield reasonable
estimates within about 5%.

########
(2.4)
The thermal conductivity values for the steels are about 50 W/ m C

[17] while the maximum heat transfer coefficient value expected is 10000
W/ m2 C for quenching in agitated water. By using the above values for ' and
(, and 0.1 for the !" number in equation 2.4, it is possible to calculate the
appropriate dimensions for the probe for measuring the heat transfer
coefficient for steels in different quenching conditions (figure 4-4).
The length of the probe is 5 times its diameter in order to neglect heat
extraction through the ends of the cylinder, consistent with the supposition
that at the half length cross-section only a radial-symmetrical heat flow exists.
Because the objective of cooling curve analysis is to measure the ability
of the quenchant to attenuate heat transfer under various conditions, it is
desirable that the experiment is not perturbed by the measurement process
itself; therefore, a probe with semi- infinite dimensions is usually selected.
4 Experimental work
4.2.5.3
102
Probe surface finish
The surface finish of the probe is kept standard by machining and

grinding all the probes surface in the same way before quenching, in order to
avoid any additional effect for the surface roughness.
Figure 4-4: The design and the dimensions of the probe,

showing positioning of thermocouple within the probe,
and details of fixture.
4 Experimental work
4.3
103
Probe preparation and test procedure

1. The probe was cleaned using an ultrasonic cleaner for 30 min before
quenching in order to avoid surface contamination between the
thermocouple and the probe surface, to insure good contact to measure
the necessary temperature.
2. A small amount of fine graphite powder was used in order to attain
better contact between the thermocouple tip and the probe.
3. Alumina paste was used to seal the gap between the probe and the
thermocouple in order to avoid the leakage of the quenchant solution
into the thermocouple, which can cause the thermocouple to cool faster
than the probe and result in erroneous readings. The alumina was
applied and furnace hardened for 8 h at 200C.
4. The furnace was set to 850C and held there for 10 min, which is the
time needed to reach 850C.
5. The probe and guide shaft was inserted through the guide hole holding
the thermocouple in the centre of the furnace for 4 min, this period of
time is enough to reach the designed quenching temperature.
6. The thermocouple is connected to the data logging system and the data
logging is started with scan rate 1000 scan/s.
7. The probe and guide shaft assembly is released and falls under gravity
until the probe enters the quenching tank when the stopping flange
reaches the guide hole in the holding frame.
8. The data logging system was switched off after the thermocouple
reading reached the quenchant temperature.
9. The used probe was removed from the end of the guide shaft, replaced
with an unused probe for the next test.
4 Experimental work
4.4
104
Data analysis
A minimum of three quenching experiments were performed to test the
repeatability of probe for each condition. In each experiment, many thousands

of data points were collected; to avoid the effect of noise, the data were
smoothed using a rolling average of 11 points before plotting or using in the
analysis. The smoothed data were used to calculate the cooling rate which is
the first derivative as a function of temperature. The cooling rate is then used
as an input in the inverse heat conduction model to estimate the heat transfer
coefficient at the metal/quenchant interface.
4.5
Experimental plan
4.5.1
Different steel compositions

The quench test was repeated many times using probes made from
different steels to show the dependence of the heat transfer coefficient on steel
composition.
4.5.2
Different quenchant type and quenchant temperatures

Different quenchant type and different quenchant temperatures were
used to determined the effect of the type and the temperature on the results,
table 4-2 shows the testing conditions during the experimental work.
Table 4-2: Quenching test conditions.
Quenchant type
Quenchant temperature / C
Water
23
42
Oil
20
85
150
Brine
20
70
100
60
75
100
4 Experimental work
4.5.3
105
Case study
A cylindrical sample was used to demonstrate the validity of the
calculated heat transfer coefficient using the modelling techniques and to

assess its applicability to different dimensions. The sample was with 52 mm
diameter and 20 mm length, and with three K-type thermocouples inserted as
illustrated in figure 4-5 (geometric centre-midpoint between the centre and the
surface 1 mm from the surface). The thermocouples were connected to the
data logger to record the cooling curves during the quenching process. The
cooling curves were then analysed to predict the hardness profile in the
sample.
Figure 4-5: The cylindrical sample with three inserted

thermocouples.
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Chapter 6
Conclusions and future work
6.1
Conclusions
1. A probe has been developed to determine the heat transfer coefficient of
steel. The probe dimensions were fixed by ensuring an appropriate Biot
number so that the probe temperature can be as uniform as possible
during the course of the experiments.
2. The latent heat of transformation does affect the temperature field and
transformation through thermal transients extending throughout the
body of the sample, even at positions away from the quenchant.
3. A general neural network model has been developed, which is capable

to predict thermal conductivity.
6 Conclusion and future work
172
4. The confidence in the measured heat transfer coefficients is supported

by the fact that reasonable predictions could be made of the cooling
curves when applied to a steel sample much larger than the probes.
5. The heattransfer coefficients when combined with calculated cooling
and time temperaturetransformation curves, can with the help of the
quench factor method enable the estimation of hardness variation as a
function of distance.
6. It has been demonstrated that the steel probe, which replicates phase
transformations during the course of cooling, is the best for determining
the heattransfer coefficients.
7. The heat transfer properties are greatly affected by the quenchant
parameters.
6 Conclusion and future work

6.2
173
Suggestions for the future work
1. Improving the mathematical model by including the latent heat in the

calculations, in this case the equation for heat transfer coefficient should
represent always the maximum values we observed for different
compositions steels.
2. Study the effect of the other quenching parameters (agitation and
surface roughness) on cooling rate, heat transfer coefficient and
mechanical properties for steels.
3. Repeat the same experiments in inert atmosphere to evaluate the effect
of surface oxide layer on heat transfer properties.
4. The thermal conductivity model could be enhanced by:
1. Including calculation of physically meaningful parameters.
For example the equilibrium volume fraction of austenite,
cementite and ferrite could be included to attempt to
distinguish the effect of the different components as they vary
as a function of temperature.
2. It seems likely that any significant improvement to the model
would require new experiments to be performed to measure
the effect of microstructure, which is required to model
thermal conductivity changes as a function of time and
temperature.
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Submitted to the Department of Electromechanical Engineering/

Failure is the opportunity to begin again more intelligently.

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3 NEURAL NETWORK MODEL FOR PREDICTION OF THERMAL

5 RESULTS AND DISCUSSION

6 CONCLUSION AND FUTURE WORK

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1 Introduction and Literature review

1 Introduction and Literature review

Figure 1-1: Coupling effect between cooling rate, phase

1: Temperature dependent phase transformations.

1 Introduction and Literature review

1 Introduction and Literature review

1 Introduction and Literature review

1 Introduction and Literature review

Table 1-1: Comparison of probe specifications standards.

Figure 1-3: Inconel 600

1 Introduction and Literature review

Figure 1-4: Multiple thermocouples

Figure 1-5: Hines-Mueller type

1 Introduction and Literature review

1.2.1!!!!!Calculation of heat transfer coefficient

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1 Introduction and Literature review

1 Introduction and Literature review

Figure 1-7: Effect of quenchant composition on the heat-transfer

Figure 1-8: Heat-transfer coefficients as a function of temperature

1 Introduction and Literature review

Figure 1-9: Cooling rates as a function of temperature obtained

'%! 2%38&'$! (&/.)2$! #$)'! '/)*(.$/! 2%$..,2,$*'! +,('/,5&',%*! ./%3! $Q8$/,3$*')0!

1 Introduction and Literature review

1 Introduction and Literature review

1 Introduction and Literature review

1 Introduction and Literature review

Objective of the study

Research work layout

1 Introduction and Literature review

1 Introduction and Literature review

2.1 Quenching and quenching stages

!"#$%&'"() '() &*+) ,&++-) ."(.+#(+/) %!&+#) 01+(.*'(2) 1(/+#) ,&%(/%#/'3+/)

Stage-A Heat Removal

Stage-B Heat Removal

Stage-C Heat Removal

Figure 2-1:!Cooling curve and cooling rate curve at the centre of a 25 mm

Cooling curve analysis

Effect of quenching parameters on cooling curve

Estimating as quenched hardness of steel from cooling curve

2.3 Quenching as a heat transfer process

Unsteady state heat transfer

Heat transfer during quenching

++++++++++F"*,+ #"9-1*)+ ;#-9+ !*#,3+ %(#&$2+ >("$'.&$2+ '*$+ /"+ 9*,."9*,&'*))0+

Determination of heat transfer coefficient using inverse method

Lumped Capacitance Models

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Applicability of lumped capacity analysis

Material physical properties

Specific heat capacity

Figure 2-3: Evolution of equilibrium phase fraction using MTDATA

Theoretical and experimental investigation

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