Open Ended lab1

Objective

To make a butt joint using the given two High Speed Steel (HSS) pieces by using arc welding.

To study the microstructure of welded (Heat Affected Zone) and non-welded zone of given sample (HSS
Sample) by using Metallurgical Microscope.

Introduction

High Speed Steel

High speed steel is a highly alloyed tool steel capable of maintaining hardness even at elevated
temperatures. High speed tool steels are so named primarily because of their ability to machine materials
at high cutting speeds. High speed steel has unusually high resistance to softening at temperatures up to
600C. it is called, red hardness.

They are complex iron base alloy of carbon, chromium, vanadium, molybdenum or tungsten or
combinations there of and some cases substantial amounts of cobalt. The carbon and alloy contents are
balanced at levels to give high attainable hardness response, high wear resistance, high resistance to the
softening effect of heat, and good toughness for effective use in industrial cutting operations.

Two basic types of HSS (AISI)

1- Tungsten type, designated T-grades

2- Molybdenum type, designated M-grades

In addition, there is a number that follows either the M or the T. Thus, there are high speed tool steels
designated M 1, M 2, M 41, T 1, T15 and so on. That number does not have any special significance
other than to distinguish one from another. For example, M 1 does not mean that it is more highly alloyed
than M 2 or has greater harden ability or poor wear resistance, and so on.

Few Common Grades OF HSS

HSS 18-4-1 is a most famous steel grade for cutting tool. It consists of:-

18-Tungsten, 4-Chromium, 1-Vandium

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Typical Alloying Ingredients

1- Carbon
2- Tungsten and Molybdenum
3- Vanadium
4- Chromium
5- Cobalt in some grades

Influenced of alloying elements on the steel properties

1- Carbon: Forms Carbides, increases wear resistance, is responsible for the basic matrix hardness.
2- Tungsten and Molybdenum: Improved red hardness, retention of hardness and high
temperatures strengths of the matrix, from special Carbides of great hardness.
3- Vanadium: Forms special Carbides of supreme hardness, increase high temperature wear
resistance, retention of hardness and high temperature strength of the matrix.
4- Chromium: Promotes depth hardening, produces readily soluble Carbides.
5- Cobalt: Improves red hardness and retention of hardness of the matrix.

Properties OF HSS

1- High working hardness

2- High wear resistance
3- High retention of hardness and red hardness
4- Excellent toughness

Applications OF HSS

1- Drill / Twist drill

2- Reamers
3- Milling cutters
4- Saw
5- Single Point cutting tools
6- Broach insert
7- Tap

Material Required

High Speed Steel pieces 1.2inch - 2 No’s

Welding Electrode

Mild Steel electrodes 3.1mm × 350mm

Welding Equipment

Air cooled transformer, Voltage 80 to 600 V, 3 phase supply, amps up to 350

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Tools and Accessories Required

1- Rough and smooth files

2- Arc welding machine (transformer type)
3- Mild steel electrode and electrode holder
4- Ground Clamp
5- Tongs
6- Face shield
7- Apron
8- Chipping hammer

Sequence of operations

1- Marking
2- Cutting
3- Edge Preparation (removal of rust))
4- Welding
5- Cooling
6- Chipping
7- Cleaning

Procedure

1- The given HSS pieces are thoroughly cleaned of rust and scale.
2- The two pieces are positioned on the welding table such that they are separated slightly for better
penetration of the weld.
3- The electrode is fitted in the electrode holder and the welding current is set to be a proper value.
4- The ground clamp is fastened to the welding table.
5- Wearing the apron and using the face shield, the arc is struck and holding the two pieces together,
first run of the weld is done to fill the root gap.
6- Second run of then weld is done with proper weaving and with uniform movement.
7- The scale formation on the welds is removed by using the chipping hammer.
8- Filling is done to remove any spanner around the weld.

Metallographic Examination

Apparatus

1- Rotating wheel for rough grinding

2- Abrasive papers of 180, 240, 600, 800, 1200 grit sizes
3- Grinding base plate
4- Grinding mediums: Silicon Carbide, Aluminum Oxide and Chromium Oxide
5- Polishing unit and polishing cloth
6- Etchant (2% Nital)
7- Soft Tissues
8- Metallurgical Microscope
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Procedure

Grinding

1- Make the surface of specimen plane by means of file or specially designed motor driven wheel.
Apply the light contact pressure during grinding, on high pressure disturb metallic layer will be
formed.
2- Keep the specimen cool during the grinding in order not to alter the structure of the specimen.
Bevel the edges and sharp corners of specimen the emery paper from tearing. Wash the specimen
and hands to prevent from coarse particles resulting from previous operation.
3- Place the SiC paper of grit size 320 on the bench plate. Apply the moderate pressure on the
specimen. Move the specimen in back and forth direction with gentle pressure. Produce the new
fine scratches at right angle to the old coarse scratches.
4- Use additional paper of increasing fineness. Wash the specimen repeatedly during grinding and
produce fine scratches at right to the old scratches. After fine grinding the specimen is ready for
final polishing operation.

Polishing

1- After fine grinding, clean the specimen by rinsing it into warm running water and dry it in air.
Rotate the polishing lap with the speed of 300 rpm and sprinkle the abrasive particles like (AL 2O3
Or Cr2O3) along with H2O.
2- Polishing is continued until mirror like, scratch free surface is obtained. Carry out microscopic
analysis after polishing the specimen just before etching to investigate the any surface defect and
non metallic inclusions distribution.

Etching

1- Prepare etching solution 2% Nital (2ml of HNO 3 in 98 ml ethyl alcohol). Clean the specimen
thoroughly with running warm water. Swab with tuft of wet cotton, rinsed in ethyl alcohol. This
cleaning will remove the debris of metal and grease etc.
2- After etching the dull surface indicate proper etching. Time of immersion should be 10 seconds.
After 10 second the specimen is washed with warm running water.
3- Microscopic examination is carried out after drying.

Results and Discussion

Figure 1.1 (a) shows that the structure consists of graphite (black) and carbide particles (white) in a
matrix of martensite. Etched in 2 percent Nital (2ml of HNO 3 in 98 ml ethyl alcohol). The medium alloy
type, with 1 percent carbon, contains up to 3 percent manganese, up to 5 percent chromium, and 1 percent
molybdenum. The increased alloyed content, particularly manganese and molybdenum, confers marked
air hardening properties and increased harden ability.

Figure 1.1 b) shows that the comparison of non welded and welded zone microstructure of high speed
steel before etching. Etched in 2 percent natal(2ml of HNO 3 in 98ml ethyl alcohol).
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a) b)

Fig. 1.1 a) The microstructure of non-welded zone High speed steel, 500x. b) The microstructure of non-
welded vs welded zone of high speed steel before etching, 100x

a) b)

Fig. 1.2 a) The comparison of non-welded vs welded zone microstructure of high speed steel, 100x. b)
The comparison of non-welded vs welded zone microstructure of high speed steel, 200x.

a) b)

Fig. 1.3 a) comparison of non-welded vs welded zone microstructure of high speed steel, Grain
boundaries are barely visible, 500x. b) The microstructure of welded zone high speed steel, 500x.
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Figure 1.3 b) shows that the large black spots are ghraphite, white spots are carbide particles, and matrix
is martensite. Etched in 2 percent Nital.These steels have good machine ability and good resistance to
decarburization; toughness is only fair, and their red hardness is as poor as the straight carbon tool steels.
They are used for taps, solid treading dies, form tools and expansion reamers.