Proceedings of the ASME 2018 13th International

Manufacturing Science and Engineering Conference

MSEC2018
June 18-22, 2018, College Station, TX, USA

MSEC2018-6457

WATER-JET ASSISTED LASER SURFACE HARDENING OF MEDIUM CARBON STEEL USING FIBER LASER

Sagar Sarkar, Ashish Kumar Nath

Department of Mechanical Engineering
Indian Institute of Technology, Kharagpur
Kharagpur, West Bengal, India-721302

KEYWORDS
Water-jet assisted laser surface hardening; Fiber laser;
Martensite; Micro-hardness; Medium carbon steel
ABSTRACT
Laser surface hardening of most of the industrial components
require depth of surface modification in the range of 100-150
micron. Conventional laser surface hardening uses laser as a
heat source to modify a particular area of the surface without
melting in an inert gas environment. However, the hardened
profile in this case shows peak hardness value at a certain depth
from the top surface. Also, hardening the top surface to get
relatively much higher hardness near the top surface in case of
thin sheets becomes difficult due to accumulation of heat below
the surface of the specimen which in turn lowers the cooling
rate. Hence, self-quenching becomes inadequate. In the present
study, an in-house fabricated laser processing head with coaxial
water nozzle has been used to flow a laminar water-jet during
the laser surface hardening process to induce forced convection
at the top surface. Thus, heat gets carried away by the water-jet
from the top surface and by the water from the bottom surface
as well. Results show that with judicious selection of process
parameters, it is possible to get higher hardness (800 HV) to
that of conventional laser surface hardening (500 HV) at the top
surface using this process. Present process can be used for those
cases where high hardness values are required near the top
surface specially for thin sheets and thermally sensitive
materials.
INTRODUCTION
Laser surface hardening is a well established process [1,2]. In
recent times there has some interest in laser surface
modification of very low carbon steel (C wt% << 0.1) thin
sheets ( ~ 1 mm thickness) with potential application in
hardening the surfaces of automobile body parts after forming
[3,4]. Most of the industrial components which undergo laser
surface hardening require high hardness values near the top
surface and a depth of surface modification in the range of 100-
150 µm [5]. However, for laser surface hardening of thin steel
sheets, self quenching becomes inadequate and becomes
difficult to achieve high hardness value at the top surface.
Sarkar et al. [3] formulated an analytical model to determine
heating and cooling thermal cycles for laser surface hardening
of low carbon (0.05% C and 0.07 % C) thin sheet considering
heat conduction along depth and radial direction with and
without heat sink and showed that almost double (average)
micro-hardness could be obtained for laser hardened specimens
to that of base material. Cooling rates more than 1000 oC/s
could be realised even in thin sheets of thickness comparable to
thermal diffusion length, sufficient for self-quenching and
austenite to martensite transformation. For laser beam diameter
more than ~ 4mm the radial heat conduction cooling tends to
rendered ineffective, resulting initial fast cooling from
temperature above Ac3 to about 500o C followed by very slow
surface cooling, a condition conducive for the austenite- bainite
transformation [6]. Syed et al. [4] also reported increase in
microhardness by 133-145 % as compared to base hardness for
a C-Mn low carbon (0.05 wt% C) automotive steel sheet of 1
mm thickness, surface hardened using high power diode laser.

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 Heat sink in conjunction of a thin steel sheet can be used to EXPERIMENTAL DETAILS
increase the hardenability of the thin steel sheet. Ki et al. [7]
used four different heat sinks (copper, steel, stainless steel, no An in-house fabricated laser processing head with coaxial water
heat sink) along with two different grades of steel DP590 and nozzle [14] has been used for carrying out the experiments and
boron steel to study the effect of heat sinks on laser its design is shown in Fig. 1. Specimens were submerged in
transformation hardening. The study showed that in presence of water and a co-axial laminar flow of 0.54 litre/min was
heat sinks, both cooling and carbon diffusion is similar to that maintained during the water-jet assisted processing. Because of
of thick plate case whereas heat treatable region remains same the scattering of the laser beam in water, a significant amount
as that of no heat sink case. In another study, Kim et al. [8] of energy gets lost [15,16], therefore a defocused laser beam of
studied the effect of different heat sink materials to control the 2 mm diameter was used. However, with the same beam
thermal deformation in laser transformation hardening of steel diameter and process parameters, heat energy input will be
and reported two different thermal deformation mechanisms-. much higher and surface will get melted while carrying out
one is plastic deformation and second one is deformation due to surface hardening in air. Therefore, the laser beam was
martensitic phase transformation. defocused to 3 mm while surface hardening in air. After several
For all the above cases, laser surface hardening in air gives experimental trails, combinations of different laser powers and
hardened profile having relatively low hardness values at top scan speeds were chosen judiciously (for both water-jet assisted
layers, peak at a certain depth and then a gradual decrease [3, 9- hardening and hardening in air) without melting the surface to
10]. In order to achieve narrow heat affected zone and uniform achieve different depth of hardness (100-170 µm) without
hardness over an extended area, many researchers have used giving any particular preference to the numerical value. Laser
water as an assist medium while laser surface hardening is power was kept little higher and scan speed were kept
carried out. Jin et al. [11] carried out a feasibility study on laser approximately half (for most of the cases) for water-jet assisted
surface hardening of tool steel underwater and found out that hardening to that of hardening in air. This was done to
depth of penetration and heat affected zone of laser surface compensate energy loss in water due to scattering of laser beam
hardened area is smaller than that of laser surface hardening and ensure surface temperature is above Ac3 austenitization
done in argon gas environment. Orazi et al. [12] also used temperature, but below the melting point.
annular water flow simultaneously while hardening AISI 1040
with an Nd-YAG laser and demonstrated uniform hardness over
an extended surface.
Apart from laser, usage different case hardening processes
(either chemical or electrical environment) namely Carburizing,
Nitriding, Cyaniding, Carbonitriding, Ferritic nitrocarburizing
can suitably modify or harden the surface of a metal object to a
certain depth while allowing the metal deeper underneath to
remain soft, thus forming a thin layer of harder metal (called
the "case") at the surface [13]. However, case hardening causes
surface modification depth in the range of 0.5 mm to 1.5 mm
which is not suitable for thin sheets of thickness less than 1 mm
since almost half or entire thickness of the sheet will get
modified making it hard and brittle.
In order to achieve high hardness value at the top surface for
thin steel sheets, an in-house fabricated laser processing head
with coaxial water nozzle has been used to flow a laminar
water-jet during laser surface hardening using an 2 KW Yb-
fiber (Make: IPG photonics) laser to induce forced convection
at the top surface. Thus, heat gets carried away by the water-jet
from the top surface and by the water from the bottom surface
as well. Results show that with judicious selection of process
parameters, it is possible to get higher hardness (800 HV) to
that of conventional laser surface hardening (500 HV) at the top FIGURE 1 - DESIGN OF IN-HOUSE FABRICATED LASER
surface using this process. Present process can be used for PROCESSING HEAD WITH COAXIAL WATER NOZZLE [14]
those cases where high hardness values are required near the
top surface especially for thin sheets and thermally sensitive Water column height used for surface modification was ~10
materials. mm. To investigate the heat sink effect, two different specimen
thicknesses 0.6 mm and 1.2 mm were chosen for both the
processing conditions. Detailed process parameters are given in
Table 1.

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 TABLE 1 - PROCESSING PARAMETERS FOR LASER A
SURFACE HARDENING
1200
In air (Laser beam diameter =3mm) Track 2 rep 1 Track 2 rep 2 Track 2 rep 3
Specimen thickness 1.2 mm Specimen thickness 0.6 mm 1000

800

Microhardness (HV) →
Laser Laser scan speed Laser fluence Laser power Laser scan speed Laser
power (W) (mm/min) (J/mm2) (W) (mm/min) fluence 600
(J/mm2)
400
500 3000 3.33 500 4000 2.5
500 4000 2.5 500 5000 2 200
500 5000 2 500 6000 1.67
0
500 6000 1.67 750 8000 1.88 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
500 8000 1.25 1000 13000 1.54
Distance from surface (µm) →
1000 13000 1.54

Water-jet assisted processing ( Laser beam diameter =2 mm)

B
Specimen thickness 1.2 mm Specimen thickness 0.6 mm 1000
Track 1 Track 2 Track 3
Laser Laser scan Laser fluence Laser power Laser scan Laser

Microhardness (HV) →
800
power (W) speed (mm/min) (J/mm2) (W) speed (mm/min) fluence
600
(J/mm2)
600 2500 7.2 500 3000 5 400
600 2000 9 500 2500 4.17
200
800 1500 16 600 2500 7.2
700 2500 8.4 0
700 3000 7 0 100 200 300 400 500 600 700

Distance from surface (µm) →

Since there is a certain loss of laser power in water, therefore
the laser fluence used in water-jet assisted processing was kept FIGURE 2 - (A) WATER-JET ASSISTED PROCESSING
CONDITION WITH SPECIMEN THICKNESS 1.2 MM LASER
on the higher side of that for laser processing in air.
POWER 600W AND LASER SCAN SPEED 2500 MM/MIN,
DEPTH OF SURFACE MODIFICATION 120 µm (APPROX); (B)
WATER-JET ASSISTED PROCESSING CONDITION WITH
RESULTS AND DISCUSSIONS SPECIMEN THICKNESS 0.6 MM LASER POWER 600W AND
LASER SCAN SPEED 2500 MM/MIN, DEPTH OF SURFACE
Surfaces of specimens were sand blasted to ensure uniform MODIFICATION 146 µm (APPROX)
absorptivity of the laser beam. Argon gas was used as a
shielding gas while carrying out the experiment in air. After, A
hardening the surface specimens were cut along its cross- 1200
section using Wire-cut Electro Discharge Machine (WEDM) Track 1 Track 2 Track 3
(Make: Elektra Maxicut, India). Specimens were polished with 1000
Microhardness (HV) →

different grade of SiC papers and then cloth polished to 1 µm

800
using an automatic polishing machine (Model: Buehler
Metaserv 250, USA). Specimens were cleaned in ethanol using 600
an ultrasonic cleaner (Make: Toshkon, India) and then etched
400
with 2 % Nital (2% Nitric acid and 98% Ethanol) solution to
reveal the laser hardened zones. Vickers micro-hardness (Make: 200
Omnitech, India) measurements along cross section were taken
with applied load as 50 gf and dwell time as 10 sec with three 0
replicates each for each processing condition. Fig.2 and 3 show 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
variation in micro-hardness values from top to bottom of the Distance from surface (µm) →
surface along the cross section with optical image of the
hardened zone given in inset for water-jet assisted and in air
conditions respectively.

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 B centered cubic (BCC) crystal structure and can dissolve
maximum 0.008 wt % C at room temperature and 0.028 wt %
1000 at eutectoid temperature, 727 C (Ac1) and above. Cementite
Track 1 Track 2 Track 3 (Fe3C) is an intermetallic compound and consists of 6.67 wt %
800
carbon. In laser hardening of hypo-eutectic steel, as the
Microhardness (HV) →

600 eutectoid temperature, Ac1 (727C) is reached during laser

heating, pearlite colonies start transforming into austenite (
400 phase).This has face centered cubic (FCC) crystal structure and
can dissolve 0.76 wt% C at eutectoid temperature and
200
maximum 2.14 wt % C in solid solution at 1147C. Cementites
0 (Fe3C) in pearlite begins dissolving and the carbon starts
0 100 200 300 400 500 600 700 diffusing into eutectoid ferrite lamellae transformed austenite.
Carbon from high content austenite also diffuses into low
Distance from surface (µm) → content austenite and proeutectoid ferrite. Proeutectoid ferrite
also starts transforming into austenite at eutectoid temperature
FIGURE 3 - (A) LASER SURFACE HARDENING IN AIR WITH
SPECIMEN THICKNESS 1.2 MM LASER POWER 500W AND
and gets completely transformed when the temperature reaches
LASER SCAN SPEED 5000 MM/MIN, DEPTH OF SURFACE Ac3 point. A sufficient holding time above austenitization
MODIFICATION 128 µm (APPROX), (B) LASER SURFACE temperature Ac3 is needed for complete transformation of pro-
HARDENING IN AIR WITH SPECIMEN THICKNESS 0.6 MM eutectoid ferrite to austenite, dissolution of cementite (Fe 3C),
LASER POWER 500W AND LASER SCAN SPEED 4000 and diffusion of carbon uniformly in austenite phase. This
MM/MIN, DEPTH OF SURFACE MODIFICATION 170 µm depends on the prior size of the pearlite colonies and that of the
(APPROX) pro-eutectoid ferrite regions.Austenitization temperature Ac3
depends on the composition of steel and varies from 912C for
The hardness value depends on the volume fraction of 0 wt% C to 723 C for 0.76 wt% C. In laser processing the
martensite formed during laser transformation hardening heating rate is usually very high in 102-104 K/s range. Ac3
process and the carbon content in the martensite lathes. In case temperature increases with increasing heating rate, and tends to
of steel having 0.45 % carbon, an average hardness value of
saturate at 912C for heating time less than 1 s [18].
around 713 HV can be achieved theoretically [17] and the
Homogeneous distribution of carbon in austenite phase is
achieved maximum hardness in the present study is more than
diffusion kinetic controlled, and depends on the raised
~900 HV which is at par of values reported in literature [17] .
temperature and the lamellae spacing in pearlite colonies and
From Fig. 3(a) it can be seen that ~ 900 HV peak hardness is
the initial ferrite grain size. Specimens having initial larger
achieved at a depth of around 100 µm below the top surface for
ferrite grain size would require longer holding time above Ac3
laser surface hardening in air. Depth of surface modification
temperature for carbon to diffuse uniformly and form
comes out to be around 128 µm. Peak hardness and depth of
homogeneous austenite.
hardening of similar ranges have been obtained for water-jet
In case of water-jet assisted hardening, lower laser scan speed
assisted processing condition also as shown in Fig. 2(a). But in
and hence higher interaction time has been used to raise the
this case the peak hardness values shifts relatively closer to the
temperature above Ac3 temperature and get a desired depth of
top surface (approx 75 µm from top surface). Similar trend can
surface modification. As a result, heating rate will be relatively
be seen for specimens with lower thickness i.e. 0.6 mm. Fig.
slower and hence Ac3 temperature will be lower than that of
3(b) shows peak hardness values around 950 HV at a depth of
hardening in air. However, due to presence of water, forced
160 µm from top surface with total depth of surface
convection will take place and cooling rate will be relatively
modification as 170 µm (approx) for laser surface hardening in
higher for water-jet assisted hardening. Lower Ac3 temperature
air, whereas Fig. 2(b) shows similar peak hardness values at a
will restrict the grain growth of austenitic microstructure; hence
depth of 100 µm from top surface with total depth of surface
relatively lower austenite grain size is expected to form.
modification as 146 µm (approx). It is also noted that the
Subsequent fast cooling by self-quenching through heat
microhardness at the surface is distinctively more in case of
conduction in the rest of the bulk material causes FCC austenite
water assisted laser processing. This kind of trend can be
phase to transform into tetragonal body centred martensite
explained as the following:
metastable phase. Martensite is a hard and brittle metastable
In case of laser surface hardening, top surface layer of the
phase, and its hardness depends on the extent of tetragonal
specimen is heated by laser to a temperature above Ac3
distortion, which in turn depends on the carbon content. Higher
austenitization temperature, but below the melting point. In the
the carbon content, higher will be the distortion. After cooling,
present study, a medium carbon steel having 0.45 % carbon,
austenite phases will convert into martensite and martensite
hence a hypo-eutectic steel, has been considered. The
with carbon content more than a critical value Cc (which is
microstructure of hypo-eutectoid steel consists of ferrite grains
usually taken to be 0.05 wt% C) will only increase hardness
and pearlite colonies which consists of lamellae of two phases,
[17].
ferrite ( phase) and cementite (Fe3C). Ferrite has body

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 Shorter processing time causes random distribution of carbides
(Fe3C) around pearlite grains leading to inhomogeneous
austenite microstructure for water-jet assisted hardening. After
self-quenching, martensite having inhomogeneous carbon
content and hence varied hardness forms. However, since the
austenite grain size for water-jet assisted hardening is relatively
less, a final martensite microstructure with relatively smaller
grain size with varied hardness forms. Therefore, when micro-
hardness is taken, indenter gets more resistance collectively
from relatively large no of small size grains and also probability
of heating a martensite structure with very high hardness near
top surfaces increases. The reverse phenomenon occurs for
laser surface hardening in air. Therefore, relatively a very high
hardness near top surface could be achieved for water-jet
assisted hardening whereas relatively low hardness could be
observed near top surface for laser surface hardening in air.
Water-jet assisted processing
Specimen thickness 0.6 mm Specimen thickness 1.2 mm
A H/W=0.18 D H/W=0.14
B H/W=0.22 E H/W=0.17
I H/W=0.13 L H/W=0.08
FIGURE 4 - LASER SURFACE HARDENING WITH WATER-
JET: SPECIMEN THICKNESS 0.6 MM (A) LASER POWER (P)
=500W AND LASER SCAN SPEED (S) =3000 MM/MIN, (B)
P=700W, S = 3000MM/MIN, (C) P=700W, S=2500MM/MIN;
SPECIMEN THICKNESS 1.2 MM (D) P=600W,
S=2500MM/MIN, (E) P=600W, S=2000MM/MIN, (F) P=800W,
S=1500MM/MIN;
LASER SURFACE HARDENING IN AIR: SPECIMEN
THICKNESS 0.6 MM (G) P=500W, S=4000MM/MIN,(H)
P=750W, S=8000MM/MIN, (I)P=1000W, S=13000MM/MIN;
SPECIMEN THICKNESS 1.2 MM (J) P=500W, S=4000MM/MIN,
(K) P=500W, S=8000MM/MIN, (L) P=1000W, S=13000MM/MIN
Fig. 4 shows optical images of cross section of hardened
surface having different depths of hardening for both using
water-jet and in air. This figure is presented just to demonstrate
that with judicious selection of laser process parameters it is
possible to get desired depth of surface modifications and
aspect ratio. In case of water-jet assisted laser surface
hardening, faster cooling leads to lower diffusion length in
radial direction. As a result, surface modification area with
higher depth to width ratio (H/W ratio) could be obtained while
compared to that of laser surface hardening in air. This effect is
particularly prominent for sheets having higher thickness (1.2
mm in this case) for selected process parameter in the present
study. The present water-jet assisted hardening process will be
particularly useful to surface harden an extended area to a
certain depth using overlapping of tracks with minimum effect
of tempering in overlapping zones.

CONCLUSIONS
C H/W=0.22 F H/W=0.19
Water-jet assisted laser surface hardening can be an effective
way to surface harden thin steel sheets having wide range of
Processing in air applications in manufacturing particularly automobile sectors.
Specimen thickness 0.6 mm Specimen thickness 1.2 mm Relatively higher hardness (800 HV) could be obtained at the
top surface as compared to conventional laser surface
hardening (500 HV) of thin (0.6 mm) steel sheets using this
process. Higher depth to width ratio of surface hardened area
obtained using this process could be useful for surface
G H/W=0.20 J H/W=0.12
hardening an extended surface with minimum tempering effect
at the overlapped zone.

FUTURE WORK

H H/W=0.16
K H/W=0.08 In a future work, metallurgical aspects of the laser hardened
zone will be studied for both surface hardening in air and water
to get a deeper insight and control of the process. Also, effect of
overlapping of tracks during water-jet assisted laser surface

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 hardening needs to be studied. Further, a suitable analytical
model will be formulated to validate the experimental result.
ACKNOWLEDGMENTS
Authors gratefully acknowledge the financial supports from the
Board of Research on Nuclear Science under Grant
2009/34/33/BRNS/2752 dt. 04/01/2010 and from the
Department of Science and Technology, Government of India,
under the FIST program - 2007 (SR/FIST/ETII-031/2007).
[11] Jin, B., Li, M., Hwang, T. W., Moon, Y. H., 2015,
“Feasibility Studies on Underwater Laser Surface Hardening
Process”, Advances in Materials Science and Engineering ,
2015, Article ID 845273, 6 pages, Hindawi Publishing
Corporation, http://dx.doi.org/10.1155/2015/845273
[12] Orazi, L., Liverani, E., Ascari, A., Fortunato, A.,
Tomesani, L., 2014, “Laser surface hardening of large
cylindrical components utilizing ring spot geometry,” CIRP
Annals - Manufacturing Technology, 63 (1), pp. 233-236.

[13] https://en.wikipedia.org/wiki/Case-hardening accessed on

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