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Module 5
Module 5
materials
Heat treatment
Heat treatment is the process of heating and cooling metals to
change their microstructure and to bring out the physical and
mechanical characteristics that make metals more desirable.
HEAT TREATMENT
BULK SURFACE
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Through hardening of the sample
The surface of is affected by the quenching medium and experiences the best possible
cooling rate. The interior of the sample is cooled by conduction through the (hot) sample and
hence experiences a lower cooling rate. This implies that different parts of the same sample
follow different cooling curves on a CCT diagram and give rise to different microstructures.
This gives to a varying hardness from centre to circumference. Critical diameter (d c) is that
diameter, which can be through hardened (i.e. we obtain 50% Martensite and 50% pearlite at
the centre of the sample).
More over the time lag between the transformations at the surface and the core results in an
unfavorable tensile residual stress at the surface.
Recall the general thumb rule that the region that transforms later is likely to have
compressive residual stress.
The surface is likely to transform first in steel having the same composition all through its
section.
Therefore surface would have residual tensile stress. Depending on its magnitude it may lead
to cracking or distortion.
The presence of residual tensile stress is also harmful as it would reduce fatigue life of critical
components like turbine shaft or landing gear of an aircraft.
The purpose of surface hardening is to develop a hard surface with compressive residual stress,
to improve its wear resistance, to increase its fatigue life and to avoid susceptibility to
distortion and cracking.
There are several other ways the strength or the hardness of the
surface can be increased without adversely affecting the toughness
of the core.
1. Induction hardening
2. Case carburizing + case hardening
3. Nitriding
4. Shot peening
5. Hard facing, coating or surface alloying
Coatings Carbonitriding
Flame hardening
Induction hardening
Laser hardening
Electron beam hardening
Ion implantation
Selective carburizing and nitriding
Induction hardening
• Induced eddy currents
heat the surface of the
steel very quickly and is
quickly followed by jets of
water to quench the
component.
• A hard outer layer is
created with a soft core.
The slideways on a lathe
are induction hardened.
Induction hardening is very effective for surface hardening of plain carbon steel
having 0.35‐0.70%C.
Carburizing, also referred to as Case Hardening, is a heat treatment process that produces a
surface which is resistant to wear while maintaining toughness and strength of the core.
This treatment is applied to low carbon steel parts after machining as well as high alloy
steel bearings, gears and other components.
Carburizing increases strength and wear resistance by diffusing carbon into the surface of
the steel creating a case while retaining a substantially lesser hardness in the core. This
treatment is applied to low carbon steels after machining.
Gas carburizing allows for accurate control of both the process temperature and carburizing
atmosphere (carbon potential).
The carbon potential of the gas can be lowered to permit diffusion, avoiding excess carbon
in the surface layer.
Carburizing cannot be done in ferrite phase as it has very low solid solubility for carbon at
room temperature. It is done in the Austenite region above 727°C in carbon rich
atmosphere.
Types of carburizing
i. Pack carburizing
ii. Gas carburizing
iii. Liquid carburizing
For iron or steel with low carbon content, which has poor to no hardenability of its own,
the case hardening process involves infusing additional carbon into the case.
Case hardening is usually done after the part has been formed into its final shape, but can
also be done to increase the hardening element content of bars to be used.
Because hardened metal is usually more brittle than softer metal, through-hardening (that
is, hardening the metal uniformly throughout the piece) is not always a suitable choice for
applications where the metal part is subject to certain kinds of stress.
In such applications, case hardening can provide a part that will not fracture (because of
the soft core that can absorb stresses without cracking) but also provides adequate wear
resistance on the surface.
Pack carburizing
• The component is packed
surrounded by a carbon-rich
compound and placed in the
furnace at 900 degrees.
• Over a period of time carbon
will diffuse into the surface of
the metal.
• The longer left in the furnace,
the greater the depth of hard
carbon skin. Grain refining is
necessary in order to prevent
cracking.
A major limitation of pack carburizing is poor control over temperature & carburization
depth.
On completion of the process the steel parts are cooled slowly. Direct quenching is not
possible as the job is surrounded by carburizing mixture packed in a sealed box having high
thermal mass.
• Gas carburizing. The object is placed in a sealed furnace with carbon monoxide allowing for fine control of the
process.
• Gas carburization is done by keeping the samples at the carburizing temperature for a specified time in a
furnace having a mixture of carburizing and neutral gas. CH4 and CO are the most commonly used
carburizing gas.
• It is usually mixed with de‐carburizing (H2 and CO2) and neutral gases (N2).
• This helps maintain a close control over carbon potential. It should be enough to maintain %C at in the range 1.0‐
1.2% at the surface.
• In the presence of Fe the carburizing gases decompose to produce nascent carbon that diffuses into steel.
CH4 = C (Fe) + 2H2
2CO = C (Fe) + CO2
• It provides excellent control over the furnace temperature and atmosphere (carbon potential).
It allows precise temperature control and rapid heat transfer. Carburization takes place due
to the formation of nascent carbon.
Nitrogen like carbon forms interstitial solid solution with iron. If it is present in excess it
forms nitride (Fe4N). It is extremely hard and brittle.
Nascent nitrogen that forms at the surface of steel as ammonia comes in contact
with Fe.
This diffuses into iron lattice and form nitride as and when the amount of
nitrogen in steel exceeds its solubility limit.
The presence of alloying elements having high affinity for nitrogen increases
nitrogen pick up.
The formation of nitride within the matrix results in a substantial increase in the
hardness of steel.
Nitriding of steel is carried out only after it has been hardened and tempered. It
is the last heat treatment given to steel.
Flame hardening
• Gas flames raise the
temperature of the outer
surface above the upper
critical temp. The core
will heat by conduction.
The plasma is gas that when exposed to an electrical potential is ionized and glows. The
parts to be nitrided are connected as a cathode and the furnace walls are the anode.
They are supplied with a potential between 0.3 and 1KV. Particles are accelerated and hit
the cathode (work piece) transferring all their kinetic energy and heating it.
For gas particles to have enough kinetic energy to transfer, they need to have a
considerable large mean free path and in this way gain speed for collision with the
substrate before colliding with another gas particle.
This is why this process and mostly all plasma processes work under vacuum as a measure
to increase the mean free path of the accelerated particles.
The pressure used for plasma nitriding is normally between 100 – 1000Pa. Other authors
suggest a narrower range between 50 – 500Pa.
This pressure is considered as a rough vacuum since there are other processes that use
much higher vacuum values.
The chemical reaction when ammonia dissociated was explained in the preceding section.
In the case of plasma nitriding, the process gases are introduced separately.
One combination that is often used is Nitrogen + Hydrogen. Argon is also used in the initial
stages as a plasma sputtering gas for surface cleaning of the substrate to be nitrided.
The voltage drop occurs in what is called the plasma sheath which is a positive charged
area where ions are accelerated towards the cathode and have their highest kinetic
energies.
During ion nitriding three reactions will occur at the surface of the material being treated.
In the first reaction, iron and other contaminants are removed from the surface of the
work by an action known as sputtering or by a reducing reaction with hydrogen.
The impact of hydrogen or argon ions bombarding the work surface dislodges the
contaminant that will be extracted by the vacuum system. The removal of these
contaminants allows the diffusion of nitrogen into the surface
During the second reaction, and as a result of the impact of the sputtered ion atoms, case
formation begins at the work surface of iron nitrides.
Sputtered Fe + N = FeN
During the third reaction, a breakdown of the FeN begins under the continuous sputtering
from the plasma.
This one causes the instability of the FeN which begins to break down into the e phase
followed by the g’ phase and a iron-nitrogen compound zone
There are following types of surface treatments.
Surface Treatment
Concepts and Applications of the process
Type
A method of forming metallic coatings (plating films) on subject metal surfaces submerged in solutions containing ions by
utilizing electrical reduction effects. Electoplating is employed in a wide variety of fields from micro components to large
Electroplating
products in information equipment, automobiles, and home appliances for ornamental plating, anti-corrosive plating, and
functional plating.
A plating method that does not use electricity. The reduction agent that replaces the electricity is contained in the plating
solution. With proper re-processing, virtually any material such as paper, fabrics, plastic and metals can be plated, and the
Electroless Plating
distribution of the film thickness is more uniform, but slower than electroplating. This is different from chemical plating by
substitution reaction.
The process creates thin films of sulfide and oxide films by chemical reactions such as post zinc plating chromate
Chemical Process treatment, phosphate film coating (Parkerizing), black oxide treatments on iron and steels, and chromic acid coating on
(Chemical Coating) aluminum. It is used for metal coloring, corrosion protection, and priming of surfaces to be painted to improve paint
adhesion.
This is a surface treatment for light metals such as aluminum and titanium, and oxide films are formed by electrolysis of
Anodic Oxidation the products made into anodes in electrolytic solutions. Because the coating (anodizing film) is porous, dyeing and coloring
Process are applied to be used as construction materials such as sashes, and vessels. There is low temperature treated hard
coating also.
Products are dipped in dissolved tin, lead, zinc, aluminum, and solder to form surface metallic films. It is also called
Hot Dipping
Dobuzuke plating and Tempura plating. Familiar example is zinc plating on steel towers.
Gasified or ionized metals, oxides, and nitrides in vacuum chambers are vapor deposited with this method. Methods are
Vacuum Plating
vacuum vapor deposition, sputtering, ion plating, ion nitriding, and ion implantation. Titanium nitride is of gold color.
There are spray painting, electrostatic painting, electrodeposition painting, powder painting methods, and are generally
Painting used for surface decorations, anti-rusting and anti-corrosion. Recently, functional painting such as electro-conductive
painting, non-adhesive painting, and lubricating painting are in active uses.
Metals and ceramics (oxides, carbides, nitrides) powders are jetted into flames, arcs, plasma streams to be dissolved and
Thermal Spraying be sprayed onto surfaces. Typically used as paint primer bases on larger structural objects, and ceramic thermal spraying
for wear prevention.
This is a process of metal surface alteration, such as carburizing, nitriding, and induction hardening of steel. The processes
Surface Hardening
improve anti-wear properties and fatigue strength by altering metal surface properties.
This is a method of forming surface alloy layers by covering the surfaces of heated metals and metal diffusion at the same
Metallic Cementation time. There is a method of heating the pre-plated products, as well as heating the products in powdered form of metal to
be coated.
What is meant by Austempering?
Austempering is heat treatment that is applied to ferrous metals, most notably steel and
ductile iron. In steel it produces a bainite microstructure whereas in cast irons it produces
a structure of acicular ferrite and high carbon, stabilized austenite known as ausferrite.