HEAT TREATMENT GROUP IMAM BUKHARI SECTION NO 1 NAME MUHTAR BIN SUHAILI MATRIC NO 003183 3 SECTION DATE 1 ST FEBTUARY 2002 NO. OF PAGE RCVD DATE* LECTURER DR.. MOHAFIZUL HAQUE & DR. ASAD KHALID ASST. LECTURER BRO. WAN AHMAD YUSMAWIZA WAN YUSUF DEMONSTRATO BRO. ABD. RAZAK TANDANG 1 REPORT 5 RS WORKSHOP TECHNOLOGY: HEAT TREATMENT INTRODUCTION Modern demand of good quality product has made heat treatment an important process for most engineering applications. Heat treatment involves the improvement of properties of metals and alloys by changing their microstructure. Heat treatment practice is the operation of heating and cooling of metal in its solid state to change its physical properties to gain some wanted properties, which are related with changes in the nature, form, size and distribution of microelements of the material. According to the procedure used, steel can be hardened to resist cutting action and abrasion, or it can be softened to allow machining. The understanding of heat treatment is hold by the broader study of -. ow we are demands of high-quality products have made heat treatment an essential process for most engineering request. !rincipally, heat treatment is used to produce strengthening, but some heat-treating processes soften, toughen, or otherwise enhance properties. Most engineering metals and alloys have simple crystal structures, li"e face centered cubic #$%%&, body centered cubic #'%%& and he(agonal closed bac"ed H%!. The microstructure is made up of micro constituents #phases& present in the materials. The engineering property of a material depends mainly on number, size, distribution and shape of grains of each phase. OBJECTIVES The ob)ectives of this wor"shop on heat treatment are* + To acquire "nowledge about heat treatment and the importance in industry. + To gain "nowledge about heat treatment and the importance in engineering fields. 2 + To understand the effect and characteristics of heat treatment process to the strength and attribute of a metal. Heat treatment can be done to accomplish any number of ob)ectives* + To diffuse carbon and alloying elements + To improve machinability + To stress relieve + To soften and harden the material + To increase toughness and wear resistance APPARATUS 5 pieces mild steel bars (250mm x 30mm x 3mm each) Heat Treatment Furnace: Nabertherm N 81/13 ater !il T"n# $ice File Hardness testin# machine (%itut"&" '() *00) PROCEDURE ,.The five pieces of mild steel bars, is prepared by cutting a long piece of metal into five pieces with the same length using the bend saw machine. -.$our pieces are placed into the electric furnace and heated until the temperature rose up to .//%. 0.1ne piece is made as the control set. 2.The heating process is stopped once the temperature of .//% was reached. 3t too" about , 4 hours for this process. 5.Then 0 pieces of the heated bar is ta"en out. 3 6 one piece is left to cool in the room temperature. 33 6 one piece is cooled by immersing in water. 333 6 one piece is cooled by immersing in oil. 7.The one left in the furnace is left to cool in the furnace. 8.After the wor" pieces are completely cooled, some tests are carried out. 3 Fatigue test 6 9ach of the metal bars is held on a vice vertically and bent until the bar fractured by using tong. The numbers of bent is recorded for each piece respectively in the :esult sheet. File test or scratch resistant test 6 The metal is clamped on a vice and scratched by using a file. The effect of the process is then compared and recorded in the :esult sheet. Hardness test 6 This test is carried out to test the hardness of the metal bars by using hardness-testing machine. Three readings are ta"en for each bar. The averages of the three readings of each bar are ta"en as the result. The result was recorded respectively in the :esult sheet. RESULT Bar No. Qu!"#$! % M&$u' No. o( )!&* +$,, (ra"+ur& -$, +*+ or *"ra+"# r*$*+a!+ +*+ Har&!* * No. Na' o( Pro"** 1 ater + Hardest 10+,8 -uenchin# 2 !il 1. /"0t 5.,5 -uenchin# 3 'ir 82 Hard 51,+ N"rmali2in # + Furnace 5. Harder *1,* 'nnealin# T# r*u,+* o( +# (a+$%u ., or *"ra+"# r*$*+a!+ a!& #ar&!** +*+*. + DISCUSSION Alhamdulillahi :abbil ;Alamin because the main ob)ectives of this wor"shop class have been achieved when 3 had gained some "nowledge about heat treatment. $rom the observation on the result of the tests, we can say that the rate of cooling control the feature of the specimens. The results show that quenching products #i.e. quenching in water <2= and quenching in oil <,8=& present the least number of bends before bro"en compared to the annealing <58= and normalizing products <>-=. This is because the higher number of bends, the lower of its rate of cooling and therefore the more stable grain will be uniformed. 3f a well fine grain uniform, it will have a better machinability and greater depth-hardening power. 3n addition to being tougher they are more ductile and tend less to distort or crac" during heat treatment. $ast cooling will ma"e the grain not well uniformed when it reaches thermodynamics state. 3n addition it will ma"e the metal hard and brittle. 3nternally, in the first part the grain in all four bars e(panded. Then the four bars were cooled separately where here the grain was shrin"ing in different rate of stabilizing. Theoretically, annealing product that was cooled in the furnace is the softest and most ductile amongst the others. That is because the grain uniform thoroughly. Then it is followed by normalizing and finally quenching products. ?uenching in water and in oil product brea"s more easily and has the hardest surface compared to others. However, from the results, we got that the metal quenched in oil is the softest, followed by normalizing, annealing and finally the hardest is the metal quenched in water. $rom the hardness test above, a metal bar quenched in water <,/2.>= is the most difficult to brea" amongst others. %ompared to the other quench medium that is a metal bar quenched in oil <58.5=, metal bar quenched in water cools faster. Theoretically, water has higher thermal conductivity and specific heat rather than oil. Thus it absorbs heat faster than in the oil. $urthermore, the grains in the water become least uniform. Then, the hardness test for annealing <7..7= is greater than that for normalizing <5..2=. 3n point of fact, the result of the test is varying from the theoretical prediction. 9ssentially, the reference specimen should lies between normalized product and quenched oil product. 3n other words, it should be softer and more ductile than oil- quenched product and harder and brittle than normalized product. The number of bents also differs@ the number of bents should be more than oil-quenched product and less than normalized product. This may appropriate to differences in force e(erted and the frequency of bent. Also because of our inattention when we do the test. However, we could get better results by giving identical forces without changing the person when bending the metals bars, as it provide equal force and more proper 5 bending. 3n addition, we have to ma"e sure that length of metal bars is equal one to another. Ahatever it is, we than" Bod because we have finished done this report. Hopefully, we can do better in the ne(t and coming report, 3nsya Allah. THEORY Heat treatment can be regarded as one of the most important process in for most engineering applications. This is due to its role as the way to improve the properties of metals and alloys by changing the microscopic structure. Heat treatment process can be defined as an operation or combination of operation involving the heating and cooling of a material in the solid state for obtaining some desirable properties, which are associated with changes of nature, form, size, and distribution of micro-constituent of the material. (eas"ns 0"r Heat Treatin#: i) Nonferrous metals onferrous parts they are heat-treated in order* ,. To offset plastic strain inherent in a particular metal by bringing about recrystallization to provide new equia(ed and stress free-grains -. To strengthen by the age 6 hardening process. 0. To relieve internal stresses resulting from $errous Metals ii) Ferrous metals $errous part can be heat treated for the following reasons* ,. To change the microstructure by refining the grain size or producing uniform grain throughout a part -. To relieve internal stresses 0. To strengthen metal part 2. To alter the surface chemistry by adding or deleting elements 5. $orming, brazing or welding Material Classification The metal group includes both ferrous and nonferrous are shown in $igure ,* * The diagram in $igure - shows outline of the stages in producing ferrous metals such as wrought iron, cast iron, carbon steel and tool steel. . Iron Carbon Phase Diara! $errous metals have greatly different properties and microstructures with changes in carbon content. These can be related to one another in terms of the iron carbon diagram shown in $igure 0. 8 The heat treatment for the standards steel can be divided into four ma)or forms that are the following*- a& Annealing b& ?uenching c& ormalizing d& Tempering. 1 a" Annealin Annealing process can be defined as a process of heating a particular article to above the critical range for a sufficient time usually followed by a slow cooling in the furnace. The temperature to which given steel should be heated in annealing depends on its composition. The heating process is done to a temperature about above the recrystallization temperature. This usually ta"es about 25 min for each inch #-5 mm& of thic"ness of the largest section. $or steel annealing recrystallization temperature it is about >//% to .//%. The ob)ectives of annealing may be of the following* ,& To improve ductility, toughness, electrical, magnetic or other physical properties -& To relieve internal stresses induced by some previous operations #rolling, forging, uneven cooling, etc& 0& To improve machinability. 2& To soften hard steel so that it may be machined or cold wor"ed. 5& To revive neutral structure and to refine crystal structure 7& To remove gases 8& To produce a definite microstructure b" Nor!ali#in The process of normalizing contains of heating to above the upper critical range for sufficient time followed by cooling in the normal and still room temperature air. The name implies to restore the structure and properties considered normal for the type of steel involved. 3t is frequently applied to castings, forgings, to refine grain structure to obtain uniform grains #homogenization& and to relieve stresses or to achieved desired results in physical properties that is set up in previous operations. 3t is commonly applied after cold wor"ing, over heating or any other operations resulting in non-uniform heating and cooling. c" $%enchin ?uenching refers to rapid cooling in any manner after the heating process such as immersing metal in water. Co, quenching of steel consists in rapid cooling of the article by immersion in liquid or gases or by contact with masses of metal. 3t consists of cooling by direct )ets of cold air, water or other fluids especially when the article is too large. However, the quenching process in water can be divided into three separate stages. As the specimen from the hardening temperature is immersed in water, a vapor film or envelope immediately surrounds it. This stage the rate of cooling is slow. ,/ &" 'e!(erin Tempering involves the reheating of the hardened article to a specific temperature for a definite period of time and cooling it at a desired rate in order to produce a mole or less definite atomic mobility. Cteel that has been hardened by rapid quenching is brittle and not suitable for most uses. 'y tempering, the hardness and brittleness may be reduced to the desired point for service conditions. As these properties are reduced there is also a decrease in tensile strength and an increase in the ductility and toughness of the steel. 11 12 )%rface Har&enin Processes 3t is separated into two different processes that are* Nitri&in + The process of saturating the surface of steel article with nitrogen by holding it for prolonged period at a temperature in range of 285D % to 585D % in a nitrogen atmosphere. + 3t is more comple( more e(pensive and more time-consuming process than any other case hardening techniques. Case Carb%ri#in Process + The oldest method of surface hardening. + A process of increasing the carbon content at the outer surface of article by having it between >5/D% to .5/D% with carbonaceous materials #i.e.* charcoal, cyanides or any other carbon having hearing media which may be solid, liquid or gases.& Table shown five ma)or forms of heat treatment for the standard steels !:1%9CC !E:!1C9 !:1%9FE:9 !HAC9 #C& Annealing To soften Clow cool from -stable range G carbide ?uenching To harden ?uench to miss 3-T curves MartensiteH 3nterrupted quenching To harden without crac"ing ?uench, followed by slow cool from M to M MartensiteH Austempering To harden without forming brittle martensite ?uench, followed by isothermal transformation above the M G carbide Tempering To toughen #usually with minimal softening& :eheating the martensite G carbide H Cteels containing martensite must be toughened by the tempering processes transformation processes for Cteels 13 Ca,"u,a+$o! *a'/, CONCLUSION 1+ 3n this e(periment, all of the ob)ectives have been fulfilled where the students had been e(posed to the annealing, quenching, normalizing and tempering processes. Also, the processes carried out during the heat treatment pro)ect have illustrated the effect of heat treatment on changing a material natural attribute and characteristics. This "nowledge ma"es it able to treat a material specifically according to needs. To do this e(periment, students should be careful and always beware while conducting the wor" will lead to the most satisfying result. Ahile conducting the process, the precaution in handling the equipment will do the treatment will lead to better result. $urthermore, the necessary precautions and steps must be strictly followed. To conclude, heat treatment is important since it can change the properties of metals and alloys by changing their microscopic structures. 3t also can be used to diffuse carbon and alloying elements, to soften and harden the materials, to improve machinability, to increase toughness and etc. Coft Annealing ormalizing Hard ?uenching Fuctile and 'rittle