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Lecture 9:
Surface hardening & tool steels
MMat 380
1
Topics to be covered
• Surface Hardening
– Heat treatment
– Case hardening
• Tool Steels
– Features
– Alloy classification
– Secondary hardening
2
Ways to surface harden a component
3
Pack carburizing
Heat treatment
Procedure:
Applies to medium and high carbon steels
• Heat surface first to austenite
– interior (core) not heated into γ
• Cool to form surface martensite
– interior unaltered
– martensite in compression
• Tempering is usually done
8
4
Heat treatment
Characteristics:
• Hardened depth depends on
– frequency (induction)
– heat flow (flame)
– i.e. Freq: 1000 Hz Depth: 4.5-9 mm
1 000 000 Hz Depth: 0.25-0.8 mm
• Surface Rc 50-60 (martensite or tempered
martensite)
• Interior Rc 10-20 (pearlite-ferrite-pearlite)
Case hardening
5
Case hardening
• Steels used
• low C
• made from Al killed ingots – fine grain size
1018; 1020; 1022
where distortion is not a problem and a high
strength core is not required (ferrite-pearlite
core)
4118; 8620 etc.
increased hardenability allows slow quench rates
so less distortion and cracking
11
Case hardening
• Carburizing gas mixtures
• CO, CO2, H2, H2O and carrier gas N2
• Reactions during carburizing:
CH4 + CO2 = 2CO + 2H2
CH4 + H2O = CO + 3H2
– Natural Gas Produces CO + H2
2CO = C (in Fe) +CO2
CO + H2 = C (in Fe) + H2O
– Control CO/CO2 + H2/H20 ratio to carburize or
decarburize (or neutral conditions)
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6
Case hardening
4. Residual stresses
800
S
Temperature
Ms
C-C
Mf C
Ms
Mf
0 S
0.1 1 10 100 1000 10000
log time
C-C
•C-C transforms to M first surface adjusts
•Surface transforms last – expands goes into
13
compression C
14
7
Case Hardening:
relationship of time and temperature to case depth
15
Carburizing time, hours
16
8
Microstructure through a carburized
surface
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18
9
Case hardening - nitriding
Procedure:
• Base: Special steels with strong nitride
forming elements Al, Cr, Mo, V (4140 OK)
• Quench and temper part (temper to 650°C)
• Heat and hold in atmosphere of atomic nitrogen
• 500-600°C for 1-100 hrs.
• N dissolves in α to form nitrides
• Very thin layer – diffusion is slow at these low
temperatures
• Slow cool – therefore no distortion from cooling or
phase transformation
19
Nitriding
Characteristics
• Cases are harder than carburized cases
• Excellent wear resistance and fatigue
resistance
20
10
Heat treatment Case hardening
%C 0.4-0.6 0.2
Austenized surface all
Speed of
procedure
Fast (secs) Slow (~10hrs)
Surface
chemistry
No change 0.8-1.0%C (or N)
Depth 1-10mm 0.5-2mm
Surface hardness Rc 57-60 Rc 65
martensite surface martensite;
Microstructure
(may be through part) centre pearlite
Control difficult easy
Surface
Residual stress Surface compressive
compressive
Core toughness Medium (high C) Good (low C)
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Cost Cheap $/part
Tool steels
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11
Tool steels - characteristics
23
Categories of
tool steels
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12
Tool steels – shock resistant
Requirements: Used at low temperature –
toughness
25
screwdriver blade
shear blade
26
13
Tool steels – cold work
Requirements: Used at low temperature –
sharpness
27
cutter punch
14
Tool steels – high speed
Requirements: Used at high temperature –
sharpness
29
drill bit
30
15
Tool steels – hot work
Requirements: Used at high temperature –
toughness
31
16
Tool steels - role of alloying elements
• Increase hardenability
Do elements dissolve in ferrite or form carbides?
Want strong carbide formers
Ti, W, Mo, Nb, V, Cr – No Mn or Ni
• Affect Eutectoid temperature
• Ti, Mo, W, Cr raise eutectoid (austenitizing) T:
ferrite stabilizers
• Ni, Mn lower eutectoid T: austenite stabilizers
33
Elements
affecting
eutectoid
temperature
34
17
Tool steels - role of alloying elements
35
%C in tool steels
36
18
Alloy additions to Weakest carbide formers
Most dissolved in α
tool steels Mn
Cr
Mo
Carbide formers
• Some dissolve in α
dissolve in α
W
• Some form carbides – some
V
in combination with Fe
Ti
Nb
(Cb)
strongest carbide formers
Least dissolved in α
37
Alloy classification
of tool steels
• 4 main groups
• Cold work tool steels – use limited
cold conditions
• will soften if over tempered
• 17-95°C
• Up to ~5% total alloy content; high %C
• High %C steels: high hardness therefore
good sharpness and wear resistance
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19
Alloy classification
of tool steels
W – water hardening
O – oil hardening
A – air hardening
D – high %C (1.5-2.25%C); high %Cr
(~12%Cr) (cold work dies – really a
stainless steel; excellent wear
resistance)
39
40
20
Table 10-1 Smith
41
Alloy classification
of tool steels
• Shock resistance (cold applications)
• Medium %C
• Toughness is the main concern
• <5% total alloys
• High speed tool steels
• Tx – tungsten
• Mx – Molybdenum
• Up to 25% total alloy content
• High %C – sharpness held e.g. HSS – drills for metal
42
21
Alloy classification
of tool steels
• Hot work tool steels: hot application H1x, H2x, H3x
• Cr, Mo, W – main alloy elements
• H1x – Cr
• H2x, H3x – W
• H4x, H5x - Mo
• Medium carbon
• Up to 25% alloy content
• Toughness at high temperature is main requirement
43
44
22
Estimated bar diameter that will through
harden to 55 HRC (50 HRC for H13)
Bar diameter, mm
Secondary hardening
• Red hardness
– due to alloy carbide precipitation at high tempering
T
• Low T: Fe3C precipitates
– C diffuses easily interstitially
• Alloy carbides only precipitate at high T
– more difficult diffusion conditions
• Shock resistant and hot work (both medium
carbon)
46
23
Secondary hardening
ppt of alloy
carbides
47
Secondary hardening
Plain carbon
steel
48
24
Secondary Secondary
hardening
hardening
49
Double temper
50
25
Double temper
γ
quench
•Carbides
•Martensite
1st temper •More carbides
•Retained γ •Tempered martensite
(high alloy) •Retained γ (low alloy)
quench
Double temper
52
26
Wear resistance
53
Hardness
54
27