Heat Treatment1

Prof.
SAJeurkar /TE(Mech) /NKOCET Solapur
Definition of Heat Treatment

These are controlled heating and cooling operations to change mechanical properties of Steels and alloy Steels in solid state. All heat treatments are carried out below solidus temp.
Heat treatment Concept

Steels are heated above upper critical temperature, they are held at this temp. for sufficient length of time and then cooled in proper medium to obtained required phase changes and micro structure. Austenite phase is converted into Pearlite/ Martensite /Bainite phases depending upon cooling rates, therefore heat treatments can be designed by changing method of cooling to obtain desired mechanical properties.
Prof.SAJeurkar /TE(Mech) /NKOCET Solapur 2
Tools used for heat treatment

1) Fe-Fe3C Diagram 2) T-T-T diagram 3) C-C-T diagram 3) Cooling curves
Objectives of Heat Treatment

1. 2. 3. 4. 5. 6. To Improve Ductility To relieve internal stresses To harden and strengthen metals and alloys To refine grain size To improve machinability To improve electrical and magnetic properties
Prof.SAJeurkar /TE(Mech) /NKOCET Solapur
General Heat Treatment Cycle
Heating/Austenitising
Fe-Fe3C Diagram and cooling curves
Austenite
Fast Cooling
Air cooling Normalizing Martensite
Intermediate Cooling
Slow Cooling
Fine Pearlite
Coarse Pearlite
Reheating Bainite
Austenite (Parent Phase)
Pearlite
Bainite
Martensite
Where Fe3C nucleate First, followed by ferrite 1)Coarse Pearlite where interlammellar spacing is large
Where ferrite nucleate first followed by Fe3C 1)Upper Bainite which is feathery type.
Where austenite(FCC) is converted into BCT martensite 1)Lath 2)Plate 3)Needle
2)Fine Pearlite where interlammellar spacing is less.
2)Lower Bainite which is acicular type
Part of the equilibrium phase diagram for the Fe-C system
How to plot T-T-T Diagram

1. Take small sized 25mm 25 mm samples of say 0.8%C eutectoid steels about 10 numbers 2. Heat these samples in furnace at A1+ 50 0C i.e.. 773 0C 3. Hold at this temperature so that surface and core temperature become same. 4. Quickly transfer these samples to a furnace held at 722 0C 5. Now hold the first sample at 722 0C for 1 sec and then Quench it in water. 6. Hold second sample at 722 0C for 5 sec and then Quench it in water. 7. Hold third sample at 722 0C for 10 sec and then Quench it in water. 8. Hold fourth sample at 722 0C for 60 sec and then Quench it in water. 9. Hold remaining samples at 0C for various longer times and Quench it in water. 10. Now cut the samples, polish them and observe under metallurgical microscope for pearlite and martensite transformation. 11. Repeat the procedure for 721 0C ,720, 0C - - - - till room temperature. 12. Record the time required to start Pearlite transformation and end of Pearlite transformation. 13. Plot a graph of % transformation on Y-axis and Time on X-axis for each sample for given temp (say 722 0C) Collect this information for all temp. 721,720,719,- - - till room temp. 14. Now plot on Y-axis Temperature and on X-axis time scale. Transfer above information i.e.. time to start pearlite transformation Ps and time to finish pearlite transformation Pf for all temperatures. Join all start points to get Start Curve and Join all end points to get Finish Curve.
Take small 25mm 25mm size samples of eutectoid steels Heat these samples at A1+50 0C i.e. 773 0C Quickly Transfer the samples to a salt bath furnace held at 722 0C (below A1 0C.)
Remove Remove Remove Remove after 5 sec after 30 sec after 5 min after 20 min
Remove after 1hr
Quench in water bath.
Polish, etch and observe microstructure

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T-T-T Diagram For Eutectoid Steel
Stable Austenite A1
Unstable austenite
Ps
Pf
Coarse pearlite
Nose Temp. Critical Cooling Rate CCR Bs Bf Upper Bainite Lower Bainite Ms Unstable Austenite +Martensite Mf Martensite Time in Log Scale
Fine pearlite
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TTT diagram quenching cycle
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Normalizing Heat Treatment

The Component is Heated to austenitising temperature(A3/A1/Acm+50 0C for Hypoeutectoid/Eutectoid/Hypereutectoid steels. It is held at this temp. for sufficient length of time to equalize surface and core temp. (usually 3-5 min per mm of cross section thickness) Then it is cooled in Air.
Temp.
% carbon
Objectives/Purpose of Normalizing
To produce a harder and stronger steel than full annealing. To produce fine Pearlite To improve the machinability. To modify and refine the grain structure. To obtain a relatively good ductility without reducing the hardness and strength. To homogenize microstructure as in the case of casting.
Applications of Normalizing H.T. 1. Steel castings 2. Steel Forgings
3. Shafts, Spindles, Round bars.

4. Pins, Cotters, Sheets, Plates, Rolled Bars
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Annealing Heat Treatment

The Component is Heated to austenitising temperature(A3/A1/A1+50 0C for Hypoeutectoid/Eutectoid/Hypereutectoid steels).
It is held at this temp. for sufficient length of time to equalize surface and core temp. (usually 3-5 min per mm of cross section thickness)
Then it is cooled in Furnace.
A1+50 degree
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Objectives/Purpose of Annealing
To relieve internal stresses generated in previous manufacturing like rolling, forging, casting. To improve machinability. To produce Coarse Pearlite.
To Soften the steel.

To refine & homogenize the structure. To remove gases. To improve ductility/malleability required for further processing. To make the steel suitable for next heat treatment.
Types of Annealing Processes

1) Full annealing
2) Process annealing
3) Stress relief annealing
4) Spherodising
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Full annealing
Procedure 1) Heat hypo eutectoid/eutectoid/hypereutectoid steels above A3/A1/A1+50 0C. 2) Hold/soak according to section thickness 3) Cool in the furnace slowly at a rate 30-200 0C per hour. Objectives 1) To obtain fine ferrite and pearlite mixture 2) To obtain fine cementite and pearlite mixture. 3) To increase machinability of steels. 4) To reduce strength and hardness
Applications Rolled bars,sheets,forgings and castings
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Process annealing
Procedure 1) Cold worked steels are heated above its recrystallization temp(600 degree C). That is below A1 temp. 2) Hold/soak according to section thickness 3) Cool in the air slowly at a rate 30-200 0C per hour. Objective 1) It removes the effect of cold working 2) It soften the steels and make the steel suitable for further cold working.
Applications Sheets, wires ,rods, plates manufactured by various cold working operations.
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Stress relief annealing

Procedure 1) Cold worked steels are heated to a temp between 500-550 2) Hold/soak according to section thickness for 1 to 2 hrs. 3) Cool in the air.
Objectives 1) To relieve internal or residual stresses. 2) To remove warpage of steels 3) To eliminate the chances of corrosion. Applications Rolled,extruded,welded and cast component of ferrous and nonferrous alloys.
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Spherodising
Procedure 1) Only hypereutectoid steels are spherodised. 2) Heat below A1 temp(between 650 and 700 0C) 3) Heating and cooling alternately at temps just above and just below A1 temp. 4) Cooling very slowly in the furnace.
Objective 1) To break pearlite and cementite network of hypereutectoid steels which is hard and brittle. 2) To convert lamellar cementite into globular cementite to improve machinability of steel.
Application 1) Hypereutectoid steel shafts, bars. 2) All high carbon cutting tools. 3) High Carbon ball bearings.
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Hardening/Quenching
1) Austenitise above A3/A1/A1 +50 0C for Hypo eutectoid/Eutectoid/Hypereutectoid steels 2) Hold/soak according to section thickness 3) Cool with required cooling rate in a suitable quenching medium(e.g. Water, Oil, Brine solution) exceeding CCR of given steel.
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Objectives/Purpose of Hardening
To increase Hardness of steel. To improve Wear resistance of Steel. To increase Strength of steel. To obtain Martensite phase in steel. To improve cutting ability of steel required for Tool Steels.
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Types of Hardening
1. Conventional hardening
2. Two media quenching.

3. Stepped Quenching/ Marquenching / Martempering
4. Austempering
5. Hardening with self Tempering
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Conventional Hardening
Procedure 1) Heat hypoeutectoid/eutectoid/hypereutectoid steels above A3/A1/A1+50 0C 2) Hold/soak according to section thickness 3) Cool in water or Brine solution.
Objective/Purpose 1) Hardening of Medium Carbon steels 2) Commonly used heat treatment. Applications Chisels, daggers, plough shave
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Two media Quenching

Procedure 1) Heat hypoeutectoid/eutectoid /hypereutectoid steels above A3/A1/A1+50 0C 2) Hold/soak according to section thickness 3) Cool in water initially then cool in oil.
Objective/Purpose 1) Hardening of Hupoeutectoid steels 2) To reduce distortion, cracking
Applications Taps, dies, milling cutters, Ball and roller bearings
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Martempering Procedure 1) Heat hypoeutectoid/eutectoid /hypereutectoid steels above A3/A1/A1+50 0C 2) Hold/soak according to section thickness 3) Cool in water below the nose in water, Hold isothermally to equalize surface & core temp. 4) Then cool again so that surface and core cool at the same time. Objective/Purpose 1) Hardening of High carbon & Low alloy steels 2) To reduce distortion, cracking 3) Chances of quench cracks are eliminated. Applications High carbon low alloy steels which are thick in cross sections.
Austempering Procedure 1) Heat hypoeutectoid/eutectoid /hypereutectoid steels above A3/A1/A1+50 0C 2) Hold/soak according to section thickness 3) Cool in water below the nose in water, Hold isothermally till Bs and Bf curves are Cut i.e.. Bainite transformation is completed. 4) Then cool in air. Objective/Purpose 1) The main purpose of this heat treatment is to obtain Bainite and not Martensite. 2) Properties of lower Bainite are similar like tempered martensite. 3) To obtain high hardness and toughness. Applications 0.3 to0.5% c steels Heavy duty structural parts, springs, lock washers, screws, pins , needles, cultivator shovels
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Hardening with self tempering
In this method hardening and tempering are combined. The component is taken out from the quenching bath ,when it have some heat in it i.e.at @200-250 0C This heat come out from the core of the job and start heating Martensite which is formed during quenching. This heat convert Martensite into Bainite.(Self Tempering) It is used for chisels, sledge hammers, centre punches, shafts, collars, gears which require high surface hardness. The disadvantage is, no close control on depth of hardness
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Various Types of Furnaces Used in Heat Treatments
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Concept of Hardenability
Hardenability is the capability of an alloy steel to form martensite as a result of a given heat treatment. High hardenability in a steel means that the steel forms martensite not only at surface but to a large degree throughout the interior. Hardenability more related to depth of hardness of a steel upon heat treat. The depth of hardening in a plain carbon steel may be 2-3 mm vs. 50 mm in an alloy steel Hardenability is not hardness. It is a qualitative measure of the rate at which hardness decreases with distance from the surface because of decreased martensite content. Hardenability is measured by the Jominy end-quench test, performed for standard cylindrical specimen, standard austenitization conditions, and standard quenching conditions (jet of water at specific flow rate and temperature).
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The Jominy End Quench Test measures Hardenability of steels. Hardenability is a measure of the capacity of a steel to be hardened in depth when quenched from its austenitizing temperature. Hardenability of a steel should not be confused with the hardness of a steel. The Hardness of a steel refers to its ability to resist deformation when a load is applied, whereas hardenability refers to its ability to be hardened to a particular depth under a particular set of conditions. Information gained from this test is necessary in selecting the proper combination of alloy steel and heat treatment to minimize thermal stresses and distortion when manufacturing components of various sizes To perform the Jominy Test: First, a sample specimen cylinder either 100mm in length and 25mm in diameter, or alternatively, 102mm by 25.4mm is obtained. Second, the steel sample is normalized to eliminate differences in microstructure due to previous forging, and then it is austenitised. This is usually at a temperature of 800 to 900C. Next, the specimen is rapidly transferred to the test machine, where it is held vertically and sprayed with a controlled flow of water onto one end of the sample. This cools the specimen from one end, simulating the effect of quenching a larger steel component in water. Because the cooling rate decreases as one moves further from the quenched end, you can measure the effects of a wide range of cooling rates from vary rapid at the quenched end to air cooled at the far end. Next, the specimen is ground flat along its length to a depth of .38mm (15 thousandths of an inch) to remove decarburized material. The hardness is measured at intervals along its length beginning at the quenched end. For alloyed steels an interval of 1.5mm is commonly used where as with carbon steels an interval of .75mm is typically employed. And finally the Rockwell or Vickers hardness values are plotted versus distance from the quenched end.
JOMINY.flv
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Quenching Baths/Quenching Media

Number Quenching bath 1 Water Characteristics Low cost, abundantly available, easy handling, No pollution/ disposal problem, Drawbacks High thermal stresses, Corrosion & scaling, form steam High cost, Corrosion & Disposal Problem, affect Human skin, High labour cost High cost, Chances of fire Suitable only For air Hardening steels Applications PCS, alloy steels
Aqueous solutions
Water+NaCl or Water+CaCl2 mixtures called as brine solutions Water+NaOH mixtures called as caustic solutions high cooling rates, low distortion, Paraffin based mineral oil Low cooling rates, low distortion and warpage, Uniform cooling, abundantly available, easy handling, No pollution/ disposal problem, low distortion and warpage, 50%KNO3+50%NaNO3 50%NaNO3+50%KNO2 20%NaOH+80%KOH Uniform cooling, free from Oxidation ,carburization, Suitable for selective hardening
All types of PCS, alloy steels
Oils
All types of PCS, alloy Steels with Large cross sections alloy Steels with Large cross sections
Air
Salt baths
High cost, Corrosion & Disposal Problem, affect Human skin, High labour Cost.
All types of PCS, alloy Steels with Large and Thin cross Sections. 41
Tempering
Martensite is very hard and brittle. Tempering is applied to hardened steel to reduce brittleness, increase ductility, and toughness and relieve stresses in martensite structure. This process increases ductility and toughness but also reduces hardness, strength and wear resistance marginally. Increase in tempering temperature lowers the hardness. In this process, the steel is heated to lower critical temperature keeping it there for about one hour and then cooled slowly at prescribed rate.
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Tempering
Low temp. Tempering (100-250 0C) High C Martensite -carbide+ Low C martensite (BCT) (HCP) -carbide is similar like Cementite (Fe3C ) but its chemical formula is(Fe2.4C) This mixture has high strength, hardness, low ductility and toughness. Used for low alloy steels, cutting and measuring tools. Medium temp. Tempering(250-500 0C) -carbide + Retained austenite Fe3C + Ferrite + Bainite (HCP) (Orthorhombic) (BCC) (Ferrite+ -carbide) This mixture has High toughness, ductility, High Yield point Used for Coil, laminated, Leaf Springs. High temp. Tempering (500-700 0C) Low C martensite Ferrite (BCC) (BCC) This mixture has High toughness. Used for connecting rods, shafts, spindles, crankshafts
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Selective Heat Treatments(Surface Hardening)

Introduction Carbon steels that have minimum carbon content of 0.4%, or alloy steels with a lower carbon content can be selectively hardened in specific regions by applying heat and quench only to those regions. Parts that benefit by flame hardening include gear teeth. These techniques are best suited for medium carbon steels with a carbon content ranging from 0.4 to 0.6%. Common Selective Hardening Processes include:
1. Flame Hardening 2. Induction Hardening
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Flame hardening
Flame Hardening A high intensity oxy-acetylene flame is applied to the selective region. The temperature is raised high enough to be in the region of Austenite transformation. The "right" temperature is determined by the operator based on experience by watching the color of the steel. The overall heat transfer is limited by the torch and thus the interior never reaches the high temperature. The heated region is quenched to achieve the desired hardness. Tempering can be done to eliminate brittleness. The depth of hardening can be increased by increasing the heating time. As much as 6.3 mm of depth can be achieved. In addition, large parts, which will not normally fit in a furnace, can be heattreated. The image on the left shows a large gear where the teeth are being
Flame hardening
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Induction Hardening
In Induction hardening, the steel part is placed inside a electrical coil which has alternating current through it. This energizes the steel part and heats it up. Depending on the frequency and amperage, the rate of heating as well as the depth of heating can be controlled. Hence, this is well suited for surface heat treatment. The details of heat treatment are similar to flame hardening.
Induction Hardening
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Case Hardening
The Carbon content in the steel determines whether it can be directly hardened. If the Carbon content is low (less than 0.25% for example) then an alternate means exists to increase the Carbon content of the surface. The part then can be heat-treated by either quenching in liquid or cooling in still air depending on the properties desired. Note that this method will only allow hardening on the surface, but not in the core, because the high carbon content is only on the surface. This is sometimes very desirable because it allows for a hard surface with good wear properties (as on gear teeth or knife), but has a tough core that will perform well under impact loading. It is possible to add additional carbon to the outer surface of a component low in carbon. This carbon case can then be heat treated in the normal way giving a hard outer skin and a soft core. This process is known as case hardening. Adding carbon in a process is known as carburizing.
Case Hardening: Carburizing

Carburizing is a process of adding Carbon to the surface. This is done by exposing the part to a Carbon rich atmosphere at an elevated temperature(950-1000 degree Centigrade)and allows diffusion to transfer the Carbon atoms into steel. This diffusion will work only if the steel has low carbon content, because diffusion works on the differential of concentration principle. If, for example the steel had high carbon content to begin with, and is heated in a carbon free furnace, such as air, the carbon will tend to diffuse out of the steel resulting in decarburization. There are a number of different ways to carburize or add carbon to the surface of a metal. We will briefly discuss three methods: The pack method Gas Carburizing Liquid Carburizing
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The Pack Method

The component is placed in a box surrounded by a carbon rich material and placed in a furnace at 920 degree C. The carbon is absorbed into the austenite. The depth of penetration of carbon into the surface depends on the temperature and the time spent in the furnace. To carburize to a depth of 1mm the component will need to be left in the furnace for up to 12 hours. After cooling, the component is immersed in a bath of molten salt. The salt is kept at a temperature of 780 C. The component remains immersed for a half an hour and it is then quenched in water. The salt used in this process will not add carbon or remove carbon from the surface. It is a neutral salt. The molten salt is used because it provides uniform heating over the entire surface of a complicated shape.
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Gas Carburizing and Liquid Carburizing

Gas Carburizing: Gas Carburizing is conceptually the same as pack carburizing, except that Carbon Monoxide (CO) gas is supplied to a heated furnace. The carbon-rich gas circulates within the furnace and around the component/part which is to be hardened. The deposition of carbon takes place on the surface of the part. This is a faster method of carburizing than the pack method and greater control over the process is possible. Liquid Carburizing: The steel parts are immersed in a molten carbon rich bath. In the past, such baths have cyanide (CN) as the main component. This process produces a thin, hard shell that is harder than the one produced by other carburizing methods, and can be completed in 20 to 30 minutes compared to several hours so the parts have less opportunity to become distorted. It is typically used on small parts such as bolts, nuts, screws and small gears. The major drawback of cyaniding is that cyanide salts are poisonous. Therefore, safety concerns have led to non-toxic baths that achieve the same result.
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Nitriding
Nitriding involves the diffusion of nitrogen into the surface layers of a low carbon steel at elevated temperature. The formation of nitrides in the nitrided layer provides the increased hardness. Nitriding is typically carried out in the temperature range of 500 - 575C, this is in the ferritic state rather than the austenitic used for carburising. This is possible since ferrite has a much higher solubility for nitrogen than it does for carbon.
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Carbo-nitriding
Carbo-nitriding is a variation of carburising where both carbon and nitrogen bearing species are used in the gaseous state, usually the inclusion of ammonia in with the carburising gas mixture. Carbo-nitriding is carried out in the austenite state, i.e.. temperatures above 850C, typically 870C. The case depths are typically lower than those achieved by carburising alone however the surface hardness levels can be higher
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Heat Treatment1

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Heat Treatment1

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Prof.

SAJeurkar /TE(Mech) /NKOCET Solapur

Definition of Heat Treatment

Heat treatment Concept

Tools used for heat treatment

Objectives of Heat Treatment

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

General Heat Treatment Cycle

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Fe-Fe3C Diagram and cooling curves

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Austenite (Parent Phase)

Where austenite(FCC) is converted into BCT martensite 1)Lath 2)Plate 3)Needle

2)Fine Pearlite where interlammellar spacing is less.

2)Lower Bainite which is acicular type

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Part of the equilibrium phase diagram for the Fe-C system

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

How to plot T-T-T Diagram

Remove after 1hr

Quench in water bath.

Polish, etch and observe microstructure

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

T-T-T Diagram For Eutectoid Steel

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

TTT diagram quenching cycle

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Normalizing Heat Treatment

Applications of Normalizing H.T. 1. Steel castings 2. Steel Forgings

3. Shafts, Spindles, Round bars.

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Annealing Heat Treatment

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

To Soften the steel.

Types of Annealing Processes

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Applications Rolled bars,sheets,forgings and castings

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Stress relief annealing

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

2. Two media quenching.

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Two media Quenching

Objective/Purpose 1) Hardening of Hupoeutectoid steels 2) To reduce distortion, cracking

Applications Taps, dies, milling cutters, Ball and roller bearings

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Hardening with self tempering

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Various Types of Furnaces Used in Heat Treatments

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Prof.SAJeurkar /TE(Mech) /NKOCET Solapur

Quenching Baths/Quenching Media