Unit 4 Heat Treatment Equipment -I

(Various heating media used for heat treatment & Temperature and atmosphere control)

Dr. S. Rajendra Boopathy, Professor,

Department of Mechanical Engineering, College of Engineering, Guindy, Anna University Chennai.

The equipment required for heat-treating consists of furnaces or other heating devices, quenching baths, temperature controls and sensors, required for the proper operation of the equipment or for the control of the process. For a heat treating process the important considerations to be focused are:
Various heating media used for heat treatment Temperature and atmosphere control Quenching media and their characteristics Various heat treatment furnaces

VARIOUS HEATING MEDIA USED FOR HEAT TREATMENT In order to obtain the required properties for a metal the heat treatment process is carried under the surrounding of several gases. Open air heat treating. Heat treating under the surrounding of some gases. Vacuum heat treating. These Are The Basic Media Used For Heat Treatment

 The heat treatment of metal components such as steel in air leads to surface oxidation. The type and thickness of oxide layers produced are dependent on the temperature of the heat treatment, the duration of exposure, and, also on the type of steel.
(Open air heat treating)

 To avoid surface oxidation the air in the heat treatment furnace must be replaced by an atmosphere that does not contain oxygen.

Another way to avoid surface oxidation is to reduce the amount of air surrounding the workpieces by vacuum heat treating.

 The use of an inert atmosphere, such as nitrogen (N2), is one method to reduce surface oxidation. Another is the use of a protective atmosphere that utilizes nitrogen in combination with reducing elements such as hydrogen (H2) and carbon monoxide (CO). Thermal processing by evacuation of air to a low level that the remaining oxygen is below the oxidation level of the material. This can be achieved by vacuum type heat treating.

Primary Furnace Gases

Nitrogen Hydrogen Carbon Monoxide Carbon Dioxide Argon and Helium Dissociated Ammonia Steam Hydrocarbons

CHARACTERISTICS OF GAS MEDIUM

Nitrogen is considered to be chemically inert and is used as a carrier gas for reactive furnace atmospheres, for purging furnaces, and in other processes requiring inert gases. However, at high temperature, nitrogen may not be compatible with certain metals such as molybdenum, chromium, titanium, and columbium. Example: NITRIDING is one example by which a case or skin of hardened steel can be produced. The piece to be case hardened is put into a furnace and heated to between 950 and 1,200F and, at the same time, is exposed to ammonia gas. The heat of the furnace causes the ammonia to break down into nitrogen and hydrogen. Some of the nitrogen combines with the elements in the steel to form chemical compounds called nitrides in the outer layer of the steel. These nitrides give the surface its hard, wearresistant qualities.

 Hydrogen is a highly reducing atmosphere that is used both for preventing steel oxidation and for oxide reduction according to the surface reactions hydrogen may be adsorbed by the metal at elevated temperatures, causing hydrogen embrittlement. Hydrogen is potentially an extremely explosive and flammable gas. However, if proper safety precautions are followed, it can be used safely in heat treatment. Carbon monoxide is also considered to be a reducing gas as it may reduce iron oxide. Although CO is a reducing atmosphere, it is not as good a reducing agent as hydrogen. Carbon dioxide is a mildly oxidizing gas. It will form oxides upon reaction with iron at elevated temperatures.

 Helium and argon are also considered to be inert gases for heat treatment processes because they will not undergo gassolid reactions, even at high temperatures. Water vapor (steam) is also an important component in heat treating. Steam will react with steel at 343oC650oC to produce a blueing effect, which imparts a wear-resistant and oxidation-resistant surface furnish. This is due to the formation of either Fe2O3, Fe3O4, or FeO, depending on the surface temperature of the steel and the ratio of water vapor pressure to hydrogen pressure in the atmosphere.

VACUUM HEAT TREATING

The term vacuum heat processing refers to heat treatment processes in which ferrous and nonferrous components are subjected to the application of thermal heat energy in a vacuum environment.

A vacuum heat treatment furnace first evacuates a particular space using vacuum pump, then heats or cools the space.

ADVANTAGES OF VACUUM HEAT TREATING

Pieces treated in atmospheric furnaces usually exhibit a light gray color even in reducing atmospheres, whereas the surfaces of vacuum heat-treated components remain bright and shiny. Heating an item in a vacuum reduces oxidation. Since a vacuum pump evacuates the space as the item is heated, all gases attached to the item can be removed.

TEMPERATURE CONTROL

The desired properties of a metal during a heat treating process can be achieved by proper control over the temperature of the furnace. So its necessary for us to measure the temperature more correctly. For the high temperatures met with in heat treatment furnaces one or other of the temperature measuring devices known as pyrometers is required.

Thermocouple pyrometer
This is the most widely used temperature measuring device for heat treatment purposes.

If the junction of two wires made from dissimilar metals (such as a copper wire and an iron wire) form part of a closed electric circuit and the junction is heated, an electromotive force (emf ) is developed whose magnitude and direction depend on the contacting materials and the temperature difference between the two points. .

The presence of this current can be indicated by a sensitive galvanometer. If the galvanometer is calibrated in degrees of temperature, we have a temperature measuring device called a pyrometer.

 The thermocouple probe consists of a junction of two wires of dissimilar metals contained within a tube of refractory metal or of porcelain. Porcelain beads are used to insulate the two wires and locate them in the sheath as shown

The radiation pyrometer

The radiant heat from the furnace or the component being heated in the furnace is focused onto the thermocouple by a parabolic mirror. Furnaces are frequently operated above the required process temperature, and the work is withdrawn from the furnace when it has reached its correct temperature as measured by a radiation pyrometer.

Uses of RADIATION PYROMETER Used for large hot components that have been removed from the furnace. Where the furnace temperature is so high it would damage the thermocouple probe. Where the hot component is inaccessible. Where the temperature of the component in the furnace needs to be measured rather than the temperature of the furnace atmosphere itself.

Temperature assessment There are simpler ways of assessing the approximate temperature; some of these will now be described. Paints and crayons These are applied to the surface of the component to be heat treated. The mark left on the surface by their application changes in colour and appearance when the desired temperature has been reached. The paints and crayons are available in a range of compositions to suit the temperature required. They have the advantage of indicating the temperature of the component at the point of application.

Ceramic cones These are also known as Seger cones and may be conical or pyramidal in shape. The cones are made with various compositions so that they soften at different temperatures. It is usual to choose three cones, one slightly below the required temperature (cone A), the second at the required temperature (cone B), and a third slightly above the required temperature (cone C).

 If the furnace is below the required temperature none of the cones soften and droop as shown in Fig. (a). If the furnace is too hot, all the cones will droop as shown in Fig. (b). If the furnace is at the correct temperature, cone A will droop a lot, cone B will just start to droop at the tip, and cone C will be unaffected. This situation is shown in Fig. (c).

These are some of the Simplest type of techniques used for temperature assessment.

ATMOSPHERE CONTROL
Reason for Atmospheric control

When natural gas is burnt in a furnace, excess air is usually present to ensure complete and efficient combustion. The resulting products of combustion (flue gases) contain oxygen, carbon dioxide, sulphur, nitrogen and water vapour. These all react to a greater or lesser degree with the surface of the workpiece & will produce heavy scaling .
What is atmospheric control?

Air in the furnace chamber can be replaced by alternative atmospheres, depending upon the process being performed and the metal being treated, in order to reduce scaling. This is known as atmosphere control.

CARBURIZING WITH GASES

A process in which carbon is added to the surface layers of low carbon steels or low alloy steels to a carefully regulated depth. This addition of carbon is called carburizing. Carburizing is achieved by heating the steel at temperatures in the homogeneous austenite phase field in an environment of appropriate carbon sources . The carburizing time depends on the de sired diffusion depth. The processes in use are classified according to their carbon sources in pack carburizing (solid compounds), salt bath carburizing (liquid carbon sources), and gas and plasma carburizing (gaseous carbon sources).

a) First, the workpiece is heated to between 900C and 950C in contact with the carburizing compound until the additional carbon has been absorbed to the required depth.

b) Second, the workpiece is removed from the carburizing compound & reheated to between 780C and 820C

After quenching a component from a temperature above 780 C

c) Finally the component is dipped in cold water for quenching.

Carburizing atmosphere
Carburizing depends upon the fact that very low carbon (0.1%) steels will absorb carbon when heated to between 900C and 950C. Various carbonaceous materials are used in the carburizing process.
 Solid media Molten salts Gaseous media

Solid media such as bone charcoal or charred leather, together with an energizer such as sodium and/or barium carbonate. The energizer makes up to 40% of the total composition.

Molten salts such as sodium cyanide, together with sodium carbonate and/or barium carbonate and sodium or barium chloride. Since cyanide is a deadly poison such salts must be handled with great care and the cyanide makes up only between 20 and 50% of the total. Stringent safety precautions must be taken in its use. The components to be carburized are immersed in the molten salts.

Gaseous media based upon natural gas (methane) are increasingly used. Methane is a hydrocarbon gas containing organic carbon compounds that are readily absorbed into the steel. The methane gas is frequently enriched by the vapours that are given off when mineral oils are cracked by heating them in contact with the

metal platinum which acts as a catalyst.

CARBON POTENTIAL MEASUREMENT (The electrical resistance of steel varies with carbon content)

Apparatus for determination of carbon content by shim-stock exposure and measurement

Measuring Procedure: AISI 1010 steel shim sample is used for measurement. AISI 1010 is a Standard grade Carbon Steel. Clean the shim test specimen with acetone and weigh it on a balance to the nearest 0.1 mg. insert it into the shim holder as shown and Be sure the furnace is operating above 871 oC. Leave the shim specimen in the furnace for 30 min.(Carburizing takes place)

 Move the shim-holder cartridge from the furnace to the cooling chamber. Remove the steel shim from the shim-holder cartridge. Reweigh the shim to the nearest 0.1 mg. And calculate the carbon potential using:

where wt% C is the original weight percent carbon content.

Nitriding process
Nitrogen is diffused into the surface of the steel being treated. The nitrogen source is usually Ammonia (NH3). At the nitriding temperature the ammonia dissociates into Nitrogen and Hydrogen.
Various NITRIDING gas atmosphere are:

Gas nitriding Salt bath nitriding Plasma nitriding

Gas Nitriding process

The reaction of nitrogen with the steel causes the formation of very hard iron and alloy nitrogen compounds.

Nitriding temperature is below the lower critical temperature of the steel and it is set between 496 oC and 565oC.

Advantage of this process

The resulting nitride case is harder than tool steels or carburized steels. The advantage of this process is that hardness is achieved without the oil, water or air quench. As an added advantage, hardening is accomplished in a nitrogen atmosphere that prevents scaling and discoloration.

 The white layer has a detrimental effect on the fatigue life of nitrided parts, and it is normally removed from parts subjected to severe service. Two stage gas-nitriding processes can be used to prevent the formation of white layer

As the nitriding time increases the effective case depth also increases

 Carbonitriding: This process involves with the diffusion of both carbon and nitrogen into the steel surface. Methane or paropane serve as the source of carbon, the ammonia serves as the source of nitrogen. Quenching is done in a gas which is not as severe as water quench. As a result of les severe quench, there is less distortion on the material to be treated.

Carbonitriding distortion than

gives

less

carburizing.

Carbonitriding is performed at temperatures above the

transformation temperature of the steels (760 oC -to 870 oC)

The process is performed in a gas atmosphere furnace using a carburizing gas such as propane or methane mixed with several percent (by volume) of ammonia.

Salt bath nitriding In salt bath nitriding the nitrogen donating medium is a nitrogen containing salt such as cyanide salt. The salts used also donate carbon to the workpiece surface making salt bath a nitrocarburizing process. The temperature used is typical of all nitrocarburizing processes: 550590 C. The advantages of salt nitriding are: Quick processing time - usually in the order of 4 hours or so to achieve Simple operation - heat the salt and workpieces to temperature and submerge until the duration has expired

The disadvantages of Salt bath nitriding are:

The salts used are highly toxic - Disposal of salts are controlled by stringent environmental laws in western countries and has increased the costs involved in using salt baths. This is one of the most significant reasons the process has fallen out of favor in the last decade or so. Only one process possible with a particular salt type - since the nitrogen potential is set by the salt, only one type of process is possible

Plasma nitriding
Plasma nitriding, also known as ion nitriding, plasma ion nitriding or glow-discharge nitriding, is an industrial surface hardening treatment for metallic materials. As an alternative to gas nitriding, plasma (ion) nitriding process has been developed to overcome the shortcomings of the earlier traditional uncontrolled gas nitriding processes and to offer certain operational advantages that gas nitriding does not have.

The gas used for plasma nitriding is usually pure nitrogen. Electric fields are used to generate ionized molecules of the gas Charged particles are responsible for the nitriding effect.

This figure shows how the metallurgical properties of the nitride layer and the white layer can be controlled in the plasma nitriding process by adjusting the process gas composition.

 Plasma is essentially a gas nitriding treatment in which the method of delivering nitrogen atoms to the surface of nitrided components is quite different from the standard gas nitriding processes. It occurs at a very low pressure and under high voltage.

Plasma offers certain distinct advantages such as: The ease of masking the component surface where nitriding is to be avoided. Ability to nitride low density powder metallurgy parts.