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Hardening
Hardening
1.reduce a brittleness,
4.Quenching medium.
5.Quenching rate.
7.Surface conditions.
The rapidly with which the heat is absorbed by the quenching bath
has a considerable effect on the hardness of the metal. Clear, cold
water is very oftenly used, while the addition of salt still increases
degree of hardness.oil, however , gives the best balance between
hardness toughness and distortion for standard steels.
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In order to increase the cooling rate the parts may be moved around
the quenching bath, either by hand, or by passing them through the
tank in basket attached to mechanical conveyer. Large parts may be
lowered into the tank by a crane and kept moving while cooling.
It is often cheaper and more efficient, however , to circulate the
cooling liquid around the hot part.
The heating rate and heating time depend on the composition of the
steel, its structure, residual stresses, the form and size of the part to
be hardened, the more the intricate and large the part being
hardened, the slower it should be heated to avoid stresses due to
temperature differences between the internal and external layers of
the metal, warping, and even cracking. The practically attainable
heating rate depends upon the thermal capacity of the furnace, the
bulk of the changed parts, their arrangement in the furnace, and
other factors. The heating rate is usually reduced, not by reducing
the furnace temperature but by preheating the articles.
The heating time for carbon tool steels and medium-alloy
structural steels should be from 25 to 30% more than for carbon
structural steels. The heating time for high-alloy structural and tool
steels should be from 50 to 100% higher.
When steel is exposed to an oxidizing atmosphere, because of the
presence of water vapor or oxygen in the furnace, a layer of iron
oxide called (scale) is formed. Thin layer of scale has very little
effect on cooling rate, but that a thick layer of oxide (0.005 in.
deep) retord the actual cooling rate.
Quenching media
The quenching media in general use are :
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Brine : it is very rapid cooling agent and may tend to cause distortion of
the parts , as will water.
Air blast : when the risk of distortion is great, quenching must be carried
out air blast. Since the rate of cooling is then lower, more hardening
elements must be added to the steel , forming an air-hardening alloy. The
air blast must be dry, since any moisture in the air will crack the steel.
Molten salts : high speed steels are often quenched in molten salt to
hardened them.
Note : hypo-eutectoid steel containing very little carbon, say less than
0.25%, cannot be easily hardened by sudden quenching because of large
amount of soft ferrite which is contains and all of which cannot be
retained in solution even on very quick cooling. The hardening capacity
of steel increases with carbon content.
Hardening methods
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1.Quenching in two media:
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This treatment will provide a structure of martensite and retained
austenite in the hardened steel. (the cooling is stopped at a point above
the martensite transformation region to allow sufficient time for the
center to cool to the same temperature as the surface. Then cooling is
continued through the martensite region, followed by the usual
tempering) [Figure 2.25 ] .
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Figure 2.26 Retained austenite (white) trapped between martensite
needles (black) ( 1000).
The martensite stars and finish temperatures are reduced when the carbon
content increases (Figure2.27). High carbon steels must be refrigerated to
produce all martensite.
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Figure 2.27 Increasing carbon reduces the Ms and Mf temperatures in
plain-carbon steels.
When steels are quenched, the surface of the quenched steel cools rapidly
and transforms to martensite. When the austenite in the center later
transforms, the hard surface is placed in tension, while the center is
compressed. If the residual stresses exceed the yield strength, quench
cracks form at the surface (Figure 2.28)
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Figure 2.28 Formation of quench cracks caused by residual stresses
produced during quenching. The figure illustrates the development of
stresses as the austenite transforms to martensite during cooling.
On the other hand, the extremely low solubility of austenite in this range
from 500 to 600°C requires a cooling rate of 200 to 500°C per second in
this range to obtain supercooling. at the same time, cooling in hot media
is much slower than in water or oil at room temperature therefore,
austenite in carbon steel can be cooled through the zone from 600 to
500°C, without decomposition, only in thin articles (upto 5.8 mm I
thickness). Such articles are expediently hardened by this method. Alloy
steel articles hardened by this method, may be considerably thicker.
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4. Isothermal quenching or austempering:
This is the second method that can be used to overcome the restrictions of
conventional quench and tempering. The quench is interrupted at a higher
temperature than for Martempering to allow the metal at the center of the
part to reach the same temperature as the surface. By maintaining that
temperature, both the center and the surface are allowed to transform to
Bainite and are then cooled to room temperature ( Figure 2.29).
Advantages of Austempering:
(2) No need for final tempering (less time consuming and more energy
efficient)
Limitations of Austempering:
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Figure 2.29 Austempering process.
For example, pearlite may forms as steel cools past the nose of the curve,
particularly because the time of the nose is less than one second in plain
carbon steels.
The rate at which the steel cools during quenching depends on several
factors. First, the surface cools faster than the center of the part. In
addition, as the size of the part increases, the cooling rate at any location
is slower. Finally, the cooling rate depends on the temperature and heat
transfer characteristics of the quenching medium (Table 2.2 ).
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Quenching in oil, for example, produces a lower H coefficient, or slower
cooling rate, than quenching in water and brine.
Sub-zero treatment
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The problem of retained austenite is more complex in alloy steels. Most
of the alloying elements increase the content of retained austenite.
A rotating shaft that delivers power from an electric motor is made from a
1050 steel. Its yield strength should be at least 145,000 psi, yet it should
also have at least 15% elongation in order to provide toughness. Design a
heat treatment to produce this part.
Solution:
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(Figure2.30) shows that the yield strength exceeds 145.000 psi if the steel
is tempered below 460oC, whereas the elongation exceeds 15% if
tempering is done above 425oC.
The A3 temperature for the steel is 770oC. A possible heat treatment is:
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