Comparison of Surface Hardening Techniques For en 353 Steel Grade

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Comparison of Surface Hardening Techniques for En 353 Steel Grade
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International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 10, October
Comparison of Surface Hardening Techniques for En 353

Steel Grade
Amandeep Singh Wadhwa1, Shalom Akhai2
Faculty UIET, Panjab University, Chandigarh, India
Faculty PEC University of Technology, Chandigarh, India
Abstract— This paper deals with the wear of the cutting
edge of the digester screw used in the wood pulp industry. The 1.1 Different Types of Surface Hardening
digester screw was made up of EN 353 steel grade .In this Methods
paper digester screw made of EN 353 steel grade is subjected I Layer additions
to four surface hardening techniques namely pack
carburizing, gas carburizing ,tungsten carbide coating using a) Hardfacing:
thermal spray and Stellite 6 coating using TIG welding. The Fusion hardfacing (welded overlay)
samples of EN 353 steel with the above said surface hardening Thermal spray (non fusion-bonded overlay)
techniques were machined to desired dimensions so that they
II Substrate treatment
could be successfully used for hardness and wear tests. Results
and conclusions were then drawn by performing wear and b) Diffusion methods:
hardness tests on the samples and the same are presented in Pack Carburizing & Gas Carburizing
tabulated and graphical form for comparison of the four
surface hardness techniques with regard to hardness and
surface wear. II. WORKPIECE : DIGESTER SCREW
In the paper industry, in order to extract the cellulose
Keywords—Keyword carburizing, surface hardening, TIG from the wood chips, the natural binder lignin must be
welding removed and the cellulose fibres laid bare. This is carried
out in the pulp digester with chemical decomposition
I. INTRODUCTION methods. However, before this is done, the wood blocks
Surface hardening is the process of hardening the must be converted into wood chips. This is done by
surface of a metal object while allowing the metal deeper feeding them into a feeder which has a digester screw
underneath to remain soft, thus forming a thin layer of which has threads which break down the wood into
harder metal (called the "case") at the surface. For smaller pieces and thus make them easier to process
steel or iron with low carbon content, which has poor to further.
no hardenability of its own, the case hardening process
involves infusing additional carbon into the case. Case
hardening is usually done after the part has been formed
into its final shape, but can also be done to increase the
hardening element content of bars to be used in a Fig 1: Digester screw in a paper industry
pattern welding or similar process. The term Hard Facing
is also used to describe this technique, when III. SURFACE HARDENING TECHNIQUES
discussing modern armour.
Because hardened metal is usually brittle than softer The various surface hardening techniques to be studies
metal, through-hardening (that is, hardening the metal in this paper are:
uniformly throughout the piece) is not always a suitable 3.1 Pack Carburizing
choice for applications where the metal part is subject to
Pack carburizing is a process in which a sample is
certain kinds of stress. In such applications, case
packed inside a container in the presence of a carbon
hardening can provide a part that will not fracture
source, coal or charcoal and an energizer such as Barium
because of the soft core that can absorb stresses without
carbonate. At high temperatures, the carbon in the charcoal
cracking but also provides adequate wear resistance on the
diffuses into the sample at the surface. This is usually done
surface.
at the austenizing temperature.
19
Once the temperature is brought down, usually through
quenching or normalizing, the austenite that is formed is
converted into martensite or bainite. These are responsible
for bringing about the hardness at the surface.
2 C + O2 → 2 CO
2 CO + Fe → C(active) + CO2
CO2 + C → 2 CO
The main agent here is the carbon monoxide that is
formed inside the pack. It is this carbon monoxide which
further donates the atomic carbon which diffuses into the
sample.
Fig 3: Gas carburizing process
3.3 GTAW Procedure

Gas tungsten arc welding(GTAW), also known
as tungsten inert gas(TIG) welding, is an arc
welding process that uses a non-consumable tungsten
electrode to produce the weld. The weld area is protected
from atmospheric contamination by an inert shielding
gas (argon or helium), and a filler metal is normally used,
though some welds, known as autogenous welds, do not
require it. A constant-current welding power supply
produces energy which is conducted across the arc through
a column of highly ionized gas and metal vapours known
Fig 2: Process of pack carburizing as plasma.
3.2 Gas Carburizing
Gas carburizing is a process which is similar to the pack
carburizing process in principle. At high temperatures, the
carbon diffuses into the sample at the surface. This is
usually done at the austenizing temperature. Once the
temperature is brought down, usually through quenching or
normalizing, the austenite that is formed is converted into
martensite or bainite. These are responsible for bringing
about the hardness at the surface.
The major difference here is that in this process, the
carbon is brought about by gases such as methane, propane
and butane.
2CO ↔ C( − Fe) +
CO2 CH4 ↔ C( − Fe) + Fig 4: Figure Illustrating SMAW process
2H2
3.4 Thermal spraying
CO + H2 ↔ C( − Fe) +
H2O This process involves spraying alloys in powder form
onto the base component. The sprayed powder may then be
These are the reactions which are responsible for used to produce a strong bond and a dense, porous-free
diffusion of carbon into the surface of the sample in a gas deposit.
carburization process.
19
Equipment used can be either hand held spraying torches It is neither externally brittle nor ductile due to its lower
or sophisticated metallizing guns for more specialized carbon content. It has lower tensile strength and malleable.
applications. Thermal spraying techniques are coating Steel with low carbon steel has properties similar to iron.
processes in which melted (or heated) materials are sprayed As the carbon content increases, the metal becomes harder
onto a surface. The "feedstock" (coating precursor) is and stronger but less ductile and more difficult to weld.
heated by electrical (plasma or arc) or chemical means Case hardening is the process of hardening the surface of
(combustion flame). metal, often low carbon steel by infusing elements into the
metal surface forming a hard, wear resistance skin but
preserving a tough and ductile applied to gears, ball
bearings, railway wheels.
In this study, we will carry out the surface hardening
procedures of on steel of grade EN 353 which is used as a
digester screw in the wood pulp industry. Due to the
pressure exerted by the wood pulp on the threads of the
screw a lot wear occurs on the component. However, we
cannot go for traditional hardening methods such as
normalizing or quenching because we want to retain the
tensile strength provided by the low carbon steel. Thus, our
best option is to perform case hardening techniques on the
sample so that it retains it tensile strength and at the same
Fig 5: Thermal Spraying time becomes hard and resistant to wear.
Hence, the techniques used in the study are:
IV. PROBLEM FORMULATION
5.1 Pack Carburizing
In this paper, we study the mechanical behavior of
digester screw in the wood pulp industry. The volume Pack carburization is the oldest method among the case
between the successive threads in the screws decreases hardening treatments. Carburizing improves the hardness
with the length however, the volume of the wood pulp tries and durability of products like carbon steel wire springs
to remain constant. Thus we see the pulp exerts a shear and carbon steel forgings. Following are the steps followed
stress on the threads. This along with the wear of the thread for pack carburizing on the samples prepared :
due to wood pulp causes the threads to chip, leading to 1. In order to perform pack carburizing we start off by
failure. machining a sample with 8mm diameter and 1 inch
The material to make the digester screw is steel EN 353 length. This is done to make sure that the component
which is low carbon steel having a good toughness. Thus it can be tested for wear analysis later.
can take the shear stress exerted by the wood pulp. 2. Next we prepare the pack by mixing charcoal and
However due to its low surface hardness, it is not able to barium carbonate in 10:1 ratio by weight in the pack
withstand the wear process. To overcome the shortfall, we box. The charcoal would provide the carbon which
will try to come up with ways of increasing the surface will diffuse into the sample surface, and BaCO3 will
hardness of the sample by performing case hardening act as an activator in this reaction.
procedures. These are, two methods of carburizing: Gas 3. The samples are placed in this pack and are
and Pack and two methods of hardfacing: TIG (using surrounded by charcoal mixture from all sides. At
Stellite 6) and Thermal Spray coating of Tungsten carbide. least 1 inch space is provided between the samples so
We will then test various properties of these samples, that the rate of carbon diffusion is uniform across the
such as surface hardness, wear loss, microstructure, etc. sample.
and will try to determine which is the best method out of 4. Then, we cover the lid and the open crevices of the
the four that we have used. pack with powder of Paris so that the gases evolved in
the pack do not dissipate and carburizing takes place
V. EXPERIMENTAL PROCEDURE effectively.
Low carbon steel has carbon content of 0.15% to 0.45%.
Low carbon steel is the most common form of steel as it’s
provides material properties that are acceptable for many
applications.
19
1. We start off by machining a sample with 8mm dia and
1 inch length. This is done to make sure that the
component can be tested for wear analysis later. A
wire is then wound around the sample and it is made
to hang from a rod.
Fig 6: The pack prepared for carburizing.
5. The pack is put into the furnace and is heated to a

temperature of 900oC and let to soak there for 3 hours. Fig 8:Samples being prepared to be put in the furnace.
This gives sufficient time for the samples to absorb
2. The samples are then heated to austenizing
the carbon.
temperature and exposed to a carbon-rich atmosphere.
Carbon is absorbed at the surface and diffuses inward
down the chemical potential gradient to create a
carbon-rich surface and a decreasing carbon
concentration profile with a low-carbon steel core.
Subsequent austenizing and hardening of the
carburized parts produces a hardness profile that is
dependent on the carbon gradient, steel hardenability,
and quench severity of the hardening operation. A
carbon-rich furnace atmosphere is produced either
from gaseous hydrocarbons, such as methane (CH 4),
propane (C3H3), and butane (C4H10), or from
vaporized hydrocarbon liquids.
Fig 7: The pack is heated to a temperature of 900oC
6. Once the sample is let to soak for that time, it is left to

be air-cooled.
7. Then, we can perform hardness testing on the sample
to see its change in surface hardness and perform
wear analysis to see how wear resistant it has become.
5.2 Gas Carburizing
Gas carburizing a little bit trickier than pack carburizing
because we need to maintain an environment of
hydrocarbons around the sample at an elevated Fig 9: Samples being heated in the furnace
temperature.
19
3. Finally the samples are quenched in a water bath to It may also contain tungsten or molybdenum and a small
get a steep cooling curve and the desired surface but important amount of carbon. It is a trademarked name
hardness. of the Deloro Stellite Company and was invented by
5.3 Thermal spray Elwood Haynes.
We have used Tungsten carbide as the powder in Stellite 6 composition:-
Thermal spray method of hardfacing. Below are the steps
followed:-
1. Make sure that the surface to be treated is completely
clean and de-greased. Grinding or sandblasting helps
produce better bonding. Procedure for TIG using Stellite 6 electrode:-
2. Lightly preheat the job with the torch to about 250 -
1) Strike the arc. This is the process of creating an electric
300°C (just light blue color).
arc between the electrode and the workpiece. If the
3. Spray the first layer of powder lightly and rapidly
electrode simply allows the current to pass directly into the
over the surface to produce a very thin coating of
grounded work piece, there will not be enough heat
alloy. This is to prevent the low alloy base material
produced to melt and fuse metal together.
from oxidizing when the work is brought to red heat.
2) Move the arc to create a bead. The bead is the metal
from the melting electrode flowing together with molten
metal from the base metal to fill the space between the
pieces being joined by welding.
3) Shape the weld bead. This is done by weaving the arc
back and forth across the weld path either in a zig zag, so
the metal spreads to the width that you want your finished
weld bead to be.
Fig 10: thermal spray illustration
4. Do the facing run in small sections: heat a small area

of the work with the torch until the surface begins to
show signs of sweating then spray a small amount of
powder on to the surface and hold the flame there
until the material melts. Repeat this procedure as you
travel along the work.
5. For large surfaces, a weaving action is recommended,
with a travel of between 25 and 35 mm. Introduce the
powder on the outward weaving motion, then apply
heat alone on the inward motion. Do not try to heat
Fig 11: GTAW process
too large an area at once, as this tends to overheat the
job and cause the hardfacing deposit to boil and 4) Chip and brush the weld between passes. Each time we
bubble. The depth of deposit is governed by the complete a pass, or trip from one end to the other of our
quantity of powder delivered to the flame. The weld, we need to remove the slag, or the melted electrode
amount of depression of the lever determines the flux material, from the surface of the weld bead so only
powder flow: Slight depression gives a small flow, clean molten metal will be filling the weld on the
full depression gives maximum flow. Use a neutral subsequent pass.
flame.
5.5 Study of Mechanical Properties
5.4 TIG (using Stellite 6 electrode) As the objective of the project is to compare the
Stellite alloy is a range of cobalt-chromium alloys mechanical properties of various surface hardened
designed for wear resistance. specimens, we will go on to study these properties.
19
This will be done by first measuring the surface hardness 5.5.2 Wear Testing
of the sample using C scale of the hardness tester. Values
which do not come under this scale will be separately Our next step is to perform wear testing on the sample
mentioned. and find out the loss in weight after a specific period in
Next we will measure the wear that takes place in each time. For this we follow the following steps:
sample, which will be done using the Wear Testing 1. We start by weighing the sample on a sensitive
machine. Finally, we will see the microstructure of each milligram scale. This is done so that we can find the
sample and try to see what is happening at the weight loss due to wear.
microstructure level.
5.5.1 Hardness Testing
The heat treated specimens hardness was measured by
means of Rockwell hardness tester. The procedure adopted
can be listed as follows:
Fig 13: Wear Testing machine
2. Next we move on to the wear testing machine where

we fix the sample onto the machine which has a
spinning metallic disc which does the wear. We need
to make sure that the fixed sample is properly leveled.
3. A load of 60N is applied on the sample at an RPM of
300. The track radius of the sample is set at 60 mm.
4. Wear testing is done on the sample for 105 min after
which it is taken out of the machine.
5. Lastly, we measure the weight of the wear tested
sample. This should be less that the initial weight and
difference between the two should give us wear loss
done in 105 min.
5.5.3 Microstructure study
The next step followed was to examining the
microstructure of the samples. This consisted of the
following steps:
1. Rough and fine grinding of the sample to remove and
scales or scratches in the surface.
Fig 12: Rockwell Hardness Tester 2. Polishing the sample on velvet until a mirror like
surface is obtained.
1. First the diamond indenter was inserted in the machine.
3. Etching the samples so that the microstructure would
2. A load of 150 kgf is used for every test.
be visible under a microscope. This consists of
3. The load is made to dwell on the sample for a period of
dipping the sample in 3% natal solution for 2-3
5 seconds.
seconds and then cleaning it with ethyl alcohol for the
4. Once these settings are configured, we start the hardness
carburized samples. Similar etchants are used for the
tester, which automatically gives us the hardness of each
other samples.
sample in HRC.
19
4. Observing the microstructure under a metallurgical 6.3 Microstructure Analysis
microscope.
In order to look at the microstructure, we first fine grind
VI. RESULTS the sample and then polish it. We then etch the sample and
observe its microstructure. The magnification of the images
Once we performed the various surface hardening is X100.
process on our given steel sample, we did the various
mechanical tests on them to determine the final properties
of the samples and try to determine which one is the best
procedure. In this section, we will present the results of the
tests we performed and the discussions and conclusions
will follow in the next chapters.
6.1 Tabulation of Hardness Testing
The load applied for the following values is 150kgf and
the dwell time is 5 seconds.
Table 1:
Hardness values of the samples
S.No. Sample Hardness Value

6.9 HRC or
1 Plain Sample 129.7 HRB
2 Pack carburized Sample 30.1 HRC
Fig 14: Etched EN353 Sample using 3% nital
3 Gas Carburized Sample 55.5 HRC
Thermal Sprayed Coated
4 58.7 HRC
Sample
5 Stelite-6 Coated Sample 49.8 HRC
6.2 Tabulation of Wear Testing

The load applied for the following values is 60N. The
RPM of the disc is 300 revolutions per second. The track
diameter of the disc is 60 mm. Wear testing is done on the
samples for 105 minutes. The values of weight loss are in
milligrams.
Table 2
Wear loss values of the samples
S.No. Sample Weight Loss

1 Plain Sample 65 mg Fig 15: Etched Pack Carburized sample (center), T = 910o, t = 3 hours
2 Pack carburized Sample 31 mg
3 Gas Carburized Sample 26 mg
Thermal Sprayed Coated
4 16 mg
Sample
5 Sterlite-6 Coated Sample 29 mg
20
Fig 19: Thermal Spray coated sample

Fig 16: Etched Pack carburized sample (edge), T = 910o, t = 3 hours
Fig 20: Stellite 6 coated sample

Fig 17: Etched Gas Carburized sample (center), T = 910o, t = 1 hour
VII. DISCUSSION
It is generally expected that a material with high
hardness value will have high wear resistance but as the
results show this is not at all the case. Greater hardness
does not always mean greater abrasion resistance or longer
wear life. Several alloys may have the same hardness rating
but vary greatly in their ability to withstand abrasive wear
Fig 21: Comparison of hardness in samples
Hardness ( HRC)
Axis Title
Fig 18: Etched Gas Carburized sample (edge), T = 910o, t = 1 hour
20
The TIG welder is small, almost like a pen, which allows
welders to use it for nearly any purpose. The inert gas used
in the welder allows it to work on different metals. Argon
is best for steel and titanium, helium is best for stainless
steel and copper, and an argon-and-helium combination is
best for aluminum and alloys that include aluminum.
In Thermal spray, there is a comprehensive choice of
coating materials to meet the needs of a wide variety of
applications, in particular protection from wear and
corrosion damage. Coatings of metal, cermets, ceramic and
plastic can be applied to any substrate that will not degrade
from the heat of the impinging particles or gas jets. The
Fig 22: Graphs of Wear Loss in the samples coating is formed with minimal heating of the substrate and
the coating does not need to fuse with the substrate to form
a bond. Substrate temperature seldom exceeds 300°C. As a
consequence, coatings can be applied to components with
little or no pre- or post-heat treatment and component
distortion is minimal. The coatings can also be applied to
thermal sensitive substrates such as low melting point
metals and plastics. Thick coatings, typically up to 10mm,
can be applied and often at high deposition rates. This
means that thermal spraying can also be used for
component reclamation and spray forming. Parts can be
rebuilt quickly and at low cost, usually at a fraction of the
replacement price. Thermal spraying has the capacity to
form barrier and functional coatings on a wide range of
substrates. More recently, thermal spraying has been
Fig 23: Comparison of Hardness and Wear loss of the samples recognized as a key process for the synthesis of specialized
coatings and materials. It offers the ability to create
Bulk hardness tests (Rockwell or Brinell) which measure freestanding structures for net-shaped manufacture of high
the average hardness of both the carbide and matrix performance ceramics, composites and functional graded
together over a relatively large area, often register the same materials. It is also used for the rapid-solidification
hardness as that of other conventional metals. synthesis of specialized materials. Thermal spraying is now
Similarly, when comparing several surfacing alloys with being considered for the synthesis of advanced functional
each other, equally high bulk hardness ratings is not the surfaces such as catalytic coatings, dielectrics, ferrites,
only factor assuring resistance to wear. Resistance bioactive materials and solid oxide fuel cells.
(especially to low- and high-stress abrasion) depends rather As for the carburizing methods, we can clearly see that
on a combination of both hardness and the metallurgical gas carburizing gives a good surface hardness as compared
microstructure of the alloy. The microstructure of alloys to the other procedures followed. Further it is a good
varies according to the ratio of carbides to matrix and the method for obtaining surface hardening for low carbon
type of carbides in the alloy. The alloy with the hardest, alloys such as EN353. However, the wear resistance of the
most evenly dispersed carbides along with the highest gas carburized product is not as good as the sample with
percentage of carbides will have the best resistance to low- the thermal spray. This goes on to show that there is no
stress and high-stress abrasion. fixed relationship between surface hardness and wear
Advantages of TIG welding offers advantages in terms resistance.
of versatility and amperage use because it uses less energy The major determinant when opting between these two
than other welding methods. A clean weld is also achieved methods is the scale of operations. gas carburizing has a
by making a low-profile weld bead, and there is no slag left relatively cheap operational cost and we can improve the
over after the welding is complete. The largest advantage surface hardness of several small samples at the same time.
of TIG welding is control, both in terms of the electrode Thus, it is a mass production oriented sample.
itself and the current.
20
Whereas, thermal spray is done on relatively small Lastly, we come to pack carburizing which is the least
batches where wear resistance is the main aim. Therefore, desirable method of all. We cannot control the case depth
for a digester screw which is several feet in length, the and the wear resistance that we get is also not great. Even
thermal spray method not only gives a better wear though it is one of the cheapest methods out there, it just
resistance, but can also be aimed to target only the parts doesn’t give us the same properties like other surface
where the wear resistance is required. hardening procedures and is not suitable for our digester
As for the pack carburizing method, it gives us the least screw problem.
surface hardness and least wear resistance. Further it is a
very labor intensive method in which most of the reactants REFERENCES
get wasted. Also, there is no easy way of giving the sample [1] A. Hultgren, J. Iron Steel Inst., July 1951, p 245–257
the case depth that is required. There’s no doubt that this [2] W.F. Gale and T.C. Totemeier, Ed., Chap. 29, Heat Treatment,
method of surface hardness is now obsolete and is not used Smithells Metals Reference Book, 8th ed., Elsevier Butterworth-
anymore. Heinemann, 2004
[3] R. Collin, S. Gunnarson, and D. Thulin, A Mathematical Model for
Predicting Carbon Concentration Profiles of Gas-Carburized Steel, J.
VIII. CONCLUSIONS Iron Steel Inst., Vol 210 (No. 10), 1972, p 785–789
From the results and discussions above, we can see that [4] O. Boudouard, Ann. Chim. Phys., Vol 24 (No. 5), 1901, p 85
the sample with the Thermal spray has the best wear [5] M.L. Schmidt, Pre-Oxidation Prior to Gas Carburizing: Theory and
resistance. Thus, it is the technique which we will be using Its Effect on Pyrowear 53 Alloy, Carburizing Processing and
Performance, G. Krauss, Ed., ASM International, 1989, p 83–100
to line the cutting edge of the digester screw to prevent
[6] J. Wunning, Weiterentwicklung der Gasaufkohlungstechnik
wear from the wood pulp. (Advances in Gas Carburizing Technique), Härt.-Tech. Mitt., Vol 23
Gas carburizing comes a close second with surface (No. 3), 1968, p 101–109
hardness almost equal to the thermal spray sample. [7] U. Wyss, R. Hoffmann, and F. Neumann, Basic Requirements for
However that main difference that separates them both is Reducing the Consumption of Carburizing Gases, J. Heat Treat., Vol
the difference in wear loss. Thermal spray is a very specific 1 (No. 3), 1980, p 14–23
process as compared to gas carburizing and gives very [8] D.W. McCurdy and S.J. Midea, Benefits of Improved Carburizing
Accuracy Using 3-Gas IR Compensation of Oxygen Probes,
excellent results. Gas carburizing, though cheap and International Automotive Heat Treating Conference, 1998, p 29–31
efficient, is more of a mass production process which is [9] Afrox product reference manual – Hardfacing Comparative study of
used for smaller samples. Hardfacing of steel by three different welding processes
As for the TIG coating using Stellite 6, though it also an [10] www.millerwelds.com/pdf/gtawbook.pdf
effective method, it is has become obsolete and has been [11] www.aws.org/w/a/wj/2002/11/feature
replaced other methods such as thermal spray. Therefore,
even though it is a decent method, there are other methods
out there which are better than it.
20
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Comparison of Surface Hardening Techniques for En 353 Steel Grade

Article · October 2014

IAQ in Air conditioned Enclosures View project

Fly Ash View project

The user has requested enhancement of the downloaded file.

Comparison of Surface Hardening Techniques for En 353

Fig 3: Gas carburizing process

3.3 GTAW Procedure

Fig 6: The pack prepared for carburizing.

5. The pack is put into the furnace and is heated to a

Fig 7: The pack is heated to a temperature of 900oC

6. Once the sample is let to soak for that time, it is left to

Fig 10: thermal spray illustration

4. Do the facing run in small sections: heat a small area

Fig 13: Wear Testing machine

2. Next we move on to the wear testing machine where

S.No. Sample Hardness Value

6.2 Tabulation of Wear Testing

S.No. Sample Weight Loss

Fig 19: Thermal Spray coated sample

Fig 20: Stellite 6 coated sample

Fig 21: Comparison of hardness in samples

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