‘Carburising, Nitriding, Carbonitriding and Boronizing. Department of Mealarsical and Materials Engincering, NIT Warangal Introduction of Carburising Process Pack or Solid Carburising Process > Raw Materials: Low Carbon Stee! > Carbon Source: Charcoal (60 wi%) and BaCO, > Temperature: 930°C (austenitic temperature zone) > Chemical Reactions: BaCO, — Ba0+ CO, CO, +¢ —+ 20 2CO+Fe —-Fe(C) +CO, CO, +C —2C0 > Quenching after Reaction: Slow cooling followed by Tempering > Case Depth: 1-2.mm depth after 68 hrs,Case Depth Measurement It can be measured by: > Chemical Ana > Microstructure Analysis > Hardness Measurement 3 ase ad Weta aperng Naa Factors Affecting Case Depth for Pack Carbu: 1. Composition of Raw Mater 2. Wor ing Temperature: 3. Working Atmosphere: 4, Surface Condition of Workpie 5. Reactivity of Carbonaceous Mat ee Case Depth for Pack Carburising Process 012 0.10 — ~ 1550 0F —1800 oF CASE DEPTH (IN.) EZ ‘4 6 8 10 CARBURIZING TIME (HOURS) “Tart [tal and srs Eng NT rng _——————————— Seesaw s_ Advantages and Disadvantages of Pack Carburising Advantages: > Itis very simple process. > Itis very cheap process. Dis-advantag > Suitable only for low carbon steel > Time consuming Pi > Pollution Problemee Liquid Carburising > Diffusion of Carbon: Liquid State so known as Salt bath Carbu > Reaction between Cyanide and Low Carbon Steel. > Salt Bath Temperature: 800 to 900 > Salt Bath Composition: NaCN with BaCl,/ Na/KCl as Activator. > Reactions: BaCl,+2NaCN —~ Ba(CN),+2 NaCl Ba(CN),+Fe ——> Fe(C)+BaCN haa derek Papago Gas Carburising > Diffusion of Carbon: Gaseous State. is the most widely used Carburising process. > Reaction between the Gas and Low Carbon Steel. is done in a sealed Furnace with Quench type. > Furnace Temperature : 850-950° C (Austenite region), ixture of Air & Hydrocarbon) 0 ete. Advantages and Disadvantages of Liquid Carburising Advantages: > It is very fast process. > It makes thin and clean harden layer (0.08mm). Dis-advantages: > Difficult to handle NaCN etc. > Extra safety precaution is required. tion Problem ble for Low Carbon Steel Fore Dupotes weg eget Potency oie bon CotSS ———————————————————— Advantages and Disadvantages of Gas Carburising > Different Chemical Reactions at High Temperature: Advantages: GH, > It is well suitable for Mass Seale Production. CHa ae 2CH, + C (Cracking of Hydrocarbons) > It makes clean Harden Layer. CHEE > Fast cooling leads to Austenite to Martensite. os +CO, ——-2C0+2H, a Taper SS eae advantages: Other Reactions: > Pollution Problem. H,+CO, ——. co+2H,0 K 2€0, Beco: CO,+Fe —_., Fe(c) +0, SS EEE eee Deer of ang oad Meck agony TPT Advances in Carburising Process > Advances in Carburising Process basically depends on Nit Thermodynamics and Kinetics Study of Diffusion Process. Nitriding ding is basically a Ferritic Thermochemical Treatment wherein Nitrogen diffuses into Steel. It is developed in 1920. > Reactiveness of Carbonaceous Materials alae ee > Diffusion of Carbon, Nitrogen and Boron in a single Process > Use of Vacuum Chamber for better Diffusion > Achievement of Uniform Case Depth > Mass scale Production with negligible Pollution >Achievement of Hardness is due to Diffusion controlled and Diffusionless Process (Austenite to Martensite).Nitriding Schematic of Nitriding Process n of Nitrogen into Steel depends o > Furnace Temperature a a > Source of Nitrogen : Nz / NH, ete. (Gas Activity) > Composition of Stee! > Exposed Surface Area 8 > Gas Pressure in the sealed Atmosphere > Pretreatment of Steel > Surface Condition of Steel > Exposed Time sag NT Womeee Case Depth for Nitriding Case Depth for Nitriding 2.NH, (550°C) —- 2N+3H, Fe+N FeN nr eae Cee oT) ee) Rice eee Hard Iron and alloy nitridesen White Layer in Nitriding > White Layer: White colour layer consists of F and Fe,N (epsilon ni (gamma prime) > Nitride Layer: FeN layer (Golden in Colour) > Effect of White Layer: Brit yer. > Removal of White layer: Lapping Operation eT ————————SS—_S]SS=S_S=S=S==ee——_- Salt bath/ Liquid Nitriding Salt_bath Diffusion of Nitrogen in a Nitrogen containing Cyanide Salt at 550-600° C. Advantages of Salt bath > Fast Process 4 hrs, > Simple Process Types of Nit ing Process > There are three types of Nitriding Process — Gas, Salt bath and Plasma, Gas Nitriding: Diffusion of Nitrogen in gaseous state. Advantages of Gas > Uniform Coating. > No size restriction of component > Low equipment cost > Process can be optimised by computer Disadvantages of Gas Nitriding: > Slow Process ~3-4 days > Reaction Kinetics is influenced by Surface conditions > Handling problem due to toxic Ammonia. Plasma Nitriding > Itis developed in 1960. A Plasma is created in the temperature range of 300-600°C by using pure Nitrogen gas. Diffusion of Nitrogen in ionized state. Advantages of Plasma Nitriding: > Uniform Coating without any unwanted phases. > Fast Process > Suitable for mass scale > No Pollution Problem Disadvantages of Gas Nitrid’ > Costly Process——a I] ing over Carburising Performance of Nit > Nitride layer has higher Corrosion and Wear Resistances. > Nitride layer has higher Hardness. ible distortion on Surface due to low working Temp. > High Fatigue Strength — Essential for Advanced Cars > Long cycle time — 0.5 mm depth after 100 hrs — slow process > Plasma Ni ling — ultra clean & single phase layer esp ond Maia Eagarrng ———— a Carbonitriding > Diffusion of both the Carbon and Nitrogen takes place into the Plain Carbon Steel. > Process is similar to the Gas Carburising. > Process Temperature: 800 to 900° C. > Gas Composition: Ammonia and Carburising > Quenching: Neutral Gas/ H,0 a Boronizing > Diffusion of Boron takes place into the Plain Carbon Steel. > Process is similar to the Pack Carburising. > Process Temperature: 900 to 1000° C > Packing Materials: Boron / B,C Powder > FeB & Fe,B layers on surface— Outer (FeB) & Inner (Fe,B) > Maximum Hardness — 1500 VHN > Case Depth — 0.15 mm at 900° C for 6 hrs Carbonitriding Neutral Gas \, Carburzing Gas “Armonia Fe Carbonitriding Zone PetEE Advantages and Disadvantages of Carbonitriding Scale Production. ian Carburising. Dis-advantages: > Process can be applied only for Plain Carbon Steel. aaa eae Diffusion Processes by Typical Case Depth | fs fs gil eaves a) = exe ay Ges earmonitrising “ie at and are Pape Bag ap a a agg Pag ee Types of Steel for Diffusion Process bin om loam Tie. (ie 5 ea tom ee = Surface Hardening Dr. Asit Kumar Khanra Pepariment of Metallurgica and Materials Engincering, NIT WarangelOE ____________ —V—V—_ gee Surface Hardening > Question: What is Surface Hardening? Answer: Surface Hardening by Rapid Phase Transformation (Asteite inte Martensie). No Change of Chem 11 Composit n. * Question: Ditference Between Normal Hardening and Surface Hardening? Answer: No basie Difference but iference in Process Control. > Question: What is the Qu: janagement Policy? ity > ISO - 9000 / QS 9000 6 Gor 9. Management Policy > Question: What is the importance of Defective Components? Answer: Recycle/ Re-melt > Manufacturing Cost Be ee ar a —§$———————————— Flame Hardening > It is developed in 1965. > Raw Material: Medium Carbon to High Carbon Steel > Heat Source: Oxyacetylene Torch > Rapid Quenching: H,O, Polymer etc. (Austenite to Martensite) > Low Temperature Tempering to relieve Residual Stress DS Types of Surface Hardening Process > Flame Hardening - Heat Source — O,: C,H, Flame. > Induction Hardening — Heat Source - Induction He Z- > Electron Beam Hardening (EDM) — Heat Source —e beam. > Laser Beam Hardening (LBM) — Heat Source — Laser ray. Flame Hardening Process Fuel gas coe + t Direction of movement of bumer ——Flame Head for FI ig Process Flame Hardening Process Advantages of Flame Hardening: > Itis very simple and Low cost process Flame Hardening Process Workpiece: Induction Hardening Process It should be magnetic. Cootant entry Inductor > a. High frequency—— Induction Hardening Process > Precise control of Heat > Itis very fast Process > Suitable for Mass Scale Production > Less Distortion/ Negligible HAZ > Costlier than Flame Hardening, ———————— Laser Beam Hardening (LBM) Process > LBM is the most promising and well suitable for mass scale. > Process is controlled by computer: > Degree of defects is very less. > No external quenching medium is required. > No Pollution Problem.