‘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
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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)
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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 Problemee
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
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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
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Potency
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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,
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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
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> Gas Pressure in the sealed Atmosphere
> Pretreatment of Steel
> Surface Condition of Steel
> Exposed Time
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Case Depth for Nitriding Case Depth for Nitriding
2.NH, (550°C) —- 2N+3H,
Fe+N FeN
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Hard Iron and alloy
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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
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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
————
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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
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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
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Advantages and Disadvantages of Carbonitriding
Scale Production.
ian Carburising.
Dis-advantages:
> Process can be applied only for Plain Carbon Steel.
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Diffusion Processes by Typical Case Depth
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Types of Steel for Diffusion Process
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Surface Hardening
Dr. Asit Kumar Khanra
Pepariment of Metallurgica and Materials Engincering, NIT WarangelOE ____________ —V—V—_
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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
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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
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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.