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Heat Treatment Process

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HEAT TREATMENT PROCESS

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Heat Treatment
An nea ling :
➢ Annealing
The various purpose of these heat treatments is to:

1) Relieve Internal stresses developed during solidification,


machining, forging, rolling or welding,
2) Improve or restore ductility and toughness,
3) Enhance Machinability,
4) Eliminate chemical non-uniformity,
5) Refrain grain size, &
6) Reduce the gaseous contents in steel.

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Heat Treatment
➢Heat treating is a group of industrial and metalworking processes used to alter
the physical, and sometimes chemical, properties of a material. The most common
application is metallurgical.
➢Heat treatment involves the use of heating or chilling, normally to extreme
temperatures, to achieve a desired result such as hardening or softening of a
material.
Heat treatment techniques include:
➢Annealing,
➢Normalizing
➢Tempering, and
➢Hardening
➢Case hardening,
TTT DIAGRAMS
 TTT diagrams, or Time-Temperature-
Transformation diagrams, are graphical
representations used in metallurgy to understand
the transformations that occur in a material as it is
heated and cooled.

 The diagram shows the rate at which a material


transforms from one phase to another as it is
subjected to different temperatures and times.
 The TTT diagram is typically divided into three regions, with each region
representing a different phase transformation.

 The first region represents the austenitic phase, where the material is heated to
a temperature above its transformation temperature and transformed into an
austenitic structure.

 The second region represents the transformation of austenite to other phases,


such as ferrite, pearlite, and bainite, as the material is cooled to different
temperatures.

 The third region represents the transformation of the remaining austenite to


martensite, a hard, brittle phase that is formed when the material is rapidly
cooled.
 The TTT diagram is useful in predicting the final microstructure
and mechanical properties of a material after heat treatment.

 By selecting the appropriate temperature and time for a given


material, the TTT diagram can be used to ensure that the
material undergoes the desired phase transformation and
achieves the desired mechanical properties.

 Overall, TTT diagrams are important tools used in metallurgy to


understand the phase transformations that occur in a material
during heat treatment. They allow engineers and metallurgists to
optimize heat treatment processes to achieve specific mechanical
Heat Treatment
T i m e T emp er a tu r e Transformation ( T T T )
Diagram:

Iron-carbon alloy
with Eutectoid
(0.8 % C)
composition.

❑ A: Austenite
❑ P: Pearlite
❑ B: Bainite
❑ M: Martensite
T emp er a tu r e Transformation ( T T T ) Diagram:
Example 1:
➢ Iron-carbon with
alloy eutectoid
composition.
➢ Specify the nature of the final
microstructure (% bainite,
martensite, pearlite etc) for the Bainite,
alloy that is subjected to the
100%
following time–temperature
treatments:

➢ Alloy begins at 760˚C and has


been held long enough to
achieve a complete and
homogeneous austenitic
structure.

➢ Treatment (a)
➢ Rapidly cool to 350 ˚C
➢ Hold for 104 seconds
➢ Quench to room
T emp er a tu r e Transformation ( T T T ) Diagram:
Example 2:
➢ Iron-carbon with
alloy eutectoid
composition.
➢ Specify the nature of the final
microstructure (% bainite,
martensite, pearlite etc) for the
alloy that is subjected to the
following time–temperature
treatments:
Austenite,
➢ Alloy begins at 760˚C and has 100%
been held long enough
to achievea complete
and
homogeneous austenitic
structure.

➢ Treatment (b) Martensite,


➢ Rapidly cool to 250 ˚C 100%
➢ Hold for 100 seconds
➢ Quench to room
T em p e ra tur e Transformation ( T T T ) Diagram:
➢ Example 3:
Austenite,
➢ Iron-carbon alloy with eutectoid 100%
composition. Almost 50% Pearlite,
50% Austenite
➢ Specify the nature of the
final microstructure (%
martensite, pearlite etc) for the
bainite,
alloy that is subjected to
following the time–
treatments: temperature Bainite, 50%
➢ Alloy begins at 760˚C and has
been held long enough to achieve
a complete & homogeneous
austenitic structure.

➢ Treatment (c)
➢ Rapidly cool to 650˚C Final:
➢ Hold for 20 seconds 50% Bainite,
50% Pearlite
➢ Rapidly cool to 400˚C
➢ Hold for 103 seconds

ANNEALING
The Steel parts produced by mechanical operation
process such as casting, rolling or drawing,
extruding, etc. develop internal stresses and change
their internal structure. This renders them hard and
brittle.
Annealing is carried out for such parts to remove the
internal stresses and make them more ductile and
less brittle.
Annealing consists of heating of steel parts to a
temperature at or near the critical temperature 900
degree Celsius hold it at that temperature for a
suitable time and when allowed to cool slowly in the
ANNEALING IS CARRIED OUT FOR
ACCOMPLISHING ONE OR MORE OF THE
FOLLOWING:
•Softening of a metal or alloy. This may be
done due to improving machinability.
•Relieving internal residual stresses caused by
the various manufacturing process.
•Refining the grain size of the metal or alloy.
•Increasing the ductility and reducing
brittleness.
Two types of annealing carried out are:
1. Process annealing.
2. Full annealing.

1. PROCESS ANNEALING:
It consists of heating the Steel to a temperature little below the critical range and then
cooling it slowly. This causes complete recrystallization in steel to form New grain
structure. This will release the internal stresses previously the strip in the steel and
improve the machinability.

2. FULL ANNEALING:
It consists of heating the Steel temperature at or near the critical point holding there for a
suitable time and then allowing it cools slowly in the Furnace itself. This courses wipes
out all traces of the previous structure and define the crystalline structure in addition to
the softening of the metal. It also removes internal stresses.
NORMALIZING:
 Normalizing is a heat treatment process similar to annealing in which the Steel is
heated to about 50 degree Celsius above the upper critical temperature followed by air
cooling.

 This heat treatment process is usually carried for low and medium carbon steel as well
as alloy steel to make the grain structure more uniform and relieve the internal
stresses.
 The grain size is finer in normalized structure than in annealed structure.
Normalizing carried for accomplishing one or more
of the following:
To refine the grain size.
 Reduce or remove internal stresses.
 Improve the machinability of low carbon steel.
 Increase the strength of medium carbon steel.
 And also To improve the mechanical properties of
the medium Carbon Steel.
➢Steels are soft in annealed condition and
tend to stick during machining. By
normalizing, an optimum combination of
strength and softness is achieved, which
results in satisfactory level of
Machinability in steels.

➢Normalizing is the effective way to


eliminate the carbide network.

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Differences Between Annealing And
Sl No
ANNEALING
Normalizing: NORMALIZING
1
Steel parts are gradually Steel parts are gradually cool in
cooled in a furnace. still air
2 Comparatively lower yield point, The comparatively higher yield point
Ultimate Tensile strength, and ultimate tensile strength and impact
impact strength. strength.
3 Comparatively soft and easily Comparatively less soft.
machinable.
4 Low hardness. BHN ranges Relatively more hard. Bhn ranges
from 125 to 220 BHN. from 140 to 245 BHN.
5 Highly ductile and percentage of The less ductile and relative
elongation is more. percentage of elongation is less
HARDENING
 Hardening is a heat treatment process carried out to increase the hardness of
Steel.
 It consists of heating Steel components to the temperature within or above its
critical range. Held at this temperature for a considerable time to ensure thorough
penetration of heat at this temperature well inside the component and then
allowed to cool separately by quenching in water oil or brine solution.
 This kind of heat treatment produced a small grain size in the metal.
 The strength and hardness of the Steel are increased but makes it more brittle
since ductility is reduced.

 Hardening is carried to accomplish the following:

 To reduce the grain size.


 Obtain maximum hardness.
 Reduce ductility to the minimum.
 To increase the wear resistance of Steel.
 Improve the magnetizing properties.
Hardening:
➢The main purpose of hardening tool steel is to develop high hardness. This enables
tool steel to cut other metals. High hardness developed by this process also improves
wear resistance. Gears, shafts and bearings. Tensile strength and yield strength are
improved considerably y hardening structural steels.

➢Because of rapid cooling, high internal stresses


are developed in the hardened steel. Hence these
steels are generally brittle. Hardening in general
is followed by another treatment known as
tempering which reduces internal stresses and
makes the hardened steel relatively stable,

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Tempering:
 This heat treatment process carried out for steel parts
which have been already hardened, in order to reduce
bitterness and unequal stress develop as a result of
hardening.
 This process reduces brittleness and hardness but
improves the tensile strength of Steel.
It increases the toughness of Steel at the expenses of
loss of some hardness.
 Almost all the cutting tools need a hard cutting edge
while at the same time they are required to be tough and
strong so as not to break when subjected to shock or
fatigue.
Tempering:
 Sampling is done by reheating the hardened Steel to some
temperature below the lower critical temperature and
then quenching in oil or salt bath.

 Reheating of Steel during tempering temperature


decreases the hardness Somewhat But improve the
toughness.

 This process is carried out to accomplish the following:


 To increase the toughness.
 Also, to decrease the hardness.
 Relieve the internal stresses.

Heat Treatment
Tempering:
➢Tempering temperatures are usually identified by the colour.
Tempering temperatures for tools and shafts along with temper colors.

➢ Depending on temperatures, tempering processes can be classified as:

1)Low- temperature
tempering (150 – 250 oC),

2)Medium –
temperature tempering (350 –
450 oC),

3)High – temperature tempering


(500 – 650 oC).
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Heat Treatment
Tempering:
➢Tempering temperatures are usually identified by the colour.
Tempering temperatures for tools and shafts along with temper colors.

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Heat Treatment
Quenching:
➢Quenching is a process of rapid cooling of materials from high
temperature to room temperature or even lower. In steels quenching
results in transformation of austenite to martensite (a non-equilibrium
constituent).

➢During cooling, heat must be extracted at


a very fast rate from the steel piece. This is
possible only when a steel piece is allowed
to come in contact with some medium which
can absorb heat from the steel piece with in
a short period.

➢Under ideal conditions, all the heat


absorbed by the medium should be rejected
to the surroundings immediately.
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Heat Treatment
Quenching:
➢The removal of heat during quenching is complex in the sense that heat
is removed in three stages.

1) Vapor Blanket,

2) Nucleate Boiling,

3) Convection.

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Heat Treatment
Quenching:
➢Vapor Blanket (stage 1)
As soon as the work-piece comes into contact with a liquid coolant
(quenchant), the surrounding quenchant layer is instantaneously heated up
to the boiling point of the quenchant and gets vaporized due to the high
temperature of the work- piece.
➢This acts as an insulator, preventing
the quenching oil from contacting the
metal surface. As a consequence, the rate
of cooling during this stage is slow.

➢At this stage the work piece is cooled


only by conduction and radiation
through the vapor film.

➢ Only the surface is cooled


considerably prior to the formation of
vapor envelop. 35
Heat Treatment
Quenching:
➢Nucleate Boiling (stage 2)
This second stage is also called as transport cooling stage or liquid
boiling stage. The temperature of the work-piece comes down, through
very slowly and the vapor blanket is no longer stable and collapses.
➢Metal surface comes into contact with the
liquid/ quenchant. Violent boiling quickly removes
heat from the quenched component while forming
bubbles and being pushed away, resulting in the
cooler fluid coming into contact with the work
piece.

➢This happens till the temperature of the work


piece comes down to the boiling point of the liquid.

➢ Maximum cooling rate is achieved during this


stage. 36
Heat Treatment
Quenching:
➢Convection (stage 3)

The third stage is called as the liquid cooling stage or the convection stage.

➢I starts when the temperature of the


surface becomes equal to the boiling
point of the quenchant.

➢Cooling at this stage takes place via


conduction and convection processes.

➢The rate of cooling is the slowest at this


stage.

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Heat Treatment
Quenching: Effect of Q u en c h i n g M e d i u m
➢Quenching medium has the profound effect on the final phase of the
material. Quenching medium is directly related to the rate of the cooling
of the material.

➢Some of the widely employed quenching media are water, aqueous


solutions, oils (mineral, vegetable and even animal oils), molten salts and
air.

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Heat Treatment
Quenching: Effect of Q u en c h i ng M e d i u m
(Water)

➢Water has maximum cooling rate


amongst all common quenchants
except few aqueous solutions.

➢It is very cheap and easily disposed


off compared to other quenchants.

➢Hence water is used for carbon steels,


alloy steels and non-ferrous alloys.

➢The layer if scale formed on the


surface during heating is also broken
by water quenching, thus eliminating
an additional process of surface
cooling. 39
Heat Treatment
Q u e n ch in g: E ffe ct of Q ue n ch in g
M e d iu m ( O I L )

➢Most of the Oils used as quenchants


are mineral oils. These are in general
paraffin based and do not possess any
fatty oils.

➢Quenching in oil provides slower


cooling rates as compared to those
achieved by water quenching.

➢The slower cooling rate reduces the


possibility of hardening defects.
➢The temperature difference between
core and the case of work piece is less
for oil quenching than for water
quenching. 40
Heat Treatment
Quenching: Effect of Q u e nc h i n g M e d i u m
(AIR)

➢Many alloy steels are capable of


getting hardened by cooling either in still
air or in a blast of air.
➢Such steels are popularly known as air
hardening steels.

➢These steels are almost free from


distortion problem. However, the
problem oxidation during
cooling
of
(quenching) may be encountered in
practice. Many grades of tool steels are
subjected to air hardening.

➢Cooling rates can be improved


by mixing air and water. 41
Heat Treatment
Quenching: Effect of Q ue n ch i n g M e d i u m :
➢Just the drastic water quench generates a fully martensite structure.

➢ Although quenched in oil the austensite converts into suitably fine pearlite.

➢ Accurate pearlite also results if the austenised eutectoid steel is air-cooled.

➢ Though, if allowed to cool in furnace coarse pearlite is appearance.

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Heat Treatment
Q u e n c h i n g : Effect of Q u e n c h i n g M e d i u m

Coarse Pearlite

- Smaller T:
colonies are
larger

Fine Pearlite

- Larger T:
colonies ar e
smaller

Figure: Microstructure resulting


from Different Cooling Rates
Applied to Austenitized Samples
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of
Eutectoid Steel
Heat Treatment
Surface Hardening:
➢ In many situations hard and wear resistance surface is required with the
tough core. Because of tough core the components can withstand impact load. The typical
applications requiring these conditions include gear teeth, cams shafts, bearings, crank pins,
clutch plate, tools and dies.

➢The combination of the these properties can be achieved by the following methods:

➢ 1. Hardening and tempering the surface layers (surface hardening)


(i) Flame Hardening (ii) Induction Hardening

➢ 2. Changing the composition at surface layers (chemical heat


➢ treatment or case hardening)
(i) Carburising (ii) Nitriding (iii) Carburising and Cyaniding

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Heat Treatment
F l a m e Ha rden ing
➢The flame hardening involves heating the surface of a steel to a
temperature above upper critical point (850 oC) with a oxyacetylene flame
and then immediately quenched the surface with cold water.

➢Heating transforms the structure of surface layers to austenite, and the


quenching changes it to martensite.

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Heat Treatment
F l a m e Ha rden ing
➢The surface layers are hardened to about 50 – 60 HRC. It is less expensive
and can be easily adopted for large and complex shapes.

➢Flame hardened parts must be tempered after hardening. The tempering


temperature depends on the alloy composition and desired hardness.

➢ The flame hardening methods are suitable for the steels with
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carbon
Heat Treatment
Induction Ha rde n in g
➢Induction hardening involves placing the steel components within a coil
through which high frequency current is passed. The current in the coil
induce eddy current in the surface layers, and heat the surface layers uotp
austenite state.

➢Then the surface is immediately quenched with the cold water to


transfer the austenite to martensite. The principle of induction hardening
is:

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Heat Treatment
Induction Ha rde nin g
➢Advantages of induction hardening over flame hardening is its speed
and ability to harden small parts; but it is expensive. Like flame
hardening, it is suitable for medium carbon and low alloy steels.

➢Typical applications for induction hardening are crank shafts, cam


shafts, connecting rods, gears and cylinders.

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Heat Treatment
Carburising
➢Carburising is carried out on a steels containing carbon less than 0.2%.
It involves increasing the carbon contents on the surface layers upto 0.7 to
0.8%.
➢In this process, the steel is heated in contact with carbonaceous material
from which it absorbs carbon. This method is mostly used for securing
hard and wear resistance surface with tough core carburising is used
for 2 CO  C + CO 2
gears, cams, bearings and clutch plates.

4
9
Heat Treatment
Carburising
➢ The Following methods are used to diffuse carbon into
surface layers:
1) Pack (solid) Carburising,
2) Gas Carburising,
3) Liquid Carburising.

Liquid Carburising

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Gas Carburising
Heat Treatment
Nitriding
➢Nitriding involves diffusion of nitrogen into the product to form nitrides.
The resulting nitride case can be harder than the carburized steel. This
process is used for alloy steels containing alloying elements (Aluminum,
Chromium and Molybdenum) which form stable nitrides.

➢Nitriding consists if heating a component in a retort to a temperature of


about 500 to 600 oC. Through the retort the ammonia gas is allowed to
circulate. At this temperature the ammonia dissociates by the following
reaction.
2 NH 3 = 2N + 3H 2
➢The atomic nitrogen diffuses into steel surface, and combines with the
alloying elements (Cr, Mo, W, V etc) to form hard nitrides. The depth to
which nitrides are formed in the steel depends on the temperature and the
time allowed for the reaction. After the nitriding the job is allowed to cool
slowly. Since there is no quenching involved, chances of cracking and
.distortion of the component are less 51
Heat Treatment
Nitriding
➢The depth of nitrided case ranges from 0.2 to 0.4 mm and no machining is
done after nitriding.

➢Nitriding increase wear and corrosion resistance and fatigue strength of


the steel. Since nitriding is done at low temperature, it requires more time
than carburising, and also the capital cost if the plant is higher than
carburising.

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Heat Treatment
C ya n idin g
➢Similar to carbonitriding, cyaniding also involves the diffusion of carbon
and nitrogen into the surface of steel. It is also called liquid carbonitriding.
The components are heated to the temperature of about 800 – 900 oC in a
molten cyanide bath consisting of sodium cyanide, sodium carbonate and
sodium chloride.

➢After allowing the components in the bath for about 15 – 20 minutes, they
are quenched in oil or water. Cyaniding is normally used for low-carbon
steels, and case depths are usually less than 0.25 mm.

➢It produces hard and wear resistance surface on the steels. Because of
shorter time cycles, the process is widely used for the machine components
subjected to moderate wear and service loads.

➢ The process is particularly suitable for screws, small gears, nuts and bolts.
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Please read the book.

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