Objectives of Heat Treatments

Abstract
Conventional surface heat-treatment processes are carried out at high temperature; hence both
the equipment and the operation costs are high. A review of literature available on electrolytic
heat-treatment has been attempted. This project introduces the development of an advanced
surface heat-treatment technique that can be operated at room temperature, with low cost and
easy control, thereby improving its competitiveness. This is an electrolytic heat-treatment
method in aqueous solution, especially using pulse current as a new aspect in the area of surface-
hardening technologies. The results obtained under this surface heat-treatment using pulse
current are presented briefly in this project, and the advantages and disadvantages of the
technology are also discussed. In the investigation reported, a test-piece made of AISI 1050 steel
has been surface hardened successfully by electrolysis in aqueous solution. Experimental work
and analysis have been carried out in order to study the effect of the average preset voltage on
the effective case depth of the test-piece under both direct-current and pulse-current conditions.
Compared with direct current, the test-piece can be surface hardened at a lower average preset
voltage and shorter heating time
TABLE OF CONTENT
1. INTRODUCTION ............................................................................... 1
2. OBJECTIVES OF HEAT TREATMENT........................................ 2
2.1. HEAT TREATMENT PROCESSES ..........................................................................................................................2
2.1.1. Full Annealing ............................................................................................................................................2
2.1.2. Spheroidizing .............................................................................................................................................2
2.1.3. Stress Relief Annealing: ............................................................................................................................3
2.2. NORMALIZING ....................................................................................................................................................4
2.3. TEMPERING PROCESSES:....................................................................................................................................5
2.3.1. Conventional Temper Process ..................................................................................................................5
2.3.2. Austempering: ............................................................................................................................................5
2.3.3. Martempering: ...........................................................................................................................................5
2.4. QUENCH MEDIA ..................................................................................................................................................7
2.4.1Water: ...........................................................................................................................................................7
2.4.2. Salt Water: .................................................................................................................................................7
2.4.3. Oil: ..............................................................................................................................................................7
2.4.4. Polymer quench: ........................................................................................................................................7
2.4.5. Cryogenic Quench: ....................................................................................................................................7
3. HARDNESS TESTING ...................................................................... 8

3.1. HARDNESS MEASUREMENT ......................................................................................................................8
3.2. HARDNESS MEASUREMENT METHODS ...............................................................................................................9
3.2.1. ROCKWELL HARDNESS .......................................................................................................................9
3.2.2. BRINELL HARDNESS ........................................................................................................................... 10
3.2.3. VICKERS HARDNESS (Micro and Macro hardness) and Knoop ..................................................... 10
3.2.3.1. Vickers Test ......................................................................................................................................................... 11
3.2.3.2. Knoop Test .......................................................................................................................................................... 11
3.3. HOW TO READ A HARDNESS NUMBER ............................................................................................................ 12
4. DESIGNATION OF STEEL ............................................................ 13

4.1. GOST (RUSSIAN STANDARD) .......................................................................................................................... 13
4.2. AISI (AMERICAN IRON & STEEL INSTITUTE) ................................................................................................. 15
4.3. DIN ................................................................................................................................................................... 19
5. SURFACE HARDENING OF STEEL ........................................... 22

5.1. HIGH FREQUENCY INDUCTION HARDENING .................................................................................................... 22
5.2. HARDENING WITH ELECTRIC CONTACT RESISTANCE HEATING ..................................................................... 27
5.3. HARDENING WITH ELECTROLYTIC HEATING .................................................................................................. 28
5.4. FLAME HARDENING .......................................................................................................................................... 29
I
6. CASE HARDENING OF STEEL .................................................... 32
6.1. CYANIDING & CARBONITRIDING OF STEEL .................................................................................................... 32
6.1.2. Liquid cyaniding ...................................................................................................................................... 32
6.1.3. Carbonitriding: ........................................................................................................................................ 35
6.1.4. High temperature Carbonitriding .......................................................................................................... 36
6.2. CARBURIZING ................................................................................................................................................... 38
6.2.1. pack carburizing: ..................................................................................................................................... 38
6.2.2. Gas carburized: ........................................................................................................................................ 39
6.2.3. Liquid carburizing: ................................................................................................................................. 40
6.3. NITRIDING ........................................................................................................................................................ 41
7. LITERATURE REVIEW ................................................................. 46

8. SYSTEM DESIGN ............................................................................ 49
8.1. SYSTEM ASSEMBLY .......................................................................................................................................... 49
8.2. THE MAIN COMPONENTS:................................................................................................................................. 50
8.3. STEEL TABLE: ................................................................................................................................................... 52
8.4. THE ELECTRODE AND ELECTRODE HOLDER ................................................................................................... 53
8.5. WORKPIECE HOLDING MECHANISM:............................................................................................................... 54
8.5.1 Workpiece holder...................................................................................................................................... 54
8.5.2 Male guide ................................................................................................................................................. 56
8.6. WORKPIECE DRIVING SCREW .......................................................................................................................... 57
8.6.1. WORKPIECE DRIVING NUT ........................................................................................................................... 57
8.7. BRIDGE WITH FEMALE SLOT (GUIDE WAY) ..................................................................................................... 58
8.8. ELECTRODE DRIVING MECHANISM.................................................................................................................. 59
8.9. WORKPIECE ..................................................................................................................................................... 60
8.10. BATH (ELECTROLYTE CONTAINER) ............................................................................................................... 60
9. CHARACTERISTICS OF POWER SUPPLY .............................. 62

9.1. RELATION BETWEEN GAP AND CURRENT AT CONSTANT VOLTAGE ................................................................ 63
9.1. RELATION BETWEEN CURRENT AND VOLTAGE AT CONSTANT GAP ................................................................ 74
10. EXPERIMENT ................................................................................ 81

10.1. PROCESS VARIABLES ...................................................................................................................................... 81
10.2. PROCESS SPECIFICATIONS ............................................................................................................................. 81
11. RESULTS AND CONCLUSIONS ................................................ 82

11.1. PULSE CURRENT CONDITION.......................................................................................................................... 82
11.2. DIRECT CURRENT CONDITION ....................................................................................................................... 82
10. RECOMMENDATIONS ................................................................ 83
II
Table of Figure
Figure (1) microscopic structure before and after Spheroidizing ....................................... 3

Figure (2) Annealing and Spheroidizing Temperatures .................................................... 3
Figure (3) Normalizing temperatures for hypoeutectoid and hypereutectoid steels. ............. 4
Figure (4) Austempering process. ................................................................................. 5
Figure (5) Martempering process.................................................................................. 6
Figure (6) nano-indentation machines........................................................................... 8
Figure (7) Rockwell test .............................................................................................. 9
Figure (8) Brinell hardness method ............................................................................. 10
Figure (9) Vickers Test .............................................................................................. 11
Figure (10) Knoop Test ............................................................................................. 11
Figure (11) principle of high frequency induction heating .............................................. 22
Figure (12) hardening with electric contact heating ...................................................... 27
Figure (13) electrolytic heating (schematic diagram) .................................................... 28
Figure (14) Relation between depth of hardening and holding time ................................. 39
Figure (15) whole system .......................................................................................... 49
Figure (16) main components .................................................................................... 50
Figure (17) Table ..................................................................................................... 52
Figure (18) Guiding nut ............................................................................................. 53
Figure (19) the electrode plate ................................................................................... 53
Figure (20) Electrode holding bar ............................................................................... 53
Figure (21) Fastener ................................................................................................. 54
Figure (22) Alloy steel rod ......................................................................................... 54
Figure (23) Bakelite box ............................................................................................ 55
Figure (24) Steel fasteners ........................................................................................ 55
Figure (25) upper part .............................................................................................. 56
Figure (26) lower part ............................................................................................... 56
Figure (27) Screw .................................................................................................... 57
Figure (28) Driving Nut ............................................................................................. 57
Figure (29) Legs ...................................................................................................... 58
Figure (30) bridge .................................................................................................... 58
Figure (31) Bridge base plate .................................................................................... 58
Figure (32) Fasteners ............................................................................................... 58
III
Figure (33) Ball Bearing ............................................................................................ 59
Figure (34) supports ................................................................................................. 59
Figure (35) Handle ................................................................................................... 60
Figure (36) Work piece ............................................................................................. 60
Figure (37) Bath ...................................................................................................... 61
Figure (38) Relation between gap and current at constant voltage at 50 V ...................... 63
Figure (39) Relation between gap and current at constant voltage at 100 V ..................... 64
Figure (45) Relation between gap and DC current at different voltage ............................. 72
Figure (46) Relation between gap and pulsed current at different voltage ........................ 73
Figure (47) Relation between current and voltage at constant gap at 50 mm ................... 74
Figure (48) Relation between current and voltage at constant gap at 100 mm ................. 75
Figure (49) Relation between current and voltage at constant gap.................................. 76
Figure (50) Relation between current and voltage at constant gap.................................. 78
Figure (51) Relation between current and voltage at different gaps ................................ 80
IV
Electrolyte Hardening Of Steel Introduction
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1. Introduction
Surface-hardening of medium-carbon steel can be accomplished using various high energy heat-
treatment methods that do not alter the chemistry of the base metal, these methods being:
Flame hardening,
Induction hardening
Hardening with electric contact resistance heating
The advantages and disadvantages of the above techniques have been compared and discussed
(Chapter 5). Each surface hardening technique has its own merits and can be applied in different
situations. The conventional methods are usually carried out at high temperature; hence both the
equipment and the operational costs are high. If an efficient surface-hardening technique for
medium-carbon steel can be developed especially one with minimal environmental impact, it
will benefit Egyptian industry.
Electrolytic surface-hardening is a special hardening method employing electrolysis in an

aqueous solution under particular conditions, the variables of this hardening process including
voltage, current and electrolyte.
If a stable hydrogen film is formed, then electrical discharge, including electrons and ion
avalanche, occurs. The work piece, acting as the cathode, will be heated violently to above the
austenitizing temperature due to the generation of resistance heat. Upon disconnecting the
electrical circuit, the hydrogen film will break and the surface of the work-piece will self quench
and/or is quenched by the cold electrolyte in the vicinity of the work-piece, the result being that
the work-piece hardens.
Hardening of low carbon steel can be accomplished using various methods of case hardening, these methods
being:
Carburizing of steel
Nitriding of steel
Carbonitriding and Cyaniding of steel
Only ferrous metals are casehardened. Case hardening is ideal for parts that require a wear-
resistant surface and must be tough enough internally to withstand heavy loading. The steels
best suited for case hardening are the low carbon and low-alloy series. In case hardening, you
change the surface of the metal chemically by introducing a high carbide or nitride content. The
core remains chemically unaffected. When heat treated, the high-carbon surface responds to
hardening, and the core toughens.
The advantages and disadvantages of the above techniques have been compared and
discussed (Chapter 6
1
Electrolyte Hardening Of Steel Objectives Of Heat Treatment
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2. Objectives of Heat Treatment

Heat Treatment is the controlled heating and cooling of metals to alter their physical and
mechanical properties without changing the product shape. Various types of heat treatment
processes are used to change the following properties or conditions of the steel:
Improve the toughness

Increase the hardness
Increase the ductility
Improve the machinability
Refine the grain structure
Remove the residual stresses
Improve the wear resistance
2.1. Heat treatment processes

2.1.1. Full Annealing
Full annealing is accomplished by heating hypoeutectoid steel to a temperature above the UCT
(Upper Critical Temperature). In practice, the steel is heated to about 50 C above the UCT, and
then It is held at this temperature for sufficient time for all the material to transform into
Austenite, . It is then slowly cooled at the rate of about 20 C/hr in a furnace to about 50 C into
the Ferrite-Cementite range. At this point it can be cooled in room temperature air with natural
convection. The grain structure has coarse Pearlite with ferrite or Cementite depending on
whether hypo or hyper eutectoid). The steel becomes soft and ductile.
2.1.2. Spheroidizing
Hypereutectoid steels consist of Pearlite and cementite. The cementite forms a brittle network
around the Pearlite. This presents difficulty in machining the hypereutectoid steels. To improve
the machinability of the annealed hypereutectoid steel spheroidize annealing is applied.
This process will produce a spheroidal or globular form of carbide in a ferritic matrix which
makes the machining easy
Note: Low carbon steels are seldom spheroidized for machining, because they are excessively
soft and gummy in the spheoridized conditions.
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Figure (1) microscopic structure before and after Spheroidizing
Figure (2) Annealing and Spheroidizing Temperatures
2.1.3. Stress Relief Annealing:

Stress Relief Anneal is used to reduce residual stresses in heavy machining or other cold-
working processes such parts tend to have stresses due to thermal cycling or work hardening.
Parts are heated to temperatures of up to 600 - 650 C and held for an extended time (about 1
hour or more) and then slowly cooled in still air
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The benefits of annealing are:
Improved ductility
Removal of residual stresses that result from cold-working or machining
Improved machinability
Grain refinement
2.2. Normalizing
The normalizing of steel is carried out by heating approximately 50 C above the UCT (Upper
Critical Temperature), and then it is held at this temperature to fully convert the structure into
Austenite, and then removed from the furnace and cooled at room temperature. Normalizing can
be applied above the UCT for hypoeutectoid and hypereutectoid steels, these results in a grain
structure of fine Pearlite with excess of Ferrite or Cementite. The resulting material is soft; the
degree of softness depends on the actual ambient conditions of cooling
Figure (3) Normalizing temperatures for hypoeutectoid and hypereutectoid steels.
The following is the list of the reasons for normalizing the steel:
To produce a harder and stronger steel than full annealing
To improve the machinability
To modify and refine the grain structure
To obtain a relatively good ductility without reducing the hardness and strength
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2.3. Tempering processes:
2.3.1. Conventional Temper Process
Tempering is a process done subsequent to quench hardening. Quench-hardened parts are often
too brittle. This brittleness is caused by a predominance of Martensite. This brittleness is
removed by tempering. Tempering results in a desired combination of hardness, ductility,
toughness, strength, and structural stability.
Tempering is done immediately after quench hardening. When the steel cools to about 40 C
after quenching, it is ready to be tempered. The part is reheated to a temperature of 150 to 400 C
In this region a softer and tougher structure is formed.
2.3.2. Austempering:
It is a quenching technique. The part is not quenched through the Martensite transformation.
Instead the material is quenched above the temperature when Martensite forms MS, around
315 C. It is held at this temperature till the entire part reaches this temperature.
As the part is held longer at this temperature, the Austenite transforms into Bainite, Bainite is
tough enough so that further tempering is not necessary, and the tendency to crack is severely
reduced.
Figure (4) Austempering process.

2.3.3. Martempering:
It is similar to Austempering except that the part is slowly cooled through the martensite
transformation. The structure is martensite, which needs to temper just as much as martensite
that is formed through rapid quenching.
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Figure (5) Martempering process.
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2.4. Quench media

Quenching is the act of rapidly cooling the hot steel to harden the steel.
2.4.1Water:
Quenching can be done by plunging the hot steel in water. The water adjacent to the hot steel
vaporizes, and there is no direct contact of the water with the steel. This slows down cooling
until the bubbles break and allow water contact with the hot steel. As the water contacts and
boils, a great amount of heat is removed from the steel. With good agitation, bubbles can be
prevented from sticking to the steel, and thereby prevent soft spots.
Water is a good rapid quenching medium, provided good agitation is done. However, water is
corrosive with steel, and the rapid cooling can sometimes cause distortion or cracking.
2.4.2. Salt Water:
Salt water is a more rapid quench medium than plain water because the bubbles are broken easily
and allow for rapid cooling of the part. However, salt water is even more corrosive than plain
water, and hence must be rinsed off immediately
2.4.3. Oil:
Oil is used when a slower cooling rate is desired. Since oil has a very high boiling point, the
transition from start of Martensite formation to the finish is slow and this reduces the likelihood
of cracking. Oil quenching results in fumes, spills, and sometimes a fire hazard
2.4.4. Polymer quench:
Polymer quenches that will produce a cooling rate in between water and oil. The cooling rate
can be altered by varying the components in the mixture-as these are composed of water and
some glycol polymers. Polymer quenches are capable of producing repeatable results with less
corrosion than water and less of a fire hazard than oil. But, these repeatable results are possible
only with constant monitoring of the chemistry.
2.4.5. Cryogenic Quench:
Cryogenics or deep freezing is done to make sure there is no retained Austenite during
quenching. The amount of Martensite formed at quenching is a function of the lowest
temperature encountered. At any given temperature of quenching there is a certain amount of
Martensite and the balance is untransformed Austenite. This untransformed Austenite is very
brittle and can cause loss of strength or hardness, dimensional instability, or cracks
7
Electrolyte Hardening Of Steel Hardness Testing
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3. Hardness Testing
WHAT IS HARDNESS?
The Metals Handbook defines hardness as "Resistance of metal to plastic deformation, usually
by indentation. However, the term may also refer to stiffness or temper or to resistance to
scratching, abrasion, or cutting. It is the property of a metal, which gives it the ability to resist
being permanently, deformed (bent, broken, or have its shape changed), when a load is applied.
The greater the hardness of the metal, the greater resistance it has to deformation.
3.1. HARDNESS MEASUREMENT
Hardness measurement can be defined as macro-, micro- or nano- scale according to the forces
applied and displacements obtained.
Micro hardness
Figure (6) nano-indentation machines
Micro hardness is the hardness of a material as determined by forcing an indenter such as a

Vickers or Knoop indenter into the surface of the material under 15 to 1000 gf load; usually, the
indentations are so small that they must be measured with a microscope Micro-indenters works
by pressing a tip into a sample and continuously measuring: applied load, penetration depth and
cycle time .Nano-indentation tests measure hardness by indenting using very small, on the order
of 1nano-Newton, indentation forces and measuring the depth of the indention that was made.
There are various mechanisms and methods that have been designed to complete nano
indentation hardness tests. One method of force application is using a coil and magnet assembly
on a loading column to drive the indenter downward. This method uses a capacitance
displacement gauge. This type of nano-indentation machine can be seen in Figure (6).
8
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3.2. Hardness measurement methods
3.2.1. ROCKWELL HARDNESS
Figure (7) Rockwell test
The Rockwell test method measures a permanent depth of indentation produced by the
preliminary and total test forces. First, a preliminary test force (pre-load or minor load) is
applied. This is the zero or reference position. Then, an additional test force (or major load) is
applied to reach the total required test force. This additional force is held for a predetermined
amount of time and then released, but with the preliminary test force still applied. The indenter
reaches the final position at the preliminary force and the distance traveled from the major load
position is measured and converted to a value into one of the many scales for Rockwell hardness.
Preliminary test forces range from 3 (superficial Rockwell) to 10 kilograms (regular Rockwell)
to 200 kilograms (macro Rockwell scale).Total test forces range from 500 grams (micro) to 15
through 150 kilograms (superficial& regular) to 500 through 3000 kilograms (macro).
A. Depth reached by indenter after application of preliminary test force (minor load).
B. Position of indenter under total test force.
C. Final position reached by indenter after elastic recovery of the material.
D. Position at which measurement is taken
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3.2.2. BRINELL HARDNESS
Figure (8) Brinell hardness method

Widely used on castings and forgings, the Brinell method applies a predetermined test force (F)
to a carbide ball of fixed diameter (D) which is held for a predetermined time and then removed.
The resulting indentation is measured across at least two diameters -usually at right angles to
each other and averaged (d).A chart is then used to convert the averaged diameter measurements
to a Brinell hardness number. Test forces range from 500 to 3000 kilograms.
Brinell Measurement Calculation
D = ball diameter
d = impression diameter
F = load
HB = Brinell Result
3.2.3. VICKERS HARDNESS (Micro and Macro hardness) and Knoop
Mostly used for small parts, thin sections, or case depth work, to perform a test, a predetermined
test force is applied with a pyramidal shaped diamond indenter. After a dwelt time, the force is
removed. Then, in the Vickers method, the indentation length of vertical and horizontal axis is
measured and averaged. In the Knoop method, only the long axis is measured. A chart is used to
convert the measurements to corresponding Vickers or Knoop hardness numbers, Test forces
range from 1 to 2000 grams, Vickers does offer higher force capabilities - up to 150 kgs.
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3.2.3.1. Vickers Test
Opposing indenter faces are set at a 136 degree angle to each other
Figure (9) Vickers Test
3.2.3.2. Knoop Test
Long side faces are set at a 172 degree, 30 minute angle to each other. Short side faces are set at
a 130 degree angle to each other
Figure (10) Knoop Test
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3.3. How to Read a Hardness Number
Table (1) How to Read a Hardness Number
Scale Name Example Explanation
Rockwell 60 HRC Hardness Rockwell C scale with a 60 test value
80.5HR15TW Hardness value in Rockwell 15T scale with 80.5

test value using a W or tungsten carbide ball
indenter.
Brinell 200 HB10/3000/15 200 test value using a 10 mm diameter carbide

ball, a 3000 kg load and a 15 second dwell
500 HBS 1/30/20 500 test value using a no-longer-valid steel (HBS)
ball of 1 mm diameter with 30 kg load and 20
second dwell
HB 200 An informal report assuming the most common

parameters- 10 mm carbide ball, 3000 kg load and
200 test result value
Microhardeness 200 HV 500/15 200test value with Vickers 500g load, 15seconds
duration
200 test value with Knoop 500g load, 15 seconds

duration
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Electrolyte Hardening Of Steel Designation Of Steel
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4. Designation of steel
4.1. GOST (Russian Standard)
Ordinary quality carbon steel

Identified by the letters CT followed by the numbers 1, 2, 3, etc.
Example: CT.1, CT.2, CT.3, etc
Increasing the number indicates:
1. Increase in carbon content
2. Increase in tensile strength
3. Decrease in ductility
Quality structural steel

Designated by the numbers 05, 08, 10, 20, 30, 45, etc. which indicates the average carbon
content in hundredths of one percent
Carbon tool steel

Designated by the Russian letter Y and a number indicating the average carbon content in
tenths of one per cent
Example: Y7 (contains 0.7 per cent carbon), Y8, Y9, Y10, Y11, etc.
Alloy steel
Designated by a combination of Russian letters and numbers
Letters indicate the presence of a certain alloying element
Table (2) Russian Symbol
Letter Alloying element
Manganese
C Silicon
X Chromium
H Nickel
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M Molybdenum
B Tungsten
Vanadium
Aluminum
T Titanium
K Cobalt
Copper
II Phosphorus
The number before letter indicate carbon content in hundredths of one per cent
The number after the letter indicates the approximate percentage of alloying element if its
content exceeds 1.5 per cent (when the content of the alloying element is less than or
about 1% the numerical index is omitted )
In all cases the letter A at the end of designation indicates that steel is of high quality
(sulfur & phosphorus content is less than 0.03% for each element).
Some alloy and high-alloy steel are classified in separate groups, each of which is
Assigned a special letter index which precedes the grade designation as following
Table (3) Russian Steel Types Symbol
Chromium stainless steel
Chromium-nickel steel
Magnetic steel
High-speed steel
Ball bearing steel
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4.2. AISI (American Iron & Steel Institute)

Specific numerical & letter designation
SAE : the society of automotive engineers
The AISI specifications follow the same numerical identification as SAE
XX XX
The first two The last two

numbers showing the numbers
type & approximate specifying the
amount carbon content
Of alloying element The first two numbersAmount of alloying eleme
Prefixes AISI letters that precedes the designation
Table (4) American Steel Types Symbol
A Basic open-hearth alloy steel
B Acid besmer carbon steel
C Basic open-hearth carbon steel
D Acid open-hearth carbon steel
E Electric furnace steel
Forms available
HB Hot rolled bars
CB Cold finished bars
B Bars
R Rods
W wire
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AISI Composition %
Number
Mn Ni Cr Mo V W Si B L
Carbon Steels
10XX 1.00
11XX
12XX
15XX 1-1.65
Manganese Steel
13XX 1.75
Nickel Steel
23XX 3.5
25XX 5
Nickel Chromium Steel
31XX 1.25 0.65,0.80
32XX 1.75 1.07
33XX 3.50 1.5,1.57
34XX 3.00 0.77
Molybdenum Steel
40XX 0.20,0.25
44XX 0.40,0.52
Chromium Molybdenum Steel
41XX 0.50,0.80,0.95 0.12,0.20,0.25,0.30
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AISI Composition %
Number
Nickel Chromium Molybdenum Steel
43XX 1.82 0.50,0.80 0.25
47XX 1.05 0.45 0.20,0.35
81XX 0.30 0.40 0.12
86XX 0.55 0.50 0.20
87XX 0.55 0.50 0.25
88XX 0.55 0.50 0.35
93XX 3.25 0.21 0.12
94XX 0.45 0.40 0.12
97XX 0.55 0.20 0.20
98XX 1.00 0.80 0.25
AISI Composition %
Number
Nickel Molybdenum Steel
46XX 0.85,1.82 0.20,0.25
48XX 3.50 0.25
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Chromium Steel
50XX 0.27,0.40,0.50,0.65
51XX 0.80,0.87,0.92,1.00
501XX 0.50
511XX 1.02
521XX 1.45
Chromium Vanadium Steel
61XX 0.60,0.80,0.95 0.10,0.15
Tungsten Chromium Steel
71XX 3.5 13.5,16.5
72XX 0.75 1.75
Silicon Manganese Steel
92XX 0.65,0.82,0.85 0.00,0.65 1.40,2.00
Low alloy high tensile steels
9XX
Stainless Steel
2XX Chromium-manganese-nickel-nitrogen austenitic steel
3XX Chromium- nickel austenitic steel
4XX Chromium ferritic & martensitic steel
5XX Silicon-Chromium steel
Boron intensified steel
XXBXX B denotes boron steels
Leaded Steels
XXLXX L denotes leaded steels
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50XX 0.27,0.40,0.50,0.65
4.3. DIN
XX OOO XX XX XX
Carbon content %
3rd Alloying element %

1ST Alloying element
2nd Alloying element 2nd Alloying element

%
3rd Alloying element 1st Alloying element %
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Table (5) Dividing Factor for alloying elements
4 10 100
Cr Chromium Al Aluminum Ce Cerium
Co Cobalt Be Beryllium C Carbon
Mn Manganese Pb Lead P Phosphor
Ni Nickel Cu Copper S Sulfur
Si Silicon Mo Molybdenum N Nitrogen
W Tungsten Nb Niobium
Ta Tantalum
Ti Titanium
V Vanadium
Zr Zirconium
Example:
DIN 25MoCr4 DIN 10CrMo9 10
C: (.23-0.29) % C: 0.13 %
Mo :( 0.40-0.50) % Cr: 2.25 %
Cr: (0.40-0.60) % Mo: 1%
DIN 15Mo3 DIN 24CrMoV55
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C: 0.16 % C: 0.24 %
Mo: 0.30 % Cr: 1.35 %
Mo: 0.55%
Special case:
If (X) precedes the designation, dont use the dividing factor:
DIN X19CrMo12.1 DIN X20CrMoV12.1
C: 0.15-0.23 % C: 0.17-0.23 %
Cr: 11-12.5 % Cr: 11-12.5 %
Mo: 0.80-1.20 % Mo: 0.8-1.2 %
V: 0.25-0.35 %
21
Electrolyte Hardening Of Steel Surface Hardening Of Steel
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5. Surface hardening of steel
5.1. High frequency induction hardening

Concept:
Heating by high frequency current (induction heating) is accomplished by the thermal effect of
current induced in the article being heated.
Figure (11) principle of high frequency induction heating
Set up:
1. Inductor.
2. Magnetic field.
3. Article being heated.
4. Capacitor battery.
5. High-frequency generator.
22
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Steps:
1. The latter is placed in an alternating magnetic field setup by the high frequency current.
2. The part to be heated is placed in the so-called inductor or inductor coil which comprises one
or several turns of copper tube or busbar.
3. When an alternating current is passed through the inductor, it sets up a magnetic field the
intensity of which varies periodically in magnitude and direction.
4. The alternating magnetic lines thread through the surface of the article being heated in the
inductor and induce in this surface an alternating current of the same frequency but reversed
in direction.
5. The current passes chiefly along the surface of the conductor. This is known as skin effect.
6. The heating is followed by quenching; the surface layer will be hardened.
The depth to which the current penetrates may be determined from the formula:
Y=5000 / f
In which:
Y is the depth of current penetration, cm.
Is the electrical resistivity, micro ohm-cm
Is the magnetic permeability of steel.
is the current frequency , cps
Applications:
Crank shafts, cam shafts, gears, and many other automobile and tractor parts are induction
hardened directly in the main production lines where these parts are machines.
Advantages:
1. It enables the time required for heat treatment to be sharply reduced, there by increasing
the labor productivity.
2. Articles may be heated with practically no scaling so that the metal allowance for
subsequent machining may be reduced.
3. Deformation due to heat treatment is considerably reduced.
4. Facilities automation of heat treating processes.
5. Enables heat treatment to be performed directly in the machining production line.
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The depth of penetration Y of the current increases with the temperature. It increases most
sharply at temperatures above the Curie point (768 Celsius) where the steel is transformed from
the ferromagnetic to the paramagnetic state.
Example:
The depth of penetration of current in a steel containing 0.45 percent c is increased 17 times as
the temperature rises from (20 Celsius) to (850 Celsius).
Table (6) recommended induction hardening temperatures and minimum surface hardnesses for various
metals
Carbon % Hardening Quench Rockwell c

temperature, hardness
F
min(b)
Carbon and alloy steels (c)
0.30 1650 to 1700 water 50
0.35 1650 water 52
0.40 1600 to 1650 water 55
0.45 1600 to 1650 water 58
0.50 1600 water 60
0.60 1550 to 1600 Water 64

oil 62
0.60 1500 to 1550 Water 64

oil 62
Process condition:
1. If ample power is available (0.3 to 1.5 Kw per sq cm), the surface layer, through which
the induced current passes, will be rapidly heated to the hardening temperature (from 2 to
10 seconds).
2. Induction hardening is adequately characterized by the parameters:
The heating time.
The specific power.
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The higher the specific power, the more rapidly steel will be heated. At a given current frequency
(), the specific power depends mainly upon the magnetic permeability ( ) and the electrical
resistivity ().
w
In which:
w : Specific power
Specific power: the energy transformed into heat per unit volume of the surface layer.
: Electrical resistivity.
: Magnetic permeability.
Table (7) power density (Kw per sq in.) required for surface hardening
Input, Kw per sq in.(b)
Frequency, kc Depth of Low (d) Optimum (e) High (f)

hardening, in.(c)
500 0.015 to 0.045 7 10 12
0.045 to 0.090 3 5 8
10 0.060 to 0.090 8 10 16
0.090 to 0.120 5 10 15
0.220 to 0.160 5 10 14
3 0.090 to 0.120 10 15 17
0.120 to 0.160 5 14 1
0.160 to 0.200 5 10 14
1 0.200 to 0.280 5 10 12
0.280 to 0.360 5 10 12
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The speed of inductor (or work piece) travel, required o obtain a hardened layer from 1 to
10 mm thick at a frequency from 2000 to 200,000 cps.
High frequency current is supplied from either vacuum-tube or machine-type generators.
At the present time machine-type generators are available for frequencies from 1000 to
10,000 cps, and have ratings from 60 to 1000 Kw .
Standard vacuum-tube generators have frequencies from 100,000 to 10,000,000 cps and a
rating from 5 to 220 Kw.
Machine-type generators are more widely used.
Induction hardening articles are subject to low tempering (160 Celsius to 200 Celsius).
Table (8) Recommended frequencies for induction hardening to a specific depth
Depth of 1.0 1.5 2.0 3.0 4.0 6.0 10.0

hardened layer,
mm
Maximum 250,000 100,000 60.000 30,000 15,000 8,000 2,500

frequency, cps
Minimum 15,000 7,000 4,000 1,500 1,000 500 150

frequency, cps
Optimum 60,000 25,000 15,000 7,000 4,000 1,500 500

frequency, cps
Recommended Vacuum- Vacuum- Vacuum- Machine Machine Machine Machine

generator tube type tube or tube or type, type, type, type, 500
machine machine 8,000 2,500 2500 - cps
type, type, cps cps 1,000
8,000 8000 cps cps
cps
Quenching:
1. A great many inductor hardening applications employ water as the quenching medium.
2. Other mediums such as conventional quenching oil, soluble oil, compressed air, plastic
quench, or brine are occasionally used.
3. Water is easiest to handle, simple to install and maintain, and generally less hazardous
than other mediums.
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5.2. Hardening with electric contact resistance heating

Concept:
This method consists in supplying alternating current of industrial frequency (50 cps) and low
voltage (2 to 6 V) to the work piece through electrodes which have the form of rollers.
Figure (12) hardening with electric contact heating

Set up:
1. Contact.
2. Roller.
3. Work piece.
Steps:
1. The power is supplied from single-phase step-down transformers.
2. The steel is rapidly heated at the point of contact with the roller.
3. The work piece is rotated and the roller is fed gradually along its length.
4. Due to these motions, the point of contact with the roller travels along the surface of the
shaft (work piece) in a helix and consecutively heats the shaft (band hardening).
Process condition:
1. The current has a density of 400 to 700 a per millimeter of roller width.
2. The feed of the roller along the work is varied in a range from 2 to 15 mm per second in
accordance with the depth of hardened layer required.
3. The roller is pressed against the surface of the work piece with a pressure of 10 to 15 kg
per millimeter of roller width.
4. The maximum hardness will lie at a depth of 0.05 to 0.1 mm below the surface.
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Disadvantage:
The helical tempered band of lower hardness on the surface after hardening.
Quenching:
Cooling is done either by heat conduction into the metal or by quenching in the ordinary manner
like quenching in water or oil.
5.3. Hardening with electrolytic heating
Concept and steps:
1. The work piece, which serves as the cathode, is immersed in an electrode (a 5 to 10

percent solution of soda or potash).
2. The shell of the bath is the anode.
3. When direct current at a high voltage (250 to 300 V) is passed through the electrolyte, a
hydrogen blanket is formed surrounding the cathode (work piece).
4. Due to its resistivity, the hydrogen blanket is rapidly heated to a high temperature (about
2,000 Celsius) and a considerable portion of its heat is transferred to the work piece.
Figure (13) electrolytic heating (schematic diagram)
Set up:
1. Work piece (cathode).
2. Electrolyte.
3. Hydrogen blanket.
4. Current supply.
5. Anode.
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Two stages may be distinguished in heating the cathode:
1. In the first stage, bubbles of hydrogen are intensively evolved and settle on the cathode.
These bubbles heat the electrolyte, immediately surrounding the cathode, and produce a
vapor blanket. This stage takes a fraction of a second.
2. In the second stage, the cathode is covered by a continuous hydrogen blanket,
surrounded, in turn, by a steam blanket. The heating rate is varied by changing the
voltage, current, the heating time.
Process condition:
1. Heating time is varied in a range from 10 to 40 seconds to suit the type of the work piece
being heated.
2. The current density varies from 3 t 6 a per sq cm.
Disadvantage:
1. The surface is inevitably overheated if a comparatively shallow depth of hardening is

required.
2. This shortcoming, in conjunction with the high power consumption and difficulties
encountered in mechanizing the process, has limited the application of this method.
Quenching:
After the process is finished and the equipment being switched off, the hydrogen bubbles a round
the work piece are removed and then the electrolyte surrounding the work piece will be in
contact with the work piece and cooling it.
5.4. Flame hardening

Concept and steps of the process:
1. Flame hardening is a heat treating process in which the surface of a hardenable ferrous
alloy is rapidly heated above the transformation temperature by direct impingement of a
high temperature flame.
2. Then cooled at a rate to produce the hardness and other properties desired.
3. The high temperature flame is obtained by combustion of a mixture of fuel gas with
oxygen or air.
4. Flame heads are used for burning the mixture.
5. Depths of hardening from a bout 1/32 in to 1/4 in (0.78 mm to 6.25 mm). Or more can be
obtained, depending on the fuels used.
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Application:
1. Because parts are so large to make conventional furnace heating and quenching
impracticable or uneconomical.
2. Because only a small segment, section or area of a part requires heat treatment.
3. Because dimensional accuracy of a part is impracticable or difficult to attain.
4. Because the use of flame hardening permits making a part from a less costly material.
Methods of flame hardening:

1. The spot (stationary) method.
2. The progressive method.
3. The spinning method.
4. The combination progressive spinning method.
Example: oxyacetylene flame hardening:

Concept and stages:
1. The surface of work piece, treated by this method, is heated by an oxyacetylene flame
having a temperature of 3000 Celsius to 3200 Celsius.
2. The large a mount of heat transferred to the surface of the work piece.
3. Heat removal into the metal due to high thermal conductivity, rapidly heats it to the
hardening temperature before the core is appreciably heated.
4. Quenching hardens the surface.
Application:
Hardening large cast gears, worms, shafts, steel guide ways, mill rolls, etc;
Process condition:
Welding torches are employed for heating: they may have single flame, slit type,
or multiple flame tips.
The heating time is 7 y seconds (in which y is the depth of the hardened layer in
mm).
The torch is traversed along the work piece at a speed of 72/y mm per sec.
Advantage:
Simplicity.
Cheap
Disadvantage:
The danger of overheating.
Coarse a circular martensite is formed at the surface after hardening.
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Quenching media:
A spray quench may be used.
Water cooled heating.
Immersion
31
Electrolyte Hardening Of Steel Case Hardening Of Steel
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6. Case Hardening of Steel

6.1. Cyaniding & Carbonitriding of steel
Heating of steel
Liquid media solid media gas media
Cyaniding Carbonitriding
6.1.2. Liquid cyaniding

Work is heated in a molten salt baths containing various Prussians
Liquid cyaniding
High temperature Medium temperature Low temperature
Table (9) Low temperature cyaniding
Low temperature cyaniding
Application Temperature Prussiates Time required Heat Diffusion

O
treatment layer mm
C
Increases life of 550 : 560 NaCn 30:50 % 5:30 minutes No further 0.02:0.04
high speed steel depending on heat thin layer of
tools Na 2 CO3 the case depth treatment is high nitrogen
20:45% required content
NaCl 10:20 %
32
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Table (10) Medium temperature cyaniding
Medium temperature cyaniding

O
treatment layer mm
C
Increases wear 750: 860 NaCN 20:35 5:90minutes Followed by 0.075: 0.25
resistance under % depending on direct
small specific the case depth quenching
loads like bolts , Na 2 CO3 from bath
nuts , screws , of and low
NaCL neutral
low and medium tempering
salts
carbon steel temperature hardness
obtained
50:60 RC
Chemical reactions for low & medium temperature cyaniding

1) 2NaCN + O 2 2NaCNO
2) 2NaCNO + O 2 Na 2 CO3+ 2N at
2CO CO 2 + C ai
Table (11) High temperature (deep) cyaniding
High temperature (deep) cyaniding

O
treatment layer mm
C
When less 900:960 BaCL 2 1 : 6 hours Followed by Case depth

deformation is direct 0.5:1.5 mm
required for 80:84% quenching
Containing
complex from bath
NaCL < 1:1.2 C &
machine parts and low
like shafts 10% tempering 0.2:0.3 N 2
temperature
NaCN 6:10%
KCL
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Table (12) Relationship between case depth and cyaniding time
cyaniding time (hours) 1 2 3 4 5
case depth (mm) 0.5:0.6 0.8:0.9 1.0:1.1 1.2:1.3 1.4:1.5
Chemical reactions for high temperature cyaniding
1) 2NaCN + BaCL 2 2NaCL + Ba(CN) 2

2) Ba(CN) 2 BaCN 2 + Ca at
3) Ba(CN) 2 + O 2 BaO + CO + 2N at
Bath containing BaCL 2 must be covered with a layer of ash-free graphite to reduce the
degree of depletion of the bath and heat loss
The bath must be periodically refreshed by BaCL 2 and NaCN in the proportion of 4:1
Table (13) Pack cyaniding
Pack cyaniding
Application Temperature Prussiates Time required disadvantages
O
C
Hardening of 540:560 Charcoal 1.5:3 hours More time than

high speed 60:80% liquid cyaniding
steel tools Doesnt ensure
Potassium stable properties
Ferro
cyanide
K 4 Fe(CN) 6
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Table (14) Effect of cyaniding temperature & time on case depth & surface carbon content
Effect of cyaniding temperature & time on case depth & surface carbon content
O O
Cyanided 1 Hr at 843 C Cyanided 1Hr at 871 C
Steel Case depth Surface C % Steel Case depth Surface C %

mm mm
1020 0.254 0.62 1020 0.254 0.5
3115 0.254 0.32 3115 0.254 0.38

O O
Cyanided 3 Hr at 843 C Cyanided 3 Hr at 871 C
Steel Case depth Surface C % Steel Case depth Surface C %

mm mm
1020 0.46 0.74 1020 0.38 0.65
3115 0.51 0.69 3115 0.46 0.6
Specimen D= 25 mm, length 150 mm
6.1.3. Carbonitriding:
Heat treatment o parts made of various tool and structural steel in a gas mixture containing a
carburizing gas and 20:30 per percent ammonia (NH 3 )
Table (15) Low temperature Carbonitriding
Low temperature Carbonitriding
Application Temperature Time Case depth

required
CO
High speed 540:560 30 minutes 0.02:0.04mm

steel tools to 3 hours hardness
like twist obtained
drills , 950:1100
reamers , VHN
cone drills
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Table (16) Medium temperature Carbonitriding
Medium temperature Carbonitriding
Application Temperature Time Heat

required treatment
CO
Complex 840:860 1.5:10 direct

machine parts hours quenching
that have a from furnace
tendency to or after pre-
wrap during cooling to
heat 800:825 C O
treatment and
tempering
temperature
at 160: 180
CO
Table (17) Relationship between case depth and Carbonitriding time for medium temperature
Carbonitriding
Carbonitriding time (hours) 1.5:2 3:4 5:6 8:10
case depth (mm) 0.2:0.3 0.4:0.5 0.6:0.7 0.8:1
6.1.4. High temperature Carbonitriding

Application: hardening of structural steels
Temperature: 900: 950 C O
Table (18) Carbonitrided Steel
Carbonitrided Steel Carbon content up to (0.25% C)
AISI DIN GOST
1010 C10E 08;10
1015 C15E 15
1020 C22E 20
1213 11SMn30 ------------
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1022 20Mn5 20GSL
1040 CK40 40
8620 20NiCrMo2-2 20ChGNM
Alloy Steel
5140 41Cr4 40Ch
8620 21NiCrMo2 ----------------
8622 ---------------- -----------------
4047 ---------------- -----------------
37
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6.2. Carburizing
Carburizing is the process of saturating the surface layer of steel with carbon
Carburization is classified as:
Carburizing
Liquid Pack Gas
Table (19) Carburizing
Temperature Diffusion
Time Heat treatment Hardness
Application layer
CO Required After Carburizing RC
mm
Low carbon
59 : 63
steel 4 : 20 Hr 1. normalizing
880 : 900 With
Alloy steel According
2. hardening 750 Average
For highly 900 : 950 to depth Up to 2.2 concentration
stressed of : 780
3. tempering 150 of carbon in
component diffusion
: 180 the surface
with tough layer
(0.8: 1.2 %)
core
6.2.1. pack carburizing:

In this process the carbonaceous medium is a solid carburizer, the chief carburizers for pack
carburizing are activated charcoal in grains from 3.5 to 10 mm
Chemical reactions for pack carburizing
2CO CO2 + C at
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Table (20) Relation between case depth and holding time
Case depth mm Hardening time hr
0.4 to 0.7 4.5 to 5.5
0.6 to 0.9 5.5 to 6.5
0.8 to 1.2 6.2 to 10
1 to 1.4 8 to 11.5
1.4 to 1.8 11.5 to 16
1.5 to 1.9 13 to 18
1.6 to 2 14 to 19
1.8 to 2.2 16 to 22
6.2.2. Gas carburized:

Its accomplished by heating the work in gaseous medium containing carbon and pure
methane CH4
Figure (14) Relation between depth of hardening and holding time
39
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6.2.3. Liquid carburizing:
This carburizing process is formed in baths of molten salts containing 75 to 85%sudium
carbonate, 10 to 15% sodium chloride and 6 to 10%silicon carbide
SiC + 2Na 2 Co 3 Na 2 Sio 2 ` +Na 2 o+2Co+C at
Table (21) Relation between holding time and diffusion layer
Holding time in 0.5 1 1.5 2 3

carburizing hr
3Depth of 0.2 0.25 0.35 0.4 0.5

diffusion layer
mm
Table (22) various types of steel in different standards
Low Carbon Steel

AISI DIN GOST
1015 C15E 15
1020 20Mn5 20
1025 C25E 25
1010 C10 10
1020 C22 20
Alloy Steel
5120 20MnCr 18ChG
5130 28Cr4 30Ch
5135 37Cr4 5Ch10
5132 34Ch4 35Ch
5015 15Cr15 15Ch
40
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8620 21MnCrMo -
8720 21NiCrMo22 -
8740 40NiCrMo22 38ChGNM
9840 36CrNiMo4 40ChN2Ma
6.3. Nitriding
Table (23) Nitriding
Heat
Temperature Time treatment Diffusion
Application Hardness RC
CO Required After layer mm
Carburizing
1. Carbon
Medium Carbon 488: 650 30 Min: 4 After nitriding Up to 0.8
steel
steel Hr the parts are
2. Alloy steel
cooled in a
Alloy steel 800-1200
steam of
Contains Al, Cr, VHN
ammonia gas
MO, V.
at 200 C O
Table (24) various types of steel in different standards
Medium Carbon Steel

AISI DIN GOST
1035 C35 35
1045 C45 45
1038 CK35 35
1023 CF35 35
1040 CK40 40
1045 CK45 45
1050 CF53 50
41
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Alloy steel contains (AL,Mo,Ni,V,Cr)

4340 34CrNiMo6 38Ch2n2MA
5030 28Cr4 30Ch
5132 34Cr4 35Ch
5140 41Cr 4 40Ch
6145 51CrV4 50ChGFA
6150 50ChGFA 50CrY4
42
Electrolyte Hardening Of Steel Case & Surface Hardening Of Steel
____________________________________________________________________________________________________________________________________________________________________
Table (25) different types of case and surface hardening of Steel
CHEMECAL COMPOSITION % TEMPERATURE HARDENESS TIME NATURE PROCESS

AISI DIN GOST DEPTH (mm) APPLICTION
(C) (RC) (Hours) OF CASE CHARACTERISTICS
C Mn P S Si Ni Cr Mo V
CASE HARDENING
PACK CARBURIZING
1020 C22 20 0.18-0.23 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ----- Crane-cable drum, motor brake wheel
1022 20 Mn 5 ----- 0.18-0.23 0.70-1.00 0.040 0.050 ----- ----- ----- ----- ----- According to Heavy duty industrial gear
depth of Low equipment costs,
1025 Ck25 25 0.22-0.28 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ----- diffusion Diffused Calendar bull gear
815-1090 50-63 125 m-1.5mm difficult to control case depth
layer carbon
accurately
1030 28 Mn6 30 0.25-0.34 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ----- 4 : 20 Hr Kiln trunnion roller
1035 C 35 35 0.32-0.38 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ----- High performance crane wheel
8620 20NiCrMo2-2 20ChGNM 0.18-0.32 0.70-0.90 0.040 0.040 ----- ----- ----- ----- ----- Processor pinch roll
GAS CARBURIZING
1024 17GS 0.19-0.25 1.35-1.65 0.040 0.040 ----- ----- ----- ----- -----
Good control of case depth,
4322 0.17-0.22 0.45-0.65 0.040 0.040 0.20-0.35 1.65-2.00 0.40-0.60 0.20-0.30 ----- According to Diffused suitable for continuous
815-980 depth of 75 m-1.5 mm
50-63 carbon operation, good gas controls
diffusion required, can be dangerous
5120 20MnCr5 18ChG 0.17-0.22 0.70-0.90 0.040 0.040 0.20-0.35 ----- 0.70-0.90 ----- ----- layer
8620 20NiCrMo2-2 20ChGNM 0.18-0.32 0.70-0.90 0.040 0.040 ----- ----- ----- ----- -----
LIQUID CARBURIZING
1020 C22 20 0.18-0.23 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ----- Arbors, die block flanges, levers
Diffused
1022 20 Mn 5 ----- 0.18-0.23 0.70-1.00 0.040 0.050 ----- ----- ----- ----- ----- carbon Faster than pack and gas Torsion-bar cap
According to processes, can pose salt
815-980 50-65 depth of 50 m-1.5 mm
1018 Ck 15 0.15-0.20 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ----- and possibly disposal problem, salt baths Link
diffusion require frequent maintenance
layer nitrogen
1010 Ck 10 10 0.08-0.13 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ----- Plate
8620 20NiCrMo2-2 20ChGNM 0.18-0.32 0.70-0.90 0.040 0.040 ----- ----- ----- ----- ----- Spool, valves, universal socket
GAS NITRIDING
3310 14NiCr14 0.08-0.13 0.45-0.60 0.025 0.025 0.20-0.35 3.25-3.75 1.40-1.75 ----- ----- gears
4130 25CrMo4 20ChM 0.28-0.33 0.40-0.60 0.040 0.040 0.20-0.35 ----- 0.80-1.10 0.15-0.25 ----- Crankshaft, piston ring
Hardest cases from nitriding
4140 41CrMo4 40ChFA 0.38-0.43 0.75-1.00 0.040 0.040 0.20-0.35 ----- 0.80-1.10 0.15-0.25 ----- steels, quenching not Clutches, feed screw, seal ring
Diffused required, low distortion,
480-590 50-70 125 m-0.75mm
4142 42CrMo4 40ChFA 0.40-0.45 0.75-1.00 0.040 0.040 0.20-0.35 ----- 0.80-1.10 0.15-0.25 ----- 30 min: 4 Hr nitrogen process is slow, is usually Helical transmission gears
a batch process
4150 50CrMo4 ----- 0.48-0.53 0.75-1.00 0.040 0.040 0.20-0.35 ----- 0.80-1.10 0.15-0.25 ----- Helical speed reducing gears
4340 34 CrNiMo 6 38Ch2N2MA 0.38-0.43 0.60-0.80 0.040 0.040 0.20-0.35 1.65-2.00 0.70-0.90 0.20-0.30 ----- Spindle, wedges, torque gear
8620 20NiCrMo2-2 20ChGNM 0.18-0.32 0.70-0.90 0.040 0.040 ----- ----- ----- ----- ----- High speed pinion
43
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GAS Carbonitriding
1010 Ck 10 10 0.08-0.13 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ----- Bearing block, brake- operating cams
1015 Ck 15 15 0.13-0.18 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ----- Cups distributor drive shafts
1018 Ck 15 0.15-0.20 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ----- Sliding spur gears, spur pinion shafts
According to Lower temperature than
Diffused carburizing (less distortion),
1020 C22 20 0.18-0.23 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ----- 760-870 50-65 Temperature 75 m-0.75mm carbon slightly harder case than Adjusting yoke
and nitrogen carburizing gas control
1022 20 Mn 5 ----- 0.18-0.23 0.70-1.00 0.040 0.050 ----- ----- ----- ----- ----- (1) critical Links
(2)
1040 Ck 40 40 0.37-0.44 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ----- Transmission slide forks
5140 42Cr4 40Ch 0.38-0.43 0.70-0.90 0.040 0.040 0.20-0.35 ----- 0.70-0.90 ----- ----- Input shafts
8622 21NiCrMo2-2 0.20-0.25 0.70-0.90 0.040 0.040 0.20-0.35 0.40-0.70 0.40-0.60 0.15-0.25 ----- Hub, Transmission main shaft sleeve
LIQUID Carbonitriding (cyaniding)
1010 Ck 10 10 0.08-0.13 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ----- According to Diffused Good for thin cases on
carbon noncritical parts, batch Increases life of high speed steel tools, wear
760-870 50-65 Temperature 2.5-125 m resistance under small specific loads like
1020 C22 20 0.18-0.23 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ----- process, salt disposal
& and nitrogen problems bolts , nuts , screws , of low and medium
carbon steel
1022 20 Mn 5 0.18-0.23 0.70-1.00 0.040 0.050 ----- ----- ----- ----- ----- Case depth
SURFACE HARDENING
Flame
HARDENESS TIME
CHEMECAL COMPOSITION % TEMPERATURE DEPTH (mm) APPLICTION
AISI DIN GOST (RC) (Sec)
C Mn P S Si Ni Cr Mo V
1025 Ck25 25 0.22-0.28 0.30-0.60 0.040 0.050 ----- ----- ----- ----- ---
0.79 : 6.35
1035 C 35 35 0.32-0.38 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ---
depending on
1050 Ck 50 50 0.48-0.55 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ---
The fuel used
small segment, section, valve stems and pushrods and the wearing surfaces of cams and levers
1055 Ck 55 55 0.50-0.60 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ---
50 : 65
3140 40 NiCr 6 40ChN 0.38-0.43 0.70-0.90 0.040 0.040 0.20-0.35 1.10-1.40 0.55-0.75 ----- --- Design of
flame head.
4130 25 CrMo 4 30ChM 0.28-0.33 0.40-0.60 0.040 0.040 0.20-0.35 ----- 0.80-1.10 0.15-0.25 ---
4140 42 CrMo 4 ----- 0.38-0.43 0.75-1.00 0.040 0.040 0.20-0.35 ----- 0.80-1.10 0.15-0.25 --- Duration of
heating
4337 34 CrNiMo 6 38Ch2N2MA 0.35-0.40 0.60-0.80 0.040 0.040 0.20-0.35 1.65-2.00 0.70-0.90 0.20-0.30 ---
52100 100 Cr 6 SchCh 15 0.95-1.10 0.25-0.45 0.025 0.025 0.20-0.35 ----- 1.30-1.60 ----- ---
Induction
1035 C 35 35 0.32-0.38 0.60-0.90 0.040 0.050 ----- ----- ----- ----- --- Shallow rocker arm shafts , couplings , pump shafts
hardened case
1036 30Mn5 27ChGSNMDTL 0.30-0.37 1.20-1.50 0.040 0.050 ----- ----- ----- ----- --- (0.254-1.524 )
Up to 65 Up to 65
1038 Ck 35 35 0.35-0.52 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ---
Deeper hardened
case gears, track pins, heavy cam shaft bearing, bearing races
1041 40Mn4 40G 0.36-0.44 1.35-1.65 0.040 0.050 ----- ----- ----- ----- ---
44
____________________________________________________________________________________________________________________________________________________________________
(1.524-6.35)
1045 C45 45 0.43-0.50 0.60-0.90 0.040 0.050 ----- ----- ----- ----- ---
4130 25 CrMo 4 30ChM 0.28-0.33 0.40-0.60 0.040 0.040 0.20-0.35 ----- 0.80-1.10 0.15-0.25 ---
4142 42 CrMo 4 ----- 0.40-0.45 0.75-1.00 0.040 0.040 0.20-0.35 ----- 0.80-1.10 0.15-0.25 ---
(1) low temperature -------------30 minutes to 3 hours

(2) medium temperature---------1.5:10 hours
45
Electrolyte Hardening Of Steel Literature Review
______________________________________________________________________
7. Literature Review
A review of the literature available on heat treatment using direct-current electrolysis was
attempted by the (S.F. Luk a,*, T.P. Leung a, W.S. Miu a, I. Pashby b) This paper briefly
introduces the development of this advanced surface heat-treatment technique that can be
operated at room temperature, with low cost and easy control, which hence improves its
competitiveness. In the investigation reported, a test-piece made of AISI 1050 steel has been
surface hardened successfully by electrolysis in aqueous solution. Experimental work and
analysis have been carried out in order to study the effect of the average preset voltage on the
hardness of the test-piece under both direct-current and pulse-current conditions. Compared
with direct current, the test-piece can be surface hardened at a lower average preset voltage
and with a Shorter heating time.
The pervious research is concluded that the optimum conditions to perform this operation are
1st pulsed conditions
from 7 to 10 s at pulse 220 V
2nd DC Conditions
From 17 to20 s at DC. 260 V

From 7 to 12 s at DC. 280 V
From 5 to 6 s at DC. 300 V
Compared to D.C., the heating time efficiency under pulse conditions is 425% greater at the
same average preset voltage. A lower average preset voltage can be employed to harden the
test-pieces under pulse conditions than under D.C. conditions for the same heating time.
Lower operating voltage implies a safer operation and less energy consumption.
In 28 July 1997 a new research was performed by (S.F. Luk a,*, T.P. Leung a, W.S. Miu a, I.
Pashby b) of surface hardening using medium carbon steel as a cathode.
Using a cathode having a diameter of 3 mm, the acceptable voltage for performing the
hardening process is above 165 Volt since a stable hydrogen film will be produced.
Using a cathode having a diameter of 12 mm immersed 15 mm into electrolyte the acceptable

voltage for performing the hardening process is above 165 Volt since a stable hydrogen film
will be produced.
Using a cathode having a diameter of 69 mm, immersed 20 mm into the same composition of
electrolyte with the end surface being masked, and the minimum voltage able to heat the
cathode to above 600C was 200 V.
The minimum concentration of sodium carbonate electrolyte to carry out electrolytic heating
successfully was 4%.
Generally When the electrolyte temperature was around 7080C or greater, the gas film
became unstable since the formation of water vapor occurred ,Thicker gas film isolated the
cathode from the electrolyte; heat loss was increased; the voltage drop was too high; and the
heating process stopped .
46
______________________________________________________________________
The primary and secondary voltages to heat a Workpiece having a diameter of 20 mm and a
length of 50 mm to the austenitizing temperature in 15% sodium carbonate electrolyte were
220 V for 12 s and 140 V for 120 s, respectively.
In 1994, electrolytic surface-hardening in 5% sodium carbonate electrolyte by d.c. was
carried out successfully on medium-carbon steel (similar to AISI 1045, composed of 0.43
0.50% C, 0.600.90% Mn, 0.040% P, and 0.050% S). The voltage used was 250 V and the
current density was found to be 369 A dm_2. The hardness achieved for the medium-carbon
steel (AISI 1045) 60HRC.
Based on the results of the D.C. case, it was found that the mechanism of electrolytic surface-
hardening of steel parts was similar to that when using a pulse, Electrolysis by pulse current
was found to be superior to that of D.C
Different heating rates can be achieved much more easily under pulse current conditions than
under D.C. conditions at the same average voltage of 15 V.
The minimum average preset voltage to heat the Workpiece to 800C or above for a pulse
current is 200 V at a pulse period of 1 s and an ON: OFF ratio of 9:1, whilst that for D.C is
260 V.
In the same year the (S.F. Luk a,*, T.P. Leung a, W.S. Miu a, I. Pashby b) is performed a new
research and found that the heating rates for different pulse periods with the same average
voltage of 200 V and an ON: OFF ratio of 9:1 increase in accordance with the increase of the
pulse periods. At each voltage. D.C. can only offer one heating rate.
Hence this technique was not widely used. In the area of the electroplating process, pulse
current was found to be superior to direct current after literature searching by different
means; the authors have found that nobody has studied this technique using pulse current.
Recently a feasibility study was carried out by the authors, the results showing that different
pulse conditions are capable of giving different heating rates.
Electrolytic surface-hardening in aqueous solution using pulse current was found to be a new
area for development, A special high-power pulse rectifier and an electrolyte bath system
were designed and fabricated to investigate this new technology of electrolytic heat-treatment
in aqueous solution using pulse current.
The measurement of the Workpiece temperature is very difficult but provides important
information to determine the optimum operating conditions. There are many methods to
measure Workpiece temperature.
Facilities/Materials Used In This Study
After a feasibility study, a high-power pulse rectifier was designed and fabricated for further
investigation. The Facilities and materials used in this study are as follows.
A high-power pulse rectifier, of external dimensions 0,8 m (L) x 0.6 m (W) x 1.9 m
(H), the features of the rectifier being as follows. (u) Inputs: (i) voltage, 3 phases. 50
Hz, 380 V (ii) current 0 - 6O A. (b) Outputs: (i) direct current, voltage. 0 to 300 V
(adjustable), current - 0 10 GO A; (ii) pulse current, on time - 0.001 to 1 s
(adjustable), ON: OFF ratio - 9:1 to1:9 (adjustable), peak current - 0 lo 60 A, peak
voltage - 0 to 300 V (adjustable); heating time: 0 to 99 s (adjustable).
The pulse outputs of the pulse rectifier are square waves, the wave forms being
measured and tested using the testing circuit.
An electrolytic bath system, of external dimensions 1 m (L) x 0.65 m (W) x I.4 m (H),
the features of the electrolytic bath system being as follows:
47
______________________________________________________________________
The capacity of the electrolytic bath is 120 I having the dimensions 0.6 m (L) x 0.4 m
(W) x 0.5 m (H).
The capacity of the circulation tank is 240 I, having the dimensions 0.8 m (L) x 0.5 m
(W) x 0.6 m.
The minimum capacity of the circulation pump is 20 L/min.
The bath system is equipped with overflow control, electrolyte circulation. Electrolyte
filtration, a viewing widow temperature measurement of electrolyte.
Safety devices are provided. The electrolyte used had the simple formulation Na2C03
50 g/l.
Whilst different pulse conditions at the same average voltage can achieve higher or
lower heating rates by the adjustment of the pulse periods. A pulse period of 1 s at the
same voltage of 200 V and an ON: OFF ratio of 9: I give the greatest heating rate, the
temperature increases exponentially with heating time and the system is capable of
heating the Workpiece to the transformation temperature (about 850C) as the
heating time is farther increased.
__________________________________________________________________________________________
a -The Hong Kong Polytechnic Uni6ersity, Kowloon, Hong Kong
b -Department of Engineering, Uni6ersity of Warwick, Co6entry,
48
Electrolyte Hardening Of Steel System Design
______________________________________________________________________
8. System Design
8.1. System assembly
Figure (15) whole system
49
____________________________________________________________________________________________________________________________________________________________________
8.2. The main components:
Figure (16) main components
50
______________________________________________________________________
Table (26) main components
Number Name
Steel table
1
The electrode and electrode holder
2
Workpiece holder
3
4 Male
5 Workpiece driving screw
6 Bridge with female slot(guide way)

Workpiece driving handle
7
Electrode driving screw
8
Supports
Workpiece
9
10 Bath
51
______________________________________________________________________
8.3. Steel table:
Figure (17) Table

Material: Steel
Additional information:
Welded legs and 7 supports to hold the bath
Finished and painted
52
______________________________________________________________________
8.4. The electrode and electrode holder
Figure (18) Guiding nut

Material: Teflon
Figure (19) the electrode plate

Figure (20) Electrode holding bar
Material: Stainless steel 304 Material: Teflon
53
______________________________________________________________________
Figure (21) Fastener

Material: Steel
8.5. Workpiece holding mechanism:

8.5.1 Workpiece holder
Figure (22) Alloy steel rod
54
______________________________________________________________________
Figure (23) Bakelite box
Figure (24) Steel fasteners
55
______________________________________________________________________
8.5.2 Male guide
Figure (25) upper part
Figure (26) lower part
56
______________________________________________________________________
8.6. Workpiece driving screw
Figure (27) Screw
8.6.1. Workpiece driving Nut
Figure (28) Driving Nut

Material: Steel
57
______________________________________________________________________
8.7. Bridge with female slot (guide way)
Figure (29) Legs
Figure (30) bridge
Figure (31) Bridge base plate

Figure (32) Fasteners
58
______________________________________________________________________
8.8. Electrode driving mechanism

(Screw handle supports bearing)
Figure (33) Ball Bearing

Figure (34) supports
Material: AISI 52100
Material:
Cast Iron
59
______________________________________________________________________
Figure (35) Handle

Material: Teflon
8.9. Workpiece
Figure (36) Work piece
8.10. Bath (electrolyte container)
60
______________________________________________________________________
Figure (37) Bath

Material: Perspex
61
Electrolyte Hardening Of Steel Characteristics of Power Supply
_________________________________________________________________________
9. Characteristics of Power Supply
DC-Pulse Power Supply

Input:
3 phase
380 V
50 HZ
Out put:
Pure DC:
Voltage: (From 0 to 300 V) (Controllable)
Current: (0 To 60 A)
Square-Wave (pulses):
Voltage: (From 0 to 300 V) (Controllable)
Current: (From 0 to 60 A)
Frequency range: (From 1 to 100 HZ)
(10 steps and smoothly varying) (Controllable)
Duty Cycle: (From 10% to 90%) (Controllable)
(10% between Steps, 10%...20%...30%...etc)
Notes:
1) All of frequency, duty cycle, voltage and current can be controlled smoothly using
potentiometers (Nobes).
2) All displays will be:
Voltage: 3 X 7 Segment displays.
Current: 3 X 7 Segment displays (2 Integers and 1 Fractions)
Frequency: 3 X 7 Segment displays.
Duty Cycle: 2 X 7 Segment displays (From 10% to 90%)
3) Interface with Computer (Serial or USB or Parallel)
62
_____________________________________________________________________________________________________________________________
9.1. Relation between gap and current at constant voltage
DC
direct pulse
14 Voltage GAP
12 Current Current
(V) (mm)
current (Amp)
10 (Amp) (Amp)
8
6
20 8.7 7.4
4 40 8.4 7.5
2
0 60 8.3 7.3
0 20 40 60 80 100 120 140 160 180 200 220
80 8.2 7.4
Gap distance (mm)
100 8.2 7.4

50
Pulsed Current 120 8.1 7.4
140 8.2 7.4

14
12 160 8.1 7.4

Current (Amp)
10
8
180 8.1 7.3
6 200 8.1 7.3

4
0
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance (m m )
Figure (38) Relation between gap and current at constant voltage at 50 V
63
_____________________________________________________________________________________________________________________________
DC
14
12 direct pulse
Current (Amp)
10 Voltage GAP
8 Current Current
(V) (mm)
6 (Amp) (Amp)
4
2 20 11.2 8.6
0
0 20 40 60 80 100 120 140 160 180 200 220 40 11.2 8.5
Gap distance (mm)
60 11 8.6
80 11.2 9
Pulsed
100 11.3 8.6
100
14 120 11.6 8.3
12
Current (Amp)
140 11.3 8.5

10
8 160 11.4 8.8
6
180 11.5 8.4
4
2 200 11.1 8.9
0
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance (mm)
64
_____________________________________________________________________________________________________________________________
DC direct pulse
Voltage GAP
Current Current
(V) (mm)
14
(Amp) (Amp)
12
Current (Amp)
10 20 6.7 5.8
8
6 40 6.7 5.7
4
60 6.8 5.9
2
0 80 9.7 5.8
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance (mm) 100 7.9 5.6
150
120 7.6 5.7
Pulsed
140 8.1 5.8
14 160 7.9 5.6

12
Current (Amp)
180 7.6 5.4

10
8 200 7.2 6
6
4
2
0
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance (mm)
65
_____________________________________________________________________________________________________________________________
DC
14 direct pulse
12 Voltage GAP
Current (Amp)
10 Current Current
(V) (mm)
8 (Amp) (Amp)
6
4 20 8.2 8.6
2
40 8.6 8.1
0
0 20 40 60 80 100 120 140 160 180 200 220
60 8.1 7.7
Gap distance (mm)
80 8.3 8.1
100 8.8 7.8

Pulsed
200
120 9.5 7.6
14
140 7.9 7.2
12
current (Amp)
10 160 8.3 7.8

8
6
180 8 8.3
4 200 8.5 10.4

2
0
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance (mm)
66
_____________________________________________________________________________________________________________________________
DC
14
direct pulse
12
Current (Amp)
Voltage GAP
10 Current Current
(V) (mm)
8
(Amp) (Amp)
6
4 20 10 10.3
2
40 10.1 10.8
0
0 20 40 60 80 100 120 140 160 180 200 220
60 10.2 10.7
Gap distance (mm)
80 10.3 10.9
100 10 10.1
240
Pulsed
120 10.1 10
14 140 10.1 10.1

12
Current (Amp)
160 10.1 10.5

10
8 180 10.1 10
6
200 10 10.2
4
2
0
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance (mm)
67
_____________________________________________________________________________________________________________________________
DC
14
12 direct pulse
Current (Amp)
Voltage GAP
10
Current Current
8 (V) (mm)
(Amp) (Amp)
6
4 20 10.6 10.3
2
0 40 10.6 10.7
0 20 40 60 80 100 120 140 160 180 200 220
60 10.8 10.3
Gap distance (mm)
80 10.8 10.7
100 10.8 10.4

pulsed current
260
120 10.5 10.8
14 140 10.6 9.9

12
Current (Amp)
10
160 12 10.3
8 180 11.7 10
6
200 10.3 10.1
4
2
0
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance (mm)
68
_____________________________________________________________________________________________________________________________
Direct current
14
12 direct pulse
current (Amp)
Voltage GAP
10
Current Pulsed
8 (V) (mm)
(Amp) (Amp)
6
4 20 14.2 12.7
2
40 12.6 12.8
0
0 20 40 60 80 100 120 140 160 180 200 220 60 14.6 13.9
Gap distance (mm)
80 14.4 13.9
100 13.4 13.6

Pulsed current 280
120 13.1 13.3
14 140 14.3 12.7

12
Current (AMP)
160 13.6 15.9

10
8 180 13.3 13.6
6
200 13.5 14.1
4
2
0
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance (mm)
69
_____________________________________________________________________________________________________________________________
Volt.. 50V Volt.. 100V Volt.. 150V

gap distance(mm)
direct current pulsed current direct current pulsed current direct current pulsed current
20 8.7 7.4 11.2 8.6 6.7 5.8
40 8.4 7.5 11.2 8.5 6.7 5.7
60 8.3 7.3 11 8.6 6.8 5.9
80 8.2 7.4 11.2 9 7.2 5.8
100 8.2 7.4 11.3 8.6 7.9 5.6
120 8.1 7.4 11.6 8.3 7.6 5.7
140 8.2 7.4 11.3 8.5 8.1 5.8
160 8.1 7.4 11.4 8.8 7.9 5.6
180 8.1 7.3 11.5 8.4 7.6 5.4
200 8.1 7.3 11.1 8.9 7.2 6
70
_____________________________________________________________________________________________________________________________
Volt.. 200V Volt.. 240V Volt.. 260V Volt.. 280V

gap distance(mm)
direct current pulsed current direct current pulsed current direct current pulsed current direct current pulsed current
20 8.2 8.6 10 10.3 10.6 10.3 14.2 12.7
40 8.6 8.1 10.1 10.8 10.6 10.7 12.6 12.8
60 8.1 7.7 10.2 10.7 10.8 10.3 14.6 13.9
80 8.3 8.1 10.3 10.9 10.8 10.7 14.4 13.9
100 8.8 7.8 10 10.1 10.8 10.4 13.4 13.6
120 9.5 7.6 10.1 10 10.5 10.8 13.1 13.3
140 7.9 7.2 10.1 10.1 10.6 9.9 14.3 12.7
160 8.3 7.8 10.1 10.5 12 10.3 13.6 15.9
180 8 8.3 10.1 10 11.7 10 13.3 13.6
200 8.5 10.4 10 10.2 10.3 10.1 13.5 14.1
71
_____________________________________________________________________________________________________________________________
DC
volt.. 50V dierect current

16
15
14 volt.. 100V dierect current
13
DC Current (Amp)
11
10
8
7
5
3
2
0
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance (mm)
Figure (45) Relation between gap and DC current at different voltage
72
_____________________________________________________________________________________________________________________________
pulsed DC
17
16 volt.. 50V pulsed current
15
13
Pulsed current(Amp)
12
10
8
6
5
3
1
0
0 20 40 60 80 100 120 140 160 180 200 220
Gap distance(mm)
Figure (46) Relation between gap and pulsed current at different voltage
73
_____________________________________________________________________________________________________________________________
9.1. Relation between current and voltage at constant gap
Pulsed direct pulsed
14
12
Loading Current Loading Current
voltage (Amp) voltage (Amp)
Current (Amp)
10
8
6
16 2,3 14 2,2
4
2 26 3,9 26 4,1
0
38 6,5 39 6,5
0 50 100 150 200 250 300 350
Voltage (volt) 49 8 50 8,2
Gap
50 (mm) 64 10,6 63 10,3
DC
98 12,6 90 11,2
14 149 8,4 155 7,6

12
Current (Amp)
10 175 7,3 173 8,3

8
194 8,8 197 8,8
6
4 222 10,5 224 9,4
2
0 242 10,1 244 10,7
0 50 100 150 200 250 300 350
256 11,8 255 11,2
Voltage (volt)
304 17,3 301 16,5

Figure (47) Relation between current and voltage at constant gap at 50 mm
74
_____________________________________________________________________________________________________________________________
DC
direct pulsed
14
12 Loading Current Loading Current
Current (Amp)
10 (Voltage) (Amp) (Voltage) (Amp)

8
6
15 2,2 16 2,2
4
26 4 26 4
2
0 41 6,4 40 6,4
0 50 100 150 200 250 300 350
Voltage (volt) 50 7,9 50 7,9
Gap100 (mm)
59 9,4 62 9,9
pulsed
90 11,3 90 12,5
14 150 7,8 150 7,7

12 172 7,5 172 7,9
Current (Amp)
10
8
199 9 201 10
6 220 9,4 224 9,7

4
2
238 10,3 239 10,2
0 254 10,6 256 11,1

0 50 100 150 200 250 300 350
Voltage (volt) 304 20 305 17,9
Figure (48) Relation between current and voltage at constant gap at 100 mm
75
_____________________________________________________________________________________________________________________________
direct pulsed
Pulsed
Voltage Current Voltage Current
14 (V) (Amp) (V) (Amp)

12
18 2,1 15 2,1
Current (Amp)
10
8 29 4 28 4
6
40 6 40 6,2
4
2 50 7,6 50 7,9
Gap150 (mm)
0
0 50 100 150 200 250 300 350 61 9,6 60 9,6
Voltage (volt)
93 12,3 86 12,1
145 9,5 151 10

DC
169 7,1 172 8
14
200 8,6 195 8,5
12
Current (Amp)
10 222 9,7 225 9,9

8
6 234 10,2 238 12
4
252 10,7 255 12,3
2
0 305 16,6 303 16
0 50 100 150 200 250 300 350
Voltage (volt)
Figure (49) Relation between current and voltage at constant gap
76
_____________________________________________________________________________________________________________________________
Direct Pulsed
Voltage Current Voltage Current Voltage Current Voltage Current
(V) (Amp) (V) (Amp) (V) (Amp) (V) (Amp)
18 2,1 156 5,4 17 2 155 5,9
31 4 154 7,6 30 3,6 156 7,4

Gap 200 (mm)
30 4,6 181 6,7 32 4,5 189 6,4
44 6 185 8,4 44 5,6 185 8,2
44 6,9 196 7,6 46 6,9 209 7,9
56 7,6 204 9,2 55 7,4 206 9,3
57 8,6 220 9,5 56 8,5 229 9
68 8,9 241 9,1 67 8,8 241 9,9
79 10,8 261 11,2 75 10,1 260 10,4
91 10,2 270 12,4 90 10,2 272 12,3
135 7,8 308 15,4 133 9,8 307 15
77
_____________________________________________________________________________________________________________________________
Pulsed
14
12
Current (Amp)
10
8
6
4
2
0
0 50 100 150 200 250 300
Voltage (volt)
DC
14
12
Current (Amp)
10
8
6
4
2
0
0 50 100 150 200 250 300
Voltage (volt)
Figure (50) Relation between current and voltage at constant gap
78
Electrolytic Hardening Of Steel
Gap 50 mm Gap 100 mm
Direct Pulsed Direct Pulsed
loading Current loading Current loading Current loading Current

voltage(v) (Amp) voltage(v) (Amp) voltage(v) (Amp) voltage(v) (Amp)
16 2.3 14 2.2 15 2.2 16 2.2
26 3.9 26 4.1 26 4 26 4
38 6.5 39 6.5 41 6.4 40 6.4
49 8 50 8.2 50 7.9 50 7.9
64 10.6 63 10.3 59 9.4 62 9.9
98 12.6 90 11.2 90 11.3 90 12.5
149 8.4 155 7.6 150 7.8 150 7.7
175 7.3 173 8.3 172 7.5 172 7.9
194 8.8 197 8.8 199 9 201 10
222 10.5 224 9.4 220 9.4 224 9.7
242 10.1 244 10.7 238 10.3 239 10.2
256 11.8 255 11.2 254 10.6 256 11.1
304 17.3 301 16.5 304 20 305 17.9
Gap 150 mm Gap 200 mm
Direct Pulsed Direct Pulsed
loading Current loading Current loading Current loading Current

voltage(v) (Amp) voltage(v) (Amp) voltage(v) (Amp) voltage(v) (Amp)
18 2.1 15 2.1 18 2.1 17 2
29 4 28 4 31 4 30 3.6
40 6 40 6.2 30 4.6 32 4.5
50 7.6 50 7.9 44 6 44 5.6
61 9.6 60 9.6 44 6.9 46 6.9
93 12.3 86 12.1 56 7.6 55 7.4
145 9.5 151 10 57 8.6 56 8.5
169 7.1 172 8 68 8.9 67 8.8
200 8.6 195 8.5 79 10.8 75 10.1
222 9.7 225 9.9 91 10.2 90 10.2
234 10.2 238 12 135 7.8 133 9.8
252 10.7 255 12.3 156 5.4 155 5.9
305 16.6 303 16 154 7.6 156 7.4
181 6.7 189 6.4
185 8.4 185 8.2
196 7.6 209 7.9
204 9.2 206 9.3
220 9.5 229 9
241 9.1 241 9.9
79
Electrolytic Hardening Of Steel
Pulsed DC
20
18
16
14
Current (Amp)
12 Gap 50 mm
Gap 100 mm
10
Gap 150
8
Gap 200 mm
6
4
2
0
0 50 100 150 200 250 300 350
loading voltage (V)
DC
22
20
18
16
Current (Amp)
14 Gap 50 mm
12 Gap 100 mm
10 Gap 150 mm
8 Gap 200 mm
6
4
2
0
0 40 80 120 160 200 240 280 320 360
loading voltage (V)
Figure (51) Relation between current and voltage at different gaps
80
Electrolytic Hardening Of Steel Experiment
______________________________________________________________________
10. Experiment
10.1. Process variables
Voltage
Current
Electrolyte (if a stable hydrogen film is formed)
10.2. Process specifications

High voltage and high power pulse rectifier
electrolyte path system
electrolyte having the simple formulation of 50gm/liter sodium carbonate Na 2 CO 3
an anode made of AISI 304 stainless steel sheet have a good corrosion resistance
having a conducting area 6.5*19 Cm sq having a composition of C 0.08% Cr 18
20% Ni 8 10% SI 1.0% Max Mo 1.0% Max Mn 2.0% Max P 0.045% Max S
0.03% Max
cathode made of medium carbon steel AISI 1050 having composition of 0.5%C,
0.35%Si and 0.8%Mn
Work piece form is a rod of D=8mm and length=60mm, immersed 5mm in electrolyte
* The W/P hardness is below 20HRC
The process is performed under two conditions

1st condition: direct current (DC)condition with different voltage
2nd condition :pulsed current (PC)condition with different voltage
The austenitizing temperature for AISI 1050 steel ranges from 800-850 C for conventional
surface hardening process.
In both condition the work piece acting as a cathode, will be heated violently to above the
austenitizing temperature due to the generation of resistance heat.
Upon disconnecting the electrical current the hydrogen film will break and the surface of W/P
will self quench and is quenched by the cold electrolyte in its vicinity.
The result being that the W/P hardened.
81
Electrolytic Hardening Of Steel Results and Conclusions
______________________________________________________________________
11. Results and Conclusions

For stable and acceptable surface hardening quality of the work piece is expected by applying
the following:
11.1. Pulse current condition
8 sec at pulse 200V gives 62 HRC.

3.5 sec at pulse 220V gives 53 HRC.
3.5 sec at pulse 240V gives 67 HRC.
2.5 sec at pulse 260V 47 HRC.
Hardening performing under pulse condition is not stable at an average preset voltage 200V.
11.2. Direct current condition
2.5 sec at 260V gives 64 HRC.

2 sec at 280V gives 48 HRC.
2 sec at 300V gives 56 HRC.
Refers to previous results the pulsed current condition required less voltage than direct
current condition.
Lower operating voltage implies a safer operation and less energy consumption.
The W/P hardness after the process is found approximately above 50HRC.
82
Electrolytic Hardening Of Steel Recommendations
______________________________________________________________________
10. Recommendations
Based on the previous experiments we can study change of:
Electrolyte type and concentration and their effect on electrical conductivity and
creation of hydrogen film
Anode material and geometry and their effect on the current density and cooling rate
Cathode material and geometry and their effect on current density and thermal and
electrical conductivity
Depth of immersion
Using a cathode with end surface being masked or whole immersed part being
masked
This research is under development and need more researches and efforts to specify
the optimum conditions.
83
Electrolytic Hardening Of Steel Recommendations
______________________________________________________________________
84

Objectives of Heat Treatments

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Abstract

3. HARDNESS TESTING ...................................................................... 8

4. DESIGNATION OF STEEL ............................................................ 13

5. SURFACE HARDENING OF STEEL ........................................... 22

7. LITERATURE REVIEW ................................................................. 46

9. CHARACTERISTICS OF POWER SUPPLY .............................. 62

10. EXPERIMENT ................................................................................ 81

11. RESULTS AND CONCLUSIONS ................................................ 82

10. RECOMMENDATIONS ................................................................ 83

Figure (1) microscopic structure before and after Spheroidizing ....................................... 3

Electrolytic surface-hardening is a special hardening method employing electrolysis in an

2. Objectives of Heat Treatment

Improve the toughness

2.1. Heat treatment processes

Figure (1) microscopic structure before and after Spheroidizing

Figure (2) Annealing and Spheroidizing Temperatures

2.1.3. Stress Relief Annealing:

Figure (3) Normalizing temperatures for hypoeutectoid and hypereutectoid steels.

2.3. Tempering processes:

2.3.1. Conventional Temper Process

Figure (4) Austempering process.

Figure (5) Martempering process.

2.4. Quench media

2.4.2. Salt Water:

2.4.4. Polymer quench:

2.4.5. Cryogenic Quench:

3.1. HARDNESS MEASUREMENT

Figure (6) nano-indentation machines

Micro hardness is the hardness of a material as determined by forcing an indenter such as a

3.2. Hardness measurement methods

3.2.1. ROCKWELL HARDNESS

Figure (7) Rockwell test

3.2.2. BRINELL HARDNESS

Figure (8) Brinell hardness method

Brinell Measurement Calculation

3.2.3. VICKERS HARDNESS (Micro and Macro hardness) and Knoop

Figure (9) Vickers Test

3.2.3.2. Knoop Test

Figure (10) Knoop Test

3.3. How to Read a Hardness Number

Table (1) How to Read a Hardness Number

Scale Name Example Explanation

Rockwell 60 HRC Hardness Rockwell C scale with a 60 test value

80.5HR15TW Hardness value in Rockwell 15T scale with 80.5

Brinell 200 HB10/3000/15 200 test value using a 10 mm diameter carbide

HB 200 An informal report assuming the most common

200 test value with Knoop 500g load, 15 seconds

4.1. GOST (Russian Standard)

Ordinary quality carbon steel

Quality structural steel

Carbon tool steel

Table (2) Russian Symbol

Letter Alloying element

Table (3) Russian Steel Types Symbol

Chromium stainless steel

Ball bearing steel

4.2. AISI (American Iron & Steel Institute)

The AISI specifications follow the same numerical identification as SAE

The first two The last two

Prefixes AISI letters that precedes the designation

Table (4) American Steel Types Symbol

A Basic open-hearth alloy steel

B Acid besmer carbon steel

C Basic open-hearth carbon steel