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6.0 INTRODUCTION:
Heat treatment is the heating and cooling process by which the microstructure and
mechanical properties of metals and alloys are improved. When metal fails to achieve
the desired properties after heat treatment, the process is said to be defective.
Sometimes, the heat-treated components may not show the desired properties in spite
of adoption of proper procedure. It is necessary to know about the possible causes of
the defects associated with heat treatment. These may be due to wrong selection of a
material, inherent defect in the material, or improper design of a tool or component.
Therefore, to have optimum properties in components after heat treatment, the first
step is proper selection of raw material and accurate design. This will ensure defect-
free components provided proper heat treatment procedure is applied to such a
component.
The most common type of defects observed in heat-treated steel are as follows:
1. Low hardness and strength after hardening
2. Soft spots
3. Oxidation and decarburization Overheating and burning
4. Formation of cracks
5. Distortion and warping
2 Fe + 02 2 FeO
4 PeO + 02 Fe203
Fe + CO2 FeO + CO
Fe + H2O FeO + H2
CO + H2O CO2 + H2
2 CO CO2 + C
For this reaction, steel behaves like a catalyst at the operating temperatures. As a
result, oxidation of the surface of steel takes place.
During oxidation at about 180C, a thick oxide layer forms on the surface of the steel.
When the temperature is raised to about 425C, porous and loose oxide layer is
formed. With growth of such an oxide layer, there is continued disintegration of the
component. Therefore, due to oxidation, the quality of the surface of steel component
is affected adversely. There are also consequential dimensional changes. Therefore,
the nature of furnace atmosphere should be such that there is negligible oxidizing
effect. The iron oxide should be reduced by the reactions
C + 02 CO2
Fe3C + 02 3 Fe + CO2
C + CO2 2 CO
Fe3C + CO2 3 Fe + 2 CO
Fe3C + H2O 3 Fe + H2 + CO
These reactions are also reversible, and the equilibrium constant determines the ratio
of CO to CO2.
The problem of oxidation and surface decarburization of steel parts may be prevented
or minimized by a number of methods. These are:
1. Steel components may be heated in molten salts, controlled atmosphere or
in vacuum. Different types of protective atmosphere, which are in use,
include products of dissociation of ammonia, purified and dried producergas
(COC02N2), and a gas mixture containing CO, CO2, N2, H2 and H2O.
2. Decarburized surface layer may be removed by machining after heat
treatment.
3. Copper layer having thickness in the range 0.013-0.025 mm may be
4. In the absence of controlled atmosphere, the steel components may be
heated with carburizing agents in boxes or with special surface coatings like
Borax.
5. Ceramic coatings may be applied to the components prior to heat treatment.
Control of distortion:
The risk of distortion during and after heat treatment can be minimized by taking care of
the following aspects: design, composition, initial condition, and machining procedure,
which we now describe.
Design: Abrupt changes, sharp corners and thin walls should be avoided in the
component.
Composition: Size distortion can be minimized by proper selection of steel from the
point of view of composition.
Initial condition: Uniform microstructure in the component and uniform temperature in
the furnace should be maintained.
Machining procedure: Rough machining to dimensions accounts for size distortion
during heat treatment.
3. Tempering
(a) Thermal stresses
Cooling from Transformation of
(b) Introduction of residual
Tempering retained austenite
stresses
temperature
Stress Relieving:
The presence of residual stresses due to previous machining or forging operation
enhances the tendency for distortion. Therefore, these fabricated stresses should be
relieved by sub critical annealing or normalizing operation. This is more important for
intricate parts with close dimensional tolerances.
Preheating:
Preheating reduces shape distortion in steels by reducing the thermal stresses
produced because of the temperature gradient between the surface and interior part of
a component. Besides this, preheating results in stress-relief treatment for machined
parts. Preheating can be performed between 400C and 800C. For a, it is preferable
to carry out Two-stage preheating is applied for large cross section and complicated
shape parts and for high alloy steels having poor thermal conductivity.
Quenching Media:
The basic aim in hardening of steels is to get martensitic structure and avoid formation
of pearlite and bainite. Therefore, the rate of cooling of heated component should be
fast enough to produce fully martensitic structure throughout the section. But faster
cooling rate increases the severity of quench. Therefore, it is necessary to use the
least drastic quenching medium that produces Martensite.
In fact, the choice of quenching medium depends on hardenability, size and shape of
the component. Shape distortions can be further reduced during quenching if cooling
conditions are made as uniform as possible. Generally, water, brine and conventional
oils are used as quenching media. Besides this, salt baths, hot quenching oils and
polymer quenchants should be considered. They give very good results.
Press Quenching:
Press quenching or die quenching of precision gears and other parts of steel is not
common to most of the commercial heat-treating industries. During press quenching,
distortion is minimized by physical restraint of a part during its rapid cooling from
austenitic condition. Quenching jigs are used for this purpose.
After heating, the part is clamped in a jig and placed in a hydraulically operated press.
The jig should be preheated to avoid rapid cooling of the surface of the component,
which comes in contact with the jigs. Along with the closing of the press, oil is flown
over the component. As a result, plane shape is maintained during quenching
operation.
1. Overheating
(a) Normal annealing and normalizing for
Causes coarse grained microstructure, Heating for long periods at temperatures
slight overheating
Widmanstatten structure in annealed steel, exceeding normal values
(b) Repeated normalizing for about 6 times
coarse crystalline Martensite in hardened steel,
reduced ductility and low impact strength value
2. Burning
Grain boundaries having
(a) Regions enriched in carbon in first stage of (a) Homogenizing followed by double annealing for f
Heating for long duration at high tem-
burning; first stage of burning
perature under oxidizing conditions or
(b) Non oxidized cavities and blowholes in (b) Forging followed by annealing for second
heating near to melting point of steel
second stage of burning and (c) iron oxide inclu- stage
sions in the third stage of burning, resulting in (c) Not remediable if third stage bas occurred
stone-like fracture and poor ductility.
Low hardening, temperate cooling rate, and Normalizing or annealing, followed by hardening with
9. Low Hardness after Quenching
insufficient soaking period at hardening proper procedure
temperature
(a) Presence of vapour blanket on the
surface of component
10. Soft Spots Normalizing or annealing, followed by hardening with
(b) Localized decarburization
Certain portions on the surface of compo- proper procedure
(c) Inhomogeneity of internal structure
nent with lower hardness
after solidification