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AFA I
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Metallurgy
CHAPTER: Metallurgy
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CHAPTER: Metallurgy
3000F
1650C
900F
480C
400F
205C
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CHAPTER: Metallurgy
Refining Process
Lower Carbon Contents
Refine the quality
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CHAPTER: Metallurgy
Ingot Molds
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Cast Iron vs. Steel
Cast Iron = Iron + 2- 4% Carbon
Brittle with little or no ductility
Steel = Iron + 0.02- 2% Carbon
Stronger, harder, tougher and ductile
CHAPTER: Metallurgy
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AFA I
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Carbon Levels for Steel
Low Carbon 0.02 - 0.25%
Medium Carbon 0.25 - 0.50%
High Carbon 0.50 - 2.00%
CHAPTER: Metallurgy
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AFA I
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Alloy Steel
Alloy Steel = Low, Medium, High Carbon Steel
+ Alloying Agent (Chrome, Nickel, Vanadium,
Tungsten, Molybdenum)

Improved properties such as tensile strength,
toughness and corrosion resistance
CHAPTER: Metallurgy
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AFA I
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Metal Structure
Inclusions
Grain
Grain
Boundary
CHAPTER: Metallurgy
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Metal Structure
CHAPTER: Metallurgy
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Forming Methods
Cast
Wrought
Rolling
Forging
Extrusion
Drawing
CHAPTER: Metallurgy
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CHAPTER: Metallurgy
Cast
Random Grain
structure

Brittle structure

Easily Machined
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CHAPTER: Metallurgy
Rolled
Grain Flow
Metal Structure
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CHAPTER: Metallurgy
Forged
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CHAPTER: Metallurgy
Cast Vs. Forged
Cast

Random
Grain
Structure
Forged

Flow
Lines
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Heat Treatment
Increased
Strength
Toughness
Wear Resistance
Tree Steps
Austenitizing
Quenching
Tempering

CHAPTER: Metallurgy
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CHAPTER: Metallurgy
Austenitizing
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Austenitizing (heat) Methods
Furnace Heating
Induction Heating
> 6 mm deep
Flame Heating
> 12 mm deep


CHAPTER: Metallurgy
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CHAPTER: Metallurgy
Quenching
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Quenching (cooling) Methods
Sprayed Water
Moving Water
Water Bath
Moving Oil
Oil Bath
Moving Air
Still Air


Induction Heating
> 6 mm deep
Flame Heating
> 12 mm deep


CHAPTER: Metallurgy
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Tempering
Relieve Stresses
Improve Toughness
CHAPTER: Metallurgy
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Case Hardening Carburizing
CHAPTER: Metallurgy
Carburizing is a method of increasing the
carbon content of the surface of low-
carbon steel through absorption and
diffusion. It is done to prepare the steel
for quench hardening. Steel is heated
above its upper critical temperature 930C
in the presence of carbon to allow it to
absorb into the metal to the desired depth.

Process Characteristics:
Applied to low-carbon steel
Produces a hard surface
Work piece cores largely retain their
toughness and ductility
Produces case hardness depths of up to
6 mm
Need quenching and tempering after
wards. May also need straightening due to
distortion.
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Case Hardening Carbonitriding
Carbonitriding is a diffusion-hardening
process for ferrous metals in which
both carbon and nitrogen are
introduced into the part surface by
heating the part while in contact with a
gas or liquid containing carbon and
nitrogen.

Process Characteristics:

The part are heated to 760C in a
carbon and nitrogen atmosphere or a
cyanide bath.
Produces thin, very hard surface layers
of uniform depth.
Little distortion
Has a maximum case depth of 0.3 mm
in.
Produces better surface wear
characteristics than carburizing


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Case Hardening Nitriding
Nitriding is a diffusion-hardening
process for ferrous metals in which
nitrogen are introduced into the part
surface by heating the part while in
contact with a gas or liquid containing
nitrogen.

The part are heated to 540C in a
nitrogen atmosphere or a cyanide
bath.
Produces thin, very hard surface
layers of uniform depth.
No distortion
Has a maximum case depth of 0.3 mm
Quenching and tempering before the
nitriding, Part is ready for use after
process

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CHAPTER: Metallurgy
Hardness Test
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Subsurface Refining impurities Defects, Inclusions)
Dirt
Slag
Furnace Brick
CHAPTER: Metallurgy
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CHAPTER: Metallurgy
Inclusion Bulls Eye
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Forming Defects
Subsurface
Shrinkage
cavities
Gas pockets
Slag Inclusions
Pipe
Flakes
Forging hot
spots
Surface
Coldshuts
Hot tears
Handling
cracks
Seams
laps
Grinder
burns
Cast
Wrought
CHAPTER: Metallurgy
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CHAPTER: Metallurgy
Shrinkage Cavity
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CHAPTER: Metallurgy
Forging Hot Spots
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CHAPTER: Metallurgy
Forging Lap
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Heat Treat Defects
Quench Cracks
Soft Spots
Straightening Cracks
CHAPTER: Metallurgy
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CHAPTER: Metallurgy
Quench Crack
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CHAPTER: Metallurgy
Straightening Crack