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maximum
Tensile stress
maximum
Tension
Radial stresses
Compression
T ension
combination of the two components.
At different stages of heat treating, the
effect of the components on total stress
Stresses
also will differ. 0 Quenching stage
Example: Figures 1 and 2 illustrate
the dynamics of (macroscopic) stress
appearance during induction hard-
Compression
ening of a carbon steel cylinder.1,4,5 At Heating stage
the first stage of the heating cycle, the
section of the cylinder located under
the coil will “try” to expand. The tem-
perature of the workpiece at this point
is relatively low: less than 500°C
(930°F). Carbon steel in this tempera- 200 (392) 400 (752) 600 (1112) 800 (1472) 1000 (1832)
Temperature, °C (°F)
ture range is in a “nonplastic” condi-
tion and cannot easily expand. The re- Fig. 2 — Stresses at the surface of a carbon steel cylinder during “heating-quenching” cycle.
sult: compressive stresses build up in
the surface of the workpiece. anced, “movement” would then result. induction hardened parts of complex
Heating: As the temperature rises, Benefits: Surface compressive shape as they are in a plain cylinder.
surface compressive stresses form and residual stresses are considered useful As a result, measurement of residual
increase in magnitude (Fig. 2). In the in most applications. They provide stresses is often not an easy task, and
520 to 750°C (970 to 1380°F) range, some protection against crack initia- special equipment and a great deal of
steels undergo plastic volumetric ex- tion and propagation caused by stress time may be needed. Techniques for
pansion and stresses begin to decrease. risers; for example, microscopic quantifying residual stresses include
Finally, when the temperature exceeds scratches, notches, and microstructural the sectioning, hole drilling, layer re-
approximately 850°C (1560°F), the heterogeneities. Compressive residual moval, bending deflection, X-ray dif-
steel’s surface freely expands, and the stresses are particularly beneficial to fraction, magnetic, and ultrasonic
diameter of the heated area becomes parts that experience bending and/or methods.3 Important process selection
greater than its initial diameter. Since torsion in service. factors include the specifics of the heat
the yield point of the surface layer is Tensile residual stresses, on the other treated part; for example, kind of
considerably lower at elevated tem- hand, can be dangerous. Note the ten- metal, grain size, and required in-
perature, the material will flow plas- sile stress maximum located just be- spection depth and accuracy. HTP
tically and surface stresses will signif- neath the hardened case in Fig. 1. These
icantly decrease. are the stresses primarily responsible References
Cooling: After quenchant is for subsurface crack initiation. 1. Handbook of Induction Heating, by V.
sprayed onto the heated surface, the Rudnev, D. Loveless, R. Cook, and M.
outermost layer quickly loses its plas- Relieving, measuring stress Black: Marcel Dekker Inc., New York, 2003,
ticity and a pronounced tensile stress The overall residual stress condition 800 p.
maximum appears at the surface of of the induction hardened part usu- 2. “Troubleshooting Cracking in Induc-
the workpiece (Fig. 2). This maximum ally increases its brittleness and notch tion Hardening,” by V. Rudnev: Heat
value typically occurs just above Ms sensitivity, which reduces toughness Treating Progress, Vol. 3, No. 5, August
2003, p. 27–28.
(martensite start) temperature. The ap- and reliability. Therefore, stress relief
3. Handbook of Measurement of Residual
pearance of martensite reduces sur- is required. Goals are to reduce sub- Stresses, Society for Experimental Me-
face tensile stresses and leads to the surface tensile stresses and move the chanics, Jian Lu (Ed.): Fairmont Press Inc.,
formation of surface compressive tensile stress maximum farther from Lilburn, Ga., 1996, 238 p.
stresses. Upon completion of cooling, regions of applied stress, while re- 4. High-Frequency Induction Heat Treating,
a complex combination of compres- taining the useful surface compressive by G. Golovin and M. Zamjatin: Mashino-
sive and tensile stresses exists within stresses. Stress relieving during in- stroenie, Saint Petersburg, Russia, 1990,
the part (Fig. 1). duction tempering is discussed in Ref. 230 p. (in Russian).
It is important to remember that the 1. In addition, a final grinding opera- 5. Industrial Applications of Induction
residual stress system is self-equili- tion also can have a pronounced effect Heating, by M. Lozinskii: Pergamon Press,
London, 1969, 420 p.
brating; that is, there is always a bal- on residual stress distribution and
6. “A Review of the Influence of Grinding
ance of stresses in the workpiece. If crack sensitivity.6 Grinding should be Conditions on Resulting Residual Stresses
certain regions have compressive considered when developing the re- After Induction Surface Hardening and
residual stresses, then somewhere else quired residual stress distribution. Grinding,” by Janez Grum: Journal of Ma-
there must be offsetting tensile Measurements: Residual stress dis- terials Processing Technology, Vol. 114, Issue
stresses. If the stresses weren’t bal- tributions are not nearly as simple in 3, 7 Aug. 2001, p. 212–226.