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Hardenability-Why study it?
Q. Why only the austenite phase is used for the carburizing process when
carbon is already present in the various other allotropic forms of carbon?
5. Austenite provides a large range of carbon compositions stable with it starting right
from 0.022wt% C to 0.76wt% C.
6. The other phases already have carbon present in combination with iron as a carbide
thus limiting the extent of the carburization process.
7. There are other phases present but they are stable only at higher temperatures
which are difficult to maintain and achieve.
Classification
Depending on the carburizing media there are mainly three types of
carburizing
• Solid
• Liquid
• Gas
Terminology
Fick’s Law
The rate at which carbon toms diffuse beneath the surface of the
specimen is determined by Fick’s Law which as follows:-
J=-S.D.δc
δx
J = amount of carbon passing per unit time across an area S in
a direction
normal to the surface S
(δc/δx) = Concentration gradient of carbon.
D= Diffusion coefficient of carbon in gamma-iron
(Temperature dependent)
Einstein also gave a much simpler law for diffusion as follows:
x=√ 2Dt
‘x’=case depth
Solid carburizing
The process involves packing the work into heat-resisting(25Cr;20Ni) boxes
along with the carburizing material so that there is a space of 50mm between
the components. The boxes are then heated slowly to the carburizing
temperature and maintained at this temperature for according to the depth of
casing required. The reactions occurring inside the boxes are as follows:
2C(charcoal)+O 2 →2CO
At surface of the work it breaks into carbon dioxide releasing
carbon
2CO→CO 2 + C
Carbon then dissolves interstitially at the surface of steel.
CO 2 + C(charcoal) 2CO
Liquid/salt-bath carburizing
This type of carburizing is carried out in a mixture of salts having
compositions varying from-
20-50% sodium cyanide.
40% sodium carbonate.
Traces of sodium or barium chloride.
The mixture is then heated in ‘calorised’ pots to a the carburizing
temperature and held at the temperature according to the depth
of the casing required.
Q. What are ‘calorised’ pots?
J. Calorised pots are heat-resistant pots developed by a process
called calorising wherein steel is put in a chamber containing
aluminium
powder and air is purged from it by forcing in argon or nitrogen.
The result is a fine layer of zinc on the surface of the work.
Reactions taking place during liquid carburizing:-
The following reactions are believed to take place
2NaCN + O 2 → 2NaCNO
Sodium cyanate formed decomposes at the surface of steel as follows
2CO CO 2 + At
C work surface
CH 4 2H 2 + C
CO + H 2 H 2 O +Away
C from work
surface
CO 2 + CH 4 2H 2 + 2CO
NH 3 3H + N
NOTE:
Disadvantages of ion-nitriding:-
Ø The process is profitable only when large number of
components are to be manufactured.
Ø If the work after nitriding is over-heated then all the hardness
would be lost and the work will have to be nitrided again.
Carbo-nitriding
As the name suggests in this type of nitriding carbon as well as
nitrogen diffuse into the work-element. Although salt-bath also
achieves the same goal but this process is carried out in
gaseous media.
The process differs only from the previous one that here
the heating is carried out via a current carrying coil.
The material to be hardened is first cast in the form of a bar
and is places within the coil and an alternating current is
passed through it giving rise to a magnetic field. When the
steel bar is introduced in the coil the various magnetic
domains start to align with the increasing magnitude
and direction of current. As the direction and current
starts to decay the various domains start to align in
the opposite direction as indicated by a hysteresis
curve.
Thus hysteresis losses as well as heat induced due to
eddy-currents heat the specimen to the austenizing
temperature in a few seconds. The entire array is then
immersed into a water-spray system quenching and
Hardenability tests
1st Step:-
First, a sample specimen cylinder either 100mm in
length and 25mm in diameter, or alternatively, 102mm
by 25.4mm is obtained. Second, the steel sample is
austenitised. This is usually at a temperature of 800 to
900°C. Next, the specimen is rapidly transferred to the test
machine, where it is held vertically and sprayed with a
controlled flow of water onto one end of the sample.
Because the cooling rate decreases as one moves further
from the quenched end, you can measure the effects of a
wide range of cooling rates that vary from rapid at the
quenched end to air cooled at the far end.
2nd Step(To ground flat the specimen along it’s length)
The specimen is ground flat to a depth of .38mm to remove
decarburised material. The hardness is measured at intervals
along its length beginning at the quenched end. For alloyed steels
an interval of 1.5mm is commonly used where as with carbon
steels an interval of .75mm is typically employed.