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What characterizes the process of residual stresses in a material?

  • They can only be negative and lead to structural failure.
  • They are easily detected and quantified by all manufacturers.
  • They only occur in metals subjected to extreme temperatures.
  • They persist after the removal of load and can affect structural integrity. (correct)
  • What is the primary transformation involved in the formation of Martensite?

  • A diffusionless shear-type transformation of FCC Austenite. (correct)
  • A phase transformation induced by high temperatures alone.
  • A gradual cooling process from cubic to hexagonal structure.
  • Diffusion-based phase change from BCC to FCC.
  • What effect does laser peening have on materials?

  • It uniformly reduces all types of residual stresses in a material.
  • It has no significant impact on residual stresses at the surface.
  • It introduces tensile residual stresses to improve flexibility.
  • It creates compressive residual stresses that enhance material strength. (correct)
  • What usually happens to the material after the load is removed?

    <p>Some materials will remain permanently deformed. (B)</p> Signup and view all the answers

    Which of the following describes a consequence of residual stresses?

    <p>They can lead to brittle fracture in structures lacking stress relief. (B)</p> Signup and view all the answers

    Which type of crystal structure does Martensite adopt after transformation?

    <p>Body-centered tetragonal (BCT) (D)</p> Signup and view all the answers

    What causes strain in materials during deformation?

    <p>The distortion of atoms and arrangement of dislocations. (C)</p> Signup and view all the answers

    What is a significant negative consequence of residual stresses in the context of engineering?

    <p>They can lead to premature failure of critical components. (C)</p> Signup and view all the answers

    What can be a factor in the failure of structures, as noted historically?

    <p>Residual stresses contributing to structural collapse. (A)</p> Signup and view all the answers

    How does the machining process affect stress and strain in materials?

    <p>Machining can lead to non-uniform plastic deformation. (D)</p> Signup and view all the answers

    What is the primary result of carburizing in steel components?

    <p>Formation of a martensitic layer with sufficient hardness (A)</p> Signup and view all the answers

    Which temperature is typically used in gas carburizing?

    <p>925°C (C)</p> Signup and view all the answers

    What is a characteristic of liquid carburizing processes?

    <p>They provide the fastest carburizing process (B)</p> Signup and view all the answers

    What advantage does nitriding have compared to other hardening processes?

    <p>Develops a very hard case without quenching (B)</p> Signup and view all the answers

    During the liquid carburizing process, what additional element is introduced to enhance hardness?

    <p>Nitrogen (B)</p> Signup and view all the answers

    In solid carburizing, what is the primary substance used to surround the components?

    <p>Coke or charcoal (C)</p> Signup and view all the answers

    What effect does nitriding have on dimensional changes of steel components?

    <p>No molecular size change occurs (B)</p> Signup and view all the answers

    How long can gas carburizing typically take to achieve a 4 mm case depth?

    <p>36 hours (C)</p> Signup and view all the answers

    What is the typical hardness value achieved on the surface of carburized steel?

    <p>700 HV (D)</p> Signup and view all the answers

    What is one major disadvantage of solid pack carburizing compared to other methods?

    <p>It is the least sophisticated carburizing process (C)</p> Signup and view all the answers

    What is the primary purpose of nitriding in steel treatment?

    <p>To diffuse nitrogen into the surface for hardness (D)</p> Signup and view all the answers

    At what temperature can an iron-base alloy absorb the maximum amount of nitrogen during nitriding?

    <p>450°C (B)</p> Signup and view all the answers

    Which of the following parameters is NOT critical for the gas nitriding process?

    <p>Metallic coating type (A)</p> Signup and view all the answers

    What happens to nitrogen levels in steel during carbonitriding?

    <p>Nitrogen stabilizes austenite (C)</p> Signup and view all the answers

    What is the maximum case depth typically produced by carbonitriding?

    <p>0.75 mm (A)</p> Signup and view all the answers

    During the carburizing step in carbonitriding, what is the temperature range typically used?

    <p>900 to 955 °C (A)</p> Signup and view all the answers

    Why is carbonitriding preferred over liquid cyaniding?

    <p>It avoids cyanide disposal issues (B)</p> Signup and view all the answers

    What type of steel can be treated by carbonitriding at a temperature of 845°C?

    <p>Heavy-duty gearing steel (A)</p> Signup and view all the answers

    What effect does nitrogen have on the hardenability of steel when carbonitriding?

    <p>Increases hardenability (D)</p> Signup and view all the answers

    What is a primary benefit of using oil quenching during carbonitriding?

    <p>Achieves full hardness with less distortion (A)</p> Signup and view all the answers

    What is the primary purpose of heat treatment?

    <p>To relieve internal stresses and augment material properties (B)</p> Signup and view all the answers

    Which phase is characterized by a solid solution of carbon and other alloying elements in ferrite?

    <p>Austenite (A)</p> Signup and view all the answers

    What is the cooling method used in quenching?

    <p>Rapid cooling from the austenitizing temperature (B)</p> Signup and view all the answers

    During which heat treatment process is a desired microstructure achieved by initially heating and then cooling a metal?

    <p>Annealing (B)</p> Signup and view all the answers

    What effect does tempering have on hardened steel?

    <p>Increases ductility and reduces hardness (B)</p> Signup and view all the answers

    What is the result of spheroidizing in steels?

    <p>Formation of globular carbides in a ferritic matrix (B)</p> Signup and view all the answers

    What is the critical temperature for austenite transformation defined as Ms?

    <p>240°C (B)</p> Signup and view all the answers

    In process annealing, how is the hardness of steel affected?

    <p>Hardness increases while ductility decreases (C)</p> Signup and view all the answers

    What occurs during stage II of tempering?

    <p>Transformation of retained austenite to ferrite and cementite (B)</p> Signup and view all the answers

    What is martempering primarily aimed at achieving?

    <p>Delaying the cooling process just above the martensitic transformation (A)</p> Signup and view all the answers

    What is the key benefit of normalizing steel?

    <p>Refinement of grain structure and size (C)</p> Signup and view all the answers

    What property is significantly reduced in ferritic steel due to stress-relief treatments?

    <p>Resistance to brittle fracture (D)</p> Signup and view all the answers

    What defines the term 'full annealing' for hypoeutectoid steels?

    <p>Heating to a temperature above A3 (D)</p> Signup and view all the answers

    Which of the following is NOT a method of heat treatment commonly used for steels?

    <p>Electroplating (C)</p> Signup and view all the answers

    Flashcards

    Stress and Strain

    Stress is the internal force acting within a material in response to an external load, while strain is the resulting deformation or change in shape of the material.

    Plastic Deformation

    Permanent change in shape of a material beyond its elastic limit.

    Residual Stresses

    Internal stresses that remain in a material after external loads are removed.

    Phase Transformations

    Change in the physical structure of a material, often involving a change in crystal structure or state (solid, liquid, gas).

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    Machining Sequence

    A series of operations involved in cutting material into a desired shape and size.

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    Hooke's Law

    A law stating that the stress in a material is proportional to the strain up to a certain limit. Stress = constant * Strain

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    Martensite

    A hard, brittle phase of steel formed by a rapid quenching process.

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    Austenite

    A phase/form of steel, typically soft and ductile.

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    Heterogeneity

    Having different properties in different parts of the material. For example, a composite material.

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    Carburizing

    Surface hardening of steel by introducing carbon.

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    Gas Carburizing

    Carburizing using a gas atmosphere containing carbon.

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    Liquid Carburizing

    Carburizing using a salt bath containing carbon.

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    Solid Carburizing

    Carburizing using a solid pack containing carbon.

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    Nitriding

    Surface hardening by introducing nitrogen.

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    Case Depth

    Thickness of the hardened surface of carburized steel.

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    Carburizing Temperature

    Temperature at which carbon diffuses into the steel.

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    Carburizing time

    Duration of the carburizing process, influencing case depth.

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    Salt Bath

    Liquid medium containing carbon and other elements for carburizing.

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    Cyanide Salts

    Improve hardness and add nitrogen to steel during liquid carburizing.

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    Carburising Medium

    Solid material surrounding the component during solid carburizing, supplying carbon.

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    Carbon diffusion

    Process by which carbon atoms move from high concentration to low concentration into steel.

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    Nitriding

    A thermochemical process of diffusing nitrogen into the surface of steels and cast irons.

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    Solubility of Nitrogen in Iron

    The amount of nitrogen that can be absorbed by iron depends on the temperature.

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    ε phase

    A surface phase that forms when the nitrogen concentration in the iron-base alloy exceeds a certain limit.

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    High Carbon Content

    A factor that increases the chance of the ε phase forming in nitriding.

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    Gas Nitriding

    A nitriding method using a controlled gas atmosphere in a furnace.

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    Carbo-Nitriding

    A modified carburizing process where nitrogen is added to the carburized case.

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    Carbonitriding vs. Liquid Cyaniding

    Carbonitriding is preferred over liquid cyaniding due to environmental concerns related to cyanide disposal.

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    Carbonitrided Case Hardness

    This process creates a hard, wear-resistant case with a depth typically ranging from 0.075 mm to 0.75 mm.

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    Carbonitriding Hardenability

    Nitrogen increases the hardenability of steel by acting as an austenite stabilizer.

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    Carbonitriding Process Steps

    Starting with carburizing, followed by carbonitriding, and ending with quenching.

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    Suitable Steels for Carbonitriding

    Steels with carbon content up to 0.25% for specific applications.

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    Heat Treatment

    Combination of heating and cooling metal in the solid state to change its properties.

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    Purpose of Heat Treatment

    Relieves internal stresses from processes like cold-working, casting, welding, and hot-working while refining grain structure and enhancing mechanical, corrosion, and tribological properties.

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    Heat Treatment of Steels

    Heat treatment applied to steel alloys of iron and carbon to control properties, avoiding the liquid phase.

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    Austenite

    Stable solid solution of carbon and other alloying elements in gamma-iron (γ-Fe).

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    Ferrite

    BCC iron phase with limited carbon solubility.

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    Cementite

    Iron carbide (Fe3C) with 6.67 wt.% carbon.

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    Pearlite

    Alternating lamellae of ferrite and cementite, formed by austenite decomposition.

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    Martensite

    Austenite transformed below Ms (240°C) temperature through a shear transformation.

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    Bainite

    Austenite transformation between pearlite and martensite formation temperatures.

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    Annealing

    Heating and cooling to soften metal, improve mechanical properties, and relieve stress.

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    Stress-Relief Annealing

    Heating below the transformation range to relieve stresses from manufacturing.

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    Normalizing

    Heating above the critical point followed by air cooling to refine grain structure.

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    Full Annealing

    Heating above the critical point for hypoeutectoid or above the lower critical temperature for hypereutectoid then slow cooling, allowing maximum softening.

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    Spheroidizing

    Heating just below the transformation range then slow cooling to create globular carbides, improving formability and machinability.

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    Process Annealing

    Subcritical heating to soften materials after cold working to restore ductility.

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    Quenching

    Rapid cooling of metal from a high temperature to achieve hardness.

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    Tempering

    Reheating hardened steel below the critical temperature, decreasing hardness and increasing toughness.

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    Martempering

    Interrupted quench to a temperature above martensite formation followed by slow cooling to relieve quenching stresses.

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    Austempering

    Isothermal transformation to bainite below pearlite formation temperature, increasing ductility and strength.

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    Carburizing

    Diffusion of carbon into the surface of a low-carbon steel part to increase surface hardness.

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    Study Notes

    Metallurgy & Materials Science

    • Presented by Dr. R. Vaira Vignesh
    • Assistant Professor, Amrita School of Engineering, Coimbatore
    • Topic is Corrosion is a Bliss
    • Presentation materials are from internet/articles/books; for classroom use only

    Heat Treatment of Steels

    • Combination of heating and cooling metal/alloy
    • Changes micro-constituents to modify properties
    • Applied to ingots, castings, semi-finished products, welds.
    • Changes micro-constituent's properties: nature, size, distribution

    Stress and Strain

    • Non-uniform plastic deformation--manufacturing sequence.
    • Includes machining, welding and grinding
    • Deformation processing (hot/cold work)
    • Thermal variation
    • Phase transformations
    • Heterogeneity of chemical or crystallographic order
    • Hooke's Law: Complication, muddle, misunderstanding, obfuscation
    • Load removed: Tries to recover elasticity.
    • Inhibited from full recovery - Adjacent material is deformed plastically.

    Residual Stresses

    • Stresses present in matrix after load removal
    • Thermal or Mechanical
    • Positive or Negative
    • Laser peening--compressive residual stresses
    • Strengthens thin sections.
    • Toughens brittle surfaces
    • Negative effects as well.
    • Invisible to manufacturers unless significant distortion.
    • Affects structural integrity
    • Thick walled structures prone to brittle fracture.
    • Undesired stresses affect fatigue performance.
    • Often a cause of premature failure of critical components.

    Heat Treatment

    • Combination of heating and cooling operations timed and applied to a metal or alloy in a solid state.
    • Changes in microconstituents—nature, size and distribution.
    • Applied to ingots, castings, semi-finished products, welded joints, and various elements of machines and instruments.

    Purpose of Heat Treatment

    • Relieve internal stresses
    • Refine grain structure (coarse to fine)
    • Augment material properties (mechanical, corrosion, tribological)

    Heat Treatment of Steels

    • Steel is alloy of Fe and C (0.2% to 2% weight %)
    • Other alloying components: up to 5% in low alloy steels
    • More alloyed steels: tool steel and stainless steel
    • Wide variety of properties
    • Liquid phase is always avoided in heat treating.

    Quick Review

    • Austenite - Solid solution of C and/or other alloying elements in γ-Fe; not stable at room temperature, unless stabilizers added.
    • Ferrite - BCC iron phase; limited solubility of C (α-Fe) - BCC
    • Cementite - Fe3C (6.67 wt.% C) - Complex orthorhombic
    • Ledeburite - Eutectic mixture of Austenite and Cementite
    • Pearlite - Alternate lamellae of Ferrite and Cementite (austenite decomposition by eutectoid reaction)

    Quick Review (cont.)

    • Martensite - Austenite transformation below Ms (240°C)--shear type transformation
    • Bainite - Austenite transforms below temp. at which pearlite is produced; above transformation temp of Martensite
    • Troosite - Radial lamellae of ferrite and cementite, tempering below 450°C
    • Sorbite - Ferrite and finely divided cementite, tempering above 450°C
    • A1 – 727°C (Eutectoid transformation temperature)
    • A2 - 768°C (Curie temperature); Ferro --> Para-magnetic
    • A3 – γ-Fe / y-Fe + α-Fe boundary
    • Acm
    • Ar3
    • AC3

    Annealing

    • Generic term—heating to a temperature and holding at that temperature.
    • Cooling at an appropriate rate to soften or improve properties.
    • Improve mechanical or electrical properties; promote dimensional stability
    • Maximum temperature = A1, A3, Acm
    • Austenite is present at temps above A1
    • Subcritical, inter-critical, super-critical.

    Annealing Cycles

    • Subcritical (Stress-Relief, Process Annealing)--(Below A1)
    • Inter-critical annealing
    • Above A1, but below A3
    • Above A1, but below Acm
    • Super-critical (Full annealing, Normalizing)--(Above A3 or Acm)

    Stress-Relief Annealing

    • Relieve stresses, consequence of manufacturing sequence.
    • Separates stress-relief from post-weld.

    Annealing (cont.)

    • Minimizing internal residual stresses.
    • Uniform heating.
    • Cooling after specified holding time

    Normalizing

    • Heating to ≥55°C above A3 for hypoeutectoid compositions.
    • Above Acm for compositions higher than eutectoid.
    • Cooling practice through transformation for desired properties.
    • Refine the grains, decrease average grain size.

    Full Annealing

    • Heating to 50°C above A3, for hypoeutectoid or A1, for hypereutectoid steels.
    • Hold at this temp. for specified time.
    • Uniform cooling to achieve the desired structure.

    Carbo-Nitriding

    • Modified form of gas carburizing.
    • Introducing ammonia into the gas carburizing atmosphere.
    • Lower temp, shorter time, shallower case than gas carburizing.

    Carbo-Nitriding (cont.)

    • Avoids cyanide-bearing waste.
    • Improves hardenability, wear resistance, case depth.
    • Adds Nitrogen for austenite stabilization.

    Spheroidizing

    • Strength of ferrite depends on its grain size and cooling rate.
    • Carbides in pearlite or spheroids affect formability of steel.
    • Spheroidized steels: globular carbides in a ferritic matrix.

    Spheroidizing (cont.)

    • Prolonged holding at just below A1.
    • Alternating heating and cooling.
    • Heating to just above A1, cooling slowly or holding below A1.
    • Prevent carbide reformation.

    Process Annealing

    • During cold working.
    • Hardness of steel increases, and ductility decreases.
    • Must be annealed to restore ductility.
    • Restore steel's ductility; merely soften steel.
    • Intermediate treatment

    Quenching

    • Rapid cooling from austenitizing temperature; minimizes grain boundary carbides.
    • Improves ferrite distribution, control martensite in microstructure.
    • Achieving toughness, hardness, minimization of residual stress, distortion and cracking.

    Tempering

    • Reheating previously hardened steel below the critical temp.
    • Increasing ductility.
    • Increasing toughness.

    Martempering

    • Interrupted quench from austenitizing temp.
    • Hold temp. above martensite transformation to equalize temp. throughout the piece.
    • Minimize distortion, cracking, and residual stress.
    • Essentially primary martensitic, untempered and brittle.

    Martempering (cont.)

    • Quench into hot fluid medium (oil, salt, etc.)
    • Holding until uniform temp.
    • Avoids large temp. difference.

    Austempering

    • Isothermal transformation below pearlite formation and above martensite.
    • Heating to a temp. in austenitizing range, usually (790 to 915 °C.)
    • Quenching in a bath maintained at a constant temp (usually 260-400 °C).
    • Transforming isothermally to bainite in the bath.
    • Cooling to room temperature.

    Austempering (cont.)

    • Molten salt is preferred quenching medium.
    • Eliminates problem of a vapor phase barrier.
    • Increased steel toughness, ductility, and strength.
    • Reduced distortion.
    • Reduced machining time, stock removal, sorting, and inspection.
    • Shortest overall time cycle possible

    Surface Hardening of Steels

    • Methods vary based on diffusion and related processes.
    • Includes surface engineering, heat treatment, and surface modifications.

    Carburizing

    • Diffusing carbon into the surface, increasing hardness.
    • Used on low-carbon steels.

    Carburizing (cont.)

    • High carbon content in surface due to rapid diffusion and high solubility of carbon in austenite.
    • Quenched and tempered surface becomes high-carbon tempered martensite - ferritic center is soft and ductile.
    • Thickness is smaller in carburized steels than flame or induction hardened steels.
    • Increased carbon content at the surface gives a martensitic layer. (wear resistant)

    Carburizing (cont.)

    • Uses methane (or propane) for decomposition into atomic carbon and hydrogen.
    • Time is 2 hours to 36 hours for 1 mm to 4 mm depth case.

    Carburizing (cont.)

    • Liquid carburising/cyaniding
    • Salt bath (cyanide-chloride-carbonate) at 845°C to 955°C.
    • Cyanide salts introduce nitrogen, improving hardness.
    • Fastest carburising process for small batch sizes.

    Carburizing (cont.)

    • Components surrounded by a carbonaceous medium
    • Process of either gas (CO->CO2) or solid carburising
    • Appropriate temps (790-845C) and times (2-36 hrs)

    Nitriding

    • Ferritic thermochemical method for diffusing nascent nitrogen into the surface of steels.
    • Diffusion process is based on solubility of N in Iron.
    • At 450°C, Iron-base alloy will absorb up to 5.7% to 6.1% of Nitrogen.
    • Beyond this, the surface phase is predominantly ɛ phase.
    • High carbon gives more potential for ɛ phase formation.

    Nitriding (cont.)

    • No molecular size change, no dimensional change.
    • Slight growth due to volumetric change.
    • Distortion induced by surface stresses being released.

    Nitriding (cont.)

    • Process parameters: Furnace temp., process control, time, gas flow, gas activity control, process chamber maintenance.

    Carbo-Nitriding

    • Modified form of gas carburizing.
    • Introducing ammonia for nitrogen addition to the carburized case.
    • Nitrogen diffuses with carbon simultaneously for a shorter time.
    • Shallower case.
    • Similar to liquid cyaniding.

    Carbo-Nitriding (cont.)

    • Preferred over liquid cyaniding due to cyanide disposal problems.
    • Hard, wear-resistant case, with better hardenability.
    • Nitrogen increases the hardenability of steel.
    • Increases retained austenite (for alloy steels).

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