Carburizing Process Research Articles

Efficient carburization of high-entropy alloys from polyethylene microplastics using a green mechanochemical process to obtain excellent wave absorbing performance

Polyethylene as a major white pollutant has a significant negative impact on the environment and the human health. Beneficial recycling of polyethylene through mechanochemical processes not only can eliminate environmental hazards, but also enable some beneficial industrial applications. In this work, polyethylene was used as the raw materials of carburization of FeCoNiMn high-entropy alloys (HEAs) by a green mechanochemical method. The phase structure, magnetic properties, high-temperature oxidation resistance, corrosion resistance and electromagnetic-wave absorbing performance of the obtained carburized HEAs were investigated in detail. The carburized-FeCoNiMn HEAs exhibited excellent corrosion resistance, suggesting great application potential for use in harsh environments. Besides, the impedance matching was optimized and the electromagnetic-wave absorption bandwidth was expanded by this carburization process. Specifically, the reflection loss of C10 (FeCoNiMnC0.1) at 8.88 GHz reached −65.07 dB at a thickness of 2.79 mm, and both the C50 (FeCoNiMnC0.5) and C90 (FeCoNiMnC0.9) exhibited a maximum absorption bandwidth of 5.45 GHz. This work provides a new concept of utilizing common microplastic pollutants to achieve efficient carburization of HEAs by a green mechanochemical process.

Evolution of Microstructure and Hardness during Carburization Heat Treatment of Heavy-duty Gear Steels: Numerical Prediction and Experimental Study

Abstract In order to solve the problems of long process cycle, low efficiency and high cost in the carburization heat treatment process of 18Cr2Ni4WA heavy-duty gear steel. The carbon concentration distribution of 18Cr2Ni4WA steel under conventional carburizing process at 930℃ was studied by combining numerical simulation with experimental research. The results show that the carbon concentration distribution predicted by the simulation is in good agreement with the experimental results. The microstructure of the surface layer after low-temperature tempering consists mainly of fine acicular tempered martensite, while the core consists mainly of lath tempered martensite and bainite. The increase in hardness after carburization is mainly attributed to the solid solution strengthening of the carbon atoms. The increase in hardness after cryogenic treatment is mainly attributed to the precipitation strengthening of the carbides. In addition, compared to the conventional carburization at 930°C, the high temperature carburizations at 950°C and 970°C reduced the carburization time by 37.2% and 53.5%, respectively.

Surface Mechanical Property Prediction and Process Optimization of 18CrNiMo7-6 Carburized Steel Stator Guide Based on Radial Basis Function Neural Network and NSGA-II Algorithm

The carburizing process is a key technology that affects the mechanical properties of the surface of the hydraulic motor stator guide rail, and the related process parameters have an important influence on surface hardness, the thickness of the carburized layer, and the deformation of the guide rail. However, at present, the relationship between the carburizing process parameters and the surface mechanical properties of the target is not clear. This paper proposes a “hardness prediction and process parameter optimization” method. Firstly, a finite element model is established, with carburizing time, temperature, and carbon potential as the three input factors; the optimal Latin hypercubic experimental design and sensitivity analysis are applied. Secondly, surface hardness, carburized layer thickness, and deformation are taken as the output values, and an RBF neural network is used to construct the prediction model. The results show that the RBF neural network can be accurately used for the prediction of surface hardness, the thickness of the carburized layer, and deformation, and for the optimization of process parameters. The optimized parameters of surface hardness and the thickness of the carburized layer were increased by 4.2% and 5.1%, respectively, and the deformation amount was reduced to 0.31 mm, achieving the goal of optimal design.

A novel route of carburizing through microwave hybrid heating

Abstract Carburizing is a surface treatment process by diffusing carbon into the steel. These days, manufacturing industries demand highly efficient processes that consume low power. Microwave processing is a newly evolving process that consumes low power. This study proposes a novel route for carburizing mild steel (substrate) through experimental and simulation studies using a microwave heating. Charcoal powder was used as a susceptor to convert microwave energy into heat energy and to deposit carbon on the surface of the specimen. The mild steel specimens were exposed to the microwave power input of 900 W and 360 W for exposure time of 1500 s and 1980 s naming it as S2 and S3 respectively. The microstructural analysis of specimens S2 and S3 confirms the formation of pearlite structures at the surface. However, the amount of pearlite structure was significantly higher for the S3. The higher carbon content is confirmed through energy-dispersive x-ray spectroscopy (EDS) analysis of specimen S3. The average hardness of the S3 specimen was determined to be 220.8 HV, which shows an increase of 38.36% compared to the S1 (base metal). x-ray diffraction (XRD) results indicate the additional cementite peaks (Fe3C) and ferrite-confirming phase transformations for carburized samples. The wear analysis of S2 and S3 was conducted through pin-on-disk testing. The peak COF of 0.73 and 0.64 was observed for S2 and S3 respectively. The hard surface of S3 resists the penetration of the counter body to a greater extent due to the fine morphology of pearlite. From the FEM study, the maximum value of 7.96 × 10 3 (V/m) was determined at the center region for the electric field distribution in the microwave cavity, which is the optimum value for efficient heating. The maximum temperature of the mild steel obtained during the carburization process was 900 °C in 1800 s. The microwave carburizing process requires relatively less time than the conventional carburizing process which will save energy consumption.

Predictive residual stress analysis in gear units: an artificial intelligence approach based on finite element data

Determining residual stresses is essential for ensuring the safety and longevity of gear components. Traditional methods, such as analytical, numerical, and experimental approaches, are often costly, time-consuming, and sometimes destructive. This study proposes a new method to predict residual stresses in gear units using artificial intelligence based on data from finite element analysis. To achieve this, a commercial finite element tool models the heat treatment and carburization processes, grounded in thermomechanical metallurgical physics. The residual stresses obtained from finite element analysis are then compared to the ones from experiment using deep hole drilling approach. This is followed by a sensitivity analysis. Next, a specific class of gearbox component geometries and the computed stress fields are utilized to train artificial neural networks. The performance of the artificial neural networks approach is compared to that of two different machine learning regression methods. It has been concluded that this technique successfully anticipates residual stresses in components with scaled geometries and similar heat treatment steps, outperforming the two regression models in accuracy and efficiency. Importantly, it achieves this with incomparable, significantly less computation time compared to standard finite element analysis.

Galling-Free Dry Near-Net Forging of Titanium Using Massively Carbon-Supersaturated Tool Steel Dies.

Massively carbon-supersaturated (MCSed) tool steel dies were developed to make galling-free forging products from titanium bar feedstocks in dry conditions without lubricating oils. Two types of tool steel dies were used, SKD11 and ACD56, following the Japanese Industrial Standard (JIS). The plasma-immersion carburizing process was employed to induce massive carbon supersaturation in two kinds of tool steel dies at 673 K for 14.4 ks. A pure titanium bar was upset in a single stroke up to the reduction of thickness of 70% using the MCSed SKD11 die. Very few bulging displacements of the upset bar proved that μ = 0.05 on the contact surface of the MCSed SKD11 die to pure titanium work. Two continuous forging experiments were performed to demonstrate that an in situ lubrication mechanism played a role to prevent the contact surface from galling to titanium works in both laboratory- and industry-scaled forging processes. After precise microstructure analyses of the contact surface, the free-carbon film formed in situ acted as a lubricating tribofilm to reduce friction and adhesive wear in continuous forging processes. The MCSed ACD56 dies were also used to describe the galling-free forging behavior of manufacturing eyeglass frames and to evaluate the surface quality of the finished temples. The applied load was reduced by 30% when using the MCSed ACD56 dies. The average surface roughness of the forged product was also greatly reduced, from 4.12 μm to 0.99 μm, together with a reduction in roughness deviations. High qualification of forged products was preserved together with die life prolongation even in dry manufacturing conditions of the titanium and titanium alloys.

Development of calibration samples made of steel 45 and 09G2S for eddy current structuroscope by carburizing

The paper describes the process of carburizing and hardening of 45 and 09G2S steels for the production of samples for the development of a technique for eddy current testing of the quality and thickness of hardened layers on ferromagnetic cores. Structural analysis of samples in the initial state, in the hardened state, as well as after carburizing and hardening was carried out. As a result of metallographic studies it was obtained that the depth of the cemented layer of steel 45 was equal to 250 microns, and in case of steel 09G2C it is in the range of 550-800 microns.

The Effects of Different Ultrasonic Composite Surface Modifications on the Properties of H13 Steel for Shield Tunnel Machine Cutter Ring

Tunnel boring machines (TBMs) are exposed to the impact of the ground shattering force and the friction of sandstone during excavation work, and are prone to wear and breakage, and other failures. Traditional heat treatment processes cannot simultaneously achieve the required high-energy composite structure of hard external and tough internal properties for cutter rings, leading to inadequate wear resistance and impact toughness under working conditions. This study utilizes H13 steel as the base material, and based on a study of carburizing, nitriding, and ultrasonic impact processes for H13 steel analyzing the effects of different high-energy composite modification processes on the hardness distribution, microstructure, and residual stress of H13 steel, the mechanisms by which high-energy composite modification processes affect the wear resistance and impact resistance of H13 steel are revealed. The results indicate that the wear amount and impact toughness of the sample subjected to carburizing and ultrasonic surface rolling composite strengthening were 1.9 mg and 27.34 J/cm2, demonstrating the best wear and impact resistance. This combination of properties allows the H13 steel cutter ring to achieve the optimal overall performance in terms of wear resistance and impact resistance.

Carburization Behavior of High-Grade Pellets After Direct Reduction in Pure Hydrogen

AbstractCarburization is a critical aspect in the iron and steel industry as it significantly affects the mechanical and chemical properties of the final product. This study provides a comprehensive analysis of the carburization potential of high-grade quality iron ore pellets after direct reduction in pure hydrogen. The results show that the porosity of the pellets has a significant impact on the efficiency and success of the direct reduction process with hydrogen. The reduction process can be completed at a lower temperature in pure hydrogen compared to carbon monoxide, with the iron carbide concentration peaking at temperatures up to 500 °C before decreasing with further temperature increases. The uniform distribution of SiO2, Al2O3, and CaO is critical to the carburizing process and affects the final properties of the steel. An increased degree of metallization and porosity are associated with an improved carburizing tendency. This study highlights the intricate interplay between temperature, carbon sources, and the resulting equilibrium concentration of iron carbides and provides insights into the complex dynamics of this phenomenon. Graphical Abstract

Atomic-level insight into the carburization process of iron-based catalysts: A ReaxFF molecular dynamics study

Transition metal carbide catalysts have garnered widespread attention due to their outstanding catalytic performance. The carbide catalysts, such as FexC and MoxC are typically obtained from their oxide carburization. The reduction and carburization processes are key steps during the activation of oxide precursors, which determine the activity and stability. An understanding of the carburization process mechanism is very important for the optimization of carbide catalysts. Iron-based catalysts are widely used in the large-scale coal-to-liquid industry because of their low price and high activity. In this paper, the carburization process of iron oxide nanoparticles was simulated by the Reactive force field (ReaxFF) molecular dynamics method. The results illustrate that the competition between CO dissociation and reduction of oxides occurs at the 100 ps time scale, which can be tuned by particle size and oxygen vacancy. We have explained the counter-intuitive finding that small oxide particles are more difficult to achieve fully carburization than larger ones; this is because rapid carbon accumulation on the surface blocks the oxygen diffusion channels from bulk to surface. The atomic distribution heat map was carried out to demonstrate the carbon and oxygen penetration processes. Meanwhile, the volumetric strain analysis reveals the driving force comes from the strong tendency to form Fe-C bonds. The dependence on surface orientation was further systematically investigated. This work provides microscopic insights into the carburization process of iron-based materials and the fundamental knowledge for the optimization of catalyst synthesis procedures.

Unified Solid Solution Product of [Nb][C] in Nb-Microalloyed Steels with Various Carbon Contents.

In this work, the solid solution product of [Nb][C] in the Nb-microalloyed steels with various carbon contents in the range of 0.20~1.80 wt.% was investigated by means of the extraction phase analysis method. The results showed that the Nb content in austenite tended to first decrease and then increase with the increase of carbon content in the steels. A unified solid solution product of [Nb][C] in austenite at different temperatures was obtained according to the results of the experimental steels. The Nb content in austenite of the experimental steels with high carbon contents was lower than that calculated by Ohtani's equation. The existence of NbC precipitates in the case and the core of the specimens carburized at 930 °C and 980 °C were verified by transmission electron microscopy (TEM) observations. The pinning effect of NbC precipitates on austenite grain growth was calculated according to the size and amount of NbC precipitates in the carburized case and the core of the carburized specimens. The calculated results of prior austenite grain sizes were in good agreement with the experimental results, which indicated that the unified solid solution product of [Nb][C] in Nb-microalloyed steels with various carbon contents was applicable for the low-pressure carburizing process.

Carburization-induced surface modification of Ti-6Al-7Nb alloy and its characterization

The Ti-6Al-7 Nb alloy and its carbide possess a wide range of engineering applications, therefore, it is utmost required to fabricate high-quality carburized layers on the alloy surface. In this study, the carburization of Ti-6Al-7 Nb alloy was conducted using molten salts (including Carbon Nano Tubes, LiCl, KCl, and KF) in a planetary ball mill, followed by placement in an alumina tube furnace under a nitrogen atmosphere at 1050 °C for various durations. Several characterization techniques were employed to analyze the results, including X-ray diffraction (XRD), field emission electron microscopy (FE-SEM), X-ray photoelectron spectroscopy (XPS), and atomic force microscopy (AFM). The XRD results reveal that as the carburization duration increased, the alloy achieved complete carburization, forming a 120 µm thick layer of TiC0.3N0.7. After 24 h of carburization, the crystallite size of TiC0.3N0.7 increased, and the micro-strain decreased, indicating improved structural quality. The morphology of the carburized layer at shorter durations exhibits micro-cracks and defects due to incomplete carburization, where carbon (C) and nitrogen (N) could not effectively occupy in the grain boundaries of alloy. After 24 h, an agglomerated, cauliflower-like layer of TiC0.3N0.7 formed, enhancing the alloy's engineering properties. XPS confirmed the presence of carbon and nitrogen in the carburized sample, which contributed to the formation of the TiC0.3N0.7 layer on the alloy surface. AFM analysis supported the SEM findings, revealing broad islands with microgrooves on the carburized layer. These features indicate a thick and well-formed carburized layer, confirming the successful carburization of Ti-6Al-7 Nb. Overall, the study demonstrates that a 24-h carburization process at 1050 °C in molten salts under a nitrogen atmosphere effectively produces a high-quality, thick, and adherent TiC0.3N0.7 layer on Ti-6Al-7 Nb alloy, significantly enhancing its engineering properties.

THE INFLUENCE OF THE CARBURIZING PROCESS ON THE IMPACT-SLIDING WEAR BEHAVIOR OF 14NiCr14 STEEL

Weapons depend largely on the barrel. Gunpowder combustion converts chemical energy into thermal and mechanical energy. Barrels give projectiles initial speed and flight direction, and helical grooves require fast spinning for stability while moving toward the target. Due of barrel exposure to heat, high pressures, gunpowder vapors, and external impacts, this weapon element needs extensive investigation. The study discusses carburizing for surface modification in high-pressure circumstances to improve gun barrel interior line tribology. Carburizing has been detected at a depth of 960 μm from the surface, as revealed by light-optical microscope images. The microhardness test has been performed on the sample's cross section, which has a maximal hardness of 650 ± 10 HV0.05 close to the surface and 250 ± 5 HV0.05 close to the interface. At room temperature (RT), this study looked at how the carburizing process affects the impact-sliding wear performance of 14NiCr14 steel, which is widely used in the barrel extensions of guns under complex loading conditions. A series of impact-sliding wear experiments were conducted on 10 mm-diameter bearing steel balls made of 52100-grade steel, for a total of 4297 loading cycles. A 2-D contact profilometer and a light optical microscope (LOM) then examined the wear tracks that had formed on the samples. The carburized steel caused a decrease in the wear rate at the impact and sliding zones of the wear track.

The Design of Hardened Case and Carburizing Process of Subway Gear Based on Spalling Fatigue

The Design of Hardened Case and Carburizing Process of Subway Gear Based on Spalling Fatigue

Fine tuning the dynamic PdCx formation for enhanced acetylene semi-hydrogenation: The role of gas environment and ZnO addition

Palladium carbide (PdCx) has been extensively reported as active phase in acetylene semi-hydrogenation that can be dynamically formed during reaction. However, fine tuning of dynamic PdCx formation towards enhanced acetylene semi-hydrogenation is of great challenge and the dynamic insights remain elusive. In this paper, the state-of-the-art in situ characterizations have been adopted to elucidate the dynamic PdCx formation for acetylene semi-hydrogenation. The role of hydrogen atmosphere and ZnO addition in tuning the carburization process were clearly identified by in situ spectroscopies. The hydrogen in the gas environment assisted the carbon infiltration via PdHx hydrides, while the addition of ZnO suppress the carburization by the surface Zn alloy. As a result, the carbon content in PdCx can be precisely modulated by altering the hydrogen atmosphere and ZnO additives, and exhibits a linear correlation with the activity of acetylene semi-hydrogenation. The carbon insertion enriched the electron state of Pd sites in PdCx that favors the activation of hydrogen for acetylene semi-hydrogenation. This work thus provides a new route for the design of Pd catalyst for high-performance acetylene semi-hydrogenation by fine tuning the reaction environment and the degree of carburization during dynamic PdCx formation.

Low-carbon steel fatigue behavior after pack carburizing with buffalo bone charcoal and barium carbonate media

The pack carburizing method is a technique that can be employed to enhance the surface hardness of Low-Carbon Steel (LCS). This method can potentially improve the hardness of the material while maintaining its strength. This study aims to investigate how different carburizing media, specifically varying percentages of Buffalo Bone Charcoal (BBC) powder as a carbon source, impact the mechanical properties of LCS. The temperature in the carburizing process ranges from 850°C and 950°C while maintaining a holding time of 2 hours. The carbon derived from buffalo bone charcoal is finely ground and mixed with barium carbonate (BaCO3) as the energizer during this process. This study used different ratios of BBC powder and BaCO3 as carburizing mediums. The ratios tested were 60% BBC + 40% BaCO3, 70% BBC + 30% BaCO3, and 80% BBC + 20% BaCO3, based on the weight of the BBC powder used in the carburizing process. The steel will be combined with BaCO3 and powdered BBC for this research. Next, the fatigue test was examined. BBC in the pack carburizing process increases LCS carbon content by 0.735% from 0.268%. This change alters the steel's microstructure, possibly increasing its hardness and wear resistance. The direct link between BBC concentration and LCS carbon enrichment shows the process's efficiency. Pack carburizing also improves LCS fatigue strength. This improvement is due to higher BBC concentration, smaller carburizing medium particles, and higher processing temperatures. After carburizing, the LCS can resist 36,625 to 61,435 cycles.

Phase composition and numerical model of low-pressure pulse carburized layer in 15Cr14Co12Mo5Ni2W steel

Aerospace engine gear steel, 15Cr14Co12Mo5Ni2W steel, requires carburizing heat treatment to achieve operational performance. However, predicting the carbon concentration during the vacuum carburizing process poses significant challenges. This paper aims to design and establish a predictive model for the carbon concentration during the vacuum carburizing process of 15Cr14Co12Mo5Ni2W steel. Given the complex phase transformations during the vacuum carburizing process caused by the ultra-high alloy content of 15Cr14Co12Mo5Ni2W steel, vacuum short-term intense carburization and diffusion experiments were designed. Characterization methods such as XRD, scanning electron microscopy, electron probe microanalysis, EBSD, and FIB+TEM were used to study the microstructure, phase composition, phase constituents, and distribution of element concentrations during the vacuum carburizing process. Subsequently, a carbon concentration distribution calculation model considering carbide changes during the vacuum carburizing process of 15Cr14Co12Mo5Ni2W steel was established. Boundary conditions for carbon absorption during the intense carburization process of 15Cr14Co12Mo5Ni2W steel were proposed, and the relationship between surface carbon concentration and boundary conditions was determined through experiments. Using the method of forward calculation with least squares fitting of experimental data, the diffusion coefficient of carbon in the austenite of 15Cr14Co12Mo5Ni2W steel and the rate of carbon exchange between carbides and the matrix were derived, providing a more precise predictive tool for optimizing the vacuum carburizing process of 15Cr14Co12Mo5Ni2W steel.

Surface integrity and corrosion resistance of 18CrNiMo7-6 gear steel subjected to combined carburized treatment and wet shot peening

Typically, a cost-effective and versatile carburizing process is used to improve the surface integrity of high-value-added gear components. In this study, carburized treatment and wet shot peening (WSP) were applied to increase the corrosion resistance of 18CrNiMo7-6 gear steel. The surface integrity and corrosion resistance after carburizing and combined treatment (carburized treatment + WSP) were analyzed. The results indicated that the combined treatment converted the retained austenite surface layer within approximately 45 μm from the surface into the martensitic phase, with a 13.9 % reduction in equivalent grain size and a 23.6 % increase in dislocation density compared with carburizing. Furthermore, electrochemical experiments in a 3.5 wt% NaCl solution indicated that the combined treatment process increased the corrosion resistance compared with carburizing (55.4 % lower corrosion current density and a higher Fe2+/Fe3+ ratio). Despite the high surface roughness obtained with combined treatment, the improved corrosion resistance is primarily ascribed to the high compressive residual stress and dislocation density. This study provides insights into the surface strengthening design of 18CrNiMo7-6 gear steel for corrosive environments—particularly the synergistic strengthening effect of carburizing and WSP.

Pemanfaatan Limbah Cangkang Kerang Simping (Amusium Pleuronectes) Sebagai Katalisator Pada Proses Carburizing

Simping clam’s a type of waste that is rarely used. The high levels of calcium carbonate in simping shells enable them to be used as a catalyst in the carburizing process. This research aimed to determine the effect of simping clam shell powder as a catalyst in the carburizing process on the hardness and impact strength values of ST 42 steel. This research used an experimental method by varying the percentage of simping clam shell powder: 0%, 10%, 20%, 30%, and coconut shell activated charcoal powder: 100%, 90%, 80%, and 70%, against ST 42 steel with variations in carburizing time: 3 hours, 6 hours, and 9 hours using a temperature of 900°C. The tests carried out were rockwell hardness tests and charpy impact tests according to ASTM E23 standards. From the test results, it was obtained that good hardness and impact strength values were obtained in 3 hours, the percentage was 30% with an average hardness value of 34.02 HRC and an impact value of 0.279 joules/mm2, in 6 hours the percentage was 30% with an average hardness value of 38. 92 HRC and an impact value of 0.229 joules/mm2, a time of 9 hours with a percentage of 30% an average hardness value of 43.68 HRC and an impact value of 0.179 joules/mm2. So by increasing the carburizing time, the hardness increases. The longer the carburizing time, the higher the percentage of simping clam shell powder used. This means that simping clam shell powder functions as a catalyst.

Nucleation and Coarsening Behavior of Aluminum Nitride and Its Effect on Abnormal Grain Growth in High-Temperature Carburizing Process

Nucleation and Coarsening Behavior of Aluminum Nitride and Its Effect on Abnormal Grain Growth in High-Temperature Carburizing Process