Case-hardening

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Colt Peacemaker, showing case-hardening colors on the frame SAA 44-40.JPG
Colt Peacemaker, showing case-hardening colors on the frame

Case-hardening or surface hardening is the process of hardening the surface of a metal object while allowing the metal deeper underneath to remain soft, thus forming a thin layer of harder metal (called the "case") at the surface. For iron or steel with low carbon content, which has poor to no hardenability of its own, the case-hardening process involves infusing additional carbon or nitrogen into the surface layer. Case-hardening is usually done after the part has been formed into its final shape, but can also be done to increase the hardening element content of bars to be used in a pattern welding or similar process. The term Face hardening is also used to describe this technique, when discussing modern armour.

Contents

Hardening is desirable for metal components that are subject to sliding contact with hard or abrasive materials, as the hardened metal is more resistant to surface wear. However, because hardened metal is usually more brittle than softer metal, through-hardening (that is, hardening the metal uniformly throughout the piece) is not always a suitable choice. In such circumstances, case-hardening can produce a component that will not fracture (because of the soft core that can absorb stresses without cracking), but also provides adequate wear resistance on the hardened surface.

History

Early iron smelting made use of bloomeries which produced two layers of metal: one with a very low carbon content which is worked into wrought iron, and one with a high carbon outer layer. Since the high carbon iron is hot short, meaning it fractures and crumbles when forged, it was not useful without more smelting. As a result, it went largely unused in the west until the popularization of the finery forge. [1] The wrought iron, with nearly no carbon in it, was very malleable and ductile but not very hard.

Case-hardening involves packing the low-carbon iron within a substance high in carbon, then heating this pack to encourage carbon migration into the surface of the iron. This forms a thin surface layer of higher carbon steel, with the carbon content gradually decreasing deeper from the surface. The resulting product combines much of the toughness of a low-carbon steel core, with the hardness and wear resistance of the outer high-carbon steel.

The traditional method of applying the carbon to the surface of the iron involved packing the iron in a mixture of ground bone and charcoal or a combination of leather, hooves, salt and urine, all inside a well-sealed box. This carburizing package is then heated to a high temperature but still under the melting point of the iron and left at that temperature for a length of time. The longer the package is held at the high temperature, the deeper the carbon will diffuse into the surface. Different depths of hardening are desirable for different purposes: sharp tools need deep hardening to allow grinding and resharpening without exposing the soft core, while machine parts like gears might need only shallow hardening for increased wear resistance.

The resulting case-hardened part may show distinct surface discoloration, if the carbon material is mixed organic matter as described above. The steel darkens significantly, and shows a mottled pattern of black, blue, and purple caused by the various compounds formed from impurities in the bone and charcoal. This oxide surface works similarly to bluing, providing a degree of corrosion resistance, as well as an attractive finish. Case colouring refers to this pattern and is commonly encountered as a decorative finish on firearms.

Case-hardened steel combines extreme hardness and extreme toughness, something which is not readily matched by homogeneous alloys since hard steel alone tends to be brittle.

Chemistry

Carbon itself is solid at case-hardening temperatures and so is immobile. Transport to the surface of the steel was as gaseous carbon monoxide, generated by the breakdown of the carburising compound and the oxygen packed into the sealed box. This takes place with pure carbon but too slowly to be workable. Although oxygen is required for this process it is re-circulated through the CO cycle and so can be carried out inside a sealed box. The sealing is necessary to stop the CO either leaking out or being oxidised to CO2 by excess outside air.

Adding an easily decomposed carbonate "energiser" such as barium carbonate breaks down to BaO + CO2 and this encourages the reaction

C (from the donor) + CO2 <—> 2 CO

increasing the overall abundance of CO and the activity of the carburising compound. [2] It is a common knowledge fallacy that case-hardening was done with bone but this is misleading. Although bone was used, the main carbon donor was hoof and horn. Bone contains some carbonates but is mainly calcium phosphate (as hydroxylapatite). This does not have the beneficial effect of encouraging CO production and it can also introduce phosphorus as an impurity into the steel alloy.

Modern use

Both carbon and alloy steels are suitable for case-hardening; typically mild steels are used, with low carbon content, usually less than 0.3% (see plain-carbon steel for more information). These mild steels are not normally hardenable due to the low quantity of carbon, so the surface of the steel is chemically altered to increase the hardenability. Case-hardened steel is formed by diffusing carbon (carburization), nitrogen (nitriding) and/or boron (boriding) into the outer layer of the steel at high temperature, and then heat treating the surface layer to the desired hardness.

The term case-hardening is derived from the practicalities of the carburization process itself, which is essentially the same as the ancient process. The steel work piece is placed inside a case packed tight with a carbon-based case-hardening compound. This is collectively known as a carburizing pack. The pack is put inside a hot furnace for a variable length of time. Time and temperature determines how deep into the surface the hardening extends. However, the depth of hardening is ultimately limited by the inability of carbon to diffuse deeply into solid steel, and a typical depth of surface hardening with this method is up to 1.5 mm. Other techniques are also used in modern carburizing, such as heating in a carbon-rich atmosphere. Small items may be case-hardened by repeated heating with a torch and quenching in a carbon rich medium, such as the commercial products Kasenit / Casenite or "Cherry Red". Older formulations of these compounds contain potentially toxic cyanide compounds, while the more recent types such as Cherry Red do not. [3] [4]

Processes

Flame or induction hardening

A flame-hardened sprocket. The discoloration around the teeth represents the area that was rapidly heated and then quenched. Flame hardened sprocket.jpg
A flame-hardened sprocket. The discoloration around the teeth represents the area that was rapidly heated and then quenched.

Flame or induction hardening are processes in which the surface of the steel is heated very rapidly to high temperatures (by direct application of an oxy-gas flame, or by induction heating) then cooled rapidly, generally using water; this creates a "case" of martensite on the surface. A carbon content of 0.3–0.6 wt% C is needed for this type of hardening.

Typical uses are for the shackle of a lock, where the outer layer is hardened to be file resistant, and mechanical gears, where hard gear mesh surfaces are needed to maintain a long service life while toughness is required to maintain durability and resistance to catastrophic failure. Flame hardening uses direct impingement of an oxy-gas flame onto a defined surface area. The result of the hardening process is controlled by four factors:

Carburizing

Carburizing is a process used to case-harden steel with a carbon content between 0.1 and 0.3 wt% C. In this process steel is introduced to a carbon rich environment at elevated temperatures for a certain amount of time, and then quenched so that the carbon is locked in the structure; one of the simpler procedures is repeatedly to heat a part with an acetylene torch set with a fuel-rich flame and quench it in a carbon-rich fluid such as oil.

Carburization is a diffusion-controlled process, so the longer the steel is held in the carbon-rich environment the greater the carbon penetration will be and the higher the carbon content. The carburized section will have a carbon content high enough that it can be hardened again through flame or induction hardening.

It is possible to carburize only a portion of a part, either by protecting the rest by a process such as copper plating, or by applying a carburizing medium to only a section of the part.

The carbon can come from a solid, liquid or gaseous source; if it comes from a solid source the process is called pack carburizing. Packing low carbon steel parts with a carbonaceous material and heating for some time diffuses carbon into the outer layers. A heating period of a few hours might form a high-carbon layer about one millimeter thick.

Liquid carburizing involves placing parts in a bath of a molten carbon-containing material, often a metal cyanide; gas carburizing involves placing the parts in a furnace maintained with a methane-rich interior.

Nitriding

Nitriding heats the steel part to 482–621 °C (900–1,150 °F) in an atmosphere of ammonia gas and dissociated ammonia. The time the part spends in this environment dictates the depth of the case. The hardness is achieved by the formation of nitrides. Nitride forming elements must be present for this method to work; these elements include chromium, molybdenum, and aluminum. The advantage of this process is that it causes little distortion, so the part can be case-hardened after being quenched, tempered and machined. No quenching is done after nitriding.

Cyaniding

Cyaniding is a case-hardening process that is fast and efficient; it is mainly used on low-carbon steels. The part is heated to 871–954 °C (1600–1750 °F) in a bath of sodium cyanide and then is quenched and rinsed, in water or oil, to remove any residual cyanide.

2NaCN + O2 → 2NaCNO
2NaCNO + O2 → Na2CO3 + CO + N2
2CO → CO2 + C

This process produces a thin, hard shell (between 0.25 and 0.75 mm, 0.01 and 0.03 inches) that is harder than the one produced by carburizing, and can be completed in 20 to 30 minutes compared to several hours so the parts have less opportunity to become distorted. It is typically used on small parts such as bolts, nuts, screws and small gears. The major drawback of cyaniding is that cyanide salts are poisonous.

Carbonitriding

Carbonitriding is similar to cyaniding except a gaseous atmosphere of ammonia and hydrocarbons is used instead of sodium cyanide. If the part is to be quenched, it is heated to 775–885 °C (1,427–1,625 °F); if not, then the part is heated to 649–788 °C (1,200–1,450 °F).

Ferritic nitrocarburizing

Ferritic nitrocarburizing diffuses mostly nitrogen and some carbon into the case of a workpiece below the critical temperature, approximately 650 °C (1,202 °F). Under the critical temperature the workpiece's microstructure does not convert to an austenitic phase, but stays in the ferritic phase, which is why it is called ferritic nitrocarburization.

Applications

Parts that are subject to high pressures and sharp impacts are still commonly case-hardened. Examples include firing pins and rifle bolt faces, or engine camshafts. In these cases, the surfaces requiring the hardness may be hardened selectively, leaving the bulk of the part in its original tough state.

Firearms were a common item case-hardened in the past, as they required precision machining best done on low carbon alloys, yet needed the hardness and wear resistance of a higher carbon alloy. Many modern replicas of older firearms, particularly single action revolvers, are still made with case-hardened frames, or with case coloring, which simulates the mottled pattern left by traditional charcoal and bone case-hardening.

Another common application of case-hardening is on screws, particularly self-drilling screws. In order for the screws to be able to drill, cut and tap into other materials like steel, the drill point and the forming threads must be harder than the material(s) that it is drilling into. However, if the whole screw is uniformly hard, it will become very brittle and it will break easily. This is overcome by ensuring that only the surface is hardened, and the core remains relatively softer and thus less brittle. For screws and fasteners, case-hardening is achieved by a simple heat treatment consisting of heating and then quenching.

For theft prevention, lock shackles and chains are often case-hardened to resist cutting, whilst remaining less brittle inside to resist impact. As case-hardened components are difficult to machine, they are generally shaped before hardening.

See also

Related Research Articles

Differential heat treatment

Differential heat treatment is a technique used during heat treating to harden or soften certain areas of a steel object, creating a difference in hardness between these areas. There are many techniques for creating a difference in properties, but most can be defined as either differential hardening or differential tempering. These were common heat treating techniques used historically in Europe and Asia, with possibly the most widely known example being from Japanese swordsmithing. Some modern varieties were developed in the twentieth century as metallurgical knowledge and technology rapidly increased.

Heat treating process of heating something to alter it

Heat treating is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve the desired result such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering, carburizing, normalizing and quenching. Although the term heat treatment applies only to processes where the heating and cooling are done for the specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding.

Austenite metallic, non-magnetic allotrope of iron or a solid solution of iron, with an alloying element

Austenite, also known as gamma-phase iron (γ-Fe), is a metallic, non-magnetic allotrope of iron or a solid solution of iron, with an alloying element. In plain-carbon steel, austenite exists above the critical eutectoid temperature of 1000 K (727 °C); other alloys of steel have different eutectoid temperatures. The austenite allotrope is named after Sir William Chandler Roberts-Austen (1843–1902); it exists at room temperature in some stainless steels.

Brazing high-temperature soldering; metal-joining technique by high-temperature molten metal filling

Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, the filler metal having a lower melting point than the adjoining metal.

Carbon steel steel in which the main interstitial alloying constituent is carbon

Carbon steel is a steel with carbon content up to 2.1% by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states:

Quenching Rapid cooling of a workpiece to obtain certain material properties

In materials science, quenching is the rapid cooling of a workpiece in water, oil or air to obtain certain material properties. A type of heat treating, quenching prevents undesired low-temperature processes, such as phase transformations, from occurring. It does this by reducing the window of time during which these undesired reactions are both thermodynamically favorable, and kinetically accessible; for instance, quenching can reduce the crystal grain size of both metallic and plastic materials, increasing their hardness.

Carburizing Heat treatment process in which a metal absorbs carbon while the metal is heated in the presence of a carbon-bearing material, such as charcoal or carbon monoxide

Carburizing, carburising, or carburization is a heat treatment process in which iron or steel absorbs carbon while the metal is heated in the presence of a carbon-bearing material, such as charcoal or carbon monoxide. The intent is to make the metal harder. Depending on the amount of time and temperature, the affected area can vary in carbon content. Longer carburizing times and higher temperatures typically increase the depth of carbon diffusion. When the iron or steel is cooled rapidly by quenching, the higher carbon content on the outer surface becomes hard due to the transformation from austenite to martensite, while the core remains soft and tough as a ferritic and/or pearlite microstructure.

Tempering (metallurgy) process of heat treating used to increase the toughness of iron-based alloys

Tempering is a process of heat treating, which is used to increase the toughness of iron-based alloys. Tempering is usually performed after hardening, to reduce some of the excess hardness, and is done by heating the metal to some temperature below the critical point for a certain period of time, then allowing it to cool in still air. The exact temperature determines the amount of hardness removed, and depends on both the specific composition of the alloy and on the desired properties in the finished product. For instance, very hard tools are often tempered at low temperatures, while springs are tempered at much higher temperatures.

Hardening is a metallurgical metalworking process used to increase the hardness of a metal. The hardness of a metal is directly proportional to the uniaxial yield stress at the location of the imposed strain. A harder metal will have a higher resistance to plastic deformation than a less hard metal.

Carbonitriding

Carbonitriding is a metallurgical surface modification technique that is used to increase the surface hardness of a metal, thereby reducing wear.

In metallurgy and materials science, annealing is a heat treatment that alters the physical and sometimes chemical properties of a material to increase its ductility and reduce its hardness, making it more workable. It involves heating a material above its recrystallization temperature, maintaining a suitable temperature for a suitable amount of time, and then allow slow cooling.

A vacuum furnace is a type of furnace in which the product in the furnace is surrounded by a vacuum during processing. The absence of air or other gases prevents oxidation, heat loss from the product through convection, and removes a source of contamination. This enables the furnace to heat materials to temperatures as high as 3,000 °C (5,432 °F) with select materials. Maximum furnace temperatures and vacuum levels depend on melting points and vapor pressures of heated materials. Vacuum furnaces are used to carry out processes such as annealing, brazing, sintering and heat treatment with high consistency and low contamination.

Hardened steel type of steel

The term hardened steel is often used for a medium or high carbon steel that has been given heat treatment and then quenching followed by tempering. The quenching results in the formation of metastable martensite, the fraction of which is reduced to the desired amount during tempering. This is the most common state for finished articles such as tools and machine parts. In contrast, the same steel composition in annealed state is softer, as required for forming and machining.

Nitriding heat treating process that diffuses nitrogen into the surface of a metal to create a case-hardened surface

Nitriding is a heat treating process that diffuses nitrogen into the surface of a metal to create a case-hardened surface. These processes are most commonly used on low-carbon, low-alloy steels. They are also used on medium and high-carbon steels, titanium, aluminium and molybdenum. In 2015, nitriding was used to generate unique duplex microstructure, known to be associated with strongly enhanced mechanical properties

Boriding, also called boronizing, is the process by which boron is added to a metal or alloy. It is a type of surface hardening. In this process boron atoms are diffused into the surface of a metal component. The resulting surface contains metal borides, such as iron borides, nickel borides, and cobalt borides, As pure materials, these borides have extremely high hardness and wear resistance. Their favorable properties are manifested even when they are a small fraction of the bulk solid. Boronized metal parts are extremely wear resistant and will often last two to five times longer than components treated with conventional heat treatments such as hardening, carburizing, nitriding, nitrocarburizing or induction hardening. Most borided steel surfaces will have iron boride layer hardnesses ranging from 1200-1600 HV. Nickel-based superalloys such as Inconel and Hastalloys will typically have nickel boride layer hardnesses of 1700-2300 HV.

Japanese swordsmithing Asian metallic weapon creation

Japanese swordsmithing is the labour-intensive bladesmithing process developed in Japan for forging traditionally made bladed weapons (nihonto) including katana, wakizashi, tantō, yari, naginata, nagamaki, tachi, uchigatana, nodachi, ōdachi, kodachi, and ya (arrow).

Diffusion hardening

Diffusion hardening is a process used in manufacturing that increases the hardness of steels. In diffusion hardening, diffusion occurs between a steel with a low carbon content and a carbon-rich environment to increase the carbon content of the steel and ultimately harden the workpiece. Diffusion only happens through a small thickness of a piece of steel, so only the surface is hardened while the core maintains its original mechanical properties. Heat treating may be performed on a diffusion hardened part to increase the hardness of the core as desired, but in most cases in which diffusion hardening is performed, it is desirable to have parts with a hard outer shell and a more ductile inside. Heat treating and quenching is a more efficient process if hardness is desired throughout the whole part. In the case of manufacturing parts subject to large amounts of wear, such as gears, the non-uniform properties acquired through diffusion hardening are desired. Through this process, gears obtain a hard wear-resistant outer shell but maintain their softer and more impact-resistant core.

Mangalloy

Mangalloy, also called manganese steel or Hadfield steel, is an alloy steel containing an average of around 13% manganese. Mangalloy is known for its high impact strength and resistance to abrasion once in its work-hardened state.

Ferritic nitrocarburizing, also known by the proprietary names Tennifer/ Tenifer and Melonite, is a range of proprietary case hardening processes that diffuse nitrogen and carbon into ferrous metals at sub-critical temperatures during a salt bath. The processing temperature ranges from 525 °C (977 °F) to 625 °C (1,157 °F), but usually occurs at 565 °C (1,049 °F). At this temperature steels and other ferrous alloys are still in a ferritic phase, which is advantageous compared to other case hardening processes that occur in the austenitic phase. There are four main classes of ferritic nitrocarburizing: gaseous, salt bath, ion or plasma, and fluidized-bed.

A laminated steel blade or piled steel is a knife, sword, or other tool blade made out of layers of differing types of steel, rather than a single homogeneous alloy. The earliest steel blades were laminated out of necessity, due to the early bloomery method of smelting iron, which made production of steel expensive and inconsistent. Laminated steel offered both a way to average out the properties of the steel, as well as a way to restrict high carbon steel to the areas that needed it most. Laminated steel blades are still produced today for specialized applications, where different requirements at different points in the blade are met by use of different alloys, forged together into a single blade.

References

  1. Ayres, Robert (1989). "Technological Transformations and Long Waves" (PDF): 12. Archived from the original (PDF) on 2012-07-07. Retrieved 2017-04-10.Cite journal requires |journal= (help)
  2. Higgins, Raymond A. (1983). Part I: Applied Physical Metallurgy. Engineering Metallurgy (5th ed.). Hodder & Stoughton. p. 474. ISBN   0-340-28524-9.
  3. Roy F. Dunlap (1963). Gunsmithing. Stackpole Books. ISBN   0-8117-0770-9.
  4. Case Hardening in a Home Garage Hemmings Sports & Exotic Car — MARCH 1, 2006 - BY CRAIG FITZGERALD