It is highly essential to use heat treatment process to change the physical and chemical properties of cast alloy depending on how it will be used. As it undergoes a heat treatment process, most of its mechanical properties be it ferrous or non-ferrous in nature will be observed through their microstructure. The heat treatment process will alter the crystalline structure of the cast alloy so that the mechanical properties will behave in a manner appropriate for its application. The heating and cooling will be controlled so that the vital properties namely hardness, strength, toughness, ductility and elasticity will change. However, one alteration no matter how minimal can affect the other, most often in a non-beneficial manner. To further understand this scenario, below are the heat treatment process used for castings.
Annealing Process
During the solidification of the cast alloy, the outcome usually results into a build-up of hardness and stress and less ductility. The annealing process is done to alter these conditions. This process is done to reduce hardness, improve ductility and relieve the stress. Also, the annealing process makes the ferrous and non-ferrous castings more machine-able. These process vary in many ways so the results would be dependent on its application. The only similarity between them is the actual process of heating to itd desired temperature and afterwards its controlled cooling.
Precipitation Strengthening Process
Precipitation strengthening process occurs when there is a controlled release of constituents to eventually form precipitate clusters. These precipitate clusters are proved to significantly increase the strength of the casting. The precipitation strengthening process usually improves the yield strength of castings such as aluminium, nickel and titanium. It also works with certain steels and stainless steels.
Tempering Process
The tempering process is done by reducing the hardness of the casting alloy which will in turn increase its ductility. As a result, the casting will be less brittle. As the casting undergoes tempering, it will be quenched to its maximum hardness. Afterwards, it will be reduced to the desired level. The process mainly consist of heating the casting to a temperature below its point. Then the austenite will form and the cooling process will be initiated. It normally works with ferrous alloys.
Carburising or Case Hardening Process
Carburising or case hardening process occurs when the casting is heated above its transformation temperature in a carbon-rich environment. Afterwards, it will be quenched and will result into a surface layer intended to increase surface hardness and wear resistance without sacrificing its loading performance brought by its softer core. It is known as a thermo-chemical diffusion that involves a carbon element in a ferrous casting.
Normalising Process
The normalising process is done to ensure a uniform and fine-grained structure so that its mechanical behaviour is predictable without the tendency for underperforming machining qualities. It is done by heating the casting to its hardening temperature then afterwards soaking it before cooling. The cooling is executed in an environment with a protective gas atmosphere that prevents oxidation and decarburisation. The normalising process is usually done because steel alloys have a non-homogenous microstructure with large grains and unwanted structural components – all by-products of casting.
Quenching Process
The quenching process varies for ferrous and non-ferrous casting alloys. For ferrous alloys, the goal is a martensite transformation for a harder metal. While for non-ferrous alloys, the end result should be a softer than normal material. This is done to ensure corrosion-resistant castings.
The nitriding process improves the life expectancy of machine parts, so reducing the consumption of steel and energy and, as a result, the cost of the entire manufacturing process. For this reason, it may be considered both economically and ecologically beneficial. Economical and ecological advantages will at the same time characterise a process in which the formation of the nitrided layer occurs in a short process time, with minimal consumption of gases and electrical energy.
There are several thermo-chemical surface treatment processes that are practiced today. The more they are, the more problems we can encounter from them. Below are some of the other problems that can occur with the nitriding process. Below are ways on how to troubleshoot nitriding process problems.
Case Exfoliation
If it is seen that the nitrided case begins to peel off, this is usually indicative that surface decarburization is present on the surface of the component. The decarburization is as a direct result of insufficient surface stock removal at the pre-nitride machining operations, decarburisation has occurred at the pre-heat-treatment operation. The component should be considered to be scrap, and it is not recommended to be salvaged.
Orange-Peel Effect
The surface of the steel is seen to be randomly “dimpled” over the affected surface. Once again, this problem can be associated with the presence of surface decarburization.
Case Chipping
If the nitrided case is seen to be chipping, particularly at corners, it is usually indicative of what is known as nitride networking. This is an over-enriched area of nitrogen where very hard and brittle nitrogen precipitates form with the nitride-forming elements in the steel. This problem will usually occur when the nitriding potential of the process gas is too high. The remedy is to check the gas flow and dissociation and reduce the flow accordingly.
Case Flaking
This can occur as a direct result of the presence of a surface contaminant on the component. Investigate the pre-cleaning method prior to nitriding and after pre-machining.
Case Crushing
This problem is usually due to a low core hardness that is failing to support the nitrided case. Another possibility is that the formed case is too shallow, and this can be remedied by increasing the case depth. However, the increase of case depth should be cautioned. Check what the application of the work piece is and what sort of load will be applied to the component. For more information about troubleshooting nitriding process problems, consult Alpha Detroit. Our company policy guarantees that we will continue to upgrade current heat treatment technologies to keep pace with changing industry demands. We have a team commitment that our experienced and qualified staff are ready to assist you with your heat treatment requirements.