Search Results (226)

The reaction system of nanocrystalline iron carburization and carbon deposit formation as an example of a parallel chemical reaction was studied. The main measurement procedure was the Chemical Potential Programmed Reaction method, according to which the course of a chemical reaction in this particular case was controlled by the methane–hydrogen mixtures of precisely selected variable composition. The measurements were performed in a tubular differential flow reactor with thermogravimetric measurement and analysis of the gas phase composition at a temperature of 650 °C under atmospheric pressure. In the current research, by measuring the mass of the solid sample at changing carburizing potential and after balancing the reacting system, the reaction rates of parallel iron carburization and carbon deposit formation were precisely determined using the model of the reaction of a nanocrystalline substance with the gas phase in states close to chemical equilibrium. The reaction rate constants for those reactions were estimated as well based on model equations. Full article

The types of carbides and their effects on the fatigue failure mechanism in carburized CSS-42L steel were systematically studied in the present investigation. The results indicate that the main carbides in carburized CSS-42L steel are Cr-rich M₂₃C₆ carbides and Mo-rich M₆C carbides. M₂₃C₆ carbides precipitate along grain boundaries and interconnect, forming network carbides. Rolling contact fatigue (RCF) tests reveal that fatigue cracks in CSS-42L steel can initiate both at the contact surface and within the subsurface. During RCF, the spalling of large-sized, networked M₂₃C₆ carbides creates micro-spalling pits on the contact surface, inducing local stress concentration that triggers the initiation of surface cracks. The surface cracks initially propagate perpendicularly to the contact surface and then shift to propagate parallelly to the contact surface, ultimately causing large-scale spalling of the surface layer. Subsurface cracks initiate at a position approximately 100 μm below the contact surface, with their propagation direction roughly parallel to the contact surface. Meanwhile, the development of subsurface cracks can connect with surface cracks, leading to the expansion of surface micro-pitting. Network carbides facilitate the propagation of secondary cracks, leading to the formation of grid-distributed crack networks. Full article

In this study, a duplex treatment combining carburizing, nitriding, and subsequent induction hardening (IH) was applied to JIS-SCM420 low-alloy steel. A comprehensive evaluation was conducted to assess surface characteristics, including microstructure, hardness, residual stress, and fatigue performance. The IH process successfully produced a high-nitrogen-content ε-Fe_2-3(N,C) compound layer (2–3 μm thick) and fine acicular martensite at the surface, significantly enhancing surface hardness (950 HV0.03) and inducing beneficial compressive residual stress (−477 MPa). The IH-treated material exhibited a plane-bending fatigue strength of approximately 775 MPa, notably higher than that of conventionally carbonitrided specimens (700 MPa). This improvement was primarily attributed to the formation of the hard ε-Fe_2-3(N,C) compound layer and refined martensitic structure resulting from induction hardening. Additionally, IH activated residual interstitial elements, promoting the precipitation of stable surface nitrides. These microstructural changes effectively suppressed fatigue crack initiation and propagation, thereby extending fatigue life under cyclic loading conditions. Full article

Taking a typical carburized alloy steel for heavy-duty gears as the research object, this work regulates carburizing–quenching and tempering processes to conduct a layer-by-layer analysis of gradient-distributed microstructures and mechanical properties in the carburized layer. The effects of tempering temperature on martensite evolution, mechanical properties, and wear resistance were specifically investigated. Results demonstrate that carburizing–quenching followed by cryogenic treatment generates high-carbon martensite at the surface, progressively transitioning to lath martensite towards the core. Low-temperature tempering promotes fine carbide precipitation, while elevated temperatures cause carbide coarsening. Specimens tempered at 175 °C achieve surface hardness of 800 HV and near-surface compressive yield strength of 2940 MPa. These samples exhibit 13% lower wear mass loss compared to 240 °C tempered counterparts, demonstrating superior wear resistance characterized by relatively flat wear surfaces, uniform contact stress distribution, and reduced cross-sectional plastic deformation zones. Key strengthening mechanisms at lower tempering temperatures involve solution strengthening, dislocation strengthening, and partial precipitation strengthening from carbides. Coherent carbides formed under these conditions impede fatigue dislocation motion via shearing mechanisms to suppress plastic deformation and fatigue crack initiation under contact fatigue stress, thereby enhancing wear performance. Full article

M50 steel is widely used in the manufacturing of high-end bearing components for aero-engine shafts, where an excellent surface performance is required to withstand harsh service conditions. In this study, plasma carburizing at different temperatures varying from 410 to 570 °C was performed on pre-nitrided M50 steel to investigate the influence of the temperature on the structural evolution and mechanical behavior of the self-lubricating functional layer. The microstructure, phase composition, hardness, and wear resistance of the carburized samples were fully characterized using scanning electron microscopy (SEM), Transmission electron microscopy (TEM), Raman spectroscopy, a nano-indenter, and other analytical techniques. The carbon-rich film with nano-domains contains a significant amount of sp³ bonds at low carburizing temperatures, exhibiting a Diamond-like carbon (DLC) film character. With the rise in the carburizing temperature, the initially distinct interface between the carbon-rich film and the compound layer gradually disappears as the nitrides are progressively replaced by carbides; the sp³ bond of the film is decreased, which reduces the hardness and wear resistance. Samples carburized at 490 °C with a homogeneous surface layer consisting of DLC film and a compound layer showed a low friction coefficient (about 0.22) and a 60% reduction in the wear rate compared with the nitrided specimen. The formation of a surface carbon-enriched layer also plays a role in avoiding oxidative wear. Full article

This study investigates the wear performance of 20CrMnTi steel, a commonly used material for spiral bevel gears, after heat treatment, with a focus on the microstructural evolution and wear behavior in both the surface and gradient direction of the carburized layer. The results show that the microstructure composition in the gradient direction of the carburized layer gradually transitions from martensite and residual austenite to a martensite–bainite mixed structure, and eventually transforms to fully bainitic in the matrix. With the extension of carburizing time, both the effective carburized layer depth and the hardened layer depth significantly increase. Wear track morphology analysis reveals that the wear track depth gradually becomes shallower and narrower, and the wear rate increases significantly with increasing load. However, the friction coefficient shows little sensitivity to changes in carburizing time and load. Further investigations show that as the carburized layer depth increases, the carbon concentration and hardness of the samples gradually decrease, resulting in an increase in the average wear rate and a progressive worsening of wear severity. After the wear tests, different depths of plowing grooves, spalling, and fish-scale-like features were observed in the wear regions. Additionally, with the increase in load and carburized layer depth, both the width and depth of the wear tracks significantly increased. The research results provide a theoretical basis for optimizing the surface carburizing process of 20CrMnTi steel and improving its wear resistance. Full article

This article provides a comprehensive overview of recent studies concerning laser heat treatment (LHT) of structural and tool steels, with particular attention to the 21NiCrMo2 steel used for carburized gear wheels. Analysis includes the influence of critical laser processing conditions—including power output, motion speed, spot size, and focusing distance—on surface microhardness, hardening depth, and microstructure development. The findings indicate that the energy density is the dominant factor that affects the outcomes of LHT. Optimal results, in the form of a high surface microhardness and a sufficient depth of hardening, were achieved within the energy density range of 80–130 J/mm², allowing for martensitic transformation while avoiding defects such as melting or cracking. At densities below 50 J/mm², incomplete hardening occurred with minimal microhardness improvement. On the contrary, densities exceeding 150–180 J/mm² caused surface overheating and degradation. For carburized 21NiCrMo2 steel, the most effective parameters included 450–1050 W laser power, 1.7–2.5 mm/s scanning speed, and 2.0–2.3 mm beam diameter. The review confirms that process control through energy-based parameters allows for reliable prediction and optimization of LHT for industrial applications, particularly in components exposed to cyclic loads. Full article

Cemented carbides are among the primary materials for tools and wear parts. Today, energy prices and carbon emissions have become key concerns worldwide. Cemented carbides consist of tungsten carbide combined with a binder, typically cobalt, nickel, or more recently, various high-entropy alloys. Producing tungsten carbide involves reducing tungsten oxide, followed by carburization of tungsten at 1400 °C under a hydrogen atmosphere. The tungsten carbide produced is then mixed with the binder, milled to achieve the desired particle size, and granulated to ensure proper flow for pressing and shaping. This study aims to bypass the tungsten carburizing step by mixing tungsten, carbon, and cobalt; shaping the mixture; and then applying reactive sintering, which will convert tungsten into carbide and consolidate the parts. The mixtures were prepared by planetary ball milling for 10 h under different conditions. Tests demonstrated that tungsten carburization successfully occurs during sintering at 1450 °C for 1 h. The samples exhibit a typical cemented carbide microstructure, characterized by prismatic grains with an average size of 0.32 μm. Densification reached 92%, hardness is approximately 1800 HV30, and toughness is 10.9 ± 1.15 MPa·m^1/2. Full article

The parking ratchet is an important safety component of the car. Cracking occurs in the grinding surface during quenching and grinding processes after carburizing; thus, the goal of this research is to clarify the key cracking cause of the parking ratchet. Optical microscopy (OM), scan electronic microscope (SEM), energy dispersive spectroscopy (EDS), X-ray stress analyzer, etc., were used to systematically test and analyze the cracking cause. The results show that the microstructure of the parking ratchet with cracks after carburizing and quenching is normal, the residual stress of the surface is normal, with no oxide and decarburized layer within the crack areas, without burning during grinding, while it was found that oxide inclusions existed on the area of the crack, which is different from the normal specimens. Hence, a conclusion can be drawn that the cracking cause on the surface of the parking ratchet results from the oxide inclusions in the raw material. This study provides a feasible direction for the failure analysis and control of the cracks on parking ratchets during the manufacturing process. Full article

Tantalum carbide (TaC) is a highly refractory material with a melting point of 4153 K, making it attractive for applications requiring excellent hardness and thermal stability. In this study, we investigated the carburization behavior of high-purity tantalum metal powder synthesized by magnesium thermal reduction of Ta₂O₅, using activated carbon and graphite as carbon sources under high vacuum. Carburization was conducted at 1100–1400 °C for durations of 5–20 h. Carbon contents were analyzed via combustion analysis, and activation energies were calculated based on Arrhenius plots. The results showed that the activated carbon significantly enhanced carbon uptake compared to graphite due to its higher porosity and surface reactivity. The formation and transformation of carbide phases were confirmed via X-ray diffraction, revealing a progression from Ta to Ta₂C and eventually to single-phase TaC with increasing carbon content. Scanning electron microscopy (SEM) analysis showed that fine particles formed on the surface as carbon content increased, indicating local nucleation of TaC. Although the theoretical carbon content of stoichiometric TaC (6.22 wt.%) was not fully achieved, the near-theoretical lattice parameter (4.4547 Å) was approached. These findings suggest that activated carbon can serve as an effective carburizing agent for the synthesis of TaC under vacuum conditions. Full article

The test method for internal stress of titanium-based nitride was optimized via penetration depth and surface roughness. Through the test method, the variations in the mechanical properties due to the ratio of the carbon gradient layer were investigated in terms of internal stress. TiN coatings were deposited on SUS 304 using RF/DC magnetron sputtering, and the penetration depth was adjusted by varying the X-ray power of HR-XRD for test specimens with the same coating thickness of 1 μm. The gradient of diagram for internal stress remained constant regardless of the penetration depth, and this was attributed to the analysis of internal stress focusing on the preferred growth orientation of the coating and excluding the influence of the substrate. In addition, we tested different surface roughness values (0.01 Sa, 0.02 Sa, and 0.03 Sa) to observe the effect on internal stress measurement. The results showed negligible difference in internal stress, confirming that this measurement method is valid for coatings with a surface roughness of 0.03 Sa or less. The test method was applied to analyze the carbon-doped TiZrN coating. TiZrN coatings were deposited on SUS 304, and coating thicknesses of 0.5 μm, 1 μm, and 2 μm were used to control the ratio of the carbon gradient layer. After applying the carbon paste for carbon doping, the TiZrN coating was irradiated with a pulsed laser. The compressive internal stress increased from −1263 MPa to −1687 MPa at a coating thickness of 0.5 μm, where the ratio of the carbon gradient layer was the highest. It was confirmed that the increase in internal stress with the ratio of the carbon gradient layer improved the mechanical properties of the carbon-doped TiZrN coating by laser carburization. Full article

This study investigates the application of Bayesian statistical methods to analyze and predict the dimensional changes in torsion bars made from 20CrMnTi alloy steel during carburizing heat treatment. The process parameters, including a treatment temperature of 920 °C followed by oil quenching, were selected to optimize surface hardness while maintaining core toughness. The dimensional changes were measured pre- and post-treatment using precise caliper measurements. Bayesian statistics, particularly conjugate normal distributions, were utilized to model the dimensional variations, providing both posterior and predictive distributions. These models revealed a marked concentration of the posterior distributions, indicating enhanced accuracy in predicting dimensional changes. The findings offer valuable insights for improving the control of carburizing-induced deformations, thereby ensuring the dimensional integrity and performance reliability of torsion bars used in high-stress applications such as pneumatic clutch systems in mining ball mills. This study underscores the potential of Bayesian approaches in advancing precision engineering and contributes to the broader field of statistical modeling in manufacturing processes. Full article

This work is a continuation of our previous research. We successfully produce low-carbon gear steel containing trace tellurium (Te) through industrial production line (EAF-LF-VD-CC), and we investigate the effects of a trace Te addition on the precipitation of MnS inclusions in sulfur-containing gear steel billets, the machinability of rods, and the high-temperature vacuum carburizing performance of rods. This study demonstrates that the addition of trace Te in steel can be achieved in industrial production without causing disruptions in the steelmaking process. The Te addition effectively induces spheroidization and refinement of MnS inclusions in industrial cast billets, showing good consistency with laboratory Te alloying experimental results. Furthermore, the Te addition reduces the deformation rate of MnS inclusions during industrial rolling processes. Benefiting from the spheroidization of MnS inclusions, the chip-breaking performance during the machining of Te-containing rods is significantly optimized, along with substantial improvement in machined surface roughness. The industrial rods exhibit excellent grain stability during 960 °C high-temperature vacuum carburizing, with carburizing rates significantly enhanced compared to conventional gear steels. This work comprehensively demonstrates the multifaceted effects of Te treatment on gear steel properties, particularly providing valuable references for developing high-temperature carburizing gear steels. Full article

To optimize heat treatment of gears for high-end equipment and enhance their fatigue resistance, this paper studied the effects of Al, Mn and Cr content on surface microstructure, i.e., martensite, retained austenite, grain size, hardened layer depth and residual stress under different carburizing temperatures and low tempering of 20MnCr5 steel FZG gear. With numerical simulation combined with experimental verification, this paper establishes a simulation model for the carburizing process of 20MnCr5 steel FZG gear, analyzing the microstructure and retained austenite volume of the gear surface, after carburizing and quenching, by a scanning electronic microscope (SEM) and X-ray diffraction (XRD). In addition, the paper reveals the influence of the optimized heat treatment on the residual stress of the gear regulated with Al, Mn and Cr content in the meshing wear range of 200~280 µm. This study provides a guiding model theory and experimental verification for regulating proportions of alloying elements and optimizing the heat treatment process of low-carbon-alloy steel. Full article

Quench–polish–quench (QPQ) nitro-carburizing of AISI 4140 steel in a salt bath was performed in this study. Nitro-carburizing in a salt bath enhanced the formation of Fe-nitride on the outer surface layer. Moreover, the oxidizing treatment formed a thin oxide layer decorated on the outermost part of the QPQ-treated sample. The dense compound layer formed after nitro-carburizing in a salt bath consisted of refined granular Fe₃N and transformed to Fe₂N after post-oxidation treatment. Micro-shot peening (MSP) was adopted before QPQ treatment to increase the treated steel’s fatigue performance. The results indicated that MSP slightly increased the thickness of the compound layer and harden depth, but it had little effect on improving the fatigue strength/life of the QPQ-treated sample (SP-QPQ) compared to the non-peened one (NP-QPQ). A deep compressive residual stress (CRS) field (about 200 μm) and a hard nitrided layer showed a noticeable improvement in the fatigue performance of the QPQ-treated ones relative to the 4140 substrates tempered at 570 °C. The ease of slipping or deforming on the substrate surface was responsible for its poor resistance to fatigue failure. The cracking and spalling of the brittle surface layer were the causes for the fatigue crack initiation and growth of all of the QPQ-treated samples fatigue-loaded at/above 875 MPa. It was noticed that fatigue crack initiation at the subsurface inclusions was more likely to occur in the SP-QPQ sample fatigue-loading at 850 MPa or slightly above the fatigue limit. Full article