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PRACTICAL APPLICATION OF INTENSIVE QUENCHING PROCESS FOR STEEL

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Conference Paper · October 2000

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 Proceedings of 20th ASM Heat Treating Society Conference, 9-12 October 2000, St. Louis, Missouri
PRACTICAL APPLICATION OF INTENSIVE QUENCHING PROCESS FOR STEEL PARTS
Michael A. Aronov, Nikolai I. Kobasko and Joseph A. Powell
IQ Technologies, Inc.
Akron, Ohio, USA
INTRODUCTION
During the last three years, Edison Material Technology
Center (EMTEC) of Dayton, Ohio, USA, funded a
demonstration study of intensive quenching for steel parts.
The goal of these efforts is to promote the transfer of the
intensive quench technology from the Ukraine to the
American market. Many steel part manufacturers and heat
treaters provided sample parts for intensive quenching. To
validate the benefits of the intensive quenching process,
known as IntensiQuenchSM, the project team conducted
extensive experimental studies at the Akron Steel Treating
Co. laboratory facility. Summaries of the results of these
demonstration experiments are presented in References 1,
2,3 and 4.
In this paper, we discuss the results of the
IntensiQuenchSM process demonstration tests conducted
during 1999-2000 under the EMTEC project.
1. WHAT IS INTENSIVE QUENCHING PROCESS?
“Intensive quenching” is a very rapid and uniform
cooling of steel parts. The part cooling rate is several times
greater than that of agitating oil or even water. In contrast
to the conventional quenching technique, fast cooling
continues through the steel martensite stage. To realize
such fast cooling within the martensite phase, it is
necessary to eliminate film boiling throughout the
quenching process, and to provide intensive convection
cooling. This is achieved by a high flow rate of quenchant
around the steel part providing high intensity convection
heat transfer.
Extensive research conducted in the Ukraine by Dr.
Nikolai Kobasko has shown that a very high rate of uniform
cooling (usually in plain water) within the martensite range
prevents quench cracking and minimizes part distortion.
This phenomenon was discovered in laboratory
experiments, which were confirmed by computer
simulation (References 5 and 6) and further substantiated
by a large number of field tests using a variety of steel parts
of varying geometry and alloy types (References 7 and 8).
The mechanism of how the IntensiQuenchSM process
minimizes cracking and distortion is described in details in
Reference 3. The intensive quench produces a firm
martensite shell that forms simultaneously over the whole
part surface area and surface compressive stresses
developed due to a fast martensite formation. This strong
martensite case and high compressive stresses prevent the
steel part from cracking and distorting.
The key element of the IntensiQuenchSM is to interrupt
rapid cooling of the steel specimen when compressive
stresses on the surface are at their maximum. The specimen
is then held at the start of the martensite forming
temperature for the remaining quench time. The martensite
phase advance ceases resulting in no further core swelling,
and these compressive stresses are maintained. Stress
relaxation during the isothermal hold (temper) reduces
slightly the final compressive stress.
Numerous laboratory and field experiments have
shown that the final strength of the hardened part is directly
related to the external rate of heat transfer. Higher heat
transfer rate results in higher strength. Hence, water jets or
high-speed uniform flow over the part during cooling will
increase strength. Both higher surface compressive stresses
and increased strength help to eliminate quench cracking
and enhance the durability (service life) of machine parts
and tools (References 9 and 10).
The optimum hardened depth, corresponding to the
maximum surface compressive stress, is a function of the
part dimensions. For best results, the steel selection and its
hardenability should be tailored to the part geometry to
ensure that hardening occurs to the optimum depth. Use of
the IntensiQuenchSM computer model makes reaching the
optimum depth a certainty.
For a steel with controllable hardenability, the intensive
quenching method will provide an optimum combination of
high surface compressive stress; high-strength, wear-
resistance; quenched layer of optimum depth; and relatively
soft but properly strengthened core (Reference 8). This
combination is ideal for applications requiring high strength
and resistance to static, dynamic, or cyclic loads. It was
also demonstrated experimentally that by applying the
IntensiQuenchSM process, the desired properties of the part
could be obtained using less expensive steels (steels
containing two or three times less alloying elements than
conventional alloy grades).
To analyze the thermal and stress/strain profiles within
the part during quenching, a complex computer model was
developed (Reference 6). This model uses a finite element
approach and includes a non-linear transient heat
conduction equation and a set of equations for the theory of
thermoplastic-plastic flow with kinematics strengthening
under the appropriate boundary conditions on the parts’
surface. The intensive quenching computer model has been
validated by numerous laboratory and field experiments.
2. EXPERIMENTAL VALIDATION
Figures 1 and 2 present the hardness distribution in the
cylindrical samples of 51 mm and 73 mm in diameter made
of 1547 steel for as quenched conditions for both intensive
quenching and conventional oil quenching. Figures 3 and
4 present the hardness distribution in the same samples after
tempering. Four micro hardness traverses were made on
both large and small diameter samples. The data were then
averaged and hardness profiles were plotted. As seen from
Figures 1 and 2, the intensively quenched samples have
reached a depth of hardness that is more than 8 times
greater than that of the oil quenched samples relatively to
50 HRC level. Comparison of the hardness profiles for the
tempered samples shows that the depth of hardening of the
intensively quenched samples is more than 7 times greater
than that of the oil quenched samples.
Table 2 presents the microstructure distribution in 5160
steel 3.6 cm torsion bar samples that were quenched in oil
and intensively quenched in our experimental quenching
system. As the results demonstrate, the part microstructure
was considerably improved.

The IntensiQuenchSM process has been validated by 70

hundreds of laboratory and field experiments. The

60 Intensively quenched
examples set forth below are but a small part of the Oil quenched
intensive quench method validation. The IQ Technologies 50
Hardness, HRC

experimental quenching system is described in Reference 2 40

and was designed only for demonstration purposes. While

30
it can rapidly cool a variety of different parts, we did not
adjust the quenching unit to any specific part and therefore 20

we did not provide the optimum cooling rate and uniformity 10

for all the parts tested. Therefore, the results presented are
not the “best possible” in terms of the hardness obtained 0
0 5 10 15 20 25 30 35

and depth of hardened layer, value of the residual Depth, mm

compressive stresses, etc. Nevertheless, these results

definitely show significant improvements of the part
mechanical properties due to the intensive quenching Figure 1 As Quenched Hardness Distribution for
process and no cracking. 73 mm 1547 Steel Cylinder
3.1 Hardenability Improvement. Table 1 shoes the
improvement of core hardness for different steel parts after
intensive quenching. Note that the parts were tempered at 60

the same temperature after intensive quenching and oil

50
quenching. As seen from these data, intensive quenching
considerably improves the core hardness. 40
Hardness, HRC

Table 1 Core Hardness Improvement 30

20 Intensively quenched
Part Core Hardness, HRC Oil quenched

Oil IQ 10

86B30 steel 2525 mm

sprocket tooth 36 50 0
0 5 10 15 20 25 30 35

52100 steel 19 mm wall Depth, mm

thickness bearing ring 56 61

4140 steel 45264 mm
king pin 30 48 Figure 2 Tempered Hardness Distribution for
73 mm 1547 Steel Cylinder
 Table 3 Mechanical Properties Improvement
70

60 Part Property Oil Intensive

50
Quench Quench
Hardness, HRC

40
1340 steel Tensile
M22123mm strength, 1093 1176
30
bolt MPa
20 Intensively quenched
Oil quenched S5 steel Impact
10 3856 mm strength,
6.8 12..2
0
punch Nm
0 5 10 15 20 25
Depth, mm 4140 steel hand Torque to
tool socket failure,
168.6 223.3
Nm
Figure 3 As Quenched Hardness Distribution for
54 mm 1547 Steel Cylinder 4140 steel 45 Ultimate
mm king pin strength,
313.6 414.8
kN
60

32% greater than after quenching in oil (the current

50 practice). The 4140 steel king pin ultimate strength
improved also by 32%. Since the part surface and core
40
hardness did not appreciably change, the significant
Hardness, HRC

30
improvements in the part mechanical properties of the
intensively quenched parts are from the increase of the
20 Intensively quenched fully hardened depth; from the surface compressive
Oil quenched
stresses; and from the finer “packed” martensite
10
structure with higher dislocation density.
0 Figure 5 shows the improvement in toughness
0 5 10 15 20 25

Depth, mm for 4037 steel bolt. Impact strength measurements

were taken in the temperature range from –100oC to
Figure 4 Tempered Hardness Distribution for
38oC. As seen, the impact strength improved by about
54 mm 1547 Steel Cylinder 9% - 37% depending on the temperature range.

Table 2 5160 Steel Torsion Bar Sample

55
Microstructure Improvement
50
Intensively quenched
Distance from Bainite Content, %
45
Surface Oil IQ Oil quenched
Impact Strength, Nxm

40
Surface 3 0
Near surface 5 0 35

½ Radius 12 2 30

Core 29 2.5 25

20
3.2 Mechanical Property Improvements. Table 3
shows the improvement of mechanical properties for 15

different steels. All parts were tempered to the same -120 -100 -80 -60 -40
o
-20 0 20 40
Temperature, C
hardness after quenching in oil and intensive quenching.
As seen from Table 3, the tensile strength for 1340 steel
bolts improved by about 8%. The impact strength for S5
steel punch improved by 1.8 times due to intensive quench. Figure 5 Impact Strength vs. Temperature for
For4140 steel hand tool socket, the average value of the 4037 Steel 19 mm Diameter Bolts
torque-to-failure obtained after intensive quenching was
 3.3 Residual Compressive Stresses. The ability of
intensive quenching to create high surface compressive
stresses was demonstrated first by calculations (Reference 0
0 0.05 0.1 0.15 0.2 0.25 0.3
6). These calculations frankly did not convince some -200
Longitudinal stresses, diameter 54 mm

members of metallurgical community. However, the results Circular stresses, diameter 54 mm

Longitudinal stresses, diameter 73 mm
of experimental studies helped to overcome their -400

Residual Stresses, MPa

Circular stresses, diameter 73 mm
objections. Table 4 below shows the results of the surface -600
compressive stress measurements obtained for different
steel parts. All measurements were made by X-ray -800

diffraction technique. Residual surface compressive -1000

stresses were measured after parts were tempered.
When quenching in oil, residual surface stresses are -1200

usually tensile or neutral (for relatively large steel parts, -1400

small compressive stresses could be observed). As seen Depth, mm

from Table 4, all parts had compressive residual surface

stresses after intensive quenching and tempering. The
benefits from these compressive stresses depend on type of Figure 6 Residual Stresses in 1547 Steel
steel and part size. (We would like to emphasize that the Cylinders at as Quenched Conditions
residual compressive stresses presented in Table 4 are not
the maximum achievable since part cooling rates applied in
our experiments were not always optimized pursuant to the 200

computer model.) 100

0
Table 4 Residual Surface Compressive Stresses 0 0.05 0.1 0.15 0.2 0.25 0.3

Residual Stresses, MPa

-100

Longitudinal stresses, IQ
Steel Part Compressive -200 Circular stresses, IQ
Longitudinal stresses, oil
Stresses, MPa -300 Circular stresses, oil

52100 steel 216 mm ring -136 -400

4140 steel 45264 mm king pin -563 -500

5160 steel 36 mm torsion bar -620 -600

sample
S5 steel 3856 mm punch
-700
-750 Depth, mm

52100 steel 75 mm roller -357

1547 steel 73 mm cylinder -626
1547 steel 51 mm cylinder -515
Figure 7 Residual Stresses at Tempered
Conditions for 54 mm Cylinder
Figures 6,7 and 8 present residual stress data obtained for
the above 1547 cylindrical samples. Measurements
were taken both longitudinal and circular to the
samples. Figure 6 shows the results for intensively 100

quenched samples for as quenched conditions. All of 0

0 0.05 0.1 0.15 0.2 0.25 0.3
the residual stresses for these samples were -100
Longitudinal stresses, IQ
compressive. Figure 7 and 8 show residual stress Circular stresses, IQ
Residual Stresses, MPa

Longitudinal stresses, oil

profiles for the small and large diameter sample -200 Circular stresses, oil

respectively for as tempered conditions after -300

quenching in oil and intensive quenching. As seen

-400
from these figures, intensively quenched and
tempered samples for every case have much greater -500

compressive residual stresses. -600

Compressive stresses on the part surface

-700
during quenching prevent part cracking and minimize Depth, mm
distortion. We intensively quenched several 5160
torsion bar samples that had small seams on their
surface. In the field conditions, such seams always Figure 8 Residual Stresses at Tempered
develop into cracks during quenching in oil due to Conditions for 73 mm Cylinder
tensile stresses on the part surface. Figure 9 shows a
 transverse section of the seam approximately through
its center and both ends for one of the intensively
quenched and tempered sample. As it seen, there was
no evidence of quench cracks.
3.4 Thermal Fatigue Resistance Improvement. It is
well-known fact that the higher the cooling rate during
quenching the high performance die steels the greater the
part thermal fatigue resistance (Reference 16). To prove
that the intensive quenching technique provides better
thermal fatigue resistance and toughness, we intensively
quenched a standard 50mm50mm178mm test block
made of H-13 steel. This steel is widely used for die
casting tools in the US. A similar test block was made from
the same steel heat lot, and quenched in oil. (The usual
hardening practice for H-13 steel is to air quench or
a) pressure quench in a vacuum furnace.) The thermal fatigue
properties for both samples were evaluated by means of the
thermal fatigue test method developed by Case Western
Reserve University (Reference 16). This test determines
the average maximum crack length and total crack area on
the four corners after a certain number of cycles of heating
(by immersion into a bath of molten aluminum at 732 oC)
and cooling. The hardened test block is internally water-
cooled. Therefore, there is a high thermal gradient
throughout the block thickness especially at the test block
corner areas. This test simulates the cyclic heating and
cooling found in aluminum die casting dies made of H-13
material. (It should be noted there were no cracks present
in any of the hardened H-13 blocks at the inception of the
cyclic testing.)
Figure 10 and 11 show the effect of thermal cycles on
the average maximum crack length and on total crack area.
b) As seen, there is practically no difference in these two
parameters for both test blocks for 5,000 and 10,000
thermal cycles. However, there is a significant difference
between these parameters for 15,000 thermal cycles. The
average maximum crack length for the intensively
quenched test block is about 27% less than for the oiled
quenched test block. The total crack area for the
intensively quenched test block is about 42% less than for
the oiled quenched test block. Since this test correlates
with the actual service life of H-13 dies (albeit
conventionally air hardened), the test indicates even greater
service life for intensively quenched dies made of H-13
steel.
3.5 Service Life Cycle Improvements. Both the
improvements in part mechanical properties and the
presence of residual compressive stresses on the part
surface due to the IntensiQuenchSM process result in the
significant increase of the product service life cycle. Data
c) regarding the service life improvement for different steel
products are presented in Reference 2. In addition to these
parts, we intensively quenched six coil springs made of
Figure 9 A transverse section through one end
9259 steel. Six identical springs made from the same steel
(a), the center (b), and another end of the seam
(c)
  Minimized part distortion (less grinding and post-
18
machining operations).
16  Use of less costly, environmentally friendly
Maximum Crack Length,x100 micron

14
quenchant (usually plain water), instead of
Quenching in Oil hazardous oil, resulting in significant reduction of
12
Intensive Quenching the heat treatment cost and related pollution.
10  Additional cost savings from less environmental
8 waste, waste stream management, cleaner plant,
cleaner parts, lower insurance, better work
6
environment., etc.
4
 Greater productivity of the quenching equipment
2 since IntensiQuenchSM processes provide much
0
faster cooling rate.
5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
Number of Thermal Cycles
In addition to the benefits to commercial heat treaters,
Figure 10 Maximum Crack Size vs. Number of part designers and captive heat treaters will benefit from the
Thermal Cycles following IntensiQuenchSM process benefits:

 Greater core hardness and depth of hardened layer.

180
 Improved part mechanical properties.
 Presence of significant residual surface
160
compressive stresses.

Total Crack Area, x106 micron2

140
Quenching in Oil Achieves the same or better metallurgical
120 Intensive
Quenching
properties while using lower alloy steel resulting
100 in significant cost savings in material.
80
 Smaller, lighter IntensiQuenchSM parts can do the
60
work of heavier sectioned oil quenched parts.
 Provides optimum combination of high surface
40
compressive stresses and a high-strength, wear-
20
resistant, fully quenched layer of optimum depth –
0
5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
all resulting in longer part service life at lower
Number of Thermal Cycles cost.

ACKNOWLEDGEMENT
Figure 11 Total Crack Surface Area vs. Number of
Thermal Cycles
The authors wish to acknowledge the Edison Material
Technology Center of Dayton, Ohio, USA for funding of
this research, the heat-treating companies for providing the
heat were quenched in oil in accordance with the current
heat-treating technology. Both groups of spring products steel parts and for conducting the metallurgical analysis,
were then subjected to a standard fatigue test. Weilbull and other project team members (Surface Combustion,
statistical analysis results showed that the B10 life of the Tenaxol, Heat Treating Network, Deformation Control
intensively quenched springs are about80% higher than of Technology, Case Western Reserve University, and Union
those that were oil quenched. It means that 90% of Carbide) for continuous project support. For more
intensively quenched spring products will exceed the information on the IntensiQuenchSM processes and the
current spring service life by 80%. computer modeling, see www. IntensiveQuench.com.

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