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Kulliyyah of Engineering
INTERNATIONAL ISLAMIC UNIVERSITY MALAYSIA

DEPARTMENT OF MECHANICAL ENGINEERING

MEC 1105 WORKSHOP TECHNOLOGY

. REPORT #7 .

HEAT TREATMENT / GRINDING

GROUP NAME SECTION DATE RCVD DATE* LECTURER ASST. LECTURER DEMONSTRATORS

ABU AYYUB SARAHAN BIN MAT DAUD th 05 SEPTEMBER 2003

SECTION NO. MATRIC NO

2 0234943 16

NO. OF PAGE (incl. cover) ASSOC.PROF.DR. MOHAFIZUL HAQUE SIS. TUTI YASMIN BR.

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OBJECTIVES
1. To know which treatment is the best to produce steel with certain criteria. 2. To know how to control the quality 3. To know how the proper method to treat steel HEAT TREATMENT OF METALS

PROCEDURE
Four square cross section bars (6 mm side) are taken. The length of each bar is 250 mm. The four bars are heated to 9000C and the first bar is quench in water, and the second in oil. The third bar is leaved to cool in air and the forth one to cool in a furnace. The results are recorded in the Table 1-1. METALS FERROUS Pig iron, Wrought iron , Cast iron (greywhite) Carbon steels (4 groups): Dead mild Mild Medium carbon High carbon ALLOYS NON-FERROUS PURE

Brass Bronze Spelter

Aluminium Tin Lead

RESULTS Quenching Medium Water Oil Air Furnace No of bends till fracture 30 66 78 115 File test or scratch resistant test Soft Soft Hard Hard Hardness no. Name of process Quenching in water Quenching in oil Normalizing Annealing MEC 1105 2

Bar no. 1 2 3 4

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Table 1-1 PRINCIPLES OF HEAT TREATMENT Heat treatment is a major way of changing the strength, hardness, ductility, and other properties of metals; it is effective only with certain alloys because it depend upon one element being soluble in another in the solid-state ion different amounts under different circumstances. Hardening (or strengthing) is done by heating an alloy to a high enough temperature, depending on the material, and cooling it rapidly. A solid solution of the alloying elements is formed at the high temperature. This become supersaturated upon cooling, and desired hardness is obtained by controlling the decomposition of the constituents. Under proper conditions, the solute id dispersed in fine particles in the crystal lattice and serve to block dislocation movements when stresses are applied. The added resistance to stresses makes the metal act stronger and harder. The amount of hardening that takes places in an alloy depends upon the size, shape, and distribution of the particles and the amount of coherence between the particles and the matrix. The size, shape, and distribution of the particles result largely from the dispersion of the solute in the Material, which depends in turn upon the temperature and time of heating. There is an optimum particles size in each case that gives best results. Large particles are imposing obstacles but are far apart, and dislocations pass between them. Particles too small do not greatly hinder the movement of dislocations. The degree of coherence between particles and primary phase has the most influence on hardening. Hardening is enhanced if the boundary between particles and matrix is coherent. This is called coherency hardening and is effective because each p[article distorts the space lattice of the phase around itself and thereby extends its influence in blocking movements of dislocations. Zones of influence may overlap. Aggregate hardening occurs with particles that have incoherent boundaries with the primary phase. Examples are plates (such as in pearlite in steel|) or globular particles. Dislocations are impeded only partially by such particles and pass readily between them. Alloys hardened by heat treatment can be divided into two major classes. One kind is nonallotropic and is hardened by age or precipitation treatments. The other is allotropic (which means the crystal structure is different at higher than at lower temperature) and can be hardened by suppressing the decomposition of the structure on cooling. The first class consist of steels and irons. Some metals, such as certain stainless steels, are treated by a combination of the two methods. The reverse of hardening, which is softening of metals, is done by heating alone or by heating and slow cooling. The effects are to gather together and coarsen the dispersed particles, control grain size, and improve the ductility and impact resistance. Common processes of this sort are annealing, normalizing, and tempering. Other purposes of heat treating are to relieve stresses, modify electrical and magnetic properties, increase heat and corrosion resistance, and change the chemical composition of metals (as by carburizing steel).The processes of hardening and softening metals will be explained in detail below, and the techniques and equipment for the processes will be described.

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HEAT TREATMENTS OF STEEL

These are five forms of heat treatment for the standard steels. Transformation processes for steel: Process Annealing Quenching Interrupted quenching Austempering Purpose To soften To harden To harden without cracking To harden without forming brittle martensite To toughen (usually with minimal softening) Procedure Slow cool from stable range Quench to miss I-T curves Quench, followed by slow cool from M0 to M1 Quench, followed by isothermal transformation above the M0 Reheating of martensite Phase(s) + carbide Martensite Martensite + carbide

Tempering

+ carbide

*NOTE: Steels containing martensite must be toughened by the tempering process.

QUENCHING Heat may be removed from hot metal by immersion in brine, water, oil, or molten salts or lead, by exposure to air or gases, or by contact with solid metallic masses. Water and oil are the most common media for full quenching. Relative quenching rates of the common methods are indicated by fig. 5-5.

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Large pieces are cooled more slowly with more different between inside and outside oil cooling rates than small pieces. The severity of water quenching cracks some parts; oil quenching is less harmful, and air quenching is even better. Oil and air quenching require alloys of higher hardenebility to make steel as hard as by water quenching. Synthetic oil-free water-base fluids have been developed inn recent years that give quenching results between water and oil. Quenching sets up stresses that wrap workpieces, and precautions are necessary to avoid distortion. Slender shafts, thin walls, and thin and thick adjacent sections are particularly vulnerable. A long slender shaft is ordinarily suspended from one end when plunged into a quenching tank. Production parts, such as gears with thin webs, may be die-quenched. This means that the piece is clamped firmly in a die in a press while lowered into the quenching medium. The die is made to contact to regulate the cooling rate and thus the quenching medium. The die is made to contact and thus chill selected areas and admit coolant at different rates to various sections to regulate the cooling rate and thus the warpage through the part.

Hot workpieces must be moved quickly and safely from the heating device to the quenching medium. This may be done by hand tongs, one piece at a time, for job work. For repetitive production, work may be transported by conveyors, and large pieces by crane or cars. Small pieces are normally handled in wire baskets or on racks. The coolant is ordinarily agitated or swirled vigorously to achieve uniform cooling and may be circulated through cooling coils.

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TEMPERING During tempering, martensite undergoes a transformation process from that of carbon atoms supersaturated in iron to a structure termed tempered martensite which consists of highly dispersed submicroscopic carbide particles in a ferrite matrix. The extent of increase in ductility hence toughness and the corresponding reduction in hardness and strength is a function of tempering temperature and time. ANNEALING If a steel bar is cooled slowly in a furnace from a temperature above its upper critical temperature to a temperature below the lower critical temperature, the structure of the steel will become ferrite and cementite again. This steel consists of a somewhat coarser grain structure that is low in strength, high in ductile and soft. This process of heat treatment is called 'Annealing'. NORMALIZING However, instead of cooling in furnace as described above, the steel is taken out from the furnace and cooled in still air, it is termed 'Normalizing'. A normalized steel bar possesses higher strength and toughness than its annealed counterpart.

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HEAT-TREATING FURNACES Usually, a heat-treating furnace consist of a box-like structure with a steel shell and an access door, a refractory lining, and temperature controls and indicators. Some of these features are lacking or are different in some cases. Furnaces may be classified by the ways the work is handled or by means of heating. For work handling, the basic types are batch furnaces and continues furnaces. As for fuels, oil and gas predominated at one time, but electricity. With combustion heating the work must be contained in a separate chamber if it is to be kept from the gases.

Heat-treating furnaces use large quantities of energy. Improvements in furnace design in recent years have been directed toward more efficient processing, improved insulation, more effective combustion control, and recovery of heat from fuel gases that would otherwise be wasted. An example of heat recycling has two facets. Usable changers to furnish about 30% of the needs of the tempering furnaces. Also, radiant heat is collected by steel walls enclosing the furnace and delivered by circulating air to heat the plant in winter. Each type of furnace has several varieties. Electric furnace looks much like other kinds. A common type has resistance heating element on the refractory wall of the chamber. The heating unit is segregated in some furnaces, and the atmosphere is blown over it into the work chamber. Electric furnace are more costly to buy and operate than gas furnaces but have the advantages of cleanliness, convenience, controllability, and few environmental restrictions. Heat is converted better and distributed more thoroughly by circulating the atmosphere in any furnace. The more rapid the circulation, the more the heat is H.TREATMENT MEC 1105 8

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transferred. Pressure in the furnace is commonly kept above that outside to prevent air from entering when the door is opened. Some furnace have a flame curtain at the door to burn any oxygen that may enter.

TESTING OF ENGINEERING MATERIALS BEND TESTS (until fracture) These multipurpose test enable determination of maximum fiber stresses, known as flexure strength, and modulus of elasticity in materials which are brittle or very hard, and which do not lend themselves to tensile testing. Plastics, glass, cast iron, and concrete are commonly tested as flexed beams. Bending tests are also useful for ductility determinations in sheet and bar stock, and for testing the soundness of welds. These tests often depend upon achieving a certain angle of bend, and tend to be qualitative rather than quantitative.

FILE TEST AND SCRATCH RESISTANT TEST This test is to know how soft and how hard particular bar after quenching in water, quenching in oil, normalizing and after annealing. We use file and also scriber upon these bar, and then make approximate comparison between them.

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HARDNESS TEST Although hardness testing does not directly give as much detailed information as does tensile testing, it is so fast and convenient that is much more widely used. Hardness is usually is defined as resistance of a material to penetration. In the most generally accepted tests, an indenter is pressed into the surface of material by a slowly applied known load, and the extent of the resulting impression is measured mechanically or optically. A large impression for a given load and indenter indicates a soft material, and the opposite is true for a small impression. The examples of hardness tester are like Brinell, Rockwell, Vickers and Tukon tester.

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IRON ORE Coke Limestone

BLAST FURNACE Air PIG IRON Slag

Puddling furnace

Cupola

Steel-making furnace

WROUGHT IRON (99.95%) ferrite Slowly cooled

CAST IRON(35% carbon) MILD AND MEDIUM CARBON STEEL (0.1% - 0.7%) Crucible Or electric furnace WHITE CAST IRON Chilled carbon

Forged

GREY CAST IRON Cast Rolled Cast Forged

TOOL STEELS ALLOY STEELS SPECIAL STEELS

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DISCUSSION:
From the result table, we can say that quenching products is the hardest followed by normalizing and annealing. If we look for the no of bends, the quenching in water is the lowest which means that it is brittle even though it is the hardest. In the other hand, it is very hard material and high brittle. Same case for the annealing, which is very soft material but it is so difficult to break because it is low in brittleness. We did not find any difficulties in the heat treatment process. It is just a simple process to prove the theory given to us. We also learned about some phase descriptions about material. Heat treatment is commonly used to enhance the mechanical properties of materials in the solid state. Although the process is usually thermal and modifies only the structure, there are thermo mechanical treatments that may modify both the structure and the surface chemistry. All three of these processes for the enhancement of properties can be classified as heat-treating. The properties and behavior of metals and alloys during manufacturing and their performance during their service life depend on their composition, structure, and processing history and on the heat treatment to which have been subjected.

CONCLUSION
All the praise and thanks be to Allah, the Lord of the Alamin. The Most Gracoius , The Most Merciful. The Only Owner (and the Only Rulling Judge) of the Day of Recompense. You (Alone) we worship, and You (Alone) we ask for help (for each and everything). Guide us to the Straight Way. The way of those on whom You have bestowed Your Grace, not (the way) of those who earned Your Anger, nor of those who went astray. Al-Fatihah : 2-7 Alhamdulllah, Thank to all demonstrators and technician,i.e Bro Mohd Razak which give the instruction, advice, and also help us to complete this heat treatment. Without them, who are us. The objectives of this project were achieved. I also was get understanding, the techniques used in the heat treatment process. Therefore I can conclude that this heat treatment process was successfully being performed.

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BIBLIOGRAPHY 1. Manufacturing processes and material for engineers, 3rd Edition, Lawrence E. Doyle/Carl A. Keyser 2. MEC 1105 Workshop Technology Course Manual, Kulliyyah of Engineering IIUM

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