CRYOGENIC PROCESSES AND THEIR APPLICATIONS

ABSTRACT This paper deals with the affects of cryogenic processes on metals and its applications in industries. As it is known the most important problems faced by the industries are the wear and tear of the machine parts. This wear of the machine parts not only increases the cost of production but also the time wasted for the replacement process. In this paper I would like to explore the enhancement in strength and durability that would be gained by cryogenically treating those machine parts. Cryogenics is the ultra low temperature processing of materials to enhance their desired metallurgical and structural properties. Cryogenic treatment process is the treating of a wide variety of materials, such as ferrous and non-ferrous metals, metallic alloys, carbides, plastics, and ceramics. These ultra-cold temperatures, below -310F, will greatly increase the strength and wear life of all types of vehicle components, castings and cutting tools. In addition, other benefits include reduced maintenance, repairs and replacement of tools and components, reduced vibrations, rapid and more uniform heat dissipation, and improved conductivity. Here in this context I shall purpose to explain about the purpose of cryogenic treatment and what happens in the metal structure along with its advantages and some of its applications INTRODUCTION

Cryogenics have been derived from the Greek word KRUOS (frost) and GENICS meaning to produce very low temperatures. At the end of eighteenth century liquefaction of some gasses was achieved and that opened the door to deep cryogenic temperatures. Some experiments with steel started at the beginning of 20th century. The results were quite discouraging because, in most of cases, the material shattered or broke due to the thermal shock when the steel was directly put into liquefied gas.

After the Second World War these tests were abandoned until the seventies when aerospace industry took up this technology again and the cryogenic treatment started to be developed as a new industrial process. Today cryogenic treatment would be regarded as one of the most important processes in the field of industries, and it is the ultra modern type of processing to make the metals more resistant to wear and more durable. The process can be used to improve the properties of a wide range of materials. Steel (cold working, hot working, HSS, inox), aluminium, copper, carbide, ceramics and even some polymers can be improved with the treatment. The results which are obtained depend basically on the treated material and on the application. The most remarkable ones are wear resistance increase and fatigue life improvement. The use of this treatment is extremely environmentally friendly, as absolutely no waste is produced during the process. Some companies have taken steps to move the industry forward. One step in that direction is involvement in the Cryogenic Society of America, Inc. (CSA) (Oak Park, IL). Compared to other cryogenic technologies, however, cryogenic processing is considered low tech. Another step intended to move the industry forward was the recent formation of an ASM International (formerly American Society for Metals) (Materials Park, OH) committee on cryogenics to address the need for more information, standardization, and trainin

THEORY OF CRYOGENIC PROCESS The theory was based on how heat-treating metal works and supposed that continuing the descent would allow for further strength increases. Using liquid nitrogen, CryoTech formulated the first early version of the
cryogenicprocessor.

Unfortunately for the newly-born industry, the

thermalshock

results were unstable, as components sometimes experienced

when they were

cooled too fast. Some components in early tests even shattered because of the ultra-low temperatures. In the late twentieth century, the field improved significantly with the rise of applied research, which coupled microprocessor based industrial controls to the
cryogenicprocessor

in order to create more stable results.

The property of the cryogenic process is generally gained due to the conversion of austenite to martensite. Proper heat treating can transform 85% of the retained austenite to martensite and the cryogenic treatment only transforms an addition of 8 to 15%. But a more uniform, refined microstructure with greater density is formed as a result of cryogenic processing. There are usually two types of cryogenic processes namely deep cryogenic treatment and shallow cryogenic treatment. Deep cryogenic treatment usually takes place around -3200F (1960C), near the temperature of liquid nitrogen. Shallow cryogenic treatment takes place around -1200F near the temperature of dry ice. Although these two processes are present but deep cryogenic treatment is the one most preferred and effective. Deep cryogenics is the ultra low temperature processing of materials to enhance their desired metallurgical and structural properties. In this case, this is a temperature about 320F, -196C, or 77K. These ultra cold temperatures are achieved using computer controls, a well-insulated treatment chamber and liquid nitrogen (LN2). The liquid form is the product of air separation, compression and liquefaction. Controlled deep cryogenic treatment system and process is capable of treating a wide variety of materials, such as ferrous and non-ferrous metals, metallic alloys, carbides, plastics (including nylon and Teflon) and ceramics. The entire process takes between 36 to 74 hours, depending on the weight and type of material being treated. Strict computer control and proper processing profiles assure that optimum results will be achieved with no dimensional changes or chance of thermal shock. This special process is not a surface treatment; it affects the entire mass of the tool or component being treated, making it stronger throughout. This means the process keeps working even after continued use and/or numerous sharpening. The hardness of the material treated is unaffected, while its strength is increased.

Figure-1 Cryogenic-Processing Equipment Processing The part to be processed is placed in a processor. It is a computer controlled process the system is controlled with proven cooling curves programmed to the computer. Any other desired coo cooling curves may be easily programmed into the processor. Computer controlled processing ensures accurate tempering cycles Liquid nitrogen is used as the cryogen in this process. Liquid nitrogen is converted to a gas before it enters the chamber, so that at no time liquid nitrogen comes in contact with parts, at assuring that the dangers of cracking from too rapid cooling are eliminated. They are gradually cooled with nitrogen gas to -320 degrees Fahrenheit. That temperature is maintained for at least 320 eight hours. The length of time varies by material and desired results. After the cooling cycle is ours. complete, the item is slowly warmed back to room temperature. Then the object is heat heat-treated, with temperatures of 100 to 400 degrees Fahrenheit, depending on the composition of the item. Finally, the item is gradually returned to room temperature. The complete process takes a minimum of 24 hours to a maximum of 7 days. Proper heat treating can transform 85% of the retained austenite to martensite and the cryogenic treatment only transforms an addition of 8 to 15%. But a more uniform, refined microstructure

with greater density is formed as a result of cryogenic processing. Additionally carbide precipitation and thermal mechanical stabilization (reduction of residual stresses in material) occurs during a cryogenic soak. As the material is cooled it passes a martensitic start temperature (Ms) at which the formation of martensite commences. As the temperature is lowered further it will eventually reach a martensitic finish temperature (Mf) at which all the retained autensite has been converted. Cryogenic processing aims to convert the entire structure to martensite, and it is not a heat treatment process that only affects the surface of the material.

EFFECTS ON CRYOGENICALLY PROCESSED MATERIALS Increases abrasive wear resistance. Requires only one permanent treatment. Creates a denser molecular structure. The result is a larger contact surface area Changes the equipment's entire structure, not just the surface. Subsequent Eliminates thermal shock through a dry, computer controlled process. Transforms almost all soft retained austenite to hard martensite. Forms micro fine carbide fillers to enhance large carbide structures. Increases durability or wear life. Decreases residual stresses in tool steels. Decreases brittleness. Increases tensile strength, toughness and stability coupled with the release of

that reduces friction, heat and wear. refinishing operations or re-grinds do not affect permanent improvements.

internal stresses.

EFECTS ON VARIOUS MATERIALS

At (-79cC) -110cF At -310c F

AISI#

Description

(-190cC)

430 303 8620 C-1020 AQS T-2 Table 1

Ferritic stainless Austenitic stainless Nickel-chromium-moly ally steel Carbon steel Graphitic cast iron Tungsten high-speed steel

116% 105% 112% 97% 96% 72%

119% 110% 104% 98% 97% 92%

Materials that did not show significant improvement

AISI# Description D-2 S-7 52100 0-1 A-10 M-1 H-13 M-2 T-1 CPM-10V P-20 440 High carbon/chromium die steel Silicon tool steel Standard steel Oil hardening cold work die steel Graphite tool steel Molybdenum high-speed steel Chromium/moly hot die steel Tungsten/moly high-speed steel Tungsten high-speed tool steel Alloy steel Mold steel Martensitic stainless At (-79C) 316% 241% 195% 221% 230% 145% 164% 117% 141% 94% 123% 128% -110F At -310 F

(-190C) 817% 503% 420% 418% 264% 225% 209% 203% 176% 131% 130% 121%

Table 2

Materials that showed significant improvement

When carbon precipitates form, the internal stress in the martensite is reduced; this minimizes the susceptibility to micro cracking. The wide distribution of very hard, fine carbides from deep cryogenic treatment also increases wear resistance. In addition to the transformation to martensite, the subjected metals also develop a more uniform, refined microstructure with greater density. Particles known as binders are coupled with the precipitation of the additional micro fine carbide fillers. The fillers take up the remaining

space in the micro voids, resulting in a much denser, coherent structure of the tool steel. These particles are largely responsible for the gains in wear resistivity. CHANGES IN THE METAL STRUCTURE Martensite, named after the German structure that is formed by
displacive metallurgist Adolf Martens

(18501914), is any crystal

diffusive austenite

transformation, as opposed to much slower

transformations. The martensite is formed by rapid cooling (quenching) of carbon atoms that do not have time to diffuse out of the crystal structure.

which traps

Martensite has a different crystalline structure (tetragonal) than the face-centered-cubic austenite from which it is formed, but identical chemical or alloy composition. The transition between these two structures requires very little thermal activation energy because it occurs displacively or martensiticly by the subtle but rapid rearrangement of atomic positions, and has been known to occur even at
cryogenic

temperatures. Martensite has a lower density than austenite, so that the

martensitic transformation results in a relative change of volume. this can be seen vividly in the Japanese katana, which is straight before quenching. Differential quenching causes martensite to form predominantly in the edge of the blade rather than the back; as the edge expands, the blade takes on a gently curved shape. Martensite is not shown in the equilibrium phase diagram of the iron-carbon system because it is a metastable phase, the kinetic product of rapid cooling of steel containing sufficient carbon. Since chemical processes (the attainment of equilibrium)
accelerate

at higher temperature,
tempering.

martensite is easily destroyed by the application of heat. This process is called some alloys, the effect is reduced by adding elements such as
cementite tungsten

In

that interfere with

nucleation, but, more often than not, the phenomenon is exploited instead. Since

quenching can be difficult to control, many steels are quenched to produce an overabundance of martensite, then tempered to gradually reduce its concentration until the right structure for the intended application is achieved. Too much martensite leaves steel brittle, too little leaves it soft.

Materials structure after treatment

Materials structure before treatment treatment

ADVANTAGES It has been proven to increase the strength and durability of the material being treated, relieve stress, create a more uniform material, and micro smooth surface. The molecular structure is micro-smooth "filled in" increasing the strength of the material by up to 400%! Also, the material will not be damaged and it will retain its shape. The sharpness will not only last longer, but you will be able to sharpen more times with less removal of material. Each sharpening will demonstrate the benefits of the treatment. Since cryogenics is a one time treatment affecting the part to the core, we can re one-time re-sharpen the tool as many times as necessary without having to re cryogenically treat the part. Therefore, re-cryogenically you may wish to treat new tools or tools that have not been worn excessively to obtain the excessively maximum amount of life for the least amount of cost. There is no need of re re-cryogenically treating a part unless it has been reheated to its fluid state. Not only the cutting tools last longer the same performance is obtained.

DISADVANTAGES Insufficient soak time, cooling or warming too quickly, and skipping the post-soak temper can posthamper the effectiveness of cryogenic treatment. Any one of these factors can cause inconsistent results--a problem that has dogged the cryogenic processing industry. Fortunately, today's a processing cryogenic processors are able to provide more consistent results than older equipment.

APPLICATIONS
APPLICATION STEEL SPRING SOURCE PLASTIC MANUFACTURING WHEEL ASSEMBLY HEAT DISSIPATION CAR MANUFACTURER COMPUTER DISTRIBUTER TOOLS SPRINGS FOR OPENING MOULD BOX KEY FOR RESULT FATIGUE INCREASED TOOLS LONGER TAMPERATURE DECREASE FROM 46 DEGRRE SLITTING PUNCHING SHAPING STEEL MANUFACTURER SHEET WORKING KITCHEN HOUSEHOLD MANUFACTURE CUTTING OF STEEL HAND TOOL MANUFACTURER METAL COLD WORK STEEL SLITTERS HSS M2 PUNCH AND DIE HSS POWDER THE TOOLS LAST 4 TIMES LONGER TOOLS PERFORMANCE INCREASED THAN 50% DEEP DRAWING BATTERY MANUFACTURER DRILLING CAPITAL EQUIPMENT MANUFACTURER TURNING OF STEEL AUTOMOTIVE SUPPLIER GEAR CUTTING GEARBOX MANUFACTURER HSS PM30 HOB CARBIDE INSERTS INSERTS LAST MORE THAN LONGER DOUBLED NUMBER OF PIECES CUT BETWEEN TWICE CARBIDE DRAWING DIE CARBIDE DRILLS DEEP DIE LIFE IS 2.5 INCREASED TIMES LONGER NUMBER OF HOLES IS DOUBLED MORE METALLURGICAL PRESS ROLL COLD WORK STEEL TOOLS(1.2379) DIE TO 42 DEGREE CELCIUS CUT2.5 TIMES MORE STEEL SHEET LESS GALLING LIFE IS FROM LAST

800 TO 2000 CYCLES WHEEL NUTS COPPER HEAT SINK IN COMMPUTERS

RESHARPENING

CONCLUSION The process of investigating the cryogenic process and finally materializing its effects on materials was overall a valuable learning experience. From this paper it is clear that this process can create a premium more profitable tool line for a manufacturer. It is also saving considerable tool expense for the end user. Among the properties which define cutting qualities of tool steel, durability is the highest importance. Results in this regard are decisive in establishing the benefits of cryogenic treatment. While various experts dispute the benefits of time-at-temperature control; available research, along with a correlation with standard heat treating processes indicates that this control is the key to maximizing the potential of cryogenic tempering. As is the case with many scientific discoveries, the cost factor limits the usefulness of this process in the production phase of the materials industry.

REFERENCE 1. Barron, Randall F. Refrigeration and Cryogenics, Louisiana Tech University, CRC Press LLC, 1998. 2. EfundaHeatTreatments http://www.efunda.com/processes/heat_treat/hardening/direct.cfm 3. Hogarth, Sharon ed. Cryogenics: A Technology Seeks Legitamacy
www.sme.org/manufacturingengineering

4. Integrated Cryogenic Systems http://www.cryogenictempering.net 5. Koepfer, Chris. Bringing Cryogenics in from the Cold
http://www.mmsonline.com/articles/0301rt2.html

6. Metallurgical Consultants http://www.materialsengineer.com/E-Titanium.htm

7. Pederson, Robert. Microstructure and Phase Transformation Lulea Technology, 2002.

University of