WHAT IS LIMIT GAUGE ?

Limit gauges are designed to check a single

distance, length or diameter, or may serve the inspection of multiple dimensions. This later may comprise contours, a combination of contours and length dimensions, geometric forms individually or combined with length, such as tapers and cylinders, or the interrelation of several forms, sizes and their location on a single body or within a assembly.

GAUGE MATERIALS:
Gauge materials should have following properties: 1. Hardness for wear resistance. 2. Metallurgical and dimensional stability. 3. Corrosion resistance. 4. Machinability. 5. Low co-efficient of thermal expansion. 6. Economic and easy availability. Based on above requirements, suitable gauge material is selected for 1. 2. 3. 4. 5.

specific application out of following list: High carbon steel Chrome plated steel Tungsten carbide Glass Invar

WHAT IS HEAT TREATMENT ?

Heat treatment is a group of industrial and metal working process used to alter the physical, and

sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering and quenching.

NEED OF HEAT TREATMENT:

Why it is required to perform heat treatment

on gauge materials ? To maintain wear resistance property. Dimensional stability of gauge material. To attain maximum hardness. To prevent presence of more percentage of austenite in finished gauge. To increase the service life of gauges.

HEAT TREATMENT OF GAUGE MATERIAL:

There are mainly three types of heat treatment

processes performed on gauges: 1. Sub-zero treatment 2. Nitriding 3. Chromium plating All the above mentioned heat treatment processes are further described in details.

SUB-ZERO TREATMENT:
The presence of austenite in hardened steel leads to the following defects a) Maximum hardness can not be obtained. b) Change in dimension occurs. c) It is non-magnetic.

Therefore the gauges are cooled below zero degree centigrade temperature to remove the austenite. Therefore this treatment is called sub zero treatment. Generally the steel is cooled to -78 degree Celsius with the help of solid carbon dioxide or dry ice. The coolants like ethylene, ethane and Freon are used to cool the gauges to still more lower temperatures. The gauges are kept at this temperature for short period and immediately taken out. Generally the cooling and holding at that temperature take half to one hour time. The sub-zero treatment should be immediately after hardening the gauge. Therefore the whole process is carried out in following sequence: a. Hardening b. Lower temperature cooling c. Tempering

Fig:- Freezer for sub zero treatment

NITRIDING:
The steel absorbs nitrogen during this process. This process takes more time as 0.1 mm thick nitriding layer takes the time of 10 hours approx. at 500 to 540 degree Celsius. This process is carried out in two stages: (a) In first stage gauge is held at a temperature of 500 to 540 degree Celsius for about 8 to 12 hours. During this stage 18 to 25% ammonia gets decomposed. (b) In second stage it is held at 560 degree Celsius temperature for a period proportional to the required thickness of coating. After nitriding is over , the gauge is slowly cooled down to 200 degree Celsius. During this cooling 20% of nitrogen is decomposed. Surface hardness of 60 to 70 rockwell can be obtained by nitriding. The nitriding of low carbon steel gauge is carried out to increase its resistance to corrosion.

Fig:- Nitriding process

Fig:- Nitriding furnace

CHROMIUM PLATING:
Chromium plating provides a layer of chromium on gauge

surface. It provides the properties like corrosion resistance, acid resistance, hardness and wear resistance. The smooth and attractive surface of the gauge is provided by this treatment. There are many methods of chromium plating. In gas coating method the mixture of hydrogen and chloride vapour is passed, the furnace heated to a temperature of 1000 degree Celsius, in which the chromium or ferrous chromium is kept. Due to chemical reaction of vapour mixture with this substances chromium dichloride gas is produced, which reacts with the gauge metal and helps in obtaining required layer of chromium on the gauge surface. This is a fast process. The chromium coated low carbon steel gauges are then hardened and tempered for improving their mechanical properties.

Fig:- Chromium plating

Fig:- Some chrome plated limit gauges