Cr(N,C) diffusion coating formation on pre-nitrocarburised H13 tool steel

The microstructural processes of Cr(N,C) coating formation by thermoreactive deposition and diffusion (TRD) on pre-nitrocarburised H13 tool steel were studied. Both nitrocarburising and TRD were performed in fluidized bed furnaces at 570 °C. During TRD, chromium was transferred from chromium powder in the fluidized bed, to the nitrocarburised substrates by gas-phase reactions initiated by reaction of HCl gas with the chromium. Addition of 30% H2 to the input inert gas was found to increase the rate of coating formation, although hydrogen reduction resulted in rapid loss of nitrogen to the surface. The reason for the increased rate of coating formation could not be established without further investigation, although several possible explanations have been proposed. It was found that porosity and the formation of an iron nitride ‘cover layer’ during nitrocarburising were the biggest influences on the microstructure of the Cr(N,C) coating. Microstructural characterization of the coatings was performed by scanning electron microscopy (SEM), X-ray diffraction (XRD) and glow discharge optical emission spectroscopy (GDOES).

Pin on disc wear investigation of nitrocarburised H13 tool steel

Nitrocarburised H13 disks were tested in dry, sliding wear against a stationary ruby ball (pin). Three different 4 h nitrocarburising treatments were compared, using N2/NH3/CO2, N2/NH3/natural gas and N2/NH3 gas mixtures, resulting in compound layers of varying thickness, hardness, porosity and oxide morphology. During mild, oxidative wear, with the formation of abrasive wear debris, the most brittle and oxidised surfaces performed poorly. Polishing to a bright, reflective finish greatly reduced wear. However, the N2/NH3/CO2 sample also frequently maintained a 'very mild' wear regime, owing to the formation of a protective film between the wear surfaces, and resulting in a lowering of the friction coefficient. This treated surface was porous and covered in a complex layer of coarse oxide+epsi-carbonitride. Nitrocarburised samples and wear tracks were characterised by optical microscopy, SEM, atomic force microscopy and stylus profilometry.

Effect of single and double austenitization treatments on the microstructure and hardness of AISI D2 tool steel

This investigation is concerned with the study of effect of Double Austenitization (DA) and Single Austenitization (SA) heat treatment processes on microstructure and mechanical property of AISI D2type cold worked tool steel. To maximize hardness, tool steels are used in a quenched and tempered condition. This involves heating the material to the austenitizing temperature (~850-1100. °C), quenching at an appropriate rate to form martensite, and tempering to reduce the retained austenite content and induce toughness. The merits of DA treatment isto promote dissolution of carbides at the same time proscribe grain coarsening significantly was attempted in D2 tool steel. The study has found that DA treatment has induced high hardness with insignificant growth in grains. The increase in hardness is attributed to increase in carbon content in matrix due to dissolution of carbides; whereas finer grains due to role of inclusions.

The effect of sliding speed on the wear of steel-tool steel pairs

This study examines the effect of sliding speed and surface temperature on the wear behavior of an unlubricated mild steel-tool steel contact pair using the pin-on-disc test. The operating conditions and contact pair are of interest to the automotive sheet metal stamping industry and the broader metal forming community, where high contact pressures and moderate forming speeds can result in significant frictional heating and thus affect tool life. It will be shown that, while adhesive wear is dominant at the tool steel surface for all sliding speeds examined, the adhesive wear rate is very sensitive to sliding speed during slow speed conditions but relatively insensitive to sliding speed during higher speed conditions. These higher sliding speeds result in high frictional heating, however, the effect of increasing bulk temperature results in a transition from adhesive wear to material removal-dominated mechanisms. It is concluded that there is a distinct difference in the wear response for comparable surface temperature and bulk temperature conditions, at the low to moderate sliding speeds and temperatures examined in this study. The SEM and profilometry analysis show that the technique of increasing sliding speed to replicate bulk temperature conditions (or vice versa), may not result in equivalent wear rates and mechanisms.

Wear mechanisms and microstructure of pulsed plasma nitrided AISI H13 tool steel

AISI H13 tool steel discs were pulsed plasma nitrided during different times at a constant temperature of 400 °C. Wear tests were performed in order to study the acting wear mechanisms. The samples were characterized by X-ray diffraction, scanning electron microscopy and hardness measurements. The results showed that longer nitriding times reduce the wear volumes. The friction coefficient was 0.20 ± 0.05 for all tested conditions and depends strongly on the presence of debris. After wear tests, the wear tracks were characterized by optical and scanning electron microscopy and the wear mechanisms were observed to change from low cycle fatigue or plastic shakedown to long cycle fatigue. These mechanisms were correlated to the microstructure and hardness of the nitrided layer.

Frictional behaviour and wear performance of a nitrocarburised coating sliding against AISI 1019 steel

This work employed a commercial nitrocaburising process to diffuse a coating onto M2 grade high speed tool steel. Properties of the nitrocaburised coating (CN) such as thickness, roughness and hardness were characterised using a variety of techniques including Glow-Discharge Optical Emission Spectrometry (GD-OES) and Scanning Electron Microscopy (SEM). A tribological test has been developed in which two nominally identical crossed cylinders slide over each other under selected test conditions. The test has been employed to investigate the wear performance of both CN coated and uncoated M2 specimens and frictional behaviour of the sliding interface between the tool and a AISI 1019 steel workpiece under unlubricated (dry) and lubricated conditions. Fourier Transform Infrared Spectroscopy (FTIR) was used to monitor the formation of chemical species from the oxidation of lubricant during tribological testing.

Ferritic nitrocarburising of tool steels

Four different tool steel materials, P20, H13, M2 and D2, were nitrocarburised at 570°C in a fluidised bed furnace. The reactive diffusion of nitrogen and carbon into the various substrate microstructures is compared and related to the different alloy carbide distributions. The effect of carbon bearing gas (carbon dioxide, natural gas) on carbon absorption is reported, as well as its influence on compound layer growth and porosity. Partial reduction of Fe3O4 at the surface resulted in the formation of a complex, epsi-nitride containing oxide layer. In H13, carbon was deeply absorbed throughout the entire diffusion zone, affecting the growth of grain boundary cementite, nitrogen diffusivity and the sharpness of the compound layer: diffusion zone interface. When natural gas was used, carbon became highly concentrated in the compound layer, while surface decarburisation occurred with carbon dioxide. These microstructural effects are discussed in relation to hardness profiles, and compound layer hardness and ductility. The surfaces were characterised using glow discharge optical emission spectroscopy, optical and scanning electron microscopy and X-ray diffraction.

Fluidised bed nitrocarburising of tool steels

The work examines how ferritic nitrocarburising, a common heat treatment process for steels, can be adapted to the fluidised bed furnace. The effect of fluidising powder contamination on repeatability, composition of the reactive gas mixture, the development of nitrocarburised tool steel microstructure and resulting wear properties were investigated.

An investigation of tribological properties of CN and TiCN coatings

Today the tool industry on a worldwide basis uses hard, wear-resistant, and low-friction coatings produced by different processes such as electrochemical or electroless methods, spray technologies, thermochemical, chemical-vapor deposition (CVD), and physical vapor deposition (PVD). In the current work, two different coatings, nitrocarburized (CN) and titanium carbonitride (TiCN) on M2-grade tool steel, were prepared by commercial diffusion and PVD techniques, respectively. Properties such as thickness, roughness, and hardness were characterized using a variety of techniques, including glow-discharge optical emission spectrometry (GD-OES) and scanning electron microscopy (SEM). A crossed-cylinders wear-testing machine was used to investigate the performances of both coatings under lubrication. The effect of coatings on the performance of lubricants under a range of wear-test conditions was also examined. Degradation of lubricants during tribological testing was explored by Fourier transform infrared (FTIR) spectroscopy.

A nitrocarburising and low-temperature chromising duplex surface treatment

A duplex surface treatment has been developed involving the pre-treatment of hardened and tempered AISI H13 chromium hot-work tool steel by a ferritic nitrocarburising process, and a subsequent treatment of the nitrocarburised surface by a low-temperature chromium thermo-reactive deposition process.  The process formed a thin and hard chromium carbonitride surface layer above a hardened diffusion zone, and the low processing temperature allowed the properties of the core material to be retained. It is expected this surface treatment will find application in the treatment  of tooling used for aluminium forming operations.

Robust control applied to metal spraying for rapid tooling

The spray forming process is a novel method of rapidly manufacturing tools and dies for stamping and injection operations. The process sprays molten tool steel from a set of arc spray guns onto a ceramic former to build up a thick steel shell. The volumetric contraction that occurs as the steel cools is offset by a volumetric expansion taking place within the sprayed steel, which allows the dimensional accurate tools to be produced. To ensure that the required phase transformation takes place, the temperature of the steel is regulated during spraying. The sprayed metal acts both as a source of mass and a source of heat and by adjusting the rate at which metal is sprayed; the surface temperature profile over the surface of the steel can be controlled. The temperature profile is measured using a thermal imaging camera and regulated by adjusting the rate at which the guns spray the steel. Because the temperature is regulated by adjusting the feed rate to an actuator that is moving over the surface, this is an example of mobile control, which is a class of distributed parameter control. The dynamic system has been controlled using a PI controller before. The paper describes the application of H∞ tracking type controller as the desire was for the average temperature to follow a desired profile. A study on the controllability of the underlying system was aimed at.

Tribology of lubricated nitrocarburised and titanium carbonitride surfaces

In the current work, two different coatings, nitrocarburised (CN) and titanium carbonitride (TiCN) on M2 grade high speed tool steel, were prepared by commercial diffusion and physical vapour deposition (PVD) techniques, respectively. Properties of the coating were characterised using a variety of techniques such as Glow-Discharge Optical Emission Spectrometry (GD-OES) and Scanning Electron Microscopy (SEM). Three non-commercial, oil-based lubricants with simplified formulations were used for this study. A tribological test was developed in which two nominally geometrically-identical crossed cylinders slide over each other under selected test conditions. This test was used to evaluate the effectiveness of a pre-applied lubricant film and a surface coating for various conditions of sliding wear. Engineered surface coatings can significantly improve wear resistance of the tool surface but their sliding wear performances strongly depend on the type of coating and lubricant combination used. These coating-lubricant interactions can also have a very strong effect on the useful life of the lubricant in a tribological system. Better performance of lubricants during the sliding wear testing was achieved hen used with the nitrocarburised (CN) coating. To understand the nature of the interactions and their possible effects on the coating-lubricant system, several surface analysis techniques were used. The molecular level investigation of Fourier Transform Infrared Spectroscopy (FTIR) revealed that oxidative degradation occurred in all used oil-based lubricants during the sliding wear test but the degradation behaviour of oil-based lubricants varied with the coating-lubricant system and the wear conditions. The main differences in the carbonyl oxidation region of the FTIR spectra (1900-1600 cm-1) between different coating-lubricant systems may relate to the effective lifetime of the lubricant during the sliding wear test. Secondary Ion Mass Spectrometry (SIMS) depth profiling shows that the CN coating has the highest lubricant absorbability among the tested tool surfaces. Diffusion of chlorine (C1), hydrogen (H) and oxygen (O) into the surface of subsurface of the tool suggested that strong interactions occurred between lubricant and tool surface during the sliding wear test. The possible effects of the interactions on the performance of whole tribological system are also discussed. The study of Time-of-Flight Secondary Ion Mass Spectrometry (TOF-SIMS) indicated that the envelope of hydrocarbons (CmHn) of oil lubricant in the positive TOF-SIMS spectra shifted to lower mass fragment after the sliding wear testing due to the breakage of long-chain hydrocarbons to short-chain ones during the degradation of lubricant. The shift of the mass fragment range of the hydrocarbon (CmHn) envelope caries with the type of both tool surface and lubricant, again confirming that variation in the performance of the tool-lubricant system relates to the changes in surface chemistry due to tribochemical interactions at the tool-lubricant interface under sliding wear conditions. The sliding wear conditions resulted in changes not only in topography of the tool surface due to mechanical interactions, as outlined in Chapter 5, but also in surface chemistry due to tribochemical interactions, as discussed in Chapters 6 and 7.

Nitrocarburising and low-temperature chromising duplex surface treatment

A new duplex surface engineering process has been developed that involves the deposition of chromium on ferritic nitrocarburised steel surfaces at low temperatures. This process formed a thin and hard chromium carbonitride surface layer and is to be applied to hardened tooling used in metal forming operations for improved wear performance and die life.

Surface alloying of metals using fluid bed reactor

The use of fluidised bed reactors for surface alloying is reviewed. Research at Deakin has includes the use of chemical vapour deposition to form chromium rich layers on ferrous substrates, including stainless and tool steel grades. These layers can be modified to carbide or nitride if required by the end application. The deposition of aluminium and silicon has also been successfully achieved.