ME 330 Engineering Materials Lecture 12 Phase Diagrams, Solidification, Phase transformations Solidification Solidification microstructures Iron-Carbon alloys Phase transformations Read Chapter 10 Chapter 9 - 1 Kinetics of phase transformations – Reaction kinetics … what happens when time is introduced to solidification – TTT curves – CCT curve – Hardenability and Jominy end quench test – Surface hardening treatments • Please read chapter 10 Chapter 9 - 2 Development of microstructure in single or two phase alloys usually involves phase transformations – alteration in the number and/or character of phases. Chapter 9 - 3 Phase transformations • At least one new phase is formed that has different physical/chemical characteristics and/or different structure that the parent phase • They do not occur instantaneously – Transformation rate (dependence of reaction progress on time) • Phase transformations have two stages – Nucleation (appearance of very small particles of new phase which are capable of growing) – Growth Chapter 9 - 4 Phase transformations 1. Simple diffusion-dependent transformation (no change in either the number or composition of phases present) Ex: solidification of pure metal, recrystallization and grain growth 2. Diffusion dependent transformation (some alteration in phase compositions and often in number of phases present) Ex: eutectoid reaction 3. Diffusionless trasformation (metastable phase is produced) Ex: martensitic transformation Chapter 9 - 5 Nucleation • Homogeneous phase – Nuclei of new phase form uniformly throughout the parent phase • Heterogeneous phase – Nuclei form preferentially at structural inhomogeneities (contain surfaces, grain boundaries, dislocations, etc) Chapter 9 - 6 Homogeneous Nucleation Free Energy Change G 4 Volume r 3 3 4 3 r Gv 4r 2 3 4r 2 r Solid Solid-liquid interface Area 4r 2 4 3 r Gv 3 Find critical radius for maximum free energy change d (G ) 4 Gv (3r 2 ) 4 (2r ) 0 dr 3 G * Activation free energy required for the formation of stable nucleus 2 r* Gv 16 3 G* 3(Gv ) 2 Chapter 9 - 7 Gv H f H f (Tm T ) is zero at Tm Tm heat given up during solidification 2 Tm 1 r H T T f m * 3 2 16 Tm 1 * G 3H 2 T T 2 f m These two quantities decrease as temperature decreases. Lowering of temperature at temperatures below the equilibrium solidification temperature, nucleation occurs more easily. Chapter 9 - 8 So far we considered temperature dependence. Next, we consider time dependence. Chapter 9 - 9 General Solid State Reaction Kinetics Time split between nucleation & growth • Measure transformation % versus time for various temperatures Transformation rate (Avrami equation) y 1 exp( kt ) n rate 1 t0.5 Q rate A exp RT Fraction of transformation,y • • Time dependence of rate Phase transformations generally time & temperature dependent Typical kinetics behavior 1.0 Fraction of transformation • • 0.5 t0.5 0 • Nucleation t 0 Growth. 5 log of heating time, t Chapter 9 - 10 Fig. 10.11 in Callister Chapter 9 - 11 Recall: Iron-Iron Carbide Phase Diagram • • • • Ferrite, – BCC structure – Carbon dissolved in iron (0.02% max.) – Soft, weak, ductile Austenite, – High temperature phase, above 727°C – FCC crystal structure – Carbon dissolved in iron (2.14% max.) Ferrite, – BCC structure Cementite – Hard, strong, brittle , Ferrite (BCC) , Austenite (FCC) , Ferrite (BCC) Cementite (Fe3C) Chapter 9 - 12 Recall: Eutectoid Solidification Start with pure austenite, Eutectoid Reaction – 0.76%C 0.022%C Fe3C 6.7%C – • 0.76 % Carbon at 727 °C Develop pearlite microstructure – – – Similar to eutectic microstructure from last time Alternating lamellae of and Fe3C Properties intermediate between constituents 1076 Steel 1000 Temperature °C • • + Fe3C 800 727 Fe3C 6.70% 600 + Fe3C 0 1% Composition (wt % C) Chapter 9 - 13 Recall: Temperature °C Eutectoid Composition 1076 Steel 1000 + Fe3C 800 727 0.022 0.76 Fe3C 6.70% 600 + Fe3C 0 • Pearlite 0.76 % C • Ferrite (white) • Cementite (black) 1% Composition (wt % C) Chapter 9 - 14 Time-Temperature-Transformation (TTT) Eutectoid composition • Transformation rate has a strong temperature dependence – Rapidly cool to given temperature – Hold to solidification • More convenient to plot time versus temperature – Plot initiation and completion lines – Eutectoid plotted as horizontal line • Valid only for – Given composition – Isothermal transformation End 100 675 °C 650 °C 50 0 Begin Austenite (unstable) Temperature °C – 0.76 % C – Fe3C Percent transformed • Austenite (stable) Te 700 Pearlite 600 50 % completion 500 100 % completion 0 % completion 400 1 10 102 time (s) 103 104 Chapter 9 - 15 105 Fig. 10.14 in Callister Chapter 9 - 16 Completing the Plots • • Other than eutectoid compositions have proeutectoid phases – Cementite (%C > 0.76) – , Ferrite (%C < 0.76) – At low enough temperatures, this phase is suppressed Bainite – Forms below “knee” of curve – Not really a new phase – Ferrite and cementite phases – No longer lamellar structure Martensite – Quench fast enough to avoid other transformations – Forms at very low temperatures – Nonequilibrium and diffusionless 800 600 +C (Hypereutectoid) (Hypoeutectoid) + +P Pearlite, P 500 +B Te 700 Temperature °C • 400 Bainite, B 300 200 10-1 M (start) M (50%) M (90%) 1 0% 50% 100% Martensite, M 10 102 103 104 time (s) Chapter 9 - 17 105 Pearlite, Bainite, Martensite • FCC Structure Above 725 C Transforms to other phases Ferrite – – – – Austenite • Compound, Fe3C Hard and Brittle Contains 6.7% C • Formed by diffusion Ferrite and cementite Lamellar structure Stronger than ferrite Bainite – – – – Iron + C in solid solution Max. C is 0.022% Ductile Cementite Pearlite Not as much diffusion Ferrite and cementite Not lamellar structure Harder that pearlite Martensite – – – – Diffusionless transformation Speed of sound BCT Structure (bodycentered tetragon) with carbon interstitials Chapter 9 - 18 Strong and brittle Bainite & Martensite • Upper bainite • Lower bainite • Martensite From: Callister Chapter 9 - 19 Pearlite Formation • • Back to eutectoid composition Above knee form pearlite as described in last lecture Thickness of lamellae depends on isotherm – Course pearlite • • • Higher temperatures Diffusion rate high Carbon travels larger distances – Fine pearlite • • Close to 540 °C Diffusion suppressed 800 Te 700 (Coarse pearlite) Pearlite, P (Fine pearlite) Temperature °C • +P 600 500 +B Bainite, B 400 300 200 10-1 M (start) M (50%) M (90%) 1 Martensite, M 10 102 103 104 time (s) Chapter 9 - 20 105 Bainite Formation Below knee form bainite Upper bainite – ~300 - 540 °C – Ferrite grows first, then Fe3C drops out – Needles of ferrite separated by elongated cementite particles • Lower bainite – ~200 - 300 °C – Thin plates of ferrite containing fine blades of cementite • • Cannot transform pearlite to bainite Can coexist with each other 800 Te 700 Temperature °C • • +P 600 500 Pearlite, P (upper Bainite) +B Bainite, B 400 300 200 10-1 M (start) M (50%) M (90%) 1 (lower Bainite) Martensite, M 10 102 103 104 time (s) Chapter 9 - 21 105 Martensite Formation • Nonequilibrium (metastable) phase Due to FCC/BCT transition – Happens quickly (velocity of sound) – Little atomic motion – Diffusionless transformation – Time independent – –46 °C for complete transformation • • • 800 Te 700 Temperature °C • 600 500 +P Pearlite, P +B Bainite, B 400 300 M (start) Lath: long thin plates (%C < 0.6) Lenticular: needlelike Characteristically brittle, strong, hard 200 M (50%) M (90%) 10-1 1 10 Martensite, M 102 103 104 time (s) Chapter 9 - 22 105 Representative TTT Diagrams Presence of other alloying elements 1021 Steel 1045 Steel 1095 Steel 4140 Steel Mn 0.77 Cr 0.98 Mo 0.21 4340 Steel Mn 0.78 Cr 0.80 Mo 0.33 Ni 1.79 Chapter 9 - 23 Alloying Effects • Higher carbon content – Shifts curve to right (slightly!) – Change proeutectoid phase from ferrite to cementite – If %C < 0.4, steel is not “hardenable” • Necessary cooling rate would be far too quick to form martensite • Book says 0.25%, but realistically very difficult below 0.4% • • Alloying other than carbon – Shift austenite nose to longer times – Formation of separate bainite nose What does this mean? – To form equilibrium products, cooling rate must be much slower – Easier to form martensite Chapter 9 – Thicker parts will have more uniform hardness 24 Continuous Cooling Transformation (CCT) • • • Isothermal heat treatment not common – Practically, want to cool steadily to room temperature Isothermal curves shifted to longer times and lower temperatures Bainite will not form for plain carbon steel Alloying agents shifts the pearlite transformation curve to the right – Now possible to obtain bainite – 2 “knees” appear on curve 800 Te +P 700 Temperature °C • Pearlite, P 600 500 Bainite, B 400 +B 300 M (start) 200 M (50%) M (90%) 10-1 1 10 Martensite, M 102 103 104 time (s) Chapter 9 - 25 105 Example: 4340 Steel 1. Martensite Pearlite 2. Martensite Banite 3. Martensite Ferrite Banite Bainite 1 2 3 4 4. Ferrite Pearlite 5 5. Pearlite Chapter 9 - 26 Linking Important Concepts • • • The composition of an alloy determines the phase change kinetics The cooling rate determines the microstructure of an alloy The microstructure determines the mechanical properties Chapter 9 - 27 Mechanical Properties (Pearlite & Bainite) • • Brinell Hardness 600 Bainite Pearlite 80 280 60 240 200 40 160 20 120 500 400 80 300 0 200 0.2 0.4 0.6 0.8 1.0 wt% C 100 500 300 400 600 700 Transformation temperature (°C) Spheroidite Coarse Pearlite Fine Pearlite Chapter 9 - 28 %RA • Cementite harder & more brittle than ferrite Spheroidite: spherical Fe3C particles in matrix, very soft & ductile Pearlite: Fine is harder & more brittle than coarse Bainite: Stronger & harder than pearlite, good ductility Brinell Hardness • Mechanical Properties (Martensite) Very strong and hard Brittle – C interstitials – Few slip systems • • Large internal stresses due to volume change from austenite phase To recover ductility, need to do special heat treatment called tempering… 700 Brinell Hardness • • ultimate 3.5 BHN MPa Martensite 600 500 400 Tempered martensite 300 200 Pearlite 100 0.0 0.2 0.4 0.6 Carbon, % 0.8 1.0 Chapter 9 - 29 Mechanical Properties (Tempered Martensite) Tempering: Reheating martensite up to a sub-eutectoid temperature for long time • Trade strength for ductility 1800 Tensile 1600 Yield 1400 1200 60 50 1000 40 800 200 30 300 400 500 600 Tempering temperature, °C Chapter 9 - 30 % RA martensite(BCT single phase) tempered martensite( Fe3C ) 4340 steel Strength, MPa • Austenitic Transformations Chapter 9 - 31 Objectives for Chapter 11 • • • • • • • • Have basic understanding of types of steels, relative C content, strength, and applications. Know fundamental differences between the types of cast iron. Describe the purpose of and procedures for process annealing, stress relief annealing, normalizing, full annealing, and spheroidizing. Define hardenability and list the class steels that have low hardenability. Know how to use the Jominy End Quench Test - see lab on hardenability. Explain the procedure to precipitation harden an alloy and what characteristics on the phase diagram allow the alloy to be hardened by this mechanism. Explain the shape of the strength vs time curve for precipitation hardened alloys in terms of the mechanism of hardening in each stage. Distinguish between the four types of forming operations. Distinguish between the four types of casting techniques. Chapter 9 - 32 Ferrous Alloys Chapter 9 - 33 Metal Fabrication Chapter 9 - 34 Heat Treating Steel Temperature °C 1000 800 600 + Fe3C 0 • + Fe3C % Carbon 1% Full Annealing – Heat to 15-40 °C above phase transition line, hold for diffusion, and slow cool (usually in a furnace, often takes number of hours). – Returns microstructure to coarse pearlite. – Often performed on steels to be machined or formed to increase ductility Chapter 9 - 35 Heat Treating Steel Temperature °C 1000 800 600 + Fe3C 0 • + Fe3C % Carbon 1% Normalizing – Heat to the fully austenite region and air cool. – Fine pearlite microstructure – Refine grain size and distribution (often done after a rolling operation) Chapter 9 - 36 Heat Treating Steel Temperature °C 1000 800 600 + Fe3C 0 • + Fe3C % Carbon 1% Spheroidizing – Heat a medium-high carbon steel below the eutectoid line and hold for several hours – Forms small Fe3C spherical particles in matrix. – For higher carbon steels, even pearlite is often brittle and difficult to deform – Spheroidizing minimizes hardness and is highly Chapter 9 machinable 37 Heat Treating Steel Temperature °C 1000 800 600 + Fe3C 0 • + Fe3C % Carbon 1% Quenching – Heat to fully austenitize steel – Rapidly cool (quench in water, oil, etc) – No time for carbon to diffuse – Produces a non-equilibrium microstructure called martensite • Very hard, strong, brittle with large internal stresses Chapter 9 - 38 Heat Treating Steel Temperature °C 1000 800 600 + Fe3C 0 • + Fe3C % Carbon 1% Tempering – After quenching to form martensite – Reheat below eutectoid temperature – Hold for several hours to precipitate carbides and relieve residual stresses – Forms tempered martensite • Relatively hard, strong, much more ductile • Often ideal microstructure ... Chapter 9 - 39 Hardenability • Hardness vs. Hardenability – Hardness – resistance to deformation – Hardenability – ability to be form martensite (to be hardened) • Formal definition: – Hardenability – ability of an alloy to be hardened by formation of martensite due to given heat treatment • High hardenability martensite forms (i.e. hardens) far into specimen, not just at surface Chapter 9 - 40 Jominy End Quench Test Standard test for measuring hardness of any material Hardness, HRC Sample of fixed geometry suspended over water jet Geometric factors all constant Only effect on hardness is alloying content Hardness measured as function of distance from quenched end Distance – – – – Cooling rate • Distance from quenched end Chapter 9 - 41 Hardness Profiles Cooling rate at 700 °C (°C/s ) • 170 70 Cooling rate 18 9 5.6 3.9 2.8 2 • Microstructure – – – – Slower Martensite Cooling Bainite Fine Pearlite Course Pearlite Hardness, HRC – Highest at quenched end 60 – Smoothly decreases with distance 8660 50 40 8640 30 8630 8620 • Often plot cooling rate and distance 10 • Increasing carbon content 20 30 40 Distance from quenched end, mm – Maximum possible hardness increases – Higher overall hardness (more hardenable) Chapter 9 - 42 50 Severity of Quench • • Rate of cooling! Depends on – Medium- Fluid in which an austenetized part is plunged • Most common: air, oil, water – Agitation - Relative motion of quenching medium during cooling • Agitation rate influences cooling rate – Surface area to volume ratio • All heat removed at surface • More surface area provides more opportunity to remove heat • Irregular shapes with edges have large quenching surfaces • For highly stressed part, want 80% martensite throughout part – Usually from a “guideline” for specific company Chapter 9 - 43 Using Cooling Curves • • Normal quenching takes place on radial surface Can predict hardness across radius of a bar from Jominy tests. Chapter 9 - 44 Review: Heat Treatment of Steel • • • • • Annealing- Heat, holding at temperature, gradual cool – General term, but also used for specific processes Tempering -Heat martensite to get diffusional transformation: – martensite (BCT single phase) tempered martensite ( Fe3C ) – Still have ultra-fine microstructure, but more ductile Process annealing -Reverse effects of cold work; recovery, recrystallization, but little grain growth Stress relief - Lower temperature anneal to undo thermal stress or transformation mismatch stress Spheroidizing - Heat pearlite just below eutectoid temp to produce spheroidal structure; makes Chapter 9 - 45 steel easier to machine Surface Hardening Techniques • • Many applications, especially wear – Strong, hard, wear-resistant surface – Tough, fracture resistant inner core – Two different heat treatments - through, then surface Methods – Chose material with steep cooling curve – Case Hardening - Change chemical composition of surface • • • Carburizing Nitriding Carbonitriding – Decremental Hardening – Very localized heat treatment • • Flame Hardening Induction Hardening Chapter 9 - 46 Alloys for Surface Hardness Cooling rate at 700 °C (°C/s ) 170 70 18 9 5.6 3.9 2.8 2 100 4340 80 A B Hardness, HRC 50 50 4140 40 8640 30 A 5140 B 1040 10 Prescribe: Percent Martensite 60 20 30 40 50 Distance from quenched end, mm Minimum hardness at A Maximum hardness at B Must know the cooling rates at each point! Chapter 9 - 47 Carburizing • Hardens steel by causing carbon to diffuse into the surface. – Furnace heat to a temperature at which carbon will diffuse – Hold until diffusion creates the proper case depth. • Must be a carbon rich environment • For steels with low carbon content (%C < 0.2) • Used extensively on gears and shafts to harden them yet maintain the core toughness. • Decarburization is opposite process for high carbon steels softer case From: Callister p. 92, 224 Chapter 9 - 48 Flame Hardening • For steels of hardenable carbon content (%C 0.4) • A high intensity oxy-acetylene flame is applied to the bring the region of interest to an austenite transformation. • The interior never reaches high temperature. • The heated region is quenched to achieve the desired hardness. • The depth of hardening can be increased by increasing the heating time. • In addition, large parts, which will not normally fit in a furnace, can be heat-treated From: Scheer p. 43 Chapter 9 - 49 Precipitation Hardening • Form extremely small, dispersed particles of a second phase • Small second phase particles called precipitates • Age hardening - strength develops as the alloy ages – Time dependent – There is a maximum attainable effect • Different than tempering martensite – Similar heat treatment procedure – Different strengthening mechanism Chapter 9 - 50 Precipitation Hardening • • Primary strengthening mechanism for – Aluminum – Nickel based superalloys – Titanium Examples Ti in b Ti matrix – Al/Cu – Cu/Sn – Mg/Al Ni3Al in Ni matrix From: Socie Chapter 9 - 51 Phase Diagrams & Treatment Temperature L L+ L+b b b Precipitation hardenable alloys have: Appreciable maximum solubility Decreasing solubility with temperature Composition less than maximum solubility Solution Treating: Heat into the single phase region and rapidly quench to room temperature to produce a supersaturated solid solution Aging: Composition Heat to a temperature below the phase transition to allow time for precipitates to form Chapter 9 - 52 Why Precipitation Harden? • Look at Aluminum rich side of Al/Cu system – Coarse q phase weakens the alloy Temperature • °C is a substitutional solid solution of copper in aluminum q is an intermetallic compound CuAl2 One slow cool in is NOT helpful in strengthening 700 600 500 400 100% (95.5% Al, 4.5% Cu) Coarse q precipitates At grain boundaries q 300 200 100 Al 5 10 wt % Cu time Chapter 9 - 53 How to Precipitation Harden • Two reheating treatments are needed: – – • Solution treatment Age hardening Fine precipitates strengthen & harden material 100% solid solution Temperature °C 700 600 500 Equilibrium Microstructure 400 q 300 Fine precipitates in grains (retained after cooling) 200 100 Al 5 10 wt % Cu time Chapter 9 - 54 Overaging If precipitates get too big, strengthening/hardening is lost Process sped up by temperature Some alloys age at room temperature Why is strength lost? 100% solid solution Temperature • • • • Fine precipitates in grains Coarse precipitates in grains taging time Chapter 9 - 55 Strength Development • • • • Fine precipitates (Guinier-Preston zones q’’ phase) are coherent with lattice Deformation of crystal impedes dislocation motion At optimal aging time, precipitates are dispersed, small, and coherent. After optimal aging time, precipitates get too big, incoherent with matrix. From: Callister Chapter 9 - 56 Age vs. Material Properties • Must age carefully to avoid overaging – Too high temperature – Too long age time • Precipitation rate maximized at intermediate temperatures – Near solvus no driving force for nucleation – Low temperatures diffusion is slow Nucleation T Diffusion t Gm G * N ~ N o exp exp kT k T From: Callister Chapter 9 - 57 Strengthening Mechanisms • Dislocation Looping • Dislocation cutting From: Hertzberg Chapter 9 - 58 What is Attractive About Aluminum? • • Upside • – Lightweight ( Al 0.3* Steel) – Ductile – Heat treatable – Castable – Corrosion resistant • – Good conductor Downside – Formability is lower • Simpler shapes E Al 31 E Steel – – For same stiffness, need larger section Longitudinal stiffness(~EA/L) E St ASt E Al AAl AAl ESt E Al ASt 3* ASt Al AAl L St ASt L Bending stiffness (~EI) – Rect. section, constant b I bh3 b 3 3 E St bhSt E Al bhAl h Al 3 ESt h E Al St h 1.44 * hSt W Al Al AAl L Al h Al b 0.43 WSt St ASt L St hSt b Chapter 9 - 59 Aluminum Designations • • – – – – Alloying Composition – – Aluminum 1xxx Aluminum • Copper • Manganese • Silicon • Magnesium • Mg and Si • Zinc Common alloys: Tempering Designations 2xxx 3xxx 4xxx 5xxx 6xxx 7xxx 2024-T4 , 6061-T6, 7075-T6 -O: Annealed -F: As fabricated -H1: Strain Hardened -H2: Strain Hardened/ Partial Annealed – -T: Thermally Processed • -T2: Annealed (cast products) • -T3: Solution treated, CW, naturally aged • -T4: Solution treated, naturally aged • -T5: Artificially aged, no solution treatment • -T6: Solution treated, artificially aged • -T7: Solution treated, over-aged • -T8: Solution treated, CW, artificially aged • -T9: Solution treated, artificially aged , CW Chapter 9 - 60 New Concepts & Terms • Applications of hardness profiles (Jominy curves) • Precipitation hardening – Heat treatment process – Effect of overaging – Microstructures – Effect on strength • Applications of aluminum – Know tradeoffs, especially with steels – Which alloys are precipitation hardenable? Chapter 9 - 61