Chapter 10: Phase Transformations ISSUES TO ADDRESS ... • Transforming one phase into another takes time. Fe γ (Austenite) C FCC Fe C 3 Eutectoid transformation (cementite) + α (ferrite) (BCC) • How does the rate of transformation depend on time and T? • How can we slow the transformation so that we can engineer non-equilibrium structures? • Are the properties of non-equilibrium structures improved? Fraction of Transformation • Fraction transformed depends on time. 1 y 0.5 Avrami Eqn. −ktn − = y 1 e fraction transformed time Adapted from Fig. 10.1, Callister 6e. Fixed T t log (t) 0.5 0 • Transformation rate depends on T. t 0.5 43 °C − = Ae Q /RT 5° C 1 11 119°C 103°C 2° C 88 °C r= Ex: recrystallization of Cu y (%) 100 13 activation energy 50 0 1 10 • r often small: equil not possible! 102 104 log (t) min Adapted from Fig. 10.2, Callister 6e. (Fig. 10.2 adapted from B.F. Decker and D. Harker, "Recrystallization in Rolled Copper", Trans AIME, 188, 1950, p. 888.) Transformations and Undercooling • Eutectoid transf. (Fe-C System): γ ⇒ α + Fe3 C • Can make it occur at: 0.77wt%C 6.7wt%C 0.022wt%C ...727ºC (cool it slowly) ...below 727ºC (“undercool” it!) T(°C) 1600 L 1400 1200 γ+L γ austenite L+Fe3C Eutectoid: γ+Fe3C γ α+ 800 Equil. cooling: Ttransf. = 727ºC 600 ∆T α+Fe3C Undercooling by ∆T: Ttransf. < 727ºC 1 2 3 4 5 6 Co, wt% C 6.7 727°C 0.77 400 0 (Fe) 0.022 α ferrite 1000 Adapted from Fig. 9.21,Callister 6e. (Fig. 9.21 adapted from Binary Alloy Phase Diagrams, 2nd ed., Vol. 1, T.B. Massalski (Ed.-in-Chief), ASM International, Materials Park, OH, 1990.) Fe3C cementite Eutectoid Transformation Rate ~ ∆T • Growth of pearlite from austenite: cementite (Fe3C) ferrite (α) • Reaction rate increases with ∆T. γ pearlite growth direction 50 0 γ α 650°C 50 675°C (∆T smaller) 1 γ Adapted from Fig. 9.13, Callister 6e. α 0 100 600°C (∆T larger) α 100 10 102 103 time (s) % austenite α α γ α α α α y (% pearlite) Austenite (γ) grain boundary Diffusive flow of C needed Adapted from Fig. 10.3, Callister 6e. Nucleation and Growth • Reaction rate is a result of nucleation and growth of crystals. 100 % Pearlite Nucleation rate increases w/ ∆T 50 Nucleation regime 0 Growth regime t50 Growth rate increases w/ T log (time) Adapted from Fig. 10.1, Callister 6e. • Examples: γ pearlite colony T just below TE Nucleation rate low Growth rate high γ T moderately below TE Nucleation rate med . Growth rate med. γ T way below TE Nucleation rate high Growth rate low Isothermal Transformation Diagrams y, % transformed • Fe-C system, Co = 0.77wt%C • Transformation at T = 675C. 100 T=675°C 50 0 102 1 T(°C) Austenite (stable) 700 Austenite (unstable) 0% 10 lite % 50 pear 0% 400 time (s) TE (727°C) isothermal transformation at 675°C Pearlite 600 500 104 1 10 Adapted from Fig. 10.4,Callister 6e. (Fig. 10.4 adapted from H. Boyer (Ed.) Atlas of Isothermal Transformation and Cooling Transformation Diagrams, American Society for Metals, 1977, p. 369.) time 102 103 104 105 (s) Ex: Cooling History Fe-C System • Eutectoid composition, Co = 0.77 wt%C • Begin at T > 727 °C • Rapidly cool to 625 °C and hold isothermally. T(°C) Austenite (stable) TE (727°C) 700 Adapted from Fig. 10.5,Callister 6e. (Fig. 10.5 adapted from H. Boyer (Ed.) Atlas of Pearlite 600 γ γ γ γ 0% 10 % 50 ite arl pe 0% 500 γ 1 10 γ Isothermal Transformation and Cooling Transformation Diagrams, American γ Society for Metals, 1997, p. 28.) 102 103 104 105 time (s) Pearlite Morphology Two cases: • Ttransf just below TE • Ttransf well below TE --Smaller T: diffusion is slower --Pearlite is finer. 10µm --Larger T: diffusion is faster --Pearlite is coarser. Adapted from Fig. 10.6 (a) and (b),Callister 6e. (Fig. 10.6 from R.M. Ralls et al., An Introduction to Materials Science and Engineering, p. 361, John Wiley and Sons, Inc., New York, 1976.) - Smaller ∆T: colonies are larger - Larger ∆T: colonies are smaller Non-Equil. Transformation Products: Fe-C • Bainite: --α lathes (stripes) with long rods of Fe3C --diffusion controlled. • Isothermal Transf. Diagram 800 Austenite (stable) T(°C) A 100% pearlite pearlite/bainite boundary 100% bainite 400 B A 103 0% 10 10 % 50 10-1 0% 200 α (ferrite) TE P 600 Fe3C (cementite) 105 time (s) 5 µm (Adapted from Fig. 10.8, Callister, 6e. (Fig. 10.8 from Metals Handbook, 8th ed., Vol. 8, Metallography, Structures, and Phase Diagrams, American Society for Metals, Materials Park, OH, 1973.) Bainite reaction rate: rbainite = e −Q / RT Adapted from Fig. 10.9,Callister 6e. (Fig. 10.9 adapted from H. Boyer (Ed.) Atlas of Isothermal Transformation and Cooling Transformation Diagrams, American Society for Metals, 1997, p. 28.) Other Products: Fe-C System (1) • Spheroidite: α --α crystals with spherical Fe3C (ferrite) --diffusion dependent. --heat bainite or pearlite for long times --reduces interfacial area (driving force) Fe3C • Isothermal Transf. Diagram 800 Austenite (stable) T(°C) A P 600 400 (cementite) TE 100% spheroidite Spheroidite B A 103 % 100 50% 10 (Adapted from Fig. 10.10, Callister, 6e. (Fig. 10.10 copyright United States Steel Corporation, 1971.) Adapted from Fig. 10.9,Callister 6e. (Fig. 10.9 adapted from H. Boyer (Ed.) Atlas of 0% 200 10-1 100% spheroidite 60 µm Isothermal Transformation and Cooling Transformation Diagrams, American Society for Metals, 1997, p. 28.) 105 time (s) Other Products: Fe-C System (2) • Martensite: --γ(FCC) to Martensite (BCT) Fe atom sites x x x 60 µm (involves single atom jumps) potential C atom sites x x x (Adapted from Fig. 10.11, Callister, 6e. • Isothermal Transf. Diagram 800 T(°C) Austenite (stable) A 600 Adapted from Fig. 10.13, 400 TE P (Adapted from Fig. 10.12, Callister, 6e. (Fig. 10.12 courtesy United States Steel Corporation.) S A B Callister 6e. % 50 0% 200 Martentite needles Austenite • γ to M transformation.. 10 0% M+A M+A M+A 10 10-1 103 0% 50% 90% 105 -- is rapid! -- % transf. depends on T only. time (s) Time-Temperature-Transformation (TTT) Diagrams Isothermal TTT Diagram Continuous Cooling TTT Diagram TTT Diagrams for a Eutectoid Steel Cooling Ex: Fe-C System (1) • Co = Ceutectoid • Three histories... Rapid Hold Rapid Hold Rapid cool to: for: cool to: for: cool to: 350°C 104s Troom 104s Troom 250°C 102s Troom 102s Troom 650°C 20s 400°C 103s Troom Case I 800 Austenite (stable) T(°C) A 600 A P S B 400 10 100%A % 50 0% 200 M + A M+A M+A 10 10-1 103 100%B 0% 0% 50% 90% Adapted from Fig. 10.15, Callister 6e. 100% Bainite 105 time (s) Cooling Ex: Fe-C System (2) • Co = Ceutectoid • Three histories... Rapid Hold Rapid Hold Rapid cool to: for: cool to: for: cool to: 350°C 104s Troom 104s Troom 250°C 102s Troom 102s Troom Case II 800 Austenite (stable) T(°C) A 650°C 20s 400°C P 600 S A B 400 0% % 200 M + A M+A M+A 10 10-1 50 100%A 10 0% 0% 50% 90% Adapted from Fig. 10.15, Callister 6e. M + trace of A 103 105 time (s) 103s Troom Cooling Ex: Fe-C System (3) • Co = Ceutectoid • Three histories... Rapid Hold Rapid Hold Rapid cool to: for: cool to: for: cool to: 350°C 104s Troom 104s Troom Case III 800 Austenite (stable) T(°C) A 100%A 600 A 50%P, 50%A P S B 400 50%P, 50%B 50%P, 50%A % 50 0% 200 M + A M+A M+A 10 10-1 250°C 102s Troom 102s Troom 650°C 20s 400°C 103s Troom 10 0% 0% 50% 90% Adapted from Fig. 10.15, Callister 6e. 50 103 %P 105 time (s) ,5 0% B Mechanical Prop: Fe-C System (1) • Effect of wt%C Adapted from Fig. 9.27,Callister 6e. (Fig. 9.27 courtesy Republic Steel Corporation.) TS(MPa) 1100 YS(MPa) Co<0.77wt%C Hypoeutectoid Hypo Hyper Co>0.77wt%C Hypereutectoid %EL Hypo Hyper 80 100 900 Adapted from Fig. 9.30,Callister 6e. (Fig. 9.30 copyright 1971 by United States Steel Corporation.) hardness 40 700 50 500 0 0.5 1 0 0.77 0 0.77 300 1 Impact energy (Izod, ft-lb) Pearlite (med) ferrite (soft) Pearlite (med) Cementite (hard) 0.5 0 wt%C wt%C • More wt%C: TS and YS increase, %EL decreases. Adapted from Fig. 10.20, Callister 6e. (Fig. 10.20 based on data from Metals Handbook: Heat Treating, Vol. 4, 9th ed., V. Masseria (Managing Ed.), American Society for Metals, 1981, p. 9.) Mechanical Prop: Fe-C System (2) • Fine vs coarse pearlite vs spheroidite Hyper Brinell hardness 320 240 fine pearlite 160 coarse pearlite spheroidite 80 0 0.5 1 wt%C 90 Ductility (%AR) Hypo Hypo spheroidite 60 coarse pearlite fine pearlite 30 0 0 • Hardness: fine > coarse > spheroidite • %AR: fine < coarse < spheroidite Hyper 0.5 1 wt%C Adapted from Fig. 10.21, Callister 6e. (Fig. 10.21 based on data from Metals Handbook: Heat Treating, Vol. 4, 9th ed., V. Masseria (Managing Ed.), American Society for Metals, 1981, pp. 9 and 17.) Mechanical Prop: Fe-C System (3) • Fine Pearlite vs Martensite: Brinell hardness Hypo 600 Hyper martensite Adapted from Fig. 10.23, Callister 6e. (Fig. 10.23 adapted from Edgar C. Bain, 400 Functions of the Alloying Elements in Steel, American 200 0 0 fine pearlite 0.5 Society for Metals, 1939, p. 36; and R.A. Grange, C.R. Hribal, and L.F. Porter, Metall. Trans. A, Vol. 8A, p. 1776.) 1 wt%C • Hardness: fine pearlite << martensite. Tempering Martensite • reduces brittleness of martensite, • reduces internal stress caused by quenching. TS(MPa) YS(MPa) 1800 Adapted from Fig. 10.25, 1400 Callister 6e. (Fig. 10.25 1200 adapted from Fig. furnished courtesy of 1000 Republic Steel Corporation.) 800 200 TS YS 60 50 %AR 40 30 %AR 400 9 µm 1600 Adapted from Fig. 10.24, Callister 6e. (Fig. 10.24 copyright by United States Steel Corporation, 1971.) 600 Tempering T (°C) • produces extremely small Fe3C particles surrounded by α. • decreases TS, YS but increases %AR Summary: Processing Options Austenite (γ) slow cool Pearlite moderate cool Bainite Martensite T Martensite bainite fine pearlite coarse pearlite spheroidite rapid quench Martensite (BCT phase diffusionless transformation) reheat Ductility Strength (α + Fe3C layers + a (α + Fe3C plates/needles) proeutectoid phase) Adapted from Fig. 10.27, Callister 6e. General Trends Tempered Martensite (α + very fine Fe3C particles) Chapter 11: Metal Alloys Applications and Processing ISSUES TO ADDRESS... • How are metal alloys classified and how are they used? • What are some of the common fabrication techniques? • How do properties vary throughout a piece of material that has been quenched, for example? • How can properties be modified by post heat treatment? Taxonomy of Metals Metal Alloys Ferrous Steels Steels <1.4wt%C <1.4wt%C Cast Irons Cast Irons 3-4.5wt%C 3-4.5wt%C Cu Al 1600 δ L 1400 γ+L γ austenite L+Fe3C 1148°C Eutectic: 4.30 1000 γ α+ α800 ferrite 600 400 0 (Fe) γ+Fe3C 727°C 1 α+Fe3C 2 3 4 Ti Adapted from Fig. 9.21,Callister 6e. (Fig. 9.21 adapted from Binary Alloy Phase Diagrams, 2nd ed., Vol. 1, T.B. Massalski (Ed.-in-Chief), ASM International, Materials Park, OH, 1990.) Fe3C cementite Eutectoid: 0.77 Mg microstructure: ferrite, graphite cementite T(°C) 1200 Adapted from Fig. 11.1, Callister 6e. Nonferrous 5 6 Co, wt% C 6.7 Steels High Alloy Low Alloy low carbon med carbon high carbon <0.25wt%C 0.25-0.6wt%C 0.6-1.4wt%C heat plain treatable Cr,V Cr, Ni Additions none none none Ni, Mo Mo Example 1010 4310 1040 4340 1095 Hardenability 0 + + ++ ++ TS 0 + ++ + EL + + 0 Name plain HSLA Uses auto bridges struc. towers sheet press. vessels plain pistons wear crank gears shafts applic. wear bolts hammers applic. blades tool Cr, V, Mo, W 4190 +++ ++ -drills saws dies increasing strength, cost, decreasing ductility Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister 6e. austentitic stainless Cr, Ni, Mo 304 0 0 ++ high T applic. turbines furnaces V. corros. resistant Basic Ideas in Alloying Steels: 1. Phase Partitioning at Austenite/Pearlite Interface Carbide Formers V, Ti, Nb Ferrite Formers (solid solution) Ni, Si, Mn Paritioning at the Austenite/Pearlite Interface Slows transformation Allows Bainite or Martensite to form on cooling Basic Ideas in Alloying Steels: 2. Alloying to Control the Eutectoid Transformation Alloying Control ‘Nose’ in TTT Diagram Control Eutectoid Temperature and C Composition Cr: added (~8 – 12wt %) to make steel ‘stainless’ Ni: High concentrations to stabilize austenite – austenitic steels Hardenability of Steels • Ability to form martensite • Jominy end quench test to measure hardenability. 1” specimen (heated to γ phase field) 24°C water flat ground 4” Adapted from Fig. 11.10, Callister 6e. (Fig. 11.10 adapted from A.G. Guy, Essentials of Materials Science, McGraw-Hill Book Company, New York, 1978.) Hardness, HRC • Hardness versus distance from the quenched end. Adapted from Fig. 11.11, Callister 6e. Distance from quenched end Why Hardness Changes with Position Hardness, HRC • The cooling rate varies with position. 60 40 20 0 1 2 3 distance from quenched end (in) T(°C) 600 A→ 0% 100% P Adapted from Fig. 11.12, Callister 6e. (Fig. 11.12 adapted from H. Boyer (Ed.) Atlas of Isothermal 400 200 Transformation and Cooling Transformation Diagrams, American M(start) Society for Metals, 1977, p. 376.) A→M 1 te rli ite ea e rl P lit ea + ar e P ite Pe in ens e F t t ar si M ten ar 0.1 M 0 M(finish) 10 100 1000 Time (s) Hardenability vs. Alloy Content • "Alloy Steels" (4140, 4340, 5140, 8640) --contain Ni, Cr, Mo (0.2 to 2wt%) --these elements shift the "nose". --martensite is easier to form. 10 3 60 2 Cooling rate (°C/s) 100 4340 80 %M 50 40 4140 8640 40 10 Adapted from Fig. 11.13, Callister 6e. (Fig. 11.13 adapted from figure furnished courtesy Republic Steel Corporation.) 100 Hardness, HRC • Jominy end quench results, C = 0.4wt%C 5140 20 0 10 20 30 40 50 Distance from quenched end (mm) 800 T(°C) 600 A 400 200 0 -1 10 10 B TE shift from A to B due to alloying M(start) M(90%) 103 105 Time (s) Quenching Medium and Geometry • Effect of quenching medium: Medium air oil water Severity of Quench small moderate large Hardness small moderate large • Effect of geometry: When surface-to-volume ratio increases: --cooling rate increases --hardness increases Position Cooling rate center small surface large Hardness small large Nonferrous Alloys • Cu Alloys • Al Alloys Brass: Zn is subst. impurity -lower ρ: 2.7g/cm3 (costume jewelry, coins, -Cu, Mg, Si, Mn, Zn additions corrosion resistant) -solid sol. or precip. Bronze: Sn, Al, Si, Ni are strengthened (struct. subst. impurity aircraft parts (bushings, landing & packaging) gear) • Mg Alloys NonFerrous Cu-Be: -very low ρ: 1.7g/cm3 Alloys precip. hardened -ignites easily for strength -aircraft, missles • Ti Alloys -lower ρ: 4.5g/cm3 • Refractory metals -high melting T -Nb, Mo, W, Ta vs 7.9 for steel • Noble metals -reactive at high T -Ag, Au, Pt -oxid./corr. resistant -space applic. Based on discussion and data provided in Section 11.3, Callister 6e. Metal Fabrication Methods (1) CASTING FORMING • Forging (wrenches, crankshafts) force JOINING • Rolling (I-beams, rails) roll die Ao blank Ad often at elev. T • Drawing force Ao die Ad roll • Extrusion (rods, wire, tubing) die Ao Adapted from Fig. 11.7, Callister 6e. (rods, tubing) Ao tensile force Ad force container ram billet container die holder extrusion die Ad Forming Temperature • Hot working --recrystallization • Cold working --recrystallization --less energy to deform --oxidation: poor finish --lower strength --less energy to deform --oxidation: poor finish --lower strength • Cold worked microstructures --generally are very anisotropic! --Forged (a) --Swaged (b) --Fracture resistant! (c) Reprinted w/ permission from R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering Materials", (4th ed.), John Wiley and Sons, Inc., 1996. (a) Fig. 10.5, p. 410 (micrograph courtesy of G. Vander Voort, Car Tech Corp.); (b) Fig. 10.6(b), p. 411 (Orig. source: J.F. Peck and D.A. Thomas, Trans. Metall. Soc. AIME, 1961, p. 1240); (c) Fig. 10.10, p. 415 (Orig. source: A.J. McEvily, Jr. and R.H. Bush, Trans. ASM 55, 1962, p. 654.) Metal Fabrication Methods (2) FORMING CASTING • Sand Casting (large parts, e.g., auto engine blocks) Sand • Die Casting (high volume, low T alloys) Sand molten metal • Investment Casting (low volume, complex shapes e.g., jewelry, turbine blades) plaster die formed around wax prototype JOINING • Continuous Casting (simple slab shapes) molten solidified wax Metal Fabrication Methods (3) FORMING • Powder Processing (materials w/low ductility) pressure heat area contact densify point contact at low T densification by diffusion at higher T CASTING JOINING • Welding (when one large part is impractical) filler metal (melted) base metal (melted) fused base metal heat affected zone unaffected unaffected Adapted from Fig. piece 1 piece 2 11.8, Callister 6e. (Fig. 11.8 from • Heat affected zone: Iron Castings Handbook, C.F. Walton and T.J. (region in which the Opar (Ed.), 1981.) microstructure has been changed). Thermal Processing of Metals Annealing: Heat to Tanneal, then cool slowly. • Stress Relief: Reduce stress caused by: -plastic deformation -nonuniform cooling -phase transform. • Spheroidize (steels): Make very soft steels for good machining. Heat just below TE & hold for 15-25h. Types of Annealing • Process Anneal: Negate effect of cold working by (recovery/ recrystallization) Based on discussion in Section 11.7, Callister 6e. • Full Anneal (steels): Make soft steels for good forming by heating to get γ, then cool in furnace to get coarse P. • Normalize (steels): Deform steel with large grains, then normalize to make grains small. Precipitation Hardening • Particles impede dislocations. 700 • Ex: Al-Cu system T(°C) • Procedure: 600 α α+L --Pt A: solution heat treat A 500 (get α solid solution) --Pt B: quench to room temp.400 C --Pt C: reheat to nucleate small θ crystals within 300 0 B 10 α crystals. (Al) θ+L α+θ 20 30 θ 50 wt%Cu Adapted from Fig. 11.22, Callister 6e. (Fig. 11.22 adapted from J.L. Murray, International Metals Review 30, p.5, 1985.) Temp. Pt A (sol’n heat treat) Adapted from Fig. 11.20, Callister 6e. 40 CuAl2 composition range needed for precipitation hardening • Other precipitation systems: • Cu-Be • Cu-Sn • Mg-Al L Pt C (precipitate θ) Pt B Time Precipitate Effect on TS, %El • 2014 Al Alloy: 500 400 300 200 • %EL reaches minimum with precipitation time. few p e “o recip r lar ve ra itate ge ge d” s %EL (2in sample) no so n-eq lid ui so l . lut i on ma p r ny s ec ipi mall “a tates ge d” tensile strength (MPa) • TS peaks with precipitation time. • Increasing T accelerates process. 149°C 204°C 1min 1h 1day 1mo 1yr precipitation heat treat time (h) 30 20 10 204°C 0 1min 1h 1day 1mo 1yr precipitation heat treat time (h) Adapted from Fig. 11.25 (a) and (b), Callister 6e. (Fig. 11.25 adapted from Metals Handbook: Properties and Selection: Nonferrous Alloys and Pure Metals, Vol. 2, 9th ed., H. Baker (Managing Ed.), American Society for Metals, 1979. p. 41.) 149°C SUMMARY • Steels: increase TS, Hardness (and cost) by adding --C (low alloy steels) --Cr, V, Ni, Mo, W (high alloy steels) --ductility usually decreases w/additions. • Non-ferrous: --Cu, Al, Ti, Mg, Refractory, and noble metals. • Fabrication techniques: --forming, casting, joining. • Hardenability --increases with alloy content. • Precipitation hardening --effective means to increase strength in Al, Cu, and Mg alloys.