Microstructure of Metal Materials

Metal specimen set
Metallurgical Study
for
TIS MOTION & CONTROL PTE LTE
NO 63 UBI AVENUE 1, #03-01,PAYA UBI INDUSTRIAL PARK
SINGAPORE 408934.
Tel.: 741 5995 Fax: 741 6656
The microstructures can tell the properties, quality, and the characteristics of metals. Metals with
different compositions and different heat treatment condition will be different in microstructures. These set of
specimens contains various kinds of ferrous metal in various conditions. These specimens can be used as the
reference in studying of Metallurgy, Foundry, Heat Treatment, and Manufacturing Processes, etc.
There are 30 pieces of specimen in this set. Each specimen is prepared, etched, and coated with
transparency coating material to protect the specimen surface and to be able to be seen under microscope.
without any cleaning process. The specimens were kept in three wooden boxes, 10 pieces each. The data and
specimen descriptions and micro-photographs are prepared and combined as a book and supplied together
with the specimens.
TIS MOTION & CONTROL PTE LTD
Preface
1. General background and Introduction . 1-7
2. Carbon steels
2.1 Low carbon steel 8-15
2.2 Medium carbon steel . 16-21
2.3 High carbon steel .. 22-29
3. Low alloy steels
3.1 AISI 4130 steel . 30-33
3.2 AISI 4340 steel . 34-35
4. Cast irons
4.1 Gray cast iron . 36-41
4.2 White cast iron . 42-43
4.3 Malleable iron .. 44-45
4.4 Nodular cast iron .. 46-49
4.5 Bainitic Ductile Iron ( BDI) . 50-51
4.6 Wear resistant cast iron(Alloy cast iron) . 52-53
5. Tool steels
5.1 High carbon high chromium tool steel ( AISI D2 ) .. 54-57
5.2 Mold tool steel (AISI P 20 ) . 58-61
5.3 High speed steel .... 62-63
6. Cast steel
6.1 High manganese steel . 64-67
Contents
1.General Background and Introduction
1.1 General Engineering Materials:
Engineering materials can be classified into two classes, Metal and Non-metal.
A Metal: an element that has several metallic properties as the followings:
1. Shiny appearance.
2. Give sonorous tone when struck.
3. Good conduction of heat and electricity.
4. High malleablity(can be rolled or pressed into shape).
5. High ductility(can be drawn into wire).
6. With possible emission of electrons when heated(thermionic effect) or when the
surface is struck by light(photoelectric effect).
7. Hard and heavy.
8. Not transparent.
All metals have some of these properties. Some metals have every one of these properties.
There are about 70 elements are classified as metals: e.g. Fe, Cr, Ni, Mg, Al, Cu etc.
A Non-metal: an element with certain physical and chemical properties opposite to those of metals
Non-metals accept electron to form negatively charged ions.
There are about 20 elements are classified as metals: e.g. S, P, C, Si and F etc.
The metals can be devided into two classes: Non-ferrous metals and Ferrous metals which are
also devided into many sub-classes as shown in Fig.1.
The Non-metals are Polymers and Ceramic are out of the scope of this book.
All specimens mentioned in this book are Ferrous metals and picked up from Carbon steels, Low
alloy steels, Cast irons, Tool steels, and Cast steels.
1.2. Steel Making
Carbon steels, Low alloy steels, and Tool steels are made as shown in Fig.2. Cast irons and Cast
steels are made as shown in Fig.3.
1.3. Specimen Selection
The specimen were cut from the specified round bars and flat bars of Carbon steels, Low alloy
steels, and Tool steels and heat treated according to the specified processes.
The specimen of Cast iron(gray cast iron, nodular iron, and Bainitic Ductile Iron)were casted by
using induction furnace and sand mold, then heat treated according to the specified processes.
Specimen No.29,30 are special alloy cast steel, also were casted in the induction furnace with
high percentage of Mn addition and good quality control. No.29 is in as cast condition and No.30 is after
annealing.
1.4. Specimen preparation
Every specimen was prepared according to the processes shown in Fig.4.
1.5. Heat treatment processes
General heat treatment processes are shown in Fig.5 and the heat treatment processes applied for
each specimens is shown in each data sheet for each specimen.
1
Steels
Polymer Ceramic Cast steel Spec.#29,30
Rubber General High-Mn
Ceramic carbon
Plastic Spec.#18 Carbon steel steel
Enginnering
Ceramic Spec.#20,21
Malleable
iron Low-C steel
Spec.#19 0.05-0.30C
Spec.#1 to 4
Alloy steel
Graphite Graphite
free bearing
Pearlitic Martensitic High-Cr iron Acicular Spec. #12 to 14
white iron white iron 11-28%Cr High strength
Wear resistant Wear resistant Wear, corrosion, wear resistant
and heat resistant
Spec.#23 Austenitic
Tool steel
18%Ni
Ni-resist Carbon tool
Heat and corrosion resistant Heat and corrosion resistant steel(W)
Ferritic Spec.#24,25 Spec.#26,27 Spec.#28
Austenitic
e.g.304,316
Alloy structural steel
heat resistant corrosion resistant
Machineries steel
Rephoshorized and
Resulfurized carbon steel
Structural Steel
Spec.#8 to 11
Stainless steel
Carbon structural steel
e.g. Spring steel, Silicon steel, Heat resisting steel, Magnetic steel, Corrosion resisting steel
Austenitic Ductile Iron
(ADI)
Bainitic Ductile Iron
(BDI)
Spec.#22
18% Ni, 5%Si
Nicrosilal
High,15%, Si iron 5% Si iron(Silal)
Ferrous Metals
General Enginnering Materials
Non-Ferrous Metals Metals e.g. Copper, Aluminum, and its alloys; Super-alloys etc.
Gray cast iron
Cast Iron
Wrought steel
Spec.#5 to 7
Spec.#15 to 17
Mottled cast iron
White cast iron
Ductile cast iron
Alloy cast iron
Composit
Material
Non-resulfurized
carbon steel
Resulfurized
carbon steel
Ultra-high-C
steel,1-2%C
Med. C steel
0.30-0.60C
High-C steel
0.60-1.00C
Low and medium
alloy steel
High alloy
steel
Ultra-high
strength
steel
High Strength
Low Alloy
Steel(HSLA)
Other alloy
steel
e.g.Mara-
ging steel
Shock re-
sisting tool
steel (S)
High speed
steel(T,M)
Cold Work
tool steel
(A,O,D)
Mould tool
steel (P)
Hot Work
tool steel
(H)
Special
purpose
tool steel
(L)
Martensitic
e.g.410,440
Ferritic e.g.
430, 439
Precipitation
hardening, PH
Fig. 1: Classification of
general engineering
materials.
Other steels
Non-Resulfurized
carbon steel
Resulfurized
carbon steel
Rephosphurized and
resulfurized carbon steel
High -
manganese
carbon steel
2
ORES
DIRECT
REDUCTION
PELLETS
ELECTRIC
FURNACE
LIME STONE
SINTER LADLE METALLURGY
Note: Ladle Metallurgy is
used to control condition
within the ladle to improve
productivity in preceding
and subsequench pro-
cessing steps and the
quality of the final product
These conditions can
CRUSHED include temperature,
pressure, chemistry, and
COAL OXYGEN momentum through stirring
SLAG
Note: A modification of the BOP is the Q-BOP
which the oxygen and other gas are
From iron ores, lime stones, and coal blown in from the bottom rather than
in the Earth's crust to space-age steel the top as shown.
this flowline shows the major steps MERCHANT
in an steel making processes. PIG IRON CASTING
BLAST FURNACE
MOLTEN IRON COKE OVENS
FURNACE
OPEN HEARTH
DIRECT
REDUCTION
MERCHANT
PIG IRON CASTING
FLUX
SCRAP
BASIC OXYGEN FURNACE
OR Q-BOF
Fig.2 Steel making processes Fig.2 Steel making processes
3
Molten steel must solidify SKELP
before it can be made into
finished products in an
infinite variety, considering
chemistry, properties, and sizes. PLATE Flat rolled products
are rolled from slabs by using sets of cylin-
drical rolls.
TEMPER
Grooved rolle squeeze billets ROLLING
into different cross-sections(round,angles,
etc.) in a sequench of operations.
RODS WIRE
TUBE ROUND
Piercing is the process
used to make seam-
less pipe and tube.
Note:
A smal but significant percentage of
heated ingot steel is squeezed in Set of grooved rolls are used to
forging presses to make large shaft to roll brooms into heavy beam
for power plants, nuclear plants, for construction or for rails.
nuclear plant components, and other
products.
HOT FORGING
CONTINUOUS CASTING
STEEL PLATES
COLD STRIP
BLOOM
BILLET
SLAB
SEAMLESS PIPE
COLD DRAWN BARS
GALVANIZED AND
OTHER COATED
FLAT ROLLED
PRODUCTS
CONVENTIONAL INGOT
TEEMING
INGOT BREAKDOWN
MILL
SLAB
BILLET
HOT STRIP
PLATE
HOT ROLLED BAR
TUBE ROUND
RAILS
STRUCTURAL
SHAPES
WELDED PIPE
COLD STRIP
Fig.2 Steel making processes, cont.
4
Pig iron
Flux
Scraps
MELTING IN INDUCTION
FURNACE
CASTING
RAW MATERIALS
PATTERN MAKING
POURING MOLTEN
MOLTEN METAL IS POURED
INTO THE LADLE
TO MOLD
MOLDING SAND PREPARATION
MOLD MAKING
METAL FROM LADLE
HEAT TREATMENT
DESGN & DRAWING
Fig. 3 Casting processes
5
1.Cutting 2.Mounting 3.Grinding 4.Polishing 5.Etching 6.Examination 7.Micro-photography
coolant coolant sand paper coolant polishing medium(Al
2
O
3
suspension) ccd camera
specimen specimen etchant specimen specimen
cutting
wheel
specimen grinding polishing polishing
wheel cloth wheel metallurgical microscope
fixed
piston
cut specimen moving
piston bekalite
specimen
1.Equipment: 1.Equipment: 1.Equipment: 1.Equipment: 1.Equipment: 1.Equipment: 1.Equipment:
Lab cut-off machine Hot mounting machine Grinding machine Polishing machine Watch glass Metallurgical microscope, Computer, printer.
2.Cut-off wheel: 2.Resin type: 2.Grinding medium: 2.Polishing medium: 2. Quenchant: CCD camera, and
Resin bonded, both soft Phenolic resin(Bekelite) Water proof sand paper Polishing cloth and water 2.1 Reagent 7a. specimen leveller.
type(for hard specimen) or Acrylic resin(transpa- grit No.240,400,800,1200, suspended Alumina 2.2 Nital 3 % 2.The magnification:
and hard type(for soft lent type) and 2400 powder, 0.3 micron 3.Etching time: 50x,100x, 200x, 500x.
specimen) 3.Temperature: 3.Coolant: 3.Coolant: 15-30 seconds and 1000x.
3.Coolant: 170-180
o
C Water Water 4.Cleaning:
Water mixed with cooling 4.Time: Note: Note: After etching, the
medium and anti-bacteria 8-12 min. The grinding must start Before polishing, the specimen must be rinsed
solution. 5.Coolant: from the coarse sand specimen and hands with flowing water and
Note: Water paper and change to must be clean. washed with alcohol and
The specimen must be Note: finer sand paper. During the polishing, the immediately blown with
well selected and may be The mounted specimen Before changing to the specimen must be kept hot air.
round square or other must be marked carefully finer sand paper, the clockwise, and counter- Note:
irregular shape. to avoid confusing. grinding line from the clockwise to prevent 1. Nital 3%:
The cutting must be previous sand paper comet tail. Nitric acid(HNO
3
): 3 cc
carried out carefully and must be disappeared and The water must be used Alcohol: 97 cc
enough coolant to the new grinding lines together with the polishing 2. Reagent 7a:
prevent overheating must be in the same powder. 3 g potassium metabi-
during cutting. direction. And before After polishing, the sulfite
starting the new sand specimen must be rinsed 1 g sulfamic acid
paper, the specimen and with water and alcohol 100 ml. Distilled water
hands must be clean. and dry with hot air. ( Reagent 7a is for color etcch )
watch glass
computer set
and printer (Keep the specimen
moving during etching)
Specimen preparation
Fig. 4 Specimen preparation
6
Gas phase deposition
Softening Hardening
Annealing Normalizing
Batch
annealing Peening
Rolling
Pressure
Sub-critical polishing
annealing
Stress relieving
HEAT TREATMENT PROCESSES
Surface Treatment
Phase un-change Phase change
Full Treatment
Process
annealing
Supercritical or
full annealing
Continuous
annealing
Intermediat
annealing
Austempering
Quench & temper
Martempering
Solution treatment & aging
Sub-zero treatment
Application of coating Influence on surface layer
Composition
changes
Composition
un-changes
Mechanical
method
Flame
hardening
Induction
hardening
Hardening by high energy heating
Electron beam hardening, etc.
Thermo-
chemical
method
Carbonitriding Carburizing Nitriding Nitrocarburizing
PVD Coating
CVD Coating
Mechanical
method
Thermal
method
Thermal
method
Thermo-
mechani-cal
method
Clading
Sintering
Currentless
Ni-deposition
Explosion
coating
Spray
coating
Tin plating
Fusion
Tin plating
Built-up
welding
Lead plating
Spark work
hardening
Nickel plating
Chemical
method
Electrochemical method
Chromium plating
Hard facing
Copper plating Spheroidizing
Carbonis
added(diffused
) through
steel surface
Solid carbu-
rizing (Pack
carburizing)
C- sources:
Carbon
granulates
Vacuum carburizing
C- sources:Hydrocarbon gas
Cyaniding
C- sources:Cyanide salt
Liquid carburizing(Salt bath carburizing)
C- sources: Cyanide salt
Gas carburizing
C- sources:Carbon rich atmosphere
Plasma(Ion) carburizing
C-sources: Hydrocabon gas
Nitrogen(N) is
added(diffused
) through
steel surface
Pack nitriding
N-sources:
Nitrogen bearing
organic compound
Gas nitriding
N-sources:Ammonia gas(NH
3
)
Plasma(Ion) nitriding
N-sources:Ammonia gas or N
2
-gas
Definition:Carbonis added to steel surface during
nitriding, but the actual process is to add nitrogen (from
NH3) to steel during carburizing process, modified from
Gas carburizing process.
High temperature
carbonitriding
The process is done
at 900-950
o
C
Low temperature
carbonitriding
The process is done
at 540-560
o
C
Medium temperature
carbonitriding
The process is done
at 840-860
o
C
Definition:Nitrogen is added to steel surface during carburizing, but
the actual process is to add carbon and nitrogen to steel surface to
produce surface enrichment in nitrogen(N) and carbon(C)
Ferritic Nitrocarburizing
To add N and C to steel
surface at temperature
within the ferrite phase
field, usually 570
o
C
Austenitic
Nitrocarburizing
The process is done in
the austenite phase field
Plasma Nitrocarburizing
The nitrocaburizing using
glow discharge
technology
Fig. 5 Heat treatment processes
7
Specimen
No.: 1
Chemical C Si Mn P S Cr Mo Ni V Ti Co W Others
composition 0.18-0.23 0.15-0.35 0.30-0.60 0.04 max 0.04max - - - - - - - -
Similar FRANCE RUSSIA CHINA SWEDEN JAPAN ITALY AUSTRALIA
steels AISI/SAE ASTM DIN KRUPP AFNOR GOST1050 GB 699 SS14 JIS UNI5598 AS1442
1020 A29:1020 1.0402 - CC20 20 20 1450 S20C 3CD20 CS1020
Characteristics: Most wildly used of several grade s containing about 0,20%carbon. Available in a variety of product forms. Excellent forgability and weldability.
No preheating and post heating required before or after welding. Machinability is notably poor. Wildy used as a carburizing steel.
Applications: Parts for case hardened condition where core strength is not critical, and shaft for large section that are not highly stressed, case hardened gears pins and chain.
Heat Descriptions Processes Tempering Tempering Nitriding
treatment Temperature,
o
C 200-250 200-250 Nitriding is
guide Soaking time, min. 2 hrs min. 2 hrs min. not recom-
Quenching medium air air mended.
55-60 HRC 55-60 HRC
Final heat treatment
o
C 870 furnace cool Process: The specimen is heated to 880
o
C for 60 min., the steel microstructures will transform to
process of this preheat 500 60 austenite, then cooldown slowly in the furnace austenite will transform to ferrite and pearlite. The steel
specimen 30 min. min. The steel will be softened,better machinability,better cold workability,and improve dimensional stability,etc
100x
Photo.1: 200x,Microstructures consist of Ferrite(yellow, blue, and purple), and Pearlite Photo.2. 1000x, same as in Photo. 1 but higher magnification. Brown area can be clearly
(brown), small black dots are inclusions remain in steel. seen Cementite and Ferrite in Pearlite. Grain boundaries are also clearly seen.
and no alloying element
BS
BS970:040A20
UK
Specimen name Material Condition
Ferrous Metal Low Carbon Steel Annealed
USA
Normalizing Through hardening Carburizing
GERMANY
Hardness
depend on case depth.
Carbonitriding
925 Because of low carbon 850-870 870-955
oil
60-62 HRC
1/2hr./25 mm.+1 hr. depend on case depth.
Microstructures
air or nitrogen Through hardening is not oil
120-130 HB advisable. 60-62 HRC
Record of Microstructures
grainboundary
Ferrite
Pearlite
8
Photo.3: 1000x, Same as in Photo.1,2 but in large area. The microstructures consist of Ferrite(blue, green, purple, yellow) and Pearlite(brown area with Cementite strips on Feerite).
9
Specimen
No.: 2
1020 A29:1020 1.0402 - CC20 20 20 1450 S20C 3CD20 CS1020
o
55-60 HRC 55-60 HRC
o
C 920 air cool Process: The specimen is heated to 920
o
C for180 min.in atmosphere controlled furnace with carbon
process of this preheat 500 180 potential o.9%. Carbon atom will diffuse into the specimen surface and combind with Fe to form Fe
3
C or
specimen 30 min. min. cementite in surface area, so pearlite increases in the surface area.
Photo.4: 100x, The photo was taken from surface to core of the specimen. At the Photo.5: 1000x, At the carburized surface of the specimen, the original strucutre are
surface, the microstructure become Pearlite because of increasing carbon. Ferrite and Pearlite , now no more free Ferrite because of carburization.
60-62 HRC
Microstructures
Hardness 120-130 HB advisable. 60-62 HRC
air or nitrogen Through hardening is not oil oil
1/2hr./25 mm.+1 hr. and no alloying element depend on case depth. depend on case depth.
Carbonitriding
Normalizing Through hardening Carburizing
Ferrous Metal Low Carbon Steel Carburized
UK USA GERMANY
BS
BS970:040A20
surface
10
Photo. 6
Photo.7 Photo.8 Photo.9
The original microstructures of the steel are Ferrite and Pearlite. After carburization, carbon diffused through the surface to the core. The structure at the surface becomes
Pearlite which consists of Cementite, Fe
3
C, and Ferrite (see Photo.7). Below the surface, the strucutres consist of Pearlite and Ferrite(see Photo.8) and at the core, the structures are
unchanged, it still be Pearlite and Ferrite as in the original condition(see Photo.9).
11
Specimen
No.: 3
1020 A29:1020 1.0402 - CC20 20 20 1450 S20C 3CD20 CS1020
o
55-60 HRC 55-60 HRC
o
C 920 oil quench Process: The specimen is heated to 920
o
process of this preheat 500 180 250 air cool potential o.9%. C atom diffused into specimen surface and combinded with Fe to form Fe
3
C(Cementite)
specimen 30 min. 120 min. which gives more pearlite and less ferrite. After hardened and tempered, pearlite and ferrite transformed
to austenite and then martensite accordingly.Tempered martensite+P+F will be achieved finally.
Photo.10: 50x,The specimen was carburized, quench, and tempered. Pearlite at the sur- Photo.11: 1000x, At the case area, the acicular or needle like structure(Martensite) will
face and below surface transformed to Martensite(left, colorfull area) be seen( purple, green, and brown).
Microstructures
60-62 HRC
Material
Low carbon steel
Condition
Carburized, quenched and tempered
BS970:040A20
air or nitrogen Through hardening is not oil oil
Normalizing Through hardening Carburizing Carbonitriding
USA GERMANY UK
BS
Specimen name
Ferrous Metal
12
Photo.13 1000x Photo.14 1000x Photo.15 1000x
Photo.12 shows the microstructures from the surface of low carbon steel to the core after carburized, quenched, and tempered. The case with green, purple, and yellow
is Martensite(see Photo.13). Between case and core are Martensite and Ferrite(see Photo.14). At the core, the microstructures remain the same as the original, Pearlite and Ferrite, some
Pearlite may transfer to Martensite, but Ferrite still unchanged(see Photo.15).
13
Photo.12,50x
Specimen
No.: 4
1020 A29:1020 1.0402 - CC20 20 20 1450 S20C 3CD20 CS1020
o
55-60 HRC 55-60 HRC
o
C 850 oil quench Process: The specimen is heated to 850
o
process of this preheat 500 180 250 air cool potential o.9%and some of NH
3
gas.C and N atom will diffuse into specimen surface and form both cemen-
specimen 30 min. 120 min. tite and nitride compounds in surface area.After quenched and tempered, tempered martensite+nitride+
pearlite+ferrite will be achieved.
Photo.16: 50x, Cross-sectioned shows the microstructures from surface to core of Photo.17: 1000x, Photo taken at the case, needlelike structure, Martensite.
the specimen. Dark case is Martensite, colorfull core are Pearlite and Ferrite.
60-62 HRC
Microstructures
air or nitrogen
870-955 850-870
Through hardening is not oil oil
UK
BS
BS970:040A20
Normalizing Through hardening Carburizing Carbonitriding
GERMANY
Condition
Ferrous Metal Low carbon steel Carbonitrided, hardened and tempered
925 Because of low carbon
Specimen name Material
USA
14
Photo.18 shows the microstructures from the surface to the core of low carbon steel after carbonitrided, quenched and tempered. The case consists of Martensite(see
Photo.19). Between the case and core, consists of Martensite and Ferrite(see Photo.20). And at the core, the original microstructures, Pearlite and Ferrite still remain(see Photo.21).
:Photo.19:500x Photo.20:500x Photo.21:500x
Photo.18:50x
15
Specimen
No.: 5
1055 A29:1055 1.1209,CM55 CM55 CX55 55 55 1665 S53C 3CD55 K1055
Characteristics: When heat treated, this steel yield a high surface hardness, combinded with relative good toughness. This grade also has good forging characteristics. It is
shallow hardening, however, and useful section size is limited. Part made from AISI1055 steel requiring strength are oil quenched; parts requiring high hardness are water quench.
Applications: Battering tools, hot upset forging dies, ring rolling tools, wear resistant parts, hand tools, and parts for agricultural imprements with high strength and low cost.
o
60-40 HRC 60 HRC
o
o
C, soaking time should be at 1/2 hour per inch of thickness
process of this preheat 500 plus 1 hour minmum and furnace cool to 650
o
Cat a rate not exceed 28
o
C per hour. Microstructures
specimen 30 min. min. consist of pearlite and ferrite. Low hardenability, good forgability, poor machinability, not recommend for
welding.
Photo.22: 100x, Medium carbon steel,annealed, consists of Pearlite and Ferrite. Photo.23: 1000x,Same as Photo.22, but in higher magnification. Light brown and brown
area are Ferrite, green and purple area with small lines are Pearlite.
60-62 HRC
Microstructures
Hardness 180-200 HB 197 HB 60-64 HRC
air or nitrogen furace cool oil or water oil
1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. depend on case depth. depend on case depth.
900 830 830 850-870
En55
Normalizing Annealing Full hardening Carbonitriding
USA GERMANY UK
BS 1429
Ferrous Metal Medium carbon steel Annealed
16
Photo.24: 500x, Same as in Photo.23, but in the larger area.The microstructures consist of Pearlite and Ferrite.
17
Specimen
No.: 6
1055 A29:1055 1.1209,CM55 CM55 CX55 55 55 1665 S53C 3CD55 K1055
o
60-40 HRC 60 HRC
o
C 830 Process: The specimen is heated to 830
o
C, pearlite and ferrite transformed to austenite, some
process of this preheat 500 60 water quench cementite remained, and then quenched in water, austenite then transformed to martensite.The martensite
specimen 30 min. min. is untempered martensite, high stess, high hardness, brittle, not suitable for any application. Some Ferrite
retained because of low hardenability of steel.
Photo.25: 100x, Medium carbon steel, heated to 830oC and quenched in water, micro- Photo.26: 1000x, Green,purple and blue area are Martensite, bright gray area are Ferrite.
structures consist of Martensite and some Ferrite still remain because of low hardenability.
60-62 HRC
Microstructures
900 830 830 850-870
UK
BS 1429
En55
Ferrous Metal Medium carbon steel Hardened by quenching, untempered
USA GERMANY
18
Photo.27: 1000x, Same as in Photo.26, but in larger area. The microstructures consist of Martensite and un-changed Ferrite.
19
Specimen
No.: 7
1055 A29:1055 1.1209,CM55 CM55 CX55 55 55 1665 S53C 3CD55 K1055
o
60-40 HRC 60 HRC
o
o
C, pearlite and ferrite transformed to austenite, and then
process of this preheat 500 60 300 quenched in water, austenite then transformed to martensite.The as quench martensite is hard and
specimen 30 min. 120 min. brittle. The specimen was tempered at 300
o
C for 120 minutes, martensite transformed to tempered mar-
tensite with lower hardness, higher toughness. The hardness can be controlled by varying temperature.
Photo.28: 100x, Medium carbon steel, quenched and tempered, microstructures consist Photo.29: 1000x, Same as in Photo.28, but in higher magnification. Tempered Martensite
of tempered Martensite, smaal dark dots are inclusions in steel. are clearly seen.
60-62 HRC
Microstructures
900 830 830 850-870
En55
USA GERMANY UK
BS 1429
Ferrous Metal Medium carbon steel Hardened by quenching and tempering
20
Photo.30: 1000x, Same as in Photo.29, but in larger area. The microstructures consist of tempered martensite.
21
Specimen
No.: 8
Similar FRANCE INDIA POLAND SWEDEN JAPAN ITALY AUSTRALIA
steels AISI/SAE ASTM DIN KRUPP AFNOR IS 1570 PN84028 SS14 JIS G4801 UNI3545 AS1442
1095 A510;A586 1.1275 - CX100 C98 DS105 1870 SUP 4 C100 K1095
Characteristics: The higher carbon of 1095 steel provides maximum surface hardness with improved wear resistance and high strength. Ther is, however, a loss of tough-
ness. Because cold forming methods are not suitable for this steel, uses are limitted to flat stampings and springs coiled from small diameter wire.
Applications: Edge tools, wear-resistant parts, mower knives, scraper blades, discs, etc.
Heat Descriptions Processes
o
C
guide Soaking time, min.
Quenching medium
o
C 870 furnace cool Process: The specimen is a hyper- eutectoid steel. The specimen was reheated to 800
o
C for 60 min.
process of this preheat 500 60 for austenitizing, then slowly cooled down the specimen in the furnace at the cooling rate not exceed
specimen 30 min. min. 28
o
C per hour until 650
o
C then air cooled to room temperature. The final microstructure are pearlite and
carbide. If the surface is not well protected, carbon content will decrease(decarburization).
Photo.31: 100x, The microstructures consist of Pearlite and carbides Photo.32: 1000x,Same as in Photo.31, but in higher magnification. The matrix is Pearlite.
white particles are carbides or Cementite, Fe
3
C.
air
Microstructures
Hardness 269-290 HB 269-290 HB 63-66 HRC
air or nitrogen furnace cool oil or water
1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 2 hrs min.
855 800 800 370-675
95CS
Normalizing Annealing Full hardening Tempering
USA GERMANY UK
BS 1449
Ferrous Metal High carbon steel Annealed
Austempering
800
1/2hr./25 mm.+1 hr.
salt bath at 315
o
C, 2 hrs., air cool
63-66 HRC 27-43 HRC
22
23
Photo.33:1000x, Same as in Photo.32, but in larger area. Microstrucutres consist of Pearlite matrix and Carbides particles.
Specimen
No.: 9
1095 A510;A586 1.1275 - CX100 C98 DS105 1870 SUP 4 C100 K1095
o
C
Quenching medium
o
C 800 water Process: The specimen was heated to 800
o
C for austenitizing and soaked for 60 minutes, pearlite
process of this preheat 500 60 quench will transform to austenite, and some cementite may remain. Then quench in water, austenite will
specimen 30 min. min. transform to martensite, needlelike structure, high stress, hard and brittlle. High carbon steel in this
condition is not suitable for any application because of brittleness.
Photo.34: 100x, The microstructures consist of martensite and carbides. Photo.35: 1000x, Same as in photo.34, but in higher magnification. Acicular structure is
Martensite and white particles are carbides. Light blue area are retained Austenite.
Ferrous Metal High carbon steel Hardened by quenching, untempered
USA GERMANY UK
BS 1449
855 800 800
95CS
Normalizing Annealing Full hardening
2 hrs min. 1/2hr./25 mm.+1 hr.
air salt bath at 315
o
C, 2 hrs., air cool air or nitrogen furnace cool oil or water
1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr.
Microstructures
Tempering Austempering
370-675 800
Condition
27-43 HRC 63-66 HRC
24
Photo.36: 1000x, Same as in Photo.35, but in larger area. The microstructures consist of Martensite, Carbides and retained Austenite.
25
Specimen
No.: 10
1095 A510;A586 1.1275 - CX100 C98 DS105 1870 SUP 4 C100 K1095
o
C
Quenching medium
o
C 800 water Process: The specimen was heated to 800
o
C for austenitizing and soaked for 60 minutes, pearlite
process of this preheat 500 60 300 air will transform to austenite, and some cementite may remain. Then quench in water, austenite will
specimen 30 min. 120 min. transform to martensite, needlelike structure, high stress, hard and brittlle. The specimen was reheated to
300oC for 120 minutes, the hardness and brittleness will be decreased and toughness increased.
Photo.37: 100x, The microstructures consist of Martensite, and carbides. Photo.38: 1000x, Same as in Photo.37, but in higher magnification.The matrix is Martensite
White particles are carbides.
Ferrous Metal High carbon steel
USA GERMANY UK
BS 1449
800
95CS
855 800 800 370-675
salt bath at 315
o
C, 2 hrs., air cool
1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 2 hrs min. 1/2hr./25 mm.+1 hr.
air or nitrogen furnace cool oil or water air
Microstructures
Condition
Hardened by quenching, tempered
27-43 HRC 63-66 HRC
26
Photo.39: 1000x, Same as in Photo.38, but in larger area. The microstructures consist of Martensite, and carbides.
27
Specimen
No.: 11
1095 A510;A586 1.1275 - CX100 C98 DS105 1870 SUP 4 C100 K1095
o
C
Quenching medium
o
C 800 furnace cool Process: The specimen is a hyper- eutectoid steel. The specimen was reheated to 800
o
C for 60 min.
process of this preheat 500 60 for austenitizing, then slowly cooled down the specimen in the furnace at the cooling rate not exceed
specimen 30 min. min. 28
o
C per hour until 650
o
C then air cooled to room temperature. The final microstructure are pearlite and
carbide. If the surface is not well protected, carbon content will decrease(decarburization).
Photo.40: 100x, The specimen is un-etched for inclusion investigation. Black dots and Photo.41: 1000x, Same as in Photo.40, but in higher magnification. Brown particles are
brown particle are inclusion embeded in steel. non-metalic inclusion. These inclusions remained from the melting processes.
Ferrous Metal High carbon steel
USA GERMANY UK
Annealed, for inclusion investigation
BS 1449
95CS
855 800 800 370-675
1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 2 hrs min.
air or nitrogen furnace cool oil or water air
Microstructures
27-43 HRC 63-66 HRC
Condition
salt bath at 315
o
C, 2 hrs., air cool
1/2hr./25 mm.+1 hr.
800
28
Photo.42:1000x, The brown area are non-metallic inclusions.
The specimen is un-etched.
29
Specimen
No.: 12
composition 0.28-0.33 0.15-0.30 0.40-0.60 0.035 max 0.040max 0.80-1.10 0.15-0.25 - - - - - -
steels AISI/SAE ASTM DIN17200 KRUPP AFNOR GOST4543 GB 3077 SS14 JIS G4105 UNI AS1444
4130 A29;A322 1.7218 7218 30CD4 30ChM 30CrMo 2233 SCM430 25CrMo4 4130
Characteristics and applications: A medium carbon, Chromium-Molybdenum steel. Available as hot rolled and cold finished bar and seamless tube, this steel is for
general purpose applications. Variations in heat treatment can obtain a broad range of strength and toughness. This steel has good hardenability, strength, wear resistance, toughness
and ductility. In heat treated condition, it offers good strength and toughness for moderately stressed parts.It is available in forging quality, and aircraft quality.
o
Quenching medium air or faster air mended.
48-22 HRC 58-60 HRC
o
C 855 furnace cool Process: The specimen was heated at 855
o
C and soak for 60 minutes for austenitizing, the original
process of this preheat 500 60 microstructure will be transformed to austenite, then cooled down slowly in the furnace, austenite will
specimen 30 min. min. be transformed to pearlite and ferrite. Strength and hardness decrease, ductility increases.
USA GERMANY UK
Ferrous Metal AISI 4130
1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr.
900 855 880
45-50 HRC
air or nitrogen furnace cool
60-62 HRC
oil or water oil
Microstructures
Hardness 163-217 HB 217 HB
CDS110
Condition
depend on case depth.
BS 1717
Annealed
850-870
Photo.44:1000x, Same as in Photo.34, but in higher magnification. Dark brown area
are Pearlite, light area are ferrite.
Photo.43:100x, The microstructures consist of Pearlite and Ferrite.
30
Photo.45:1000x, Same as in Photo.44, but in larger area. Light area are Ferrite, dark area are Pearlite.
31
Specimen
No.: 13
composition 0.28-0.33 0.15-0.30 0.40-0.60 0.035 max 0.040max 0.80-1.10 0.15-0.25 - - - - - -
4130 A510;A586 1.1259 - CX80 80 80 1778-02 S80C 3CD80 K1082
Characteristics and applications: A medium carbon, Chromium-Molybdenum steel. Available as hot rolled and cold finished bar and seamless tube, this steel is for
general purpose applications. Variations in heat treatment can obtain a broad range of strength and toughness. This steel has good hardenability, strength, wear resistance, toughness
and ductility. In heat treated condition, it offers good strength and toughness for moderately stressed parts.It is available in forging quality, and aircraft quality.
o
48-22 HRC 58-60 HRC
o
C 880 Process: The specimen was heated at 880
o
process of this preheat 500 60 250 microstructure will be transformed to austenite, then quench in water, austenite will be transformed to
specimen 30 min. 120 min. martensite, high strees, high hardness, then tempered at 250oC for 120 minutes. Martensite will be trans-
formed to tempered martensite with lower hardness and higher toughness.
60-62 HRC
Microstructures
air or nitrogen furnace cool oil or water oil
1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. depend on case depth.
900 855 880 850-870
80CS
USA GERMANY UK
BS 1449
Ferrous Metal AISI 4130 Hardened by quenching and tempering
Photo.46:100x, Microstructure after quenching and tempering is Martensite. Photo.47:1000x, Same as in Photo.46, but in higher magnification.The structures are
Martensite.
32
200
Photo.48:500x, The microstructures are Martensite
33
Specimen
No.: 14
composition 0.38-0.43 0.15-0.30 0.60-0.80 0.05 max 0.040max 0.70-0.90 0.20-0.30 1.65-2.00 - - - - -
4340 A29: 4340 1.6582 6582 - - - 1778-02 SNCM439 40NiCrMo7 4340
Characteristics and applications: A high hardenabiliy steel, higher in hardenability than other standard AISI grade. AISI 4340 steel is nickel-chromium-molybdenum
alloy steel. It is normally heat treated by quenching in oil and tempering to the desired hardness. It exibits good response to heat treatment and posses a good combination of strength,
ductility, and toughness in quenched and tempered condition. AISI4340 is found in aircraft and truck parts and some ordnance materials, and also for gear, shafts, die block, etc.
o
48-22 HRC 58-60 HRC
o
C 855 furnace cool Process: The specimen was heated at 855
o
process of this preheat 500 60 microstructure will be transformed to austenite, then cooled down slowly in the furnace, austenite will
specimen 30 min. min. be transformed to pearlite and ferrite. Strength and hardness decrease, ductility increases.
60-62 HRC
Microstructures
air or nitrogen furnace cool oil or water oil
1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. 1/2hr./25 mm.+1 hr. depend on case depth.
900 855 880 850-870
818Mo
USA GERMANY UK
BS 4670
Ferrous Metal AISI 4340 Annealed
Photo.49:100x, Microstructures are Pearlite and ferrite. Photo.50: 1000x, Same as in Photo.49, but in higher magnification. Light area are
Ferrite, dark area are Pearlite. Fine bright particles are Carbides.
34
Photo.51: 500x, The microstrucutres are Pearlite and Ferrite. Fine bright particles are Carbides.
35
Specimen
No.: 15
composition 2.50-4.00 1.00-3.00 0.20-1.00 0.002-1.00 0.02-0.25 - - - - - - - -
Similar Germany RUSSIA CHINA SWEDEN JAPAN ITALY AUSTRALIA
steels AISI/SAE ASTM DIN 1691 GOST1412 GB 699 SS14 JIS UNI5007 AS1830
- A48: 25 GG15 SCh18 - 0115.00 FC25 G15 T180
Characteristics and applications: Cast irons are alloys of iron(Fe), carbon, and silicon(Si) in which more carbon is present than can be retained in in solid solution in
austenite at the uetectic temperature. The carbon that exceeds the solubility in austenite precipitates as flake graphites. Gray cast iron is used for many different types of parts in a very
wide variety of machines and structures. For example: machine bed, motor housing, gear, pulley, wheel, etc.
o
C 250-650 Nitriding is
guide Soaking time, min. 2 hrs min. - not recom-
Quenching medium air or faster mended.
48-22 HRC
Manufacturing pro- Process: The charges (consist of pig iron, cast iron scraps, steel scraps, FeSi, FeMn, flux) were
cess of this specimen charged into induction furnace and melted into liquid metal, then the molten metal was dicharged into the
charge melting pouring casting crucible and then poured into prepared sand mould. Molten metal will be solidified and taken out of the
sand mould. The casting was cut to specimen and ground, polished, un-etched to show graphite flakes.
Ferrous Metal Gray Cast Iron As cast, un-etched
USA UK
BS 1452
180
885-925 790-900 755-790 Carbonitriding of
furnace cool oil or water recommended
1hr./25 mm.+1 hr. 1hr./25 mm.+1 hr. 1hr./25 mm.+1 hr. gray cast iron is not
Microstructures
FRANCE
AFNOR NF A32101
FGL200G
air or nitrogen
Photo.52:100x, Gray cast iron, un-etched, showing graphite flakes distribution
Photo.53:1000x, Same as in Photo.52, but in higher magnification, the dark gray scripts are
graphite flakes.
36
Photo.54: 200x, Showing graphite flake distribution and orientation. Dark gray particles and scripts are graphite flakkes. The matrix is un-revealed.
37
Specimen
No.: 16
composition 2.50-4.00 1.00-3.00 0.20-1.00 0.002-1.00 0.02-0.25 - - - - - - - -
- A48: 25 GG15 SCh18 - 0115.00 FC25 G15 T180
o
48-22 HRC
cess of this specimen charged into induction furnace and melted into liquid metal, then the molten metal was dicharged into the
charge melting pouring casting crucible and then poured into the sand mould. Molten metal will be solidified into solid(casting). The casting
was cut, mounted, dround, polished, and etched to show both graphite flakes and matrix.
Ferrous Metal Gray Cast Iron As cast, etched
USA FRANCE UK
AFNOR NF A32101 BS 1452
FGL200G 180
recommended
163-217 HB 160-180 HB 45-50 HRC
Microstructures
Hardness
Photo.55:100x, Gray cast iron, as cast, etched, showing graphite and matrix. Photo.56:1000x, Same as in Photo.55, but in higher magnification, dark scripts are gra-
phite flakes, matrix are Pearlite and Ferrite.
Ferrite Pearlite Graphite
38
Photo.57:Same as in photo.56, but in larger area. Dark gray branches are graphite flakes. The matrix consists of Pearlite(small lines of cementite and Ferrite), and Ferrite.
39
Specimen
No.: 17
composition 2.50-4.00 1.00-3.00 0.20-1.00 0.002-1.00 0.02-0.25 - - - - - - - -
- A48: 25 GG15 SCh18 - 0115.00 FC25 G15 T180
o
48-22 HRC
Final processes of
o
C w Process: The specimen was heated to 790
o
C for austenitizing. During austenitizing, the matrix which
this specimen air consist of pearlite and ferrite, will transform to austenite, graphite flakes still remain. After soaking at the
min. temperature, the specimen was quenched in water, austenite transformed to martensite. The as quench
microstructure consists of martensite and graphite. Martensite will be tempered martensite after tempering.
Ferrous Metal Gray Cast Iron Hardened by quenching and tempering
USA FRANCE UK
FGL200G 180
recommended
163-217 HB 160-180 HB 45-50 HRC
Microstructures
Hardness
790
60
300
60
Photo.58:100x, Gray cast iron, quenched and tempered. The matrix is Martensite.
Graphite flakes still remain.
Photo.59:1000x, Same as in Photo.58, but in higher magnification. The matrix are
Martensite. Gray area are graphite flakes.
40
Photo.60:1000x, Acicular structures are Martensite, dark gray scripts are graphite flakes, and the yellow and light brown surrounded the grapgite flakes
are Ferrite.
41
Specimen
No.: 18
composition 1.80-3.60 0.50-1.90 0.25-0.80 0.06-0.20 0.06-0.20 - - - - - - - -
Similar USA RUSSIA CHINA SWEDEN JAPAN ITALY INDIA
steels AISI/SAE - - - - IS7925
- - - - - 1
Characteristics and applications: Exhibits a white, crystalline fracture surface because fracture occures along the iron carbide plates; it is the result of metastable
solidification(Fe
3
C eutectic). Hard and brittle. Good wear resistant. Weldability is poor. Machinability is poor. If reheated above eutectoid interval, soaked and cooled through eutectic
interval, malleable iron will be achieved. Alloying elements can be added to white iron to make alloy cast iron, e.g. Cr is added for wear resistant purpose.
Heat treatment guide: Only stress relieving is recommended for white cast iron when high wear resistant is required. Stress relieving of white cast iron can be done by heating
the parts to about 550-650
o
C, soking time is 1 hour per 25 mm. of thickness and air cool. White cast iron can be hardened also to get martensite matrix but seldomly practice.
Manufacturing pro- Process: Raw materials ( pig iron, scraps, ferro-alloy material, and fluxes) are put in the induction
cess of this specimen furnace and poured into prepared sand mould. The raw materials added must be calculated and weighed
charge melting pouring casting before charging into the furnace to achieve the composition required.
Ferrous Metal White Cast Iron As cast, etched
1A G-X300NiMo3Mg
FRANCE UK
AFNOR NF A32-401 BS 4844
Germany
DIN 1695
FBO
Microstructures
Photo.61:100x, White cast iron(hypo-eutectic cast iron), as cast, microstructures consist of
Pearlite(brown and dark brown area), and Ledeburite(eutectic:Cementite and Pearlite).
Photo.62:1000x, Same as in Photo.61, but in higher magnification. Large brown islands are free
Pearlite which transformed from primary Austenite, small islands are Pearlite, parts of
Ledeburite(eutectic). Bright area are cementite(Fe
3
C), parts of Ledeburite.
42
Photo.63:1000x, Same as in Photo.62, but in larger area, showing Pearlite, and Ledeburite.
Cementite Pearlite
43
Specimen Condition
No.: 19 annealed
composition 2.20-2.90 0.90-1.90 0.15-1.20 0.02-0.20 0.02-0.20 - - - - - - - -
Similar USA RUSSIA JAPAN ITALY INDIA
steels ASTM A220 GOST1215 JIS G5704 - IS2640
45006 KCh45-7 FCMP45 - PM440
Characteristics and applications: Malleable is a type of cast iron that has most of carbon in the form of irregular shaped graphite nodules instead of flakes. Malleable
iron is produced by first casting the casting as a white iron and then heat treating the white iron to convert the iron carbide into the irregularly shaped nodules of graphite. This form of
graphite is called temper carbon because it is formed in the solid state during heat treatment. Malleable iron is good for making flanges, pipe fittings, valve parts for railroad, marine, etc.
Heat treatment guide: Malleble iron can be hardened by the following methods: 1. First stage anneal of the casting and air cool, about 0.75% of combined carbon will remain in the
matrix. 2. Reheat the casting at 885
o
C for 60 min. to reaustenize the matrix and homogenize the combined carbon; and then quench in heated(50-55
o
C) and agitated oil to form martensite
with the hardness of about 555 to 627 HB. Then temper to the required hardness. And also malleable iron can be carburized, carbonitrided, and nitrided to add surface wear resistance.
Manufacturing 955
o
C 1. Casting: The raw materials were calculated, weighrd and charged and
processes melted in the induction furnace, then poured into the sand mould. After the
of this specimen charges melting pouring casting annealing solidification, the casting was taken out from the mould for the next process.
2. Annealing: Step 1.: Heating to 955
o
C, the temper carbon nucleus will be initiated. Step 2: Holding at 955
o
C: this step is called first-stage graphitization(FSG),massive carbides are
eliminated from the iron structure. The soaking time may be about at least 48 hours. Then the casting is rapidly cooled to 740oC prior to entering the second-stage graphitization.
Step 3: Slow cooling; the casting was slow cooled through the allotropic transformation range of the iron; this step is called second-stage graphitization(SSG), a completely ferritic matrix
free of pearlite and carbide is obtained.
Specimen name
Ferrous Metal
ISO5922 AFNOR NF A32-702 BS 6681
NETHERLANDS
NEN 6002-C
Material
Malleable iron(annealed white cast iron)
Microstructures
P45-06 MN450-6 P45-06 GSMp45
INTERNATIONAL FRANCE UK
Photo.64:100x,Dark gray islands are tempered graphites. Purple and blue-green area are
Ferrite.
Photo.65:1000x, Same as in Photo.64, but in higher magnification. Dark gray islands are
tempered graphite. The matrix is Ferrite.
tempered graphite
44
500
Photo.66:500x, Same as in Photo.65, but in larger area. Dark gray islands are tempered graphite. Purple and blue-green area are Ferrite.
ed graphite
Ferrite
grain boundary
45
Specimen
No.: 20
composition 3.000-4.00 1.80-2.80 0.10-1.00 0.01-0.10 0.01-0.03 - - - - - - - -
Similar Germany SWEDEN JAPAN
steels DIN 1693 SIS 1407 JIS G5502
GGG45 0722-00 FCD45
Characteristics and applications: Nodular cast iron can be called Ductile cast iro or spheroidal graphite(SG) cast iron, it is cast iron in which the graphite is present as tiny
spheres(nodules). The eutectic graphite separates from the molten iron during solidification and grows as spheres due to the additives introduced into the molten iron before casting.
Some of the applications for nodular cast iron include: gears, high-fatigue strength application, high-impact application, automotive crankshafts, compreesor crankshafts, joints, etc.
Heat Descriptions Processes Nitriding
o
C 550-650
guide Soaking time, min. 10-75 hrs.
Quenching medium furnace cool
550-650HV
cess of this specimen charged into induction furnace and melted into liquid metal, then the molten metal was discharged into the
charge melting pouring casting crucible and then poured into the sand mould. Molten metal will be solidified into solid(casting). The casting
was cut, mounted, ground, and polished to show graphite shapes, sizes and ditribution.
30HRC-80HRB
Austempering
845-925
1hr./25 mm.+1 hr.
oil or water
45-58 HRC
air or faster
Microstructures
ASTM A536-84
60-42-10
ISO 1083
450-10
GOST7293
VCh45
Tempering
425-600
1hr./25 mm.+1 hr. 1hr./25 mm.+1 hr. 1hr./25 mm.+1 hr. 2 hrs min.
510-565 870-900 845-925
FGS450-10 450/10
USA FRANCE UK
INTERNATIONAL RUSSIA
Ferrous Metal Nodular Cast Iron Annealed, un-etched
Photo.67:100x, Nodular cast iron, unetched, showing spheroidal graphites(dark brown
particles).
Photo.68:1000x, Same as in Photo.67, but in higher magnification. Dark gray island is
spheroidal graphite.
graphite
matrix
46
Photo.69:200x, Round particles are spheroidal graphites. The matrix can not be revealed in unetched condition.
47
Specimen
No.: 21
composition 3.00-4.00 1.80-2.80 0.10-1.00 0.01-0.10 0.01-0.03 - - - - - - - -
Similar Germany SWEDEN JAPAN
steels DIN 1693 SIS 1407 JIS G5502
GGG45 0722-00 FCD45
Characteristics and applications: Nodular can be called Ductile cast iron or spheroidal graphite(SG) cast iron, it is cast iron in which the graphite is present as tiny
spheres(nodules). The eutectic graphite separates from the molten iron during solidification and grows as spheres due to the additives introduced into the molten iron before casting.
Some of the applications for nodular cast iron include: gears, high-fatigue strength application, high-impact application, automotive crankshafts, compreesor crankshafts, joints, etc.
Heat Descriptions Processes Nitriding
o
C 550-650
guide Soaking time, min. 10-75 hrs.
Quenching medium furnace cool
550-650HV
cess of this specimen charged into induction furnace and melted into liquid metal, then the molten metal was discharged into the
charge melting pouring casting crucible and then poured into the sand mould. Molten metal will be solidified to solid(casting). The casting
was cut, mounted, ground, and polished to show graphite and matrix.
Ferrous Metal Nodular Cast Iron Annealed, etched
UK
ASTM A536-84 AFNOR NF A32201 GOST7293 ISO 1083 BS 72892
USA FRANCE RUSSIA INTERNATIONAL
60-42-10 FGS450-10 VCh45 450-10
425-600
450/10
Normalizing Annealing Full hardening Tempering Austempering
air or faster
845-925
1hr./25 mm.+1 hr. 1hr./25 mm.+1 hr. 1hr./25 mm.+1 hr. 2 hrs min. 1hr./25 mm.+1 hr.
510-565 870-900 845-925
oil or water
Hardness 163-217 HB 160-180 HB 45-58 HRC 30HRC-80HRB 45-58 HRC
Microstructures
Photo.70:100x, Nodular cast iron, etched, brown round particles are spheroidal graphites. The
matrix are Ferrite(white, purple area), and Pearlite(brown islands).
Photo.71:1000x, Same as in Photo.70, but in higher magnification. Gray area is graphite.
Purple and blue-green area are Ferrite.
Ferrite
graphite
Pearlite
graphite
Ferrite
grain boundary
48
Photo.72:500x, Same as in Photo.71, but in larger area. The microstructures consist of spreroidal graphites, Pearlite and Ferrite. Bull's eyes structure can be seen in this Photo. ( Bull's structure
consists of graphit nodule in the center surrounded with Ferrite, and the outmost area is Pearlite. It looks like Bull's eyes.
Pearlite Ferrite
graphite
grain
boundary
49
Specimen
No.: 22
composition 3.50 2.50 0.90 0.050 0.040 - 0.25 3.00 - - - - -
or BDI.
Characteristics and applications: Bainitic Ductile Iron(BDI) is the high strength and wear resistant alloy cast iron. Microstructure of BDI consists of graphite nodules
and bainite as the matrix. BDI obtained through alloying during melting to produce bainite matrix which is hard and good wear resistant. Bainite matrix in BDI obtained in as cast condition
without any heat treatment. The applications of BDI are: gear, crank shafts, etc.
Heat treatment:
Manufacturing Process: The charges (consist of pig iron, cast iron scraps, steel scraps, FeSi, FeMn, flux) were
process of this charged into induction furnace and melted into liquid metal, Ni, Mo, and inoculant were added during the
specimen charge melting pouring casting process, the liquid metal was discharged into the crucible and then poured into the sand mould. The liquid
metal will solidify as the casting then cut, mounted, ground, polished, and etched for the examination.
Similar grade of BDI: The common name of this special cast iron is Bainitic Ductile Iron or BDI. Most foundries are also produce this kind of cast iron under the name Bainitic Ductile
Ferrous Metal Bainitic Ductile Iron(BDI) as cast
BDI may be tempered to adjust the hardness. The tempering temperature depends on the hardness required. The other heat treatment processes may not
be required because the casting has been aalready hardened by alloying.
Microstructures
Photo.73,100x, Bainitic Ductile Iron(BDI), etched, showing Bainite matrix and sphreoidal graphite. Photo.74:1000x, Same as in Photo.73, but in higher magnification. Brown round area is spheroidal
graphite surrounded with Bainite(purple,orange, blue-green, and brown area).
50
Photo.75:1000x, Same as in Photo.74, but in larger area. The microstructures consist of spheroidal graphites, and Bainite matrix. Some ferrite remained beside graphite.
51
Specimen
No.: 23
Chemical C Si Mn P S Cr Mo Ni Cu Ti Co W Others
composition 2.00-3.30 1.50 max 2.00 max 0.10 max 0.06 max 23.00-30.00 3.00 max 2.50 max 1.20 max - - - -
Similar
steels
Characteristics and applications: This grade of cast iron is in the group of The high alloy white irons which are primarily used for abrasion-resistant applications and
are readily cast in the shapes needed in the machinery used for crushing, griding, and general handling of abrasive materials. The eutectic carbides in the microstructures provided the
high hardness needed for crushing and griding other materials. All high-alloy white irons contain chromium to prevent graphite formation and provide the stability of carbide phase.
o
C
Quenching medium
Manufacturing pro- 1010 250 Processes: The raw material(pig iron, scraps,ferro-alloys,etc.) were charged
cess of this specimen
charge melting pouring casting full hardening
of the molud and heated to 1010
o
C and air cooled and tempered at 250
o
C.
** For heavy sections the rule of 1 hour per 25 mm. thickness
Microstructures
into the induction furnace for melting. Then the liquid metal was discharged and
poured into the sand mould. After the solidification, the casting was taken out
Hardness - - - is usually adequate.
SIS 140466
466
Germany
DIN 1695
G-X260Cr27; G-X300CrMo271
-80 to -196 1010-1020* 205 to 260
air air/oil air
60 min./25 mm. thickness 3 to 4 hours minimum.** 3 to 4 hours minimum.*
3D
* Heavy sections usually require higher temperatures within
the range.
Sub-zero treatment Full hardening Tempering Note:
Ferrous Metal Wear resistant cast iron As cast
USA FRANCE INDIA
BS 4844
IIIA:25% Cr FBCr26MoNi
ASTM A532 AFNOR NF A32-401 IS 4771-3
SWEDEN UK
HCr27/400
Photo.76:100x, Wear resistant cast iron, etched. The structures are chromium carbides. Photo.77:1000x, Same as in Photo.76, but in higher magnification.
chromium carbide
52
Photo.78:500x, Same as in Photo.77, but in larger area. The structures are chromium carbides.
53
Specimen
No.: 24
composition 1.40-1.60 0.60 max 0.60 max 0.03 0.03 11.00-13.00 0.70-1.20 - 1.10 max - - - -
Similar CHINA SWEDEN JAPAN ITALY INDIA
steels AISI/SAE ASTM A681 DIN 17350 KRUPP GB 1299 SIS14 JISG4404 UNI2955 IS 3749
D2 D2 1.2379 2379 3-2Cr12MoV 2310 SKD11 DCT-AR T160Cr12
Characteristics and applications: Most available and most popular of the D series tool steels. Deep hardening, with low distorsion and high safety in weldability.
resistant to softening and medium resistant to decarburization. Readily nitrided. D2 steel is air hardening and attain full hardness when cooled in still air. D2 steel contain massive amount
of carbides, which make it susceptible to edge brittleness. Typical applications of D2 steel include long run dies for blanking, forming,thread rolling, deep drawing, slitter knives, etc.
Heat Descriptions Processes Tempering Nitriding
o
C 205-540 500
guide Soaking time, min. 2 hrs min. 10-75 hrs.
Quenching medium air furnace cool
61- 54 HRC >750 HV
o
o
process of this preheat 815 90 austenite, then cool down slowly in the furnace, austenite will transform to ferrite and pearlite. The steel
specimen 30 min. min. will be softened,better machinability,better cold workability,and improve dimensional stability,etc.
Ferrous Metal High C-High Cr Tool steel(AISI D2) Annealed
USA GERMANY UK
BS 4659
FRANCE
AFNOR NF A35-590
BD2
Normalizing Annealing Stress relieving
90 min./inch of thickness 60 min./inch of thickness
Do not normalize 870 - 900 675-705 Pre:815;Aus:980-1025
furnace cool air
Hardness 217-255 HB -
Z160CDV 12
Hardening
air or nitrogen gas
62 to 64 HRC
15 min.(small);45 min.(large)
Microstructures
Photo.79:100x, AISI D2 Tool steel, annealed. Microstructures consist of Ferrite matrix
and Carbides.
Photo.80:1000x, Same as in Photo.79, but in higher magnification. Ferrite matrix is
colred greenand brown, Carbides remained bright particles.
54
200
Photo.81:1000x, Same as in Photo.80, but in larger area, showing the distribution of Carbides in Ferrite matrix.
55
Specimen
No.: 25
composition 1.40-1.60 0.60 max 0.60 max 0.03 0.03 11.00-13.00 0.70-1.20 - 1.10 max - - - -
Similar CHINA SWEDEN JAPAN ITALY INDIA
steels AISI/SAE ASTM A681 DIN 17350 KRUPP GB 1299 SIS14 JISG4404 UNI2955 IS 3749
D2 D2 1.2379 2379 3-2Cr12MoV 2310 SKD11 DCT-AR T160Cr12
Characteristics and applications: Most available and most popular of the D series tool steels. Deep hardening, with low distorsion and high safety in weldability.
resistant to softening and medium resistant to decarburization. Readily nitrided. D2 steel is air hardening and attain full hardness when cooled in still air. D2 steel contain massive amount
of carbides, which make it susceptible to edge brittleness. Typical applications of D2 steel include long run dies for blanking, forming,thread rolling, deep drawing, slitter knives, etc.
Heat Descriptions Processes Tempering Nitriding
o
C 205-540 500
guide Soaking time, min. 2 hrs min. 10-75 hrs.
Quenching medium air furnace cool
61- 54 HRC >750 HV
o
o
process of this preheat 815 90 520 520 austenite, then quench in nitrogen gas(in vacuum furnace), austenite will transform to martensite and
specimen 30 min. min. then temper immediately at 520
o
C after the specimen has cooled to about 50
o
C, Double temper.
USA GERMANY FRANCE
Quenched and tempered
Condition
UK
AFNOR NF A35-590 BS 4659
Ferrous Metal High C-High Cr Tool steel(AISI D2)
Z160CDV 12 BD2
Normalizing Annealing Stress relieving Hardening
Do not normalize 870 - 900 675-705 Pre:815;Aus:980-1025
90 min./inch of thickness 60 min./inch of thickness 15 min.(small);45 min.(large)
furnace cool air air or nitrogen gas
Hardness 217-255 HB - 62 to 64 HRC
Microstructures
Photo.82:100x, AISI D2 Tool steel, quenched and tempered. Microstuctures consist of
Martensite and Carbides.
Photo.83:1000x, Same as in Photo.82, but in higher magnification. Martensite tinted
variuos colors. Carbides remained bright particles.
56
Photo.84:1000x, Same as in Photo.83, but in larger area. The matrix is Martensite tinted various colors, and bright particles are carbides.
57
Specimen
No.: 26
composition 0.10 max 0.10-0.40 0.10-0.40 0.025 max 0.025 max 0.75-1.25 0.15-0.40 0.10-0.50 - - - - -
Similar RUSSIA UK
steels AISI/SAE ASTM A681 DIN KRUPP SS14 ASSAB DAIDO HITACHI N.KOSHUHA GOST BS4659
P20 P20 1.2311 2311 USA P20 718Supreme PX 4 YSS: HPM 2 Plasmold20 4ChS USA P20
Characteristics and applications: Mold steel AISI P20 normally is supplied heat treated to 30-36 HRC, a condition in which it can be machined readily into large, intricate
dies and molds. Because this steel is prehardened, no subsequench high temperature heat treatment is required, and distortion and size changes are avoided. However, when used
for plastic mold, type P20 is sometimes carburized and hardened after the immpression has been machined. Most application is for plastic mold making.
o
C
Quenching medium
o
o
process of this preheat 815 60 austenite, then cool down slowly in the furnace, austenite will transform to ferrite and pearlite. The steel
specimen 30 min. min. will be softened, better machinability, better cold workability, and improve dimensional stability,etc.
Annealed
Ferrous Metal Mould tool steel ( AISI P20)
USA GERMANY FRANCE
AFNOR NF A35-590
35CM7D
Normalizing Annealing Stress relieving Hardening
900 760-790 650-675 Carburize:920, Harden: 815-870
oil
60 min./inch of thickness 60 min./inch of thickness 60 min./inch of thickness Carburize:to case depth;Harden:15 min
149-179 HB 149-212 HB -
air furnace cool air
60 to 64 HRC
Microstructures
SWEDEN JAPAN
Tempering
Carburized mold:175-230
2 hrs min.
air
62- 58 HRC Hardness
Photo.85:100x, AISI P20 Mold Tool steel, annealed. Microstructures consist of Ferrite
and Carbides. Black dots are porosities.
Photo.86:1000x, Same as in Photo.85, but in higher magnification.Blue-green area are Ferrite.
Bright particles are Carbides.
58
Photo.87:1000x, Same as in Photo.86, but in larger area.
59
Specimen
No.: 27
composition 0.10 max 0.10-0.40 0.10-0.40 0.025 max 0.025 max 0.75-1.25 0.15-0.40 0.10-0.50 - - - - -
Similar RUSSIA UK
steels AISI/SAE ASTM A681 DIN KRUPP SS14 ASSAB DAIDO HITACHI N.KOSHUHA GOST BS4659
P20 P20 1.2311 2311 USA P20 718Supreme PX 4 YSS: HPM 2 Plasmold20 4ChS USA P20
Characteristics and applications: Mold steel AISI P20 normally is supplied heat treated to 30-36 HRC, a condition in which it can be machined readily into large, intricate
dies and molds. Because this steel is prehardened, no subsequench high temperature heat treatment is required, and distortion and size changes are avoided. However, when used
for plastic mold, type P20 is sometimes carburized and hardened after the immpression has been machined. Most application is for plastic mold making.
o
C
Quenching medium
o
o
process of this preheat 600 15 300 300 austenite, then quench in oil, austenite will transform to martensite. Then temper at 300oC for 120 min.
specimen 30 min. min. The microstructure will be tempered martensite. Double temper.
SWEDEN JAPAN USA GERMANY FRANCE
Material Condition
Ferrous Metal Mould tool steel ( AISI P20) Quenched and tempered
Specimen name
AFNOR NF A35-590
35CM7D
Normalizing Annealing Stress relieving Hardening Tempering
900 760-790 650-675 Carburize:920, Harden: 815-870 Carburized mold:175-230
2 hrs min.
air furnace cool air oil air
60 min./inch of thickness 60 min./inch of thickness 60 min./inch of thickness Carburize:to case depth;Harden:15 min
Hardness 149-179 HB 149-212 HB - 60 to 64 HRC 62- 58 HRC
Microstructures
Photo.88:100x, Microstructures consist of tempered Martensite and some inclusions
Photo.89:1000x, Same as in Photo.88, but in higher magnification. Martensite is clearly
seen in brown and gray.
60
Photo.90:1000x, Same as in Photo.88, but in larger area. The strucutre is tempered martensite.
61
Specimen
No.: 28
composition 0.95-1.05 0.20-0.45 0.15-0.40 0.03 max 0.003 max 3.75-4.5 4.50-6.75 0.30 max 2.25-2.75 - - 5.00-6.75 -
Similar RUSSIA UK
steels AISI/SAE ASTM A600 DIN Bohler SS14 ASSAB JIS G4403 HITACHI N.KOSHUHA GOST BS4659
M2 M2 high C 1.3345 S600 2722 ASP-41 SKH 51 YXM 1 H 51 R6M5 BM2
Characteristics and applications: M2 is the most widely used high speed steel suitble for a multitude of applications and available with several carbon contents. M2 is
very high in resistance to wear and to softening at elevated temperature. It rates low in toughness, but using a lower austenitizing temperature with the resulting slightly lower hardness
improves its impact resistance. Mostly M2 is used for various cutting tools e.g. hack saw blades, drills, taps, cutters, single point cutting tools, etc.
Heat Descriptions Processes Tempering
o
C 540-595
guide Soaking time, min. 120
Quenching medium air
65-60
o
C 850 1190 Process: The specimen was double preheat at 650 and 850
o
C and austenitized at 1190
o
C for 15 min.
process of this preheat 650 15 590 590 590 in vacuum furnace. Then nitrogen quenched and triple temper at least 120 min. each for soaking time. The
specimen 30 min. min. final microstructures will be tempered martensite and carbides.
Ferrous Metal High Speed Steel (AISI M2) Quenched and tempered
USA GERMANY FRANCE SWEDEN
Do not normalize 870-900 650-675
JAPAN
AFNOR NF A35-590
4301 6-5-2
Normalizing Annealing Stress relieving
furnace cool air
60 min./inch of thickness 60 min./inch of thickness
Microstructures
Hardening
Double preheat:650/850;Austenitize:1190-1230
15
Nitrogen quench in vacuum furnace
64-66 HRC Hardness 212-241 HB -
Photo.91:100x, High speed steel, quenched and tempered. Microstructures consist of
Martensite and Carbides.
Photo.92:1000x, Same as in Photo. 91, but in higher magnification. Brown and dark gray
background are Martensite. Light brown particles are Carbides.
62
Photo.93:1000x, Same as in Photo. 92, but in larger area. Microstructures consist of Martensite(brown and dark gray needle structures), and carbides(light brown round and
elongated particles).
63
Specimen
No.: 29
Chemical C Si Mn P S Cr Mo Ni V Ti Cu W Others
composition 1.268 0.525 13.38 0.042 0.004 2.105 0.094 0.074 0.023 0.029 0.368 - -
Similar USA AUSTRALIA GERMANY ITALY ROMANIA
steels ASTM A128 AS 2074 DIN UNI 3160 STAS3718
A H19 1.3802 GX120Mn12 T105Mn120
Characteristics and applications: The original austenitic manganese steel, containing about 1.2%C and 12%Mn, was invented by Sir Robert Hadfield in 1882.It
combined high toughness and ductility with high-hardening capacity and excellent resistance to wear. It is still used extensively, with composition and heat treatment modification, prima-
rily in the fields of earthmoving, mining, quarrying, oil well drilling, railroading,and in the manufacture of cement and clay products.Example:rock crusher, bucket,wear plate, etc.
Manufacturing Process: The charges (consist of pig iron, cast iron scraps, steel scraps, FeSi, FeMn, flux) were
process of this charged into induction furnace and melted into liquid metal, Fe-Mn was added during the melting process.
specimen charge melting pouring casting The liquid metal was discharged into the crucible and then poured into the sand mould. The liquid metal
will solidify as the casting then cut, mounted, ground, polished, and etched for the examination.
UK
BW10(En 1457)
SPAIN
AM-X-120Mn12
UNE 36253 BS3100 G5131
SCMnH3
MNC 720E
2183
Material
High manganese steel
Condition
As cast
Specimen name
Ferrous Metal
Microstructures
JAPAN MEXICO
Photo.94:50x, High-Manganese steel casting, as cast. Microstructure are Austenite. White
particles along grain boundaries and in the Austenite grains are Carbides.
Photo. 95:1000x, Same as in Photo. 94, but in higher magnification. Austenite grains are
tinted various colors. Carbides along grain boundaries are colored light purple.
64
1000
Photo. 96:200x, Same as in Photo. 95, but in larger area. Austenite grains are tinted various colors. Carbides are shown along grain boundaries and in Austenite grains.
grain boundary
with carbides
Carbide
inclusion
Austenite
65
Specimen
No.: 30
Chemical C Si Mn P S Cr Mo Ni V Ti Cu W Others
composition 1.268 0.525 13.38 0.042 0.004 2.105 0.094 0.074 0.023 0.029 0.368 - -
Similar USA AUSTRALIA GERMANY ITALY ROMANIA
steels ASTM A128 AS 2074 DIN UNI 3160 STAS3718
A H19 1.3802 GX120Mn12 T105Mn120
Characteristics and applications: The original austenitic manganese steel, containing about 1.2%C and 12%Mn, was invented by Sir Robert Hadfield in 1882.It
combined high toughness and ductility with high-hardening capacity and excellent resistance to wear. It is still used extensively, with composition and heat treatment modification, prima-
rily in the fields of earthmoving, mining, quarrying, oil well drilling, railroading,and in the manufacture of cement and clay products.Example:rock crusher, bucket,wear plate, etc.
Heat treatment guide: Heat treatment strengthens austenitic manganese
steel so that it can be used safely and reliably in variety of engineering applications.
Solution annealing and quenching are the standard processes.
Manufacturing pro- 1050 water Processes: The raw material(pig iron, scraps,ferro alloy, etc.) were charged
cess of this specimen
charge melting pouring casting
of the mold and heated to 1050
o
C and quench in water.
into the induction furnace for melting. Then the liquid metal was discharged and
poured into the sand mould. After the solidification, the casting was taken out
Solution annealing and quenching
Temerature,
o
C
Soaking time
Quenchant
1010-1090
1 to 2 hours per 25 mm. of thickness
agitated water
UNE 36253 BS3100
SCMnH3 2183 AM-X-120Mn12 BW10(En 1457)
SPAIN UK
Ferrous Metal High manganese steel Solution annealed
G5131 MNC 720E
JAPAN MEXICO
Microstructures
Photo.97:50x, High Manganese Steel casting, annealed. Microstructures are Austenite.
The purple area shows the trace of dendrite.
Photo.98:1000x, Same as in Photo. 97, but in higher magnification. The carbide along
grain boundaries decreased after annealing.
Carbides remained along
grain boundary
66
Photo.99:200x, Same as in Photo. 98, but in larger area. The microstructures are Austenite. The grain boundaries are thinner and less carbide after annealing.
Austenite grain boundary
Carbide
67

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