EMG 2201 270924

Iron-Carbon Phase Diagram

Alloy metals can exist in various phases, which are physically homogeneous states of the alloy. Each phase
has a specific chemical composition, characterized by a particular arrangement and bonding of atoms.

The atomic structure of each phase gives rise to distinct properties, allowing us to select the phase that
best suits our applications.

Only certain specialized alloys can exist in multiple phases. By heating the metal to specific temperatures
through heat treatment processes, we can induce the formation of different phases. Some specialized
alloys can even maintain more than one phase at the same temperature.

What Are Phase Diagrams?

Phase diagrams are graphical tools that illustrate the phases present in an alloy under varying conditions
of temperature, pressure, or chemical composition.

These diagrams indicate the conditions required for two or more phases to exist in equilibrium. For
example, the water phase diagram highlights the "triple point," where water can coexist in three different
phases simultaneously, occurring just above the freezing temperature (0.01°C) and at a pressure of 0.006
atm.

Using the Diagrams

Alloy phase diagrams serve four main purposes:

1. Alloy Development: They guide the creation of new alloys tailored to specific application
requirements.

2. Alloy Production: They inform the manufacturing processes for these alloys.

3. Heat Treatment Optimization: They assist in the development and control of suitable heat
treatment procedures (e.g., tempering, annealing, normalizing) to enhance the chemical, physical,
and mechanical properties of new alloys.

4. Troubleshooting: They help identify and resolve issues that may arise during the application of
new alloys, ultimately improving product reliability.

In alloy development, phase diagrams help avoid overdesign, which can reduce costs and processing times.
They also facilitate the creation of alternative alloys or variations of existing alloys with different alloying
elements, minimizing the need for scarce, hazardous, or expensive materials.

From a performance perspective, phase diagrams aid metallurgists in identifying which phases are
thermodynamically stable, metastable, or unstable over time. This knowledge enables the selection of

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appropriate alloying elements to prevent machinery failures. For instance, improper material selection for
exhaust piping can result in breakdowns at elevated temperatures.

Additionally, the service life of materials improves as phase diagrams provide insights into addressing
issues such as intergranular corrosion, hot corrosion, and hydrogen damage.

The iron-carbon phase diagram is commonly used to study the various phases present in steel and cast
iron. These alloys are composed of iron and carbon, along with small amounts of trace elements. It is
plotted with the carbon concentrations by weight on the X-axis and the temperature scale on the Y-axis.

Carbon acts as an interstitial impurity in iron, and the alloy can adopt either a face-centered cubic (FCC)
or body-centered cubic (BCC) lattice structure. It forms solid solutions with the α, γ, and δ phases of iron.

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Boundaries

The diagram features several lines labeled A1, A2, A3, A4, and ACM, where "A" stands for "arrest." These
lines represent boundaries at which phase changes occur as the metal's temperature rises or falls, with
the phase transformation happening when the temperature reaches the boundary value.

Typically, when heating an alloy, its temperature increases continuously. However, along these lines (A1,
A2, A3, A4, and ACM), the temperature temporarily halts as the alloy undergoes structural realignment
into a new phase. This phenomenon, known as thermal arrest, occurs because the temperature remains
constant until the phase transformation is complete.

Alloying elements such as nickel, manganese, chromium, and molybdenum influence the position of these
boundaries on the phase diagram. Depending on the element, the boundaries may shift in either direction.
For instance, in the iron-carbon phase diagram, nickel lowers the A3 boundary, while chromium raises it.

Eutectic Point

The eutectic point is where multiple phases converge on a phase diagram. In the iron-carbon alloy
diagram, the eutectic point is the intersection of the A1, A3, and ACM lines, forming a coincidental point.

At this point, eutectic reactions occur, where a liquid phase solidifies into a mixture of two solid phases.
This happens as a liquid alloy with eutectic composition cools down to its eutectic temperature.

The alloys formed at this point are called eutectic alloys. Alloys to the left and right of the eutectic point
are referred to as hypoeutectic and hypereutectic alloys, respectively, with "hypo" meaning "less than"
and "hyper" meaning "greater than" in Greek.

Phase Fields
The intersecting boundaries on the Fe3C diagram define different regions known as phase fields.

Within each phase field, either a single phase or a combination of two phases can exist. A phase change
takes place along these boundaries. The phase fields represent the phases present at a given composition
and temperature of the alloy. Let's now explore the various phases of the iron-carbon alloy.

Different Phases

α-ferrite
α-ferrite is a solid solution of carbon in body-centered cubic (BCC) iron, present at low temperatures and
low carbon content. This phase is stable at room temperature and appears as a narrow sliver on the left
side of the iron-carbon phase diagram, bounded by the Y-axis and the A2 line. Below 768°C, α-ferrite is
magnetic. It has a maximum carbon content of 0.022%, and at 912°C, it transforms into γ-austenite.

γ-austenite
γ-austenite is a solid solution of carbon in face-centered cubic (FCC) iron, with a maximum carbon solubility
of 2.14%. Upon further heating, it transitions into BCC δ-ferrite at 1395°C. This phase is unstable at
temperatures below the eutectic temperature (727°C) unless cooled rapidly and is non-magnetic.

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δ-ferrite
δ-ferrite has the same BCC structure as α-ferrite but exists only at high temperatures. It can be found at
the upper left corner of the diagram and has a melting point of 1538°C.

Fe₃C or Cementite
Cementite (Fe₃C) is a metastable phase with a fixed composition, slowly decomposing at room
temperature into iron and carbon (graphite). This process is so slow that it exceeds the typical service life
of most applications. However, factors like high temperatures or certain alloying elements can accelerate
this decomposition by promoting graphite formation. Cementite is hard and brittle, contributing to the
strength of steel. Its mechanical properties are determined by its microstructure and how it interacts
with ferrite.

Fe-C Liquid Solution

Labeled as "L" in the upper region of the diagram, this phase represents a liquid solution of carbon in
iron. Since δ-ferrite melts at 1538°C, the melting point of iron decreases as carbon content increases.

Some Videos for your review:

1. https://youtu.be/tYk5NMylHc0
2. https://youtu.be/h5dwpTqacqc
3. https://youtu.be/IUMcbctDNtM

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Assignment for submission by 11.10.24

1. Ledeburite

• Define Ledeburite and explain the conditions under which it forms in the iron-carbon
system.Identify the temperature and composition range where Ledeburite appears on the phase
diagram, particularly in hypereutectic alloys during slow cooling.

• Describe the microstructure of Ledeburite and explain how Ledeburite forms as the liquid phase
solidifies into these two phases and its subsequent transformation as the alloy cools further.

• Discuss the mechanical properties of Ledeburite and provide examples of applications where
Ledeburite is encountered, particularly in cast iron, and how it affects material performance.

2. Repeat the above exercise for Martensite and Pearlite

Self-Test Assessment

1. Introduction to the Iron-Carbon Phase Diagram

a) Explain the purpose and importance of the iron-carbon phase diagram in metallurgy.
b) Briefly describe the major components of the diagram, including the key lines (A1, A2, A3, A4,
and ACM).

2. Phases in the Iron-Carbon Alloy

a) Define and describe the different phases present in the iron-carbon system (α-ferrite, γ-
austenite, δ-ferrite, and cementite).
b) Discuss the structural differences between these phases (BCC, FCC) and their significance in
the mechanical properties of iron-carbon alloys.

3. Eutectic and Eutectoid Reactions

a) Explain what happens during a eutectic and eutectoid reaction in the iron-carbon system.
b) Identify the eutectic and eutectoid points on the diagram and describe the phases involved in
each transformation.
c) Provide examples of eutectic, hypoeutectic, and hypereutectic alloys, and explain how their
properties differ.

4. Effect of Alloying Elements

a) Discuss how alloying elements like nickel, chromium, and manganese influence the position of
critical lines (A3, ACM, etc.) on the phase diagram.
b) Provide an example of how alloying is used in industry to modify steel properties (e.g.,
stainless steel or tool steel).

5. Applications of the Iron-Carbon Phase Diagram

a) Analyze the importance of the iron-carbon phase diagram in the heat treatment of steel, such
as annealing, quenching, and tempering.

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b) Provide examples of real-world engineering applications where the understanding of phase

transformations in the iron-carbon system is essential.

6. Thermal Arrest and Phase Boundaries

a) Define thermal arrest and explain its significance during phase transformations in iron-carbon
alloys.
b) Describe the effect of thermal arrest during heating and cooling of steel.