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Organizational Chart
Agenda
Define distortion
Identify factors influencing distortion during heat treatment
Process of selecting a vacuum furnaces to minimize distortion
Demonstrate new furnace design to minimize distortion
Validate importance of convection heating and isothermal quench
Provide useful information
Furnace
Furnace
Phase transformation
Dissimilar metals
Part design
Material accounts for over 50% of variability. Study by Bell Helicopter and IIT
Research Institute.
Type of Distortion
SIZE DISTORTION
Total size distortion is equal
to the sum of the distortions
arising during the heating and
cooling . Changes in
dimensions are due to
structural transformation and
are characterized by material
shrinkage or expansion.
SHAPE DISTORTION
Internal stresses are created
by a lack of uniformity in
temperature during
phase transformations.
Definition
Residual stresses (are induced before heat treatment by casting, forging, machining etc.)
Thermal stresses (temperature gradient while heating and quenching)
Transformation stresses (transformation from ferrite to austenite during heating and
transformation from austenite to martensite / bainite during quenching)
These stresses add up to the total stress in the component. They depend on part-geometry, steelgrade, casting, forging, machining etc. and they depend on the heat treatment. If the total stress in
the component exceeds the yield stress we get plastic deformation. This means we get distortion of
the component.
Soft
Heated to
Austenitize
Quenched to
Martensite
Before Hardening
After Hardening
AC1
Size
AC3
MF
MS
392
752
1112
1472
1832
1472
1112
752
392
200
400
600
800
1000
800
600
400
200
Temperature
oF
oC
Temperature
oC
2012
1832
1652
1472
1292
1112
932
752
572
392
212
1100
1000
900
800
700
600
500
400
300
200
100
E - Expanding
C - Contracting
Surface
Temp.
Core
Temp.
Surface
Temp.
MF
MS
Core
Temp.
10
Time (Hours)
Stage Temperature
range
1
0-200C
32-392F
2
200-300C
392-572F
3
230-350C
446-662F
4
350-700C
662-1292F
Decomposition of
retained austenite
Expansion
Expansion
Temperature distribution
2
5000
10000
15000
20000 [W/m K]
700C
750C
Film Boiling
Bubble Boiling
l
oil
Wasser
water
700C
600C
500C
400C
300C
200C
Convection
t = 10 s
t = 10 s
ref.: Stick, Tensi, HTM 50, 1995
2000
3000
Temperature distribution
2
4000 [W/m K]
Gas direction
750C
650C
550C
450C
Only convection
350C
250C
400
600
Plastic
deformation
occurs above
curve
Temperature Difference, oF
300
250
160
140
120
200
100
150
80
60
100
40
50
Thermal stresses
below yield point
under curve
400
Source: C.C. Tennenhouse
800
20
1200
1600
2000
Temperature, oF
Temperature Difference, oC
200
Temperature, oC
800
1000 1200
400
800
1200
Temperature, oF
1600
2000
.018
.016
.014
.012
.010
.008
.006
.004
.002
100 200 300 400 500 600 700 800 900 1000 1100
Temperature, oC
Source: NASA
Recrystallization annealing.
Claim: Distortion
Cause: Wrong jigging
Uniformity of Cooling
Pressure
Gas velocity - design, furnace size, blower, water system,
ratio between load and hot zone surface
Gas type
Cooling speed
Material
- shape
- weight
- material
- production
- specifications
Furnace
- horizontal
- vertical
- internal
- external
- hot zone
- heating
elements
Metallurgy
Production
Cost
Cooling Gas
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CONVECTION
CONVECTION
CONVECTION
MIN. DISTORTION
23
COST
MIN. DISTORTION
140
120
100
80
60
40
20
0
Out-of roundness
24
CONVECTION
Out-of-flatness
RADIATION
Source: Altena
Uniformity of Cooling
25
Pressure
Gas velocity - design, furnace size, blower, water
system, ratio between load and hot zone surface
Gas type
Cooling speed
t = (V/A p c)s (1/) ln [(T1 Tg) / (T2 Tg)
Heat exchange coefficient
=c w.7 p .7 -.39 cp .31 .69
26
Hot Zone
Heat
Exchanger
Quench
Motor
Quench Fan
Charge/ Load
27
External Cooling
Radiation
Shields
External fan
Cooling
Blower
Isolation Valve
28
C
H
A
N
G
E
100
50
m
0
Out-of-roundness
29
15 Bar / Horizontal
Out-of-flatness
10 Bar / Horizontal
15 Bar / Vertical
Load Configuration
31
Distortion Control
Control temperature uniformity during the phase transformation.
Heat up the parts uniformly up to to stress reliving temperature within +/- 80F until the stress relief
temperature is reached.
Use properly designed fixtures with tolerance for thermal expansion. (Graphite best/Inconnel good)
Use smart loading dummy parts, shields, low gage fixtures, baskets and grid made from low
expansion material. (Graphite or CFC material)
32
Summary
Optimized LPC & HPGQ process
-application of convective heating
-application of Dynamic / Reversing
Quenching and choose Helium as quench-gas
Fixture design
- Optimized mech. support of components
and optimized gas flow pattern in the load
THANK YOU
Janusz Kowalewski
janusz@dynatechfurnaces.com
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