carburization process modeling - nistcecamp/tms2005/tmscarburization-sisson.pdf · commercial...
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Carburization Process Modeling
Richard D. Sisson, Jr.Md. ManiruzzamanOlly Karabelchikova
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Outline
• History (1939 – 2005)• Issues
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1939
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1939
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1939
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1939
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1948
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1948
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Metals Handbook - Harris - 1948
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8th Edition- 1964
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8th Edition - 1964
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8th Edition - 1964
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8th Edition- 1964
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8th Edition - 1964
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Volume 4 - 1991
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Volume 4 - 1991
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Desk Edition-1998
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Desk Edition-1998
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Desk Edition - 1998
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1978 – Met Trans
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1988 – Met Trans
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1998 – Met Trans
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Commercial Models are currently Available - alphabetically
• DANTE• DEFORM• DICTRA• SYSWELD
• Use FEA for heat and diffusion as ell as deformations and strains
• Provide data to the models via some database
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Carburization Modeling
• Carburization rates are controlled by:– Mass transfer coefficients at the surface– Carbon diffusion in the steel
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Surface boundary conditionFlux Balance
( )dx
daDaahsurfacecsurface
cgascm −=−
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Mass transfer coefficient hm
• The mass transfer coefficient hm controls the rate that carbon is absorbed by the steel
• It depends on temperature, alloy composition, surface chemistry and oxides
• We want to enhance the surface reactions between the gas and the steel by controlling surface condition and chemistry
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Carbon Diffusion Coefficient
• The diffusion coefficient D(T,ac)controls the rate that carbon can diffuse in the steel.
• It depends on temperature, alloy composition and carbon concentration
• We need to maximize the diffusion coefficient by increasing temperature and controlling alloy compositions
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Fishbone diagram for Carburization
FeatureGeometry
Size
Part
Carbon activityPressure
TemperatureComposition
Gas
Surface
FinishChemistry
OxideMass transfer coeff.
Alloy
CompositionTTT
CCT TTP
Diffusion coeff.
Method
GasVacuum
Time, Temp. Pressure
Gas circulation Output
• Case Depth (τ)• Carbon Conc. (x,τ)• Hardness (x,τ)
Output
• Case Depth (τ)• Carbon Conc. (x,τ)• Hardness (x,τ)Carbon
activity Diffusion
coefficient
Temp.
rackingSize
VacuumGas
Furnace
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Alloy Effects
• Designation and real composition– Transformation diagrams– Carbon diffusion coefficient D(T,ac)– Surface chemistry– Mass transfer coefficient hm(T,ac)– Carbon activity
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Surface Condition
• Surface chemistry• Oxide formation• Roughness• Mass transfer coefficient hm(T,ac)
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Gas
• Composition – Endogas– Methane/propane etc.– Other gases or liquids– Activity of carbon– Equilibrium?
• Boost/diffuse ?
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Temperature
• Single or boost/diffuse?• Profile in furnace• Profile in part• Carbon Diffusion coefficient D(T,ac)• Mass transfer coefficient hm(T)?
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Carburization Modeling Issues• Do we know D (T,c) ?• How well do we need to know D (T,c)• Databases?• Do we know hm (T) ?• How well do we need to know h(T) ?• Databases?• Phase Transformation kinetics?• Databases?