Influence Of Different Surface Treatments On Fatigue ... Mechanical...2Dept. of Mechanical Engg.,...

ADVANCES in NATURAL and APPLIED SCIENCES

ISSN: 1995-0772 Published BY AENSI Publication EISSN: 1998-1090 http://www.aensiweb.com/ANAS

2016 Special10(7): pages 326-341 Open Access Journal

To Cite This Article: M. Senthil kumar, S. Ragunathan, M. Suresh, V. R. Srinivashan., Influence Of Different Surface Treatments On Fatigue Behavior Of En8 Steel. Advances in Natural and Applied Sciences. 10(7); Pages: 326-341

Influence Of Different Surface Treatments On

Fatigue Behavior Of EN8 Steel

1M. Senthil Kumar, 2S. Ragunathan, 3M. Suresh, 4V. R. Srinivashan

1Dept. of Mechanical Engg., Sona College of Technology, Salem-5, India. 2Dept. of Mechanical Engg., AVS Engineering College, Salem-3, India. 3Dept. of Mechanical Engg., Sona College of Technology, Salem-5, India. 4Dept. of Mechanical Engg., AVS Engineering College, Salem-3, India.

Received 25 April 2016; Accepted 28 May 2016; Available 5 June 2016

Address For Correspondence: M. Senthil kumar, Dept. of Mechanical Engg., Sona College of Technology Salem-5, India. E-mail: [email protected]

Copyright © 2016 by authors and American-Eurasian Network for Scientific Information (AENSI Publication).

This work is licensed under the Creative Commons Attribution International License (CC BY).

http://creativecommons.org/licenses/by/4.0/

ABSTRACT This paper tells about the fatigue behavior of EN8 steel under different treatments such as coating, nitriding, induction hardening and combined nitriding and induction hardening. The base metal EN8 steel was exposed to Nitriding in cyanide salt bath with 560˚C. The specimens undergone with induction hardening experienced the electrical input of 32kW at 180˚C. As combined heat treatment exhibits better output in fatigue strength, the nitrided specimens were introduced induction hardening with 80 KHz frequency. Ni-Zn coating was done on both Nitrided and base metal specimens by pulse electro deposition. The results of Tensile and Hardness were studied. Fatigue behavior of each category was tested in Cantilever type Rotary Bending Fatigue machine.

Results showed that coating on nitrided specimens produces high fatigue resistance than coating on base metal specimens and improved fatigue strength was obtained by the hybrid heat treatment (nitriding and induction hardening). Fracture study was done using SEM.

KEYWORDS: nitriding, Ni-Zn coating, pulse plating, induction hardening , tensile, fatigue, SEM and micro hardness.

INTRODUCTION

EN8 steel shows major application on manufacturing rotary elements like transmission shafts, crankshafts

and gears which is generally subjected to wear and corrosion due to cyclic loading. The enhancement of surface properties of EN8 steel was obtained by heat treatment and coating.

Fatigue failure of crankshafts in automobiles is led by dynamic loading on rotary components. [1] Fatigue failure are classified in three stages say, i) Crack Initiation (ii) Crack Propagation & iii) Initiation and propagation of fracture. Fatigue failure in crankshaft is started from critical locations [2].

Uniform deposition of fine particles that provides the lower porosity with reduced stress and improved adhesion property was achieved by pulse electro deposition [3]. The uniform distribution of particle with higher amounts of particle incorporation is possible through pulse plating than DC Plating. Results say that high mechanical properties were obtained by pulse plating than DC plating [4].

The Fatigue resistance can be achieved by Heat treatment, Coating & Shot peening. The crack initiation and propagation can be resisted by joining any two or more methods [5].

Wear resistant hard chromium plating deposits lead to the fatigue strength reduction in aeronautical steel [6].

The under layers of electroless nickel plating are the reason for increase of fatigue strength of steel. The electroplating induces the compressive residual stress [7]. A thin film Zinc coating was applied on steel by electro deposition that increased mechanical properties [8].

327 M. Senthil kumar et al., 2016/ Advances in Natural and Applied Sciences. 10(7) Special 2016, Pages: 326-341

Protection of iron and steel components with least price can be done by Zinc coatings. From pure metal baths plating, it is not possible to obtain change in the electrodeposits which is the main reason for plating in alloy bath. The electro-deposition of nano crystalline zinc-nickel coatings were done on mild steel from an electrolyte which has zinc bromide, NiCl and boric acid to obtain excellent mechanical properties. [9]

In pulse electro deposition method Nickel/nano-Al2O3 composite coatings are produced. An AISI 1018 mild steel specimen electroplated were investigated in a Watt’s type bath. The investigations are on the influence of pulse parameters, say, voltage, duty cycle and current density on the microstructure, pulse frequency, hardness and wear resistance. The effect of pulse parameters were considered for improving hardness [10].

The fatigue life of material was increased by diffusion coating. Initiation of surface crack is homogeneous. Nucleation period of the dominant crack in the specimen is continued in the coated material. Crack propagation path is coincided both coated and uncoated super alloy with the inter dendritic regions [11].

The investigations on the effect of mechanical properties were done, using Ni-Co thin film, on specimen [12].

Results and analysis showed that coating effects were not in unique manner, but they depended on the specific technology and parameters. To increase the wear resistance and contact fatigue life of machinery components, coating methods along with nano particles is used.[13].

Incase of plasma nitrided PH-42 Supra steel, fatigue limit stress was 710 Mpa which is much higher than non-nitrided specimen of 440 MPa or the bulk material. Hence, the fatigue limit was increased by 61% by plasma nitriding process [14].

Various types of coating material were investigated. With the optimized input parameters, fatigue strength of nickel zinc based coating had improved. The surface properties have been studied using metallurgical microscope [15].

By using chloride bath by electroplating process Nickel zinc coating were carried out, the effect of parameter had been discussed and also given optimized input parameters. Optimization with the help of Taguchi method was done. [16].

Failure reasons were identified and also by using software fatigue analysis are carried out for crankshaft with coating and without coating. Here, crankshaft with coating had higher fatigue strength. Microscopic behavior also was investigated. [17].

A structural component may influence the fatigue resistance because of the effects of environmental, mechanical and metallurgical variables [18]. The major role of decrement in fatigue limit is due to the defects on surface of high strength steels [19]. Crankshaft manufacturing is mostly done using EN8 steel which ensures more strength and more toughness. Fatigue failure is the major problem to the components experiencing repeated loads [20]. The fatigue behavior is improvised by Surface treatments on machine elements.

The fatigue strength is improved approximately by 50% with case depths and 12% of fatigue strength is obtained with respect to liquid nitriding specimens [20]. Nitrided samples exhibit excellent resistance on scuffing while comparing with the base metals, the nitride specimens provide the fine wear resistance and also improve the life of the material [21]. The plasma nitriding treatment enhances fatigue life and fatigue strength of the material with presence of compound layer upto 10µm [22].

The fatigue strength of AISI 4340 steel was increased up to 91% by ion nitriding process [23]. In the stainless steel specimens, the residual stress were induced induction heating which increases the high cycle fatigue lives [24]. Hybrid surface modification process gives higher fatigue strength which is greater than that of substrate and nitride specimens [25].

The heat treatment process such as nitriding and induction hardening was selected then few mechanical tests were experimentally conducted. The result shows fatigue strength of heat treatment had increased [26]. Mostly nitriding improves all mechanical properties especially fatigue strength. Micro hardness was improved due to the internal stress and properties modification in the layer of nitriding. Corrosion and wear resistance also was increased by nitriding process [27].

After machining, the dies are subjected to a temper and quench operation followed by a surface treatment, which is usually plasma nitriding, salt bath nitro carburising or gas nitriding.Low hardness (500-550 HV) ensures the necessary die toughness, while the surface treatment yields a hard layer with a depth of 0.2 - 0.5 mm and a hardness up to 1100-1200 HV, that ensures the wear and the fatigue resistance. Also the compound layer (around 4-10 μm) is reason for tribological and lower corrosion of the die surface. [28].


Methodology:

EN8 STEEL

Coating

(Ni-Zn)Heat treatment

Induction

HardeningCombination

(Nitriding and

Induction Hardening)

Nitriding

Testing of Mechanical Properties

Tensile, Micro hardness and Fatigue

Ni-Zn

Coating

Improved Endurance Limit and Fatigue Life

Fig. 1: Methodology Flow Chart

Fig. 2: Specimen Dimension

Material is EN8 steel and its composition is shown in the Table 1. The initial EN8 steel rod of 16mm

diameter is machined as per the specifications of the fatigue testing machine. Table 1: EN8 Chemical Composition

Element Content (Range) Content (Measured) Carbon 0.35%-0.45% 0.45% Manganese 0.60%-1.00% 0.86% Silicon 0.05%-0.35% 0.24% Sulphur 0.060% 0.032% Phosphorous 0.060% 0.014%

Table 2: EN8 Mechanical Properties

Tensile strength 780 - 850 Mpa Yield Strength 465 Mpa Hardness 201-255 BHN

Fig. 3: Specimen prepared for all processes Table 3: Specimens Of All Categories

Sl.No. Specimen Tensile Testing Fatigue Testing 1. Base metal 1 15 2. Ni-Zn coating 1 15 3. Nitriding 1 15 4. Nitriding + Ni-Zn coating 1 15 5. Induction Hardening 1 15 6. Combined 1 15


A. Coating A.1. Pre-treatment for coating

The steel specimens were taken for 3 pre-treatment processes before coating. Those are, Mechanical polishing, Ultrasonic cleaning, , Anodizing (ie.reverse plating). Using frequency and formula, Pulse ON and OFF time and duty cycle was calculated.

A.2. Electro deposition

Fig. 4: Pulse Plating Set up

Polished EN8 steel rod specimen was cathode and high purity Nickel was anode (Ni plate was a soluble

electrode). Chloride electrolyte bath was selected to get high mechanical properties. Coating process was carried out using Dynatronix pulse rectifier. Table 4: Pulse Parameter Values

Parameters VALUES Frequency (Hz) 100Hz Duty cycle (%) 80% Current density (A/cm2) 1.0

Electrolytic bath compositions for Ni-Zn coating is shown in table.5.

Table 5: Electrolytic bath composition

Constituents Ni-Zn Nickel chloride (NiCl2·6H2O)

85g/L

Nickel sulfate (NiSO4·6H2O)

35g/L

Zinc chloride 195 g/L Boric acid (H3BO3) 50g/L NaCl 75 g/L Sodium dodecyl sulfate 0.15 g/L Anodes Ni

A.3. Coating Thickness calculation:

Coating thickness = weight of coating material covered/ (Average density of coating material x Total area of coating)

tc = Wc /(ρavg x A); Weight of coating material covered = weight of specimen after coating – weight of specimen before

coating. Wc = Wac - Wbc By calculation the coating thickness was achieved in the range of 90 μm -100 μm.

B.Nitriding: Mechanical properties of metals can be improved by heat treatment. Nitriding process has an advantage such

as improved hardness, compressive residual stresses & wear and corrosion resistance. The tensile residual stress was increased by nitriding process which leads to increase in fatigue as well all the mechanical properties.


Nitriding on steel resulted 400 MPa compressive residual stress, which increases 35% of fatigue strength [29]. The fatigue life for the specimen subjected to ion nitriding can be improved by 50% [30]. The specimens here subjected to liquid nitriding (salt bath) which is heated to 560o C. Nitrogen in the salt bath diffuses on the surface of the specimen. By increasing the time period nitrogen diffusion rate on case depth varies.

Fig. 5: Nitrided Specimens C Induction Hardening: Table 6: Induction Hardening Specification

Induction hardening Specifications Power 32 KW

Speed Major ф: 1900 mm/min Minor Ф: 2300 mm/min

Dwell 0.2 seconds Frequency 80 KHz Coil ID 17 mm

By induction hardening process the residual stress (tensile) in the core increases and the compressive stress

increases on the surface, it leads to increase fatigue strength as well as wear strength [31]. By induction hardening process, surface hardness can be improved upto 600 HV and the compressive residual

stress along the longitude direction of 500Mpa obtained which also increases fatigue strength [32]. Hence, hybrid heat treatment shows the better result for fatigue life, same amount of nitrided specimens are subjected to induction hardening.

D. Combined Nitriding and Induction Hardening:

Nitriding was carried out and then the specimen was subjected to induction hardening process, Fig.6. shows thee combinational processed fatigue testing specimens.

Fig. 6: Combined Nitrided and Induction Hardened Specimens

RESULTS AND DISCUSSION

A. Tensile Testing:

The Specimen is fitted in the Universal Testing Machine and the load was applied gradually and yield and ultimate load are measured.


Graph 1: Tensile result of base metal

Graph. 2: Tensile result of coated base metal

Graph. 3: Tensile result of nitrided base metal


Graph. 4: Tensile result of Ni-Zn coated nitrided base metal

Graph. 5: Tensile result of Induction Hardened base metal


Graph. 6: Tensile result of combinational heat treated base metal. Table 7: Tensile Testing Results

S.No. Treatment Yield Stress Ultimate Stress 1. Base metal 465.61 707.3 2. Base metal + Ni-Zn coating 486.18 687.28 3. Nitrided 615.176 757.23 4. Nitrided + Ni-Zn coated 626.044 729.673 5. Induction hardening 607.026 737.047 6. Combined 650.944 752.80

B. Micro hardness:

The hardness of specimens after coating and heat treatment were measured with Vickers micro hardness testing machine using a diamond indenter for the coated surface by applying 500g load in 15 seconds.

The results of micro hardness of different categories are represented in table.8. Table 8: Micro Hardness Test Results

S.No Specimen Average Micro Hardness (HV)

1. Base metal 250.6 2. Base metal + Ni-Zn coating 303.5 3. Nitrided 550.2 4. Nitrided + Ni-Zn coated 602.6 5. Induction Hardening 525 6. Combined 620

Graph. 7: Micro hardness of all categories

C. Fatigue testing:

In FTG (cantilever type), the rotating bending fatigue test was carried out. After clamping one end of the specimen in the load cell, the other end was fitted on the collect which is connected to motor.

Load was applied on the load cell mechanically and the respective number of cycle was noted from counter from the obtained data S-N curve was plotted.


Fig. 7: Fatigue Testing Machine

Figure.7. shows the cantilever type fatigue testing machine. To calculate the bending stress, P = load applied L = 130 cm, Bending moment (Mb) = PL Bending stress (fb) = Mb/Z kg/cm2 Where, Z = section modulus = Πd3/32. Stress and number of cycles to failure are listed from table.9 to table.14 for all categories.

Table 9: S-N values for base metal

Specimen No. Base metal Stress (MPa)

Number of cycles

1. 646.55 1.25 x103 2. 594.11 2.21 x103 3. 542.12 8.3 x103 4. 490.15 2.05 x104 5. 439.66 5.6 x104 6. 439.66 1.65 x105 7. 387.92 7.5 x105 8. 336.18 1.1 x106 9. 310.41 1.62 x106

10. 284.44 1.65 x106 11. 271.56 2.0 x106 12. 271.56 2.1 x106 13. 258.67 2.72 x106 14. 258.67 2.82 x106 15. 258.67 2.75 x106

Table 10: S-N values for Base metal with Ni-Zn coating

Specimen No. Base metal with Ni-Zn coating Stress (MPa)

Number of cycles

1. 646.55 1.35 x103 2. 594.11 3.3 x103 3. 542.12 9.2 x103 4. 490.15 1.82 x104 5. 439.66 6.5 x104 6. 439.66 1.75 x105 7. 387.92 7.91 x105 8. 336.18 1.30 x106 9. 310.41 1.71 x106 10. 295.01 1.70 x106 11. 295.01 1.72 x106 12. 284.44 2.1 x106 13. 284.44 2.09 x106 14. 271.67 2.80 x106 15. 271.67 2.8 x106


Graph. 8: S-N Curve for Base Metal and Ni-Zn Coating

Table 11: S-N values for nitrided Base metal

Specimen No. Nitrided base metal Stress (MPa)

Number of cycles

1. 620.7 2.32 x104 2. 594.84 6.12 x104 3. 568.98 8.9 x104 4. 543.12 9.21 x104

5. 517.252 2.87 x105 6. 491.39 5.34 x105 7. 465.53 9.25 x105 8. 439.66 1.32 x106 9. 413.79 4.23 x106 10. 413.79 3.5 x106 11. 387.93 6.91 x106 12. 387.93 6.72 x106 13. 362.08 1.02 x107 14. 362.08 1.01 x107 15. 362.08 1.05 x107

Table 12: S-N values for nitrided Base metal + Ni-Zn Coating

Specimen No. Nitrided base metal + Ni-Zn coating Stress (MPa)

Number of cycles

1. 594.84 2.56 x104 2. 568.98 7.82 x104 3. 543.12 9.52 x104 4. 517.252 1.34 x105 5. 491.39 4.95 x105 6. 465.53 8.34 x105 7. 439.66 1.32 x106 8. 413.79 4.98 x106 9. 413.79 5.21 x106 10. 400.85 8.1 x106 11. 400.85 8.5 x106 12. 387.92 1.05 x107 13. 387.92 1.01 x107 14. 375.26 2.1 x107 15. 375.26 2.5x107


Graph. 9: S-N curve for Base Metal with Nitriding and Nitriding with coating

Table 13: S-N Detail for Induction Hardened base metal

Specimen No. Induction Hardened base metal Stress (MPa)

No. of cycles

1. 594.84 1.02 x104 2. 568.98 2.36 x104 3. 543.12 5.45 x104 4. 517.252 6.98 x104 5. 491.39 9.54 x104 6. 465.53 3.54 x105 7. 439.66 6.72 x105 8. 413.79 9.71 x105 9. 413.79 9.82 x105 10. 387.93 3.23 x106 11. 387.93 3.96 x106 12. 362.08 6.82 x106 13. 362.08 6.32 x106 14. 336.21 9.20 x106 15. 336.21 9.56 x106

Table 14: S-N Detail for Combined (Nitriding and Induction HardeninG) Specimens

Specimen No. Combined (Nitriding + Induction Hardening) Stress (MPa) No. of cycles

1. 650 3.25x104 2. 620 6.25 x104 3. 594.84 9.2 x104 4. 568.98 1.07 x105 5. 543.12 4.35 x105 6. 517.252 8.92 x105 7. 491.39 1.24 x106 8. 465.53 4.34 x106 9. 439.66 7.54 x106 10. 439.66 7.72 x106 11. 413.79 9.75 x106 12. 413.79 9.86 x106 13. 387.93 1.23 x107 14. 387.93 1.24 x107 15. 387.93 1.30 x107


Graph 10: S-N Curve for Combined Nitriding and Induction Hardening Specimens

Table 15: Endurance limit for ALL CATEGORY specimens

Specimen Endurance limit (N/mm2) Fatigue life (N) cycles Base metal 258.67 2.75 x106 BM-Ni-Zn 271.67 2.81 x106 Nitrided BM-Ni-Zn 375.26 2.5 x107 Nitriding 362.08 1.05 x107 Induction hardening 336.01 9.56 x106 Combined 387.93 1.30 x107

Table 16: Endurance limit for surface treated EN8 STEEL

Properties

Treatment

Ni-Zn Coating on Base Metal Ni-Zn Coating on Nitrided Base Metal

Induction Hardening on Nitrided Base Metal

Endurance limit (N/mm2) 271.67 375.26 387.93 Fatigue life (N) cycles 2.81 x106 2.5 x107 1.30 x107

E.SEM Analysis:

Fig. 8: Fracture surface of base metal


Fig. 9: Crack initiation and propagation in the base metal

Fig. 10: Crack-initiation sites around the specimen periphery. General fracture surface with several crack-initiation sites around the specimen periphery.

Fig. 11: Fracture surface of Ni-Zn Coated base metal

Micro cracks density distributed along thickness.


Fig. 12: Fracture surface of Nitrided base metal

Brittle fracture occurs on the surface of specimen up to the nitride layer and the remaining portion exhibits

ductile fracture.

Fig. 13: Ductile fracture in the core of specimen

Fig. 14: Fracture surface of Ni-Zn electroplated Nitrided base metal


Fig. 15: SEM image of Hybrid treatment (Nitriding and induction Hardening)

Two kinds of fracture region can be observed, one is the ductile zone that occurs in the centre and the other is

brittle in the edge of a brittle layer. The Nickel-Zinc layer is responsible for the improvement in fatigue strength of EN8 Steel. This compressive

residual stress was initiated that was arrested, delayed the crack propagation from the coating layer to base metal. Radial micro cracks are along the coating thickness direction, which did not allow the micro cracks to grow

in direction to the substrate and fatigue crack nucleation site at the coating/substrate interface. Crack nucleation occurs at the interface. The cracks initiation from the surface is less compare compared with base metal due to Ni-Zn electroplating.

Conclusion:

• Experimental fatigue testing result shows coated specimens have more fatigue strength compared to the uncoated specimens, either base metal or nitrided base metal. The endurance limit was higher for the coated specimens.

• Ni-Zn coated specimen has higher Tensile strength and micro hardness by comparing base metal specimens.

• The Nickel-Zinc layer is resason for the increase in fatigue strength of EN8 Steel. Compressive residual stresses were induced are arrested and also delayed the crack propagation.

• Nitriding and induction hardening processes increases hardness on the surface. Hybrid treatment gives 620Hv that is greater than individual treatments.

• Tensile strength increases based on increase in hardness. • The fatigue life increases for increment in tensile strength. The endurance limit of Hybrid treatment

showed higher value than remaining surface treatments.

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