arburizing,[1] carburising (chiefly British English), or carburization is a heat treatment process
in which iron or steel absorbs carbonliberated when the metal is heated in the presence of a
carbon bearing material, such as charcoal or carbon monoxide, with the intent of making the
metal harder. Depending on the amount of time and temperature, the affected area can vary in
carbon content. Longer carburizing times and higher temperatures typically increase the depth of
carbon diffusion. When the iron or steel is cooled rapidly byquenching, the higher carbon content
on the outer surface becomes hard via the transformation from austenite to martensite, while the
core remains soft and tough as a ferritic and/or pearlite microstructure.[2]
This manufacturing process can be characterized by the following key points: It is applied to lowcarbon workpieces; workpieces are in contact with a high-carbon gas, liquid or solid; it produces
a hard workpiece surface; workpiece cores largely retain their toughness andductility; and it
produces case hardness depths of up to 0.25 inches (6.4 mm). In some cases it serves as a
remedy for undesireddecarburization that happened earlier in a manufacturing process.
Contents
[hide]
1Method
2Hardening agents
3Geometrical possibilities
4Dimensional changes
5Workpiece material
6Comparing different methods
7Choice of equipment
8See also
9References
10Further reading
11External links
Method[edit]
Carburization of steel involves a heat treatment of the metallic surface using a source of carbon.
[3]
Carburization can be used to increase the surface hardness of low carbon steel. [3]
Early carburization used a direct application of charcoal packed onto the metal (initially referred
to as case hardening), but modern techniques apply carbon-bearing gases or plasmas (such
as carbon dioxide or methane). The process depends primarily upon ambient gas composition
and furnace temperature, which must be carefully controlled, as the heat may also impact the
microstructure of the rest of the material. For applications where great control over gas
composition is desired, carburization may take place under very low pressures in
a vacuum chamber.
Plasma carburization is increasingly used in major industrial regimes to improve the surface
characteristics (such as wear and corrosion resistance, hardness and load-bearing capacity, in
addition to quality-based variables) of various metals, notably stainless steels. The process is
used as it is environmentally friendly (in comparison to gaseous or solid carburizing). It also
provides an even treatment of components with complex geometry (the plasma can penetrate
into holes and tight gaps), making it very flexible in terms of component treatment.
The process of carburization works via the implantation of carbon atoms into the surface layers
of a metal. As metals are made up of atoms bound tightly into a metallic crystalline lattice, the
implanted carbon atoms force their way into the crystal structure of the metal and either remain in
solution (dissolved within the metal crystalline matrix this normally occurs at lower
temperatures) or react with the host metal to form ceramic carbides (normally at higher
temperatures, due to the higher mobility of the host metal's atoms). Both of these mechanisms
strengthen the surface of the metal, the former by causing lattice strains by virtue of the atoms
being forced between those of the host metal and the latter via the formation of very hard
particles that resist abrasion. However, each different hardening mechanism leads to different
solutions to the initial problem: the former mechanism known as solid solution strengthening
improves the host metal's resistance to corrosion whilst impairing its increase in hardness; the
latter known as precipitation strengthening greatly improves the hardness but normally to
the detriment of the host metal's corrosion resistance. Engineers using plasma carburization
must decide which of the two mechanisms matches their needs.
Gas carburizing is normally carried out at a temperature within the range of 900 to 950 C.
In oxy-acetylene welding, a carburizing flame is one with little oxygen, which produces a sooty,
lower-temperature flame. It is often used to anneal metal, making it more malleable and flexible
during the welding process.
A main goal when producing carbonized workpieces is to ensure maximum contact between the
workpiece surface and the carbon-rich elements. In gas and liquid carburizing, the workpieces
are often supported in mesh baskets or suspended by wire. In pack carburizing, the workpiece
and carbon are enclosed in a container to ensure that contact is maintained over as much
surface area as possible. Pack carburizing containers are usually made of carbon steel coated
with aluminum or heat-resisting nickel-chromium alloy and sealed at all openings with fire clay.
Hardening agents[edit]
There are different types of elements or materials that can be used to perform this process, but
these mainly consist of high carbon content material. A few typical hardening agents
include carbon monoxide gas (CO), sodium cyanide and barium carbonate, or hardwood
charcoal. In gas carburizing, the CO is given off by propane or natural gas. In liquid carburizing,
the CO is derived from a molten salt composed mainly of sodium cyanide (NaCN) and barium
chloride (BaCl2). In pack carburizing, carbon monoxide is given off by coke or hardwood
charcoal.
Geometrical possibilities[edit]
There are all sorts of workpieces that can be carburized, which means almost limitless
possibilities for the shape of materials that can be carburized. However careful consideration
should be given to materials that contain nonuniform or non-symmetric sections. Different cross
sections may have different cooling rates which can cause excessive stresses in the material and
result in breakage.[4]
Dimensional changes[edit]
It is virtually impossible to have a workpiece undergo carburization without having some
dimensional changes. The amount of these changes varies based on the type of material that is
used, the carburizing process that the material undergoes and the original size and shape of the
work piece. However changes are small compared to heat-treating operations. [4]
Change in material properties[4]
Work material properties
Mechanical
Physical
Effects of carburizing
Increased surface hardness
Increased wear resistance
Increased fatigue/tensile strengths
Grain growth may occur
Chemical
Change in volume may occur
Increased surface carbon content
Workpiece material[edit]
Typically the materials that are carbonized are low-carbon and alloy steels with initial carbon
content ranging from 0.2 to 0.3%. The workpiece surface must be free from contaminants, such
as oil oxides, alkaline solutions, which prevent or impede the diffusion of carbon into the
workpiece surface.[4]
Comparing different methods[edit]
In general, pack carburizing equipment can accommodate larger workpieces than liquid or gas
carburizing equipment, but liquid or gas carburizing methods are faster and lend themselves to
mechanized material handling. Also the advantages of carburizing over carbonitriding are greater
case depth (case depths of greater than 0.3 inch are possible), less distortion, and better impact
strength. This makes it perfect for high strength and wear applications (e.g. scissors or swords).
The disadvantages include added expense, higher working temperatures, and increased time. [4]
Choice of equipment[edit]
In general, gas carburizing is used for parts that are large. Liquid carburizing is used for small
and medium parts and pack carburizing can be used for large parts and individual processing of
small parts in bulk. Vacuum carburizing (low pressure carburizing or LPC) can be applied across
a large spectrum of parts when used in conjunction with either oil or high pressure gas quenching
(HPGQ), depending on the alloying elements within the base material. [4]
