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Tribology Transactions

ISSN: 1040-2004 (Print) 1547-397X (Online) Journal homepage: http://www.tandfonline.com/loi/utrb20

Effect of Spot Continual Induction Hardening on


the Tribological Performance of Grey Cast Iron
with Curved Surface

Xunpeng Qin, Kai Gao, Zhou Wang & Xuliang Chen

To cite this article: Xunpeng Qin, Kai Gao, Zhou Wang & Xuliang Chen (2017): Effect of Spot
Continual Induction Hardening on the Tribological Performance of Grey Cast Iron with Curved
Surface, Tribology Transactions, DOI: 10.1080/10402004.2017.1300969

To link to this article: http://dx.doi.org/10.1080/10402004.2017.1300969

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Mar 2017.
Published online: 01 Mar 2017.

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TRIBOLOGY TRANSACTIONS
http://dx.doi.org/10.1080/10402004.2017.1300969

Effect of Spot Continual Induction Hardening on the Tribological Performance of Grey


Cast Iron with Curved Surface
Xunpeng Qina,b, Kai Gaoa,b, Zhou Wanga,b, and Xuliang Chena,b
a
Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Wuhan, Hubei, P. R. China; bHubei
Collaborative Innovation Center for Automotive Components Technology, Wuhan University of Technology, Wuhan, Hubei, P. R. China

ABSTRACT ARTICLE HISTORY


In order to investigate the effect of a spot continual induction hardening (SCIH) process on the tribological Received 14 December 2016
performance of grey cast iron with a curved surface, dry sliding wear tests were performed under different Accepted 24 February 2017
loads. The curved surface structure of the workpiece and feed velocity of the inductor were considered KEYWORDS
important influence factors. X-ray diffractometry (XRD), energy-dispersive spectroscopy (EDS), and Spot continual induction
scanning electron microscopy (SEM) were used to investigate the phases, compositions, and hardening; curved surface;
morphologies of grey cast iron after the SCIH process and tribological tests. The results showed that the feed velocity; tribological
wear mechanism of grey cast iron was always adhesive and abrasive wear at different loads when the performance; grey cast iron
workpiece was not strengthened. In the case of partial strengthening, the wear mechanism changed from
adhesive and abrasive wear to fatigue–exfoliative wear with increasing load. Oxidative wear always
appeared as the dominant wear mechanism when the workpiece was completely strengthened. The wear
resistance of the concave surface was always larger than that of the convex surface under the same feed
velocity of the inductor. Relatively low feed velocity of the inductor in the SCIH process can optimize the
wear resistance of grey cast iron with a curved surface.

Introduction
wear resistance. Results demonstrated that laser carburizing
Grey cast iron is being used widely for a variety of industrial was a more effective means of improving fatigue wear
applications, especially for some bulky, complicated compo- resistance than laser remelting and that the improvement was
nents. This is attributed to its useful properties, such as good significantly affected by an increase in energy density during
formability, machinability, and low price (Vadiraj, et al. (1). treatment. Slatter, et al. (7) studied the impact wear resistance
Wear failure is an important failure form for many bulky, com- of untreated and induction D hardened compacted graphite
plicated components, such as auto panel stamping dies. There- iron. The induction hardening improved the impact wear resis-
fore, it is necessary to improve the wear resistance of these tance of the compacted graphite iron and it performed much
components. Due to the huge bulk and complicated surface better compared to the laser-hardened cast iron. Compared to
profile, partial surface strengthening processes for these com- other surface strengthening methods, induction hardening
ponents are still being explored. shows favorable features of controlled heating depth, energy
There are many surface strengthening methods that can savings, and low cost (Leatherman and Stutz (8).
improve wear resistance, such as flame, laser, and induction The spot continual induction hardening (SCIH) process,
strengthening (Lee, et al. (2); Wang, et al. (3); Totik, et al. (4). which is a modified induction hardening process, has been
Some researchers have considered the effect of laser and induc- carried out in previous works (Gao, et al. (9), (10). The
tion strengthening processes on the tribological performance of inductor consists of a single-turn copper coil and a
cast iron. Pang, et al. (5) manufactured samples with micro- magnetizer. Due to the small size of the inductor, it can be
hardness differencees between bionic coupling units and the assembled to a five-axis cooperating computer numerical
base metal by laser surface remelting in order to improve the control machine tool to strengthen more than one small area
wear resistance of gray cast iron guide rails. The results indi- or relatively large area on the complicated component
cated that when the microhardness difference was 561 HV0.2, surface by controlling the movement and rotation of the
the wear resistance was the best. Chen, et al. (6) improved grey inductor. Compared with through-hardening, the SCIH
cast iron fatigue wear resistance through laser cladding carbon, process has the features of a relatively large temperature
a proposed process referred as laser carburizing. Optimization gradient and high heating rate. In addition, the nonlinearity
of laser carburizing processing conditions was achieved by of the workpiece surface profile and inductor feed path
studying the effects of input energy density on sample fatigue further complicate the SCIH process.

CONTACT Xunpeng Qin qxp915@hotmail.com


Color versions of one or more figures in this article can be found online at www.tandfonline.com/utrb.
Review led by Robert Errichello.
© 2017 Society of Tribologists and Lubrication Engineers
2 X. QIN ET AL.

Table 1. Chemical composition of grey cast iron used in this process. Table 2. Geometrical and kinematics parameters for the SCIH process.

Grey cast iron (wt%) Convex and concave radii (mm) Feed velocity of the inductor (mm/s)

C Si Mn P S Al K Mo Ti 110.17 1
3
3.32 2.85 0.89 0.04 0.05 0.10 0.07 0.02 0.21 5
7

Some researchers have also considered the effect of material


structure and many experimental parameters on the tribological with a maximum power of 50 kW. The material of the coil and
performance of cast iron. Wei, et al. (11) compared the wear magnetizer are copper and ferrite, respectively. The cross
characteristics of spheroidal graphite cast iron with carbon steel. section of the square coil is 10 mm £ 10 mm. The inductor was
They found that the spheroidal graphite cast iron presented moved along the profile of the curved surface (including convex
obviously different wear behaviors than the carbon steel, which and concave surfaces) workpiece by a five-axis cooperating
may be attributed to the presence of graphite. Prasad (12) inves- computer numerical control machine tool and the distance
tigated the influence of test parameters such as applied load, slid- between the center of the bottom surface of the inductor and
ing speed, and test environment on the sliding wear behavior of workpiece was 2 mm. It should be noted that the average
grey cast iron. The wear response of the samples was discussed distance between the inductor and workpiece was different due
in terms of specific characteristics such as load bearing, lubricat- to the different curved surface structures. In addition, the aver-
ing, and cracking tendencies of different microconstituents of age distance of the convex surface was larger than 2 mm but
the cast iron. Straffelini and Maines (13) investigated the rela- that of the concave surface was less than 2 mm. The spraying
tionship between the dry sliding wear rates of two commercial water synchronously cooled the area behind the feed track of
semimetallic friction materials against a conventional cast iron the inductor during the SCIH process. Four different feed
counterface using a block-on-disc geometry. Wear was con- velocities of the inductor (1, 3, 5, and 7 mm/s) were selected.
trolled by the abrasivity of friction materials in the first region The detailed SCIH process parameters are given in Table 2.
and by the contact temperature in the second region.
In order to investigate the effect of the SCIH process on the
Tribological tests
tribological performance of grey cast iron with a curved surface,
X-ray diffractometry (XRD), energy-dispersive spectroscopy Tribological tests were carried out after the SCIH process. The
(EDS), and scanning electron microscopy (SEM) were used to sampling positions on the curved surface workpiece and
study the phases, compositions, and morphologies of grey cast
iron after the SCIH process and tribological tests. The feed
velocities of the inductor and curved surface structures were
considered important influence factors.

Experimental procedures
Spot continual induction hardening process
The chemical composition of grey cast iron (normalized condi-
tion) used in the present work is listed in Table 1 and the initial
hardness value was about 164 HV. Figure 1 shows a schematic
diagram of the SCIH process. During the SCIH process, a high-
frequency (30 kHz) induction heating power supply was used,

Figure 2. (a) Schematic diagram of sampling position on the curved surface work-
Figure 1. Schematic diagram of the SCIH process. piece and (b) experimental setup for tribological tests.
TRIBOLOGY TRANSACTIONS 3

calculated by the following equation:

DM
WD ; (1)
rL

Figure 3. (a) Schematic diagram of the contact condition between the curved sur-
face of the pins and disc and (b) contact area evolution with wear length of convex
and concave surfaces.

experimental setup for tribological test are shown in Figs. 2a and


2b, respectively. Dry sliding wear tests were performed in air on
a pin-on-disc wear tester. The induction-hardened grey cast iron
was machined into pins with dimensions of 6 mm on each side
and 18 mm height. The contact conditions between the curved
surface of the pins and disc were different due to the difference
in geometry between convex and concave surfaces. A schematic
diagram of the contact condition between the curved surfaces of
the pins and disc is shown in Fig. 3a. It can be seen that when
wear appeared in region 1, the contact conditions on the disc
surface were different for convex and concave surfaces. In
addition, the contact conditions were the same when wear
appeared in region 2. Figure 3b shows the contact area evolution
with wear length of the convex and concave surfaces. From
Fig. 3b it can be seen that the contact area between the curved
surfaces and disc increases with increasing wear length. How-
ever, the contact area of the convex surface is always larger than
that of the concave surface at the same wear length in region 1.
The disc used in this work was quenched AISI D3 steel,
whose hardness was about 750 HV. The disc and pin specimens
were polished to a roughness (Ra) level of 0.4 mm prior to initi-
ating the wear tests. As mentioned above, wear failure is an
important failure form for many bulky, complicated compo-
nents, such as auto panel stamping dies. Therefore, the sliding
parameters were determined based on the actual working con-
ditions as follows: 20 C ambient temperature; 50–150 N with
an interval of 50 N normal load; 0.5 m/s sliding velocity; 600 m
sliding distance. The specimens were cleaned and weighed
Figure 4. SEM images of convex surface specimens after the SCIH process under
using a microbalance with a precision of 0.1 mg after the tests different feed velocities: (a) 7 mm/s, (b) 5 mm/s, (c) 3 mm/s, and (d) 1 mm/s and
in order to determine the wear loss. The wear rate (W) was (e) optical microscope image of the initial structure.
4 X. QIN ET AL.

where DM is the weight loss (g), r is the density of materials the fine martensite was obtained and the graphite shape did
(g/cm3), and L is the sliding distance (m). For the grey cast iron, not change. With a feed velocity of 1 mm/s, more needlelike
a density of 7.2 g/cm3 was adopted to calculate the wear rate. martensite can be found in Fig. 4d due to the higher heating
The average value of three repeated tests was used as the temperature.
final result. The phases, compositions, and morphologies of the
SCIH specimens were examined using XRD, EDS, and SEM.
Microhardness measurements were performed using a micro- Microhardness after SCIH process
hardness tester with a load of 0.5 N and a hold time of 5 s.
Figure 5 shows transverse microhardness profiles of the phase
transformation zones with depth under different feed veloci-
Results ties. It can be seen in Fig. 5a that the average hardness value
and depth of the phase transformation region decrease with
Microstructure after SCIH process
increasing feed velocity of the inductor for convex surface
Figure 4 shows the microstructures of convex surface speci- specimens of the workpiece. The maximum hardness value
mens after the SCIH process under different feed velocities and and depth of the phase transformation region are about 767
with initial structures. It should be noted that with an increase HV and 1.8 mm, respectively, in the case of 1 mm/s and the
in feed velocity of the inductor, the heating temperature maximum hardness value and depth of phase transformation
decreased. It can be seen from Fig. 4a that with a feed velocity region are about 482 HV and 1.3 mm, respectively, in the case
of 7 mm/s, martensite phase transformation did not occur. The of 3 mm/s. The difference in the maximum hardness values
mixture microstructures of pearlite, ferrite, and plate-like between these two cases is due to the higher martensite
graphite are the same as the initial microstructure, which can content in the case of 1 mm/s, which can be seen in Fig. 4d.
be seen in Fig. 4e. This is because the heating temperature did Compared to the hardness of the workpiece before the SCIH
not reach the austenite transformation temperature. A similar process, the maximum hardness value still increases slightly
microstructure can be also found with a feed velocity of 5 mm/ from about 164 to 205 HV in the case of 5 mm/s but no mar-
s, which can be seen in Fig. 4b. From Fig. 4c it can be seen that tensite can be found in Fig. 4b. This indicates that pearlite

Figure 5. Transverse microhardness profiles of the phase transformation zones


with depth under different feed velocities: (a) convex surface specimens and (b) Figure 6. Wear rate of (a) convex surface and (b) concave surface specimens after
concave surface specimens. the SCIH process under different feed velocities and loads.
TRIBOLOGY TRANSACTIONS 5

Figure 7. XRD patterns of the worn surfaces of convex surface specimens under different feed velocities: (a) 7 mm/s, (b) 5 mm/s, (c) 3 mm/s, and (d) 1 mm/s.

Figure 8. SEM images of the wear tracks on convex surface specimens after the SCIH process at 50 N load under different feed velocities: (a) 7 mm/s, (b) 5 mm/s, (c)
3 mm/s, and (d) 1 mm/s.
6 X. QIN ET AL.

transformation occurred in the case of rapid cooling, which of 3 mm/s is larger at different loads due to the lower mar-
can also increase the hardness value. In the case of 7 mm/s, tensite content and lower hardness. In the cases of 5 and
the maximum hardness value does not change. Similar varia- 7 mm/s, all of the wear rates increase significantly with
tion can be found in Fig. 5b for concave surface specimens increasing load from 50 to 100 N and from 100 to 150 N.
under different feed velocities. However, the depth of the It can also be seen in Fig. 6b that a similar variation can be
phase transformation region of concave surface specimens is found for concave surface specimens. However, the wear
larger than that of the convex surface for the same feed veloc- rate of concave surface specimens is lower than that of con-
ity of the inductor. As mentioned above, the average distance vex specimens at a load of 50 N under the same feed veloc-
of the concave surface was less than that of the convex surface, ity of the inductor. On the one hand, the contact
which results in higher heating temperature and a larger heat- conditions between the pin and disc were different for con-
affected zone for the concave surface. vex and concave surface specimens, which can be seen in
Fig. 3a. On the other hand, the hardness value of the con-
cave surface was larger than that of the convex surface
Wear rate under the same feed velocity of the inductor (except for the
Figure 6 shows the wear rate of convex surface and concave case of 7 mm/s). According to Figs. 4, 5, and 6, the tribo-
surface specimens after the SCIH process under different logical test result for the case of 7 mm/s can represent the
feed velocities. It can be seen in Fig. 6a that all wear rates tribological performance of the unstrengthened structure of
increase with increasing feed velocity of the inductor at the the workpiece before the SCIH process. Therefore, it can be
same load. In the case of 1 mm/s, the wear rate is low at concluded that the SCIH process can improve the wear
different loads due to the high hardness of the martensite resistance of convex and concave surfaces efficiently when
in the surface layer of specimens. In the case of 3 mm/s, the feed velocity of inductor is lower than 3 and 5 mm/s,
the wear rate increases markedly with increasing load from respectively. A relatively low feed velocity of the inductor in
50 to 100 N and then increases slightly from 100 to 150 N. the SCIH process can optimize the wear resistance of grey
Compared to the case of 1 mm/s, the wear rate in the case cast iron with a curved surface. XRD, SEM, and EDS results

Figure 9. SEM images of the wear tracks on convex surface specimens after the SCIH process at 100 N load under different feed velocities: (a) 7 mm/s, (b) 5 mm/s, (c)
3 mm/s, and (d) 1 mm/s.
TRIBOLOGY TRANSACTIONS 7

of convex surface specimens were used for the following sparse amount of oxide particles in the cases of 7, 5, and 3 mm/
analysis. s, which can be seen in Figs. 8a–8c. However, the wear mor-
phology in Fig. 8d showed a difference in the case of 1 mm/s
and the sliding direction cannot be distinguished clearly com-
XRD analysis of the worn surface
pared to the other three cases. At a load of 100 N, the wear
XRD patterns of the worn surfaces of convex surface specimens morphology was similar to the load of 50 N in the cases of 7
under different feed velocities are shown in Fig. 7. In the case and 5 mm/s (see Figs. 9a and 9b). However, it can be seen from
of 7, 5, and 3 mm/s, only characteristic peaks of Fe can be Fig. 9c that many delaminated regions were found in the case
found at different loads. However, the peak intensity of Fe of 3 mm/s. The smooth black regions should be tribooxide
decreases with increasing load in the case of 3 mm/s but shows layers according to Zhang, et al. (14), though they cannot be
no obvious difference in the other two cases. In the case of observed from the XRD results due to the low amount of oxide.
1 mm/s, tribooxides with corresponding characteristic peaks of Moreover, a large amount of agglomerated tribooxides was
Fe2O3 and Fe3O4 at different loads exist. This indicates that the found in the case of 1 mm/s (see Fig. 9d). At a load of 150 N,
temperatures of the worn surfaces reach a high level. In addi- the wear morphologies in Figs. 10a and 10b were still similar to
tion, the amount of tribooxides increases and Fe decreases with those at loads of 50 and 100 N in the cases of 7 and 5 mm/s.
increasing load. However, more delaminated regions and agglomerated triboox-
ides appeared in the cases of 3 and 1 mm/s, respectively (see
Figs. 10c and 10d), which was certified by the XRD results.
SEM morphology of worn surface
In order to identify the composition of material produced
Figures 8, 9, and 10 show SEM images of the wear tracks on during the wear process, EDS analysis was carried out and
convex surface specimens after the SCIH process under differ- the measured regions are marked in Fig. 10. Figure 11 shows
ent feed velocities at 50, 100, and 150 N loads, respectively. At a EDS results of different worn regions marked in Figs. 10b
load of 50 N, adhesive and abrasive traces appeared with a and 10d. It can be seen in Fig. 11a that oxide particles

Figure 10. SEM images of the wear tracks on convex surface specimens after the SCIH process at 150 N load under different feed velocities: (a) 7 mm/s, (b) 5 mm/s, (c)
3 mm/s, and (d) 1 mm/s.
8 X. QIN ET AL.

Figure 11. EDS results of different worn regions: (a) EDS 1, (b) EDS 2, (c) EDS 3, and (d) EDS 4.

appeared in region 1 (EDS 1) with an oxygen content of different feed velocities can be obtained as follows (convex
28.56%. EDS results in Fig. 11b indicate that the black plate- surface): In the case of 7 mm/s, the SCIH process had no
like structure of region 2 (EDS 2) had a high carbon content effect on the grey cast iron and its microstructure and hard-
(33.77%). According to the initial microstructure of grey cast ness were the same as in the initial condition. When the
iron, it can be deduced that worn plate-like graphite appeared load increased from 50 to 100 N and then to 150 N, the
in this region. It can be seen in Fig. 11c that the oxygen con- wear rate increased approximately linearly. In addition,
tent of region 3 (EDS 3) reached 45.29%. This indicates that adhesive traces and grooves always appeared on the worn
the tribooxides appearing in this region were different from surfaces. It can be deduced that adhesive and abrasive wear
those in region 1 due to the difference in oxygen content were the main wear mechanisms. In the case of 5 mm/s,
between regions 1 and 3. EDS analysis of region 4 (EDS 4) though the hardness increased slightly, the wear mechanism
demonstrated that the tribolayer consisted of multiple ele- did not change according to wear rate results and SEM
ments, such as O, Fe, C, and Si. It is clear that the tribolayer morphology of the wear track. In the case of 3 mm/s, the
was a tribooxide layer. The appearance of carbon indicated wear mechanism was still adhesive and abrasive wear when
that plate-like graphite was worn and its particles were dis- the load was 50 N. When the load increased to 100 N,
tributed on the worn surface during the wear process. numerous delaminated tracks appeared on the partially
worn surface with some tribooxide layers. This indicates
that when the load reached a certain value, fatigue–exfolia-
Discussion
tive wear became the main wear mechanism. When the
According to the results, the wear mechanism of grey cast load reached 150 N, delaminated tracks appeared more due
iron with a curved surface after the SCIH process under to the greater mechanical disruption. According to the XRD
TRIBOLOGY TRANSACTIONS 9

result in Fig. 3b, there was no obvious characteristic peak of Funding


oxide. This indicates that the tribooxide layer was relatively Financial support of the National Natural Science Foundation of China
thin. In the case of 1 mm/s, the amount of tribooxides (NSFC) (No. 51175392 and No. 51575415) and the Natural Science Foun-
increased with increasing load and oxidative wear became dation of Hubei Province of China (No. 2016CFA077) is gratefully
the main mechanism at different loads. It can be concluded acknowledged.
that when the load was greater than 100 N, the wear mech-
anism changed from adhesive and abrasive wear to fatigue– References
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