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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
Article views: 20
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.
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
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
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.
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 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