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International Journal of Emerging Technology and Advanced Engineering Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012) 550 Development of Fe-C-Si-Mn-B Electrode for Overlaying Low Carbon Steel Substrate by MMAW Santhosham. M 1 , Rajendra boopathy.S 2 1 Professor , Department of Mechanical Engineering C.Abdul Hakeem College of Engineering &Technology, Melvisharam, Vellore-632509, Tamil Nadu, India. 2 Professor, Department of Mechanical Engineering, CEG Campus, Chennai-600025, Tamil Nadu, India. Absract ---- Hard facing of functional components of heavy engineering equipments enhances the resistance to wear and abrasion. To facilitate such a need, a set of iron base electrodes are made in the laboratory. The Iron base alloys made contain carbon, silicon, manganese and boron. Overlay of the alloys are made on low carbon steel plates by manual metal arc welding. The Fe-C-Si-Mn-B deposits exhibited an average hardness of 700VHN.The intermixing between the substrate and the deposit is quite appreciable. The evidence of the shift of C-curve to the right in the isothermal transformation diagram by promoting tempered martensite and lower bainite without quenching is evident. Boron addition in very small quantities in steel with enhanced contents of silicon and manganese generates the formation of tempered martensite and lower bainite, which shall be utilized for hardfacing Keywords ---- Carbon, Silicon, Manganese, Boron C- Curve, Tempered Martensite, Lower Bainite, Hardness, Hardfacing I. INTRODUCTION Most of the functional components of heavy engineering equipments are subjected to wear and abrasion. Such never ending natural problems create a need for protection and extension of service life of functional components in huge equipments from wear and abrasion. The loss on economy is also quite alarming due to material deterioration. By wear and abrasion, there is a progressive deterioration of metallic surfaces leading to plant inefficiency and shut down. When non metallic materials slide or roll over a metallic surface, abrasive wear occurs. An approximate ratio of wear categories generally occur are metal to metal wear-22%, impact wear-16%, abrasive wear-52% and corrosive wear-10%. Abrasive wear has a linear relationship with hardness. Hardness is the index, which is inversely proportional to material loss by wear and abrasion. It is quite evident that abrasive wear is the most prominent of all other categories. The Simplified wear theory equation is Q=N/H, Where Q is the volume loss due to abrasive wear, N is the applied load, H is the hardness [1]. To combat such material deterioration due to abrasion, several methods of protections such as cladding, coating and hard facing are followed. For wear resistance and dimensional restoration weld overlays by hardfacing are preferred [2]. The surface metallurgy can be changed by overlaying the substrate. The microstructure of the deposit plays the major role in achieving the hardness. In all the specified methods, hard facing can be done for higher thickness of deposit by manual metal arc welding. The advantage of hardfacing is that, it may be applied to functional areas of the component, which is subjected to wear and make the availability of hard wear resistant phases to resist material deterioration. Such wear resistant deposits provide extension of surface life and protection in depth to the predetermined level. Efficient deposition of metal or alloy can be done by manual metal arc welding (MMAW). Most of the engineering industries adopt MMAW, since it a versatile, cost effective, easy technique adopted in shop floor and in field applications [3]. Fe-C-Cr electrodes are utilized in many engineering industries for hard facing since; the deposit gives the anticipated hardness. Due to chromium carbide formation, the deposits are quite hard and serve the purpose. At the same time carbon in the deposit is to be maintained sufficiently in order to form chromium carbide. Fe-C-Cr welding rods are cheaper than the electrodes which contain W, Mo, Co, Ti, etc., which form complex carbides with high hardness [4].Depending on the application, economy and the surface hardness, hardfacing electrodes are chosen. To certain extent hardness can also be achieved with high carbon steels after heat treatment. In this work a new iron alloy has been developed with the addition of boron as well as with an enhancement of silicon and manganese to deteriorate the abrasive effect to certain level. The microstructure obtained shows tempered martensite and lower bainite. 22% 16% 52% 10% Ratio of wear categories
Transcript

International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)

550

Development of Fe-C-Si-Mn-B Electrode for

Overlaying Low Carbon Steel Substrate by MMAW Santhosham. M

1, Rajendra boopathy.S

2

1Professor , Department of Mechanical Engineering C.Abdul Hakeem College of Engineering &Technology, Melvisharam,

Vellore-632509, Tamil Nadu, India. 2Professor, Department of Mechanical Engineering, CEG Campus, Chennai-600025, Tamil Nadu, India.

Absract ---- Hard facing of functional components of

heavy engineering equipments enhances the resistance to

wear and abrasion. To facilitate such a need, a set of iron

base electrodes are made in the laboratory. The Iron base

alloys made contain carbon, silicon, manganese and boron.

Overlay of the alloys are made on low carbon steel plates by

manual metal arc welding. The Fe-C-Si-Mn-B deposits

exhibited an average hardness of 700VHN.The intermixing

between the substrate and the deposit is quite appreciable.

The evidence of the shift of C-curve to the right in the

isothermal transformation diagram by promoting tempered

martensite and lower bainite without quenching is evident.

Boron addition in very small quantities in steel with

enhanced contents of silicon and manganese generates the

formation of tempered martensite and lower bainite, which

shall be utilized for hardfacing

Keywords ---- Carbon, Silicon, Manganese, Boron C-

Curve, Tempered Martensite, Lower Bainite, Hardness,

Hardfacing

I. INTRODUCTION

Most of the functional components of heavy

engineering equipments are subjected to wear and

abrasion. Such never ending natural problems create a

need for protection and extension of service life of

functional components in huge equipments from wear

and abrasion. The loss on economy is also quite alarming

due to material deterioration. By wear and abrasion, there

is a progressive deterioration of metallic surfaces leading

to plant inefficiency and shut down. When non metallic

materials slide or roll over a metallic surface, abrasive

wear occurs. An approximate ratio of wear categories

generally occur are metal to metal wear-22%, impact

wear-16%, abrasive wear-52% and corrosive wear-10%.

Abrasive wear has a linear relationship with hardness.

Hardness is the index, which is inversely proportional

to material loss by wear and abrasion. It is quite evident

that abrasive wear is the most prominent of all other

categories. The Simplified wear theory equation is

Q=N/H, Where Q is the volume loss due to abrasive

wear, N is the applied load, H is the hardness [1]. To

combat such material deterioration due to abrasion,

several methods of protections such as cladding, coating

and hard facing are followed. For wear resistance and

dimensional restoration weld overlays by hardfacing are

preferred [2].

The surface metallurgy can be changed by overlaying

the substrate. The microstructure of the deposit plays the

major role in achieving the hardness. In all the specified

methods, hard facing can be done for higher thickness of

deposit by manual metal arc welding. The advantage of

hardfacing is that, it may be applied to functional areas of

the component, which is subjected to wear and make the

availability of hard wear resistant phases to resist

material deterioration. Such wear resistant deposits

provide extension of surface life and protection in depth

to the predetermined level. Efficient deposition of metal

or alloy can be done by manual metal arc welding

(MMAW). Most of the engineering industries adopt

MMAW, since it a versatile, cost effective, easy

technique adopted in shop floor and in field applications

[3]. Fe-C-Cr electrodes are utilized in many engineering

industries for hard facing since; the deposit gives the

anticipated hardness. Due to chromium carbide

formation, the deposits are quite hard and serve the

purpose. At the same time carbon in the deposit is to be

maintained sufficiently in order to form chromium

carbide. Fe-C-Cr welding rods are cheaper than the

electrodes which contain W, Mo, Co, Ti, etc., which form

complex carbides with high hardness [4].Depending on

the application, economy and the surface hardness,

hardfacing electrodes are chosen. To certain extent

hardness can also be achieved with high carbon steels

after heat treatment.

In this work a new iron alloy has been developed with

the addition of boron as well as with an enhancement of

silicon and manganese to deteriorate the abrasive effect

to certain level. The microstructure obtained shows

tempered martensite and lower bainite.

22%

16%

52%

10%

Ratio of wear categories

International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)

551

Mostly these alloys can be utilized for buildup of

layers under other alloy compositions that show better

abrasion resistance and toughness. Where ever there is no

possibility of heat treating a component after hardfacing,

due to constraints in size, etc., this new alloy can be

employed. Deposition of hardfacing material is facilitated

in the form of an electrode with 4.0 to 6.0 mm in

diameter, with sufficient flux coating containing the

alloying elements required. Hardfacing of carbon steel

substrates are very easy, particularly which contain

carbon content below 0.35%. The composition of the

substrate, especially the carbon content is to be

maintained at a specific level. Higher the carbon content

of the substrate, more difficult will be the hardfacing.

High carbon alloy steel deposits must be pre and post

treated after hard facing to attain uniform microstructure

[5]. A substrate of plain carbon steel with 0.15%C is

chosen in this work and there is no need for pre and post

heat treatment. Carbon content with an average of

0.7wt% is maintained in the Fe-C-Si-Mn –B alloy, such

that martensite structure is formed at room temperature.

Same carbon content is maintained for the electrode Fe-

C-Si-Mn alloy which has no boron. Addition of

manganese is made to stabilize the formation of

martensite and lower bainite and as well reduce the

eutectoid composition of the alloy as per Gulliet’s

diagram. Further, manganese shifts the A1 and A3

temperatures to aid the formation of martensite and

bainite [6]. Silicon beyond 2% eliminates the austenite

and is expected to aid the flow ability of the alloy in

order to obtain defect less deposits and also increases the

toughness. Combination of silicon with manganese

increases the tendency of formation of martensite in air

cooling. It is also being a very strong oxidizer, recovers

the manganese to a larger extent and allows the eutectic

temperature to be lowered. Boron shifts nose of the C-

curve to the right sufficiently in the isothermal

transformation diagram and facilitates the easy formation

of hard phases, like martensite and lower bainite. But

boron addition should be maintained below 1% to get

optimum results [7].Therefore sufficient addition of

manganese, silicon and boron are made in the alloy

expecting the anticipated hardness in air cooling after

depositing the alloy by MMAW. The expected hardness

is achieved, without the addition of costly elements,

which form complex carbides.

An average hardness of 400VHN in Fe-C-Si-Mn alloy

and an average hardness of 700BHN in Fe-C-Si-Mn-B

are expected on the deposits and are attained.

II. EXPERIMENTAL PROCEDURE

Fe-C-Si-Mn and Fe-C-Si-Mn-B electrodes are made in

the laboratory by manually coating the flux on bare wire.

Required amount of various ingredients are mixed in a

mini muller to form the flux. The flux mixture contains

oxidizing agent, reducing agent, binder, slag remover,

coating strengthener and gas shield to obtain defect free

deposits [8, 9, 10, and 11].

Required amount of silicon and manganese are added

in the form of ferrosilicon and ferromanganese.

Ferromanganese plays a dual role, while being an

oxidizing agent, it also acts as an alloying element. Borax

is added to obtain boron in the deposit. Charcoal is added

to pick up carbon. Detail of raw materials in flux is as

shown in table.1.

After manual coating, the electrodes are dried in the

muffle furnace at 350° C for four hours. A flux to bare

wire ratio of 1.5:1 is maintained. Mild steel wire with 4

mm diameter is chosen for flux coating to form the

electrodes. Overlaying is done on 5mm thick low carbon

steel plate.

Fig.1 Pm Vs (Ac3-Ac1)

Fig .2 Weld deposit by

60708090

100

1.1197 1.2316 1.005 0.9579

(Pm) Vs (Ac3-Ac1)

International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)

552

Table 1.

(Flux weight distribution for each electrode. All weights are in grams)

Material Bentonite FeO FMn CaF2 Asbestos Caco3 Sodium Carbon FeSi H3BO3

Silicate

E0 1.80 2.04 3.08 0.50 2.10 3.16 0.47 0.50 1.80 -

E1 1.80 2.04 3.08 0.50 2.10 3.16 0.47 0.50 2.20 0.60

E2 1.80 2.04 3.08 0.50 2.10 3.16 0.47 0.50 1.80 0.60

E3 1.80 2.04 3.08 0.50 2.10 3.16 0.47 0.50 1.60 0.60

E4 1.80 2.04 3.08 0.50 2.10 3.16 0.47 0.50 1.00 0.60

E0 is the deposit produced with Fe-C-Si-Mn electrode and E1, E2, E3, E4 are the deposits produced with Fe-C-Si-Mn-B electrodes.

Table 2

________________________________________

Welding Parameters

Welding Welding Preheat Rate of Number of Voltage

Current Deposition layers

----------------------------------------------------------------

120V 80A Nil 4.0 mm /s 03

_______________________________________

Table.2 represents the welding parameters maintained

during weld deposition for three layers. An average

voltage of 120V is maintained during the deposition and

a constant current of 80A is generated from the MMAW

equipment. Perfect ripples of weld beads are deposited

with 4.0 mm per second and three layers are made.

Continuous overlaying without any interval is done to

avoid idle time to resemble the field conditions. But,

cleaning is done after the completion of each layer. After

finishing the last layer the deposit is allowed to cool to

room temperature. Then it is cut across the layer along

with the substrate and subjected to metallographic

examination at 500x.

Hardness is measured at various locations on the cut

section. Spectrographic analysis is made on substrate and

on the deposits to check the chemical composition. Fig .2

shows the weld deposit made in three layers over the low

carbon steel substrate.SEM analysis is done for the

deposits.

III. RESULT AND DISCUSSION

The chemical composition of the alloys produced is

shown in the table.3. Fig. 9 shows the microstructure of

the substrate, which comprises the phases of ferrite and

pearlite. Fig. 10a, 11a, 12a and 13a show the

microstructure of the deposit with considerable variations

in the content of tempered martensite and lower bainite.

From the microstructures 10b, 11b, 12b and 13b, it is

understood that the intermixing is quite good. The

intermixing between the substrate and the deposit in all

four cases is found to be satisfactory [12].

The deposit of composition 0.707%C-4.084%Si-

3.852%Mn-0.0168%B exhibiting an hardness of

711VHN.(electrode2)

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553

Table 3

Mat %C %Si %Mn % S % P %B %Fe

Average

Hardness

(VHN)

Sub 0.150 0.240 0.900 0.0010 0.0013 - Rest 143

E0 0.712 3.995 3.725 00386 0.0122 - Rest 450

E1 0.751 4.656 3.828 0.0493 0.0229 0.0168 ,, 663

E2 0.707 4.084 3.852 0.0316 0.0178 0.0168 ,, 711

E 3 0.698 3.668 3.715 0.0419 0.0222 0.0168 ,, 688

E4 0.611 2.591 3.529 0.0375 0.0285 0.0168 ,, 581

E0-Electrode without Boron addition, E1, E2, E3, E4 - Electrodes with Boron addition, Sub-Substrate, Mat-Material

Fig .3 C/Si+Mn Vs C/B

Fig.4 (Ac3-Ac3) Vs Hardness

Fig.5 Pm Vs Hardness

The deposit of electrode 2 shows the maximum

hardness of all the four deposits. Since the cooling curve

shifts to the right side, the formation of martensite and

lower bainite occurred in the deposits instantaneously.

Boron addition causes the shift of C-curve to the right

side eliminating the continuous cooling transformation,

which is shown by pictorial illustration (temperature vs.

time, transformation diagram) in fig.7. Lower bainite is

formed to certain extent, which contributes to the overall

hardness Large amount of martensite forms during

solidification and gets tempered by the heat supplied

from the top or bottom layer as the welding process is in

progress [13, 14, 15].But the Fe-C-S-Mn alloy without

boron addition forms lower bainite and the

transformation touches the nose of the c-curve as seen in

fig.8, exhibiting lesser hardness than that of Fe-C-Si-Mn-

B deposits.

High silicon available in the solution increases the

fluidity of the alloy to form a quite satisfactory and

defect free deposit.

0

10

20

30

40

50

0.0885 0.0891 0.0945 0.0998

C/B

C/Si+Mn

Elemental Ratio

0

100

200

300

400

500

600

700

800

88.980492.94781.831577.5836

0

1000

1.1197 1.2316 1.005 0.9579

(Pm) Vs Hardness(VHN)

International Journal of Emerging Technology and Advanced Engineering

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554

Silicon enables the matrix to remain tough enough

[16].Manganese contributes to the enhancement of

hardness by reducing the eutectic composition,

facilitating the instantaneous formation of hard phases.

During solidification of Fe-C-Si-Mn-B alloy, silicon

reduces the solubility of carbon and diffuses in to the

austenite which is an iron rich phase. Silicon forms

substitution solid solution in the crystalline phase which

leads to micro transformation [17, 18]. Boron addition

increased the hardenability of the steel resulting in better

wear and abrasion resistance and making it to be utilized

for hardfacing purposes. It also occupies the grain

boundaries and suppresses the formation of ferrite to a

greater extent(19,20,21).The martensite transformation

does not depend on the carbon content of an alloy.

Moreover higher the carbon content, lower will be the

acceleration of the martenstic transformation. Therefore

nominal carbon content is maintained as shown in the

table.3. Graphitization is arrested as there is

transformation of martensite simultaneously. The content

of transformed martensite and bainite depends on the

carbon content and it is quite evident from the fig 10a,

11a, 12a, 13a. The content of martensite and lower

bainite depends on the carbon while silicon and

manganese facilitate the formation of the hard phases in

air cooling itself.

The relationship between manganese and the

microstructure are depicted from the Gulliet’s diagram.

Manganese stabilizes austenite by raising the A1 and A3

temperatures in steel. In Fe-C-S-Mn-B alloy A1 and A3

are shifted by manganese addition such a way that hard

structures are allowed to form. In the Fe-C-Si-Mn-B

alloys silicon varies from 2.591 to 4.656 wt%.

Manganese varies from 3.715to3.852wt%. Such variation

of compositions cause variations in the hardness

values.The Fe-C-Si-Mn (electrode 0) alloy is also of

similar composition, which is almost equivalent to the

electrode2. Hardness varies from 581 to 711 VHN, for

alloys with boron and 475VHN for alloys without boron,

while the substrate shows a hardness of 143VHN.

Content of martensite and lower bainite in the

microstructure vary depending on the content of carbon,

silicon and manganese.When the martensite content is

increased, it is found that the hardness is enhanced.

Especially, this is evidently observed in the

microstructure of electrode 2 (Fig 6a). Electrode 1, 3 and

4 also show higher hardness when compared to the

electrode 0. But depending on the carbon, silicon and

manganese content the hardness variation is found in the

deposits of the electrodes.

Fig.6

0

100

200

300

400

500

600

700

800

0.00885 0.0891 0.0945 0.0998

Har

dn

ess

, (V

HN

)

(C/Si+Mn)

(C/Si+Mn) vs (Hardness of the deposit)

International Journal of Emerging Technology and Advanced Engineering

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555

Fig.7 Fig.8

Deposit of electrode 4 showed an hardness of

581VHN, since the carbon content is 0.611%, which is

low, compared to the other deposits .But due to the boron

addition the hardness value is more than the E0 electrode

even though it contains is 0.712% carbon.

Hardness of the plain carbon steels are increased by

the process of heat treatment. But Silicon and manganese

enhance the hardness without heat treatment as seen in

the microstructures of the deposits, shown in fig 10a, 11a,

12a and 13a. Fig 2shows the effect of boron addition

(shift of the nose of CCT–curve) which allows the

formation of martensite and lower bainite, which is

similar to the quenching effect [21].

Boron enhances the further opportunity of hardening

in air or natural cooling, as the process of solidification in

welding process cooling is generally in ambient

atmosphere.Fig.8 shows the transformation without the

effect of boron, but of the similar chemical composition

of deposit E0. Fig 7and 8 shows the transformation of Fe-

C-Si-Mn-B and Fe-C-Si-Mn alloy during air cooling. In

fig 6, it is clear that the transformation of E1, E2, E3, E4

electrodes are similar to quenching effect. Fig.14 shows

the microstructure of electrode E0. The electrode deposits

E1, E2, E3, and E4 do not touch the nose of the CCT

diagram during solidification, but E0 passes through the

CCT curve to certain extent and retains certain soft

phases. The hardness of E0 is less when compared to E1,

E2, E3, E4.The effect of Boron is evident in the reactions

and results. The microstructure in fig. 11a represents the

deposit of electrode 2, which is Fe-C-Si-Mn alloy

without the addition of boron [22]. The micrograph

shows more of lower bainite and lesser amount of

martensite. Carbon being the important element for the

transformation and leading to hard structures the content

of the same plays an important role.

In this study and development of hard alloys it is

proved that carbon variations lead to the solidification of

hard structures like martensite and lower bainite. The

various combinations of carbon, silicon and manganese

with the aid of boron form hard structure, which shall be

utilized for hardfacing.

Fig 9. Microstructure of substrate

Fig 10a .Microstructure of electrode 1

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556

Fig 10b. Microstructure of intermixing of Electrode1 with substrate

Fig 11a. Microstructure of electrode 2

Fig 11b. Microstructure of intermixing of Electrode 2 with

substrate

Fig 12a.Microstructure of electrode 3

Fig 12b.Microstructure of intermixing of Electrode 3 with substrate

Fig 13a.Microstructure of electrode 4

Fig 13b.Microstructure of intermixing of Electrode 4

Fig 14.Microstructure of electrode 0

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557

SEM images are made on the deposits of electrodes

E1, E2, E3, E4 and are shown in the fig 15, 16, 17and

18.The lower bainite content is found to be more in the

micrographs of fig 15,17 an18,of which the martensite

background increases in the order of electrode 1, 3 and

4. And the hardness also varies accordingly. The deposits

which contain more of martensite show higher hardness.

In the deposit of electrode 2 it is very clear that the

martensite content is the highest and with the least lower

bainite, which is the cause for highest hardness of

711VHN, when compared to the other deposits.

Fig 10.SEM image for electrode 1

Fig 11. SEM image for electrode 2

Fig 12.SEM image for electrode 3

Fig 13. SEM image for electrode 4

IV. CONCLUSION

1. Micro segregation of silicon retains austenite phase

before transformation of marten site and bainite.

2. Martensite is formed without quenching, since

boron shifts c-curve to the right.

3. The silicon, manganese combination promotes hard

structures along with sufficient carbon.

4. Since boron occupies the austenitic grain

boundaries, the formation of ferrite is suppressed.

5. Pearlite is suppressed by manganese and bainite is

promoted.

6. Manganese also stabilizes the austenite to a large

extent by raising A1 and A3 temperatures.

7. 0.7 Wt% Carbon is sufficient enough to form hard

structures, with sufficient silicon and manganese

along with boron.

8. It is evident that boron increases the hardenability

of Fe-C-Si-Mn alloys.

Acknowledgement:

The authors thank the management of PSG College of

Technology, Coimbatore, Tamil Nadu, India,

especiallyProf.V.Balusamy of the Department of

Metallurgical Engineering, for providing metallographic

facilities and hardness testing. Thanks to the management

of C.Abdul Hakeem College of Engineering &

Technology, Vellore, Tamil Nadu, India for general

engineering facilities. Authors thank United Foundries

Limited, Ranipet, Vellore, and Tamil Nadu for providing

the spectroscopic analysis. Finally the authors thank

Anna University, Chennai, India for the facility provided

to take images in SEM.

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