J.O.a,* S.I....Table 3 The compositional results obtained from bench top arc spectrometer Elemental composition(%) C Si Mn Cr S P 1.29 0.68 13.72 1.49 0.005 0.005 2.3 Heat treatment

97

AdvancesinProductionEngineering&Management ISSN1854‐6250

Volume10|Number2|June2015|pp97–107 Journalhome:apem‐journal.org

http://dx.doi.org/10.14743/apem2015.2.195 Originalscientificpaper

Wear characteristics of heat‐treated Hadfield austenitic manganese steel for engineering application

Agunsoye, J.O.a,*, Talabi, S.I.b, Bello, O.a aDepartment of Metallurgical and Materials Engineering, University of Lagos, Akoka, Nigeria bDepartment of Materials and Metallurgical Engineering, University of Ilorin, Ilorin, Nigeria

A B S T R A C T A R T I C L E I N F O

ThewearbehaviourwasinvestigatedofheattreatedHadfieldausteniticman‐ganesesteel(HAMnS).Theweartestwascarriedoutusingspinondiscappa‐ratusunderdifferentloadingloadsandspeedconditions.Ascanningelectronmicroscopy (SEM), an X‐ray diffractometer andmicro‐hardness testingma‐chineswereusedforexaminingthemorphology,compositionsandtomeas‐urethehardnessofthemanganesesteel,respectively.Theresultsoftheweartest showed that the sliding speed‐time interactions effect gave the mostsignificant effect on the austeniticmanganese steel.The solutionheat treat‐ment programme increased thewear resistance of the alloy steel under in‐creasing load,speedandtime.Theas‐castmicrostructurewascharacterizedbyheterogeneouslydispersedchromiumcarbidessecondphaseparticle,andwas responsible for the observed non‐uniform wear rate. In regard to thesolution heat treated HAMnS, the segregated carbides were dissolved at1050°Canduniformlydispersedwithinthematrixofitsmicrostructureafterrapid water quenching to room temperature. This later development wasresponsiblefortheuniformandimprovedwearresistanceofthemanganesesteelcasting.Thisworkdemonstratedsignificantlythatthereisadirectrela‐tionshipbetweenthesecondphasecarbides,theirdistributionandthewearratepatternofHAMnScasting.

©2015PEI,UniversityofMaribor.Allrightsreserved.

Keywords:ManganesesteelWearbehaviourSolutionheattreatmentMicrostructureHardness

*Correspondingauthor:[email protected](Agunsoye,J.O.)

Articlehistory:Received18November2014Revised30March2015Accepted7April2015

1. Introduction

Alotofmoneyhasbeenspentonusingelectricityandexplosivetobreakrocks.Themotivationtoreduceenergyconsumptionhasledtotheuseofnon‐explosivemeanstobreakrocksandex‐tractvaluableminerals[1].Thenon‐explosivemeanshasadvantageofavoidingsuddenremovalofplastic‐elasticenergythatcancausefracturebyblasting.Butduetowear,thematerialsusedin breaking this rocks usually required early replacement. The replacement of item involvesbothmaterialandmanpowercost.Therearedifferentkindsofwear‐resistantmaterialsthatareused for processing of solidmineral vis‐a‐vis crushing and grinding.The traditionalmaterialsincludewear resistance high chromium iron, hyper‐steel,medium carbon steel that are case‐hardened,manganesesteeletc. Ingeneral terms,thehighchromiumironsuitable forwearre‐sistingapplicationsfallwithinthecompositionallimitsboundedbytheausteniticphasefieldoftheternaryliquidussurfaceoftheiron,chromium,carbondiagram[2].Howevertheuseofhighchromiumwearresistantironcomesatahugecost.Thematerialisalsoknowntobecharacter‐isticallyveryhardandbrittle.Consequently thisgradeofmaterial isprone to crackunder re‐peatedimpactloadinareaswhereimpactiscommon[3].Theyareusuallyusedinthequarryas

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Agunsoye, Talabi, Bello

98 Advances in Production Engineering & Management 10(2) 2015

cast plate for bottom liners and as side plate for crushing of hard solidminerals. Regrettablyoncetheyarebroken,thereisnopossibilityofsalvagethroughhard‐facingwithwearresistanceelectrodes.Becauseofthefrequentbreakageofhighchromiumresistantiron,thereisaneedforthe development of awear‐resistant alloy steel thatwill have highwear resistant, tough andhardat thesametime.So in1882,austeniticmanganeserichsteel (Hadfieldsteel), containingbetween11%and14%manganeseandabout1.2%carbon,wasdevelopedabout13decadesago and its consequent use for high‐wear applications [4]. Major advantages of this materialincludeitstoughnessandductility,andthefactthatcontinuoussurfaceimpactsresultinwork‐hardeningwithout any increase inbrittleness.Consequently,Hadfield steels and their techno‐logicaldescendantsprovideboth strengthandabrasion resistance;qualities that are essentialforwearpartsthatcanwithstandtherigorsofthecrushingprocess[5].Ithasalsotherequisitetoughnesstoundergoplasticdeformationwithoutcracking.Presently,themajorchallengefac‐ingthequarryingindustryinNigeriaisthehighcostassociatedwithworn‐outwearplatethatarepredominantlymadeormanufacturedfrommanganesesteel.

ResearchershaveperformedmanystudiestoimprovethewearresistanceofHadfieldsteels[6‐9].Microstructuralphasetransformationwhich is temperaturedependentcanbeemployedasarouteforenhancingthewearcharacteristicsofHadfieldausteniticmanganesesteelthroughtheinterplayofheattreatment.Intheheattreatmentprocess,thegrainsizeinausteniticman‐ganesesteelsbeforequenchingistremendouslyinfluencedbydiffusiveanddiffusionlessphasetransformations, and precipitation [10]. The austenite grain size affects overall mechanicalproperties such as strength, hardness and ductility, hence its wear behaviour. Therefore, theinfluenceof,solutionheattreatmentonthewearresistanceofatypicalHadfieldausteniticman‐ganeseuseinquarryingindustrywasinvestigated.

2. Materials and methods

2.1 Material preparation

AsamplerepresentativefromHadfieldausteniticmanganesesteelwithcompositionofequiva‐lent specification toNFMn128Cwas taken from a batch of 500 kg electric induction furnacemelttocast4barof20011×11mmtoconducttheexperiment.Thechargedmaterialsusedconsistof203kgfoundryreturns,220kglowcarbonsteel,10kgoflowcarbonFerromanga‐nese,65kghighcarbonFerromanganese,8kglowcarbonFerrochromium,2.19kgFerrosiliconand2.24kggraphitepowderrespectively.Themeltingwascarriedoutinaneutrallinedrefrac‐toryfurnace.Adigitalpyrometerwithdisposablethermocoupletipwasusedfortemperaturemeasurementduringmelting andpouring.Themoltenmetalwaspoured into an improvisedCO2mouldsinamechanizedfoundrysituatedinSango‐OttaattheoutskirtofLagos,Nigeria.

2.2 Method

Patternsofdimension20211.211.2mmwereproducedforthesandcastingoftheexperi‐ment.Thesandusedforthemouldswaspreparedbymixingdriedsilicasand,sodiumsilicate,waterandbentoniteincompliancetoBritishstandard.Thereafter,CO2gaswaspassedthroughthemouldsfor80secondstocurethemouldsand.Toensurecorrectmouldidentification,themouldswerelabelledasA,B,CandDrespectively.Thechargemake‐upforthemeltconsistofMn‐Steelfoundryreturns(1.1%C,0.64%Si,12.4%Mn,1.2%Cr,0.006%S,0.005%P,and84.65%Fe),Steel(0.20%C,0.35%Si,0.42%Mn,0.005%S,0.005%P,and99.02%Fe),LowCarbonFerroManganese(0.23%C,75%Mn),HighCarbonFerroManganese(1.1%C,62%Mn),MediumCarbonFerroChromium(0.5%C,67%Cr),FerroSilicon(0.02%C,70%Si)andGraphitePowder(67%).

TheestimatedchargemakewascalculatedfromEq.1.

%/ %

(1)


Advances in Production Engineering & Management 10(2) 2015 99

InEq.1,Mdenotesmelt,FeAdenotesferroalloy,SdenotesscrapandFcdenotesfurnaceca‐pacity.Thefurnacecapacityrepresentsthetotalchargein(kg),theQrepresentsthequantityofchargeand%meltrepresentelementalconcentrationinthemelt.

ThestandardcompositionscontainingthelowerandupperrangesofthespecificationforthemeltofequivalentstandardtoNFMN128CispresentedinTable1.

Manganeseasanelementexhibitshighoxidationtendency,thereforethemanganesecompo‐sitionwasdeliberatelycalculatedtobehigherthantheupperlimittoensurethatthepercentageofmanganeseiswithinthelimitasaresultofexpectedoxidationduringholdingofthemoltenmetalinthefurnaceandde‐slagging.

Therawmaterialsascontainedinthechargemake‐upinTable2forthemeltwerechargedintothefurnaceinaparticularorder.Thelowcarbonsteelwaschargedfirstintoa500kgmedi‐umfrequencyelectricfurnacelinedwithaneutralrefractorymaterialandallowedtomeltcom‐pletely. The selection of a neutral refractorywasmade deliberately tominimize furnacewallerosionasaresultofslagattack.Thiswasfollowedbythechargingofthefoundryreturns,Ferrosilicon,HighcarbonandLowcarbonFerromanganeseandlastlygraphitepowder.Themeltingwas completed after 94minutes. The temperature of themolten bathwas taken by a digitalprobepyrometerwithadisposabletipandrecordedonanimproviseddailyfurnacereport.Allproceduresincludingpersonnelsafetywereobservedduringthemeltingandpouringoperation.

TheactualcompositionobtainedaftermeltingispresentedinTable3.Themoltenmetalwaspouredat1410°CintotheimprovisedCO2moulds,andallowedtosolidifytoroomtemperatureafter12hbeforetheywereknockedoutandshotblasted.The4‐numbercastingswerecarefullyfettledona tablegrindingmachinetotherequireddimensions2001010mm.Duringthegrinding,carewastakentoavoidworkhardeningonthesurfaceofthecasting.

Table1ChemicalanalysisresultofmeltofequivalentstandardtoNFMN128C

SpecificationElementalcomposition (%)

C Si Mn Cr S PUpperlimit 1.30 0.80 14.00 1.50 0.005 0.005Lowerlimit 1.00 0.60 12.00 1.00 0.005 0.005Aim 1.28 0.70 14.34 1.52 0.004 0.005

Table2TheEstimatedchargemake‐upforHadfieldausteniticmanganesesteel

DescriptionCharge(kg) Elementalcomposition(%)

C Si Mn Cr S P FeFoundryreturns 203 0.437 0.25 4.84 0.47 0.002 0.002 balSteel 220 0.085 0.15 0.18 ‐ 0.002 0.002 balLowCarbonFe‐Mn 10 0.004 ‐ 1.46 ‐ ‐ ‐ ‐HighCarbonFe‐Mn 65 0.139 ‐ 7.87 ‐ ‐ ‐ ‐FerroChromium 8 0.007 ‐ ‐ 1.05 ‐FerroSilicon 2.19 0.000 0.30 ‐ ‐ ‐ ‐ ‐Graphite 2.24 0.555 ‐ ‐ ‐ ‐ ‐ ‐Total 512 1.278 0.70 14.34 1.52 0.004 0.005 bal

Table3Thecompositionalresultsobtainedfrombenchtoparcspectrometer

Elementalcomposition (%)C Si Mn Cr S P

1.29 0.68 13.72 1.49 0.005 0.005

2.3 Heat treatment

Thesolutionheattreatmentprocessinvolvesheatingthesampleataparticularheatingrate.Thechoiceoftheheatingratedependsonsomefactorssuchasthecompositionofthesample,shapeof casting and the section thickness among other. For low carbon alloys and other alloy likemanganesesteels,theirpropensitytocrackisextremelylow,assuch,theheatingrateof75°Cper hour. For high carbon specification or castingwherewarping of the samplemay occur, alowerheatingisadopted.Thesamplewasheatedto1050°Candheldatthistemperaturefor24



min to allow the segregated carbides dissolve completely in solution in accordance to Britishstandard.Thereafteritwasquenchedquicklyina500lagitatedwatertankandallowedtocoolroomtemperature.

2.4 Microstructural determination

Asamplerepresentativewastakenfromoneas‐castandoneheattreatedcastbar.Thesurfaceswere carefully prepared grinding on a tehrapol‐31machine, then polishedwith Allegrolwithdiamond suspension using a colloidal suspension of 0.04 µm silicon dioxide before they areetchedinasolutionof100mlalcoholand3mlHNO3acidattheMetallographiclaboratory,De‐partmentofMechanicalEngineering.UniversityofOttawa,Ontario,Canada.AnopticalinvertedMetallurgicalmicroscopewasused to study themicrostructures.On theotherhand, themor‐phologyoftheas‐castandheattreatedsampleswerecarriedoutusingScanningElectronMicro‐scope(SEM)andEnergyDispersiveSpectrum(EDS).Thesurfacemorphologyof thewornoutsamplewasalsoexamined.

2.5 Micro‐hardness value determination

Samplerepresentativeswerecutfromtheas‐castandheattreatedbarsforhardnesstesting.Thesampleswerecastedintoresinmould,groundflatandpolished.ThehardnesstestwascarriedoutonaDuramin‐1micro‐hardnesstesterstruers.Anaverageoffivemeasurementsofhardnessvalueswastakenforascastandheattreatedmanganesesteel.

2.6 Wear test

Abrasiveweartestwerecarriedoutontwopreparedmanganesesteelcastings(as‐castandheattreated) samplesusingpin‐on‐disc typeequipment [11].Thewear testwas carriedoutundervariedload,andspeed.Aftertesteachcycleofweartest,themassofthewornoutsampleswasmeasuredwiththeaidofadigitalweighingdevicewith0.001mgaccuracytoobtaintheweightlost.Weight lost fromthetestswasusedtocalculatespecificwearrateW,aparameterwhichdefineswearseverityfromEq.1.FromEq.1,Vdenotesvolumelossofwornoutsample,dsde‐notesslidingdistance,andLdenotesappliedload.

(2)

Thesurfacemorphologyofthewornoutsampleaftertheweartestwasexaminedusingopti‐

calmicroscope.Theexaminedmicrostructureofthewornout,heattreatedsampleunderhighspeed4.72m/sand16kNloadispresentedinFig.10.Thesurfacemorphologyischaracterizedbyneedlelikemartensiticstructure.

3. Results and discussion

3.1 Hardness and XRD test results

TheresultofthehardnesstestispresentedinTable4.Theindentationphototakenduringthemicro‐hardnesstestisshowninFig.1(a)andFig.1(b)

forheat treatedandas‐castsamplesrespectively.Thesolutionheat treatmentprocess inreasethehardnessoftheHAMnSsample.Theincreaseinhardnessmightbeduetofairlyuniformdis‐tributionofthecarbidephaseintheaustenitephase[2].

Table4Resultsofmicro‐hardnessmeasurement

Description Hardness,(HB)As‐castMn‐steel 188HeattreatedMn‐steel 220



(a) (b)

Fig.1(a)HeattreatedHAMnSindentation;(b)As‐castHAMnSindentation

TheidentifiedphasesandcompoundformulafromtheXRDtestforthemanganesesteelcast‐ingispresentedinTable5.

Table5IdentifiedphasesandtheirchemicalformulaScore Compoundname Chemicalformula38 Manganese Mn23 Carbon C21 Iron Fe21 IronSiliconCarbide Fe9SiC0.414 ManganeseSiliconCarbide Mn22.6Si5.4C412 ChromiumCarbide Cr4C1.0617 ManganeseSilicon MnSi

Fig.2TheXRDprofileofelementalsegregationofmanganesesteel

Intensity



3.2 Comparism between wear results and microstructure of as‐cast manganese steel

Fig.3representsagraphicalbehaviouroftheweartestresultsobtainedfordifferentloadatthespeedof2.36m/sforas‐castHAMnS.Thereisageneraldecreaseinwearratewithincreaseinload. These phenomenamay be attributable to increase interlocking of dislocationmovementandtosomeextendwork‐hardeningcharacteristicsofthealloy.Thissameobservedbehaviourisreplicated inasimilar,but inamorepronouncedmannerathigherspeed4.72m/s(Fig.6).Hence,itcanbeinferthatspeedhassignificanteffectonthewearbehaviourofthemanganesesteelsample.

Theobservednon‐uniformityinthewearprofilecurvesofFig.1andFig.2canbeattributedtothein‐homogeneityoftheas‐castHAMnSasrevealedbythemicrostructureseeFig.3.Anon‐uniform dispersion of the second phase (inter‐metallic carbide) in themicrostructure can beobserved.Themoreheterogeneousthedistributionofsecondphaseparticles,themoreirregu‐larthewearpatternoftheas‐castHAMnS.Thisrevealedthatthereisastrongrelationshipbe‐tweendistributionofsecondphase(Chromiumcarbide)andthewearnatureofmanganesesteel.

Fig.3Wearrateofas‐castHAMnSwithtimeat2.36m/sandvaryingloads

Fig.4Wearcoefficientofas‐castHAMnSwithtimeat4.72m/sforvaryingload



Fig.5WearrateofAs‐castHAMnSwithtimeat2.36m/sand4.72m/sforload6N

Fig.6TheOpticalmicrographofas‐castmanganesesteelshowingsignificantheterogeneously

dispersedchromiumcarbidewithintheaustenitematrixofthemicrostructureat100x

ThewearrateoftheHAMnSreducessignificantlyasthespeedincreases(Fig.5).ThisfurtherjustifiestheearlierassumptionthatspeedhassignificantonthewearrateoftheHAMnSsample.IncreasingspeedtendstoimprovethewearbehaviouroftheMn‐steelsample.

3.3 Comparison between wear results and microstructure of heat treated manganese steel

Fig.7showssmootherwearprofilecomparedtoFig.3.Thiscanbeattributedtothehomogenei‐ty of the heat treatedmanganese steel as revealed in themicrostructure obtained after heattreatment(Fig.9).Thesecondphaseparticle(chromiumcarbide)asshowninTable5andFig.2intheXray‐Diffractionresultisuniformlydispersedwiththeaustenitematrix.Thisdevelopmentwasattainedafterheattreatment(hardening)operationwascarriedoutwhentheheterogene‐



ouslysegregatedsecondphasechromiumcarbide(Cr4C1.06)particleweredissolvedinsolutionat1050°C,andquenchinagitatedwatertotrapthecarbidewithinthematrixoftheaustenite.

Amarkedeffectofloadwhichbecamealmostconstantwithincreasingcanalsobeobserved.TimehasnosignificanteffectonthewearrateofMn‐steelsample.Similartotheas‐castsample,Fig.8showsthatspeedhassignificanteffectonthewearbehaviouroftheheattreatedsample.

Fig.7WearrateofHeattreatedMn‐Steelwithtimeat2.36m/sforvaryingload

Fig.8WearrateofHeattreatedMn‐Steelwithtimeat2.36m/sand4.72m/s,load6N



Fig.9TheOpticalmicrograph(100x)ofheat‐treatedmanganesesteelshowinghighlyhomogenousstructure

The examinedmicrostructure of theworn out, heat treated sample under high speed 4.72m/sand16kNloadispresentedinFig.10.Thesurfacemorphologyischaracterizedbyneedlelikemartensiticstructure.

Fig.10Opticalmicrographat100xmagnificationofheat‐treatedmanganesesteelwornout‐surfacewithevidenceofhighworkhardenabilityafterweartest

Fig.11showstheresultofSEMandEDSanalysisoftheas‐castHAMnS.Itwasobservedfrom

Fig.11 that theSEMmicrograph isheterogamous innature.Thisobservation is similar to theOpticalmicrostructureobtainedinFig.6.ThecorrespondingEDScorroboratethehighdegreeofcarbidesegregationofironandmanganese.

Fig.11TheSEMmicrographandEDSofAs‐castmanganesesteel



The SEM micrograph with the corresponding EDS of the heat treated manganese steel isshowninFig.12.Itwasobservedfromthemicrographthatthesecondphasechromiumcarbideparticle isuniformlydispersedwith theausteniticmatrix.Again, thisobservationcollaboratedtheearlierresultsobtainedinFig.9andagreedwiththeresultof[5].Thedegreeofcarbideseg‐regationhadbeenreducedconsiderablyfromthecorrespondingenergydispersionspectrumforheattreatedHAMnS.

Fig.12TheSEMandEDSmicrographofheattreatedmanganesesteel

4. Conclusion

ThewearbehaviourofheattreatedHadfieldausteniticmanganesesteelhasbeeninvestigated.FromtheresultsoftheinvestigationsontheheattreatedHAMnSthefollowingconclusionweredrawn.

1. Themorphologyandsizeofcarbidephasehassignificanteffectonthewearresistanceofausteniticmanganesesteel.

2. Theslidingspeed‐timeinteractionseffectgavethemostsignificanteffectontheausteniticmanganesesteel

3. Thesolutionheat treatmentprogramme increased thewear resistanceof thealloysteelunderincreasingload,speedandtime.

4. Theimprovedwearresistanceofthemanganesesteelobtainedwasduetotheformationofhardcarbidephasewithinthematrixstructureofausteniticmanganesesteel.

5. Thewearbehaviourofausteniticmanganesesteelcanconsiderablybeoptimizedbysolu‐tionheattreatmentandadequatequenchingtoredistributetheheterogeneousandsegre‐gated second phase chromium carbide to form amore homogenous and uniformly dis‐persedsecond‐phaseparticletoenhancethewearresistanceofthemanganesesteel.

Acknowledgement

TheauthorsacknowledgethesupportfromNigerianFoundriesLimited,IlupejuIndustrialEstate,Lagosfortheexclu‐siveuseofherfacilitiestocarryoutthisstudy.TheauthorswouldliketothankDr.MichealNganbe,anassociatePro‐fessorattheDepartmentofMechanicalEngineering,UniversityofOttawa,OntarioCanadaforhistechnicalinputandDr.MohammedYadouziaresearchfellowatthesameDepartmentwhofacilitatedopticalmicrographstestsandin‐terpretations.

Wear characteristics of heat-treated Hadfield austenitic manganese steel for engineering application

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Documents

J.O.a,* S.I....Table 3 The compositional results obtained from bench top arc spectrometer Elemental composition(%) C Si Mn Cr S P 1.29 0.68 13.72 1.49 0.005 0.005 2.3 Heat treatment