PROJECT Word
PROJECT Word
A
Project Report on
HEAT TREATMENT OF LOW ALLOY
CAST STEEL WHEELS
In partial fulfillment of the requirements of
Registration no.:J01/H01/2/019
Department of Metallurgy
CERTIFICATE
This is to certify that that the work in this thesis report entitled
ACKNOWLEDGEM
ENT
conclusion.
Dr.Rekha Singh
(Membership no.51525)
Registration no.J01/H01/2/019
Page |4
Contents
A....................................................................................................................................1
SYNOPSIS.......................................................................................................................5
Chapter1............................................................................................................................... 6
INTRODUCTION:-.....................................................................................................6-8
Chapter 2.............................................................................................................................. 9
Literature survey:............................................................................................9-15
Chapter 3............................................................................................................................ 16
EXPERIMENTAL DETAILS........................................................................................ 19
Chapter 4............................................................................................................................ 25
Results&Discussion................................................................................................. 25
Chapter 5............................................................................................................................ 26
CONCLUSION:......................................................................................................... 26
Chapter 7............................................................................................................................ 28
References:.................................................................................................................28
SYNOPSIS
Page |5
The objective of this project work is to study the effect of heat treatment on
In this project work, heat treatment is subjected on low carbon steel wheels of two
Two classes of cast steel wheels were selected for this purpose.
tensile strength is done to get idea about heat treated low carbon steel wheels, which has
extensive uses in all industrial and scientific fields. Heat treatment is often associated
Chapter1
Page |6
INTRODUCTION:-
Heat treatment involves the improvement of the properties of materials by bringing
Solidification of the cast wheel progress in a dendritic mode, which inherently leads
anomalies present in the wheel,all wheels must be heat treated. We know there is a
little bit of steel in everybody life. Steel has many practical applications in every
aspects of life. Steel with favorable properties are the best among the goods. The
steel is being divided as low carbon steel, medium carbon steel, high carbon steel on
Low alloy carbon cast steel wheels has carbon content of 0.45% to 0.70%. It is
neither externally brittle nor ductile due to its lower carbon content. It has desirable
tensile strength and impact resistance. Steel with low carbon content has properties
similar to iron. As the carbon content increases,with suitable alloying elements the
metal becomes harder and stronger but less ductile and more difficult to weld. It
The process heat treatment is carried out first by heating the metal and then cooling
it in water following tempering The purpose of heat treatment is to soften the metal,
to change the grain size, to modify the structure of the material and relive the stress
The heat treatment of wheels provides a high strength and yield point, combined
with significant ductility even in large section. As it has been established that
Page |7
movement of line imperfection, called dislocations, along definite slip system and
the kind of phase present in a material that are governed by the type of interaction
among atoms of its constituent elements, into the metal surface forming a hard, wear
resistance skin but preserving a tough and ductile applied to railway wheels.
the reaction.
¥Fe(0.8%C)¿ α Fe (0.02%C)+Fe3C(6.67%).
The proper metallurgical structure for satisfactory service is attained by heating the
wheel until the hub reaches a temperature of 921°c±22° and holding the wheel at
this homogenizing temperature for 45 minute cooling of the wheel from the
of 0 to 2.54 mm , which is the major of differential cooling between hub and tread.
Following the intial heat treatment the tread of the wheel is sprayed with water until
After quenching , the wheels are tempered at desired temperature for 2 hrs in the
tempering furnace . tempering relieves the stresses developed during quenching and
So we go through the most important heat treatments and their purposes are: Stress
Chapter 2
2. Literature Review:
2.1Present status of knowledge
All basic heat treatment/treating processes for steel involve the transformation or
products determine the physical &mechanical properties of any given steel .The
heating temperature of steel depends upon its chemical composition ,principally its
carbon contents .Low alloy Carbon steel is steel which contain main alloying element
as carbon with manganese and silicon . Here we find maximum up to 0.70% carbon
and other alloying elements like manganese, silicon. It is divided into the following
cooling it in the water . The purpose of heat treatment is to soften the metal, to
change the grain size, to modify the structure of the material and to relieve the stress
set up in the material after hot and cold working. The various heat treatment
These heat treatments are aimed at imparting hardness along with workable
The process consists of heating the steel to facilitate subsequent operation, for steel
These heat treatments are done mostly to meet the delivery condition or service
requirements.
These wheels are manufactured from steel made by electric process and refined by
secondary refining process. Chemical composition of both wheels decides the heat
The heat treatment for our cast steel wheels consist treatment of rim only.
For this the wheels are uniformally reheated to proper temp. to refine the grain.
When cast wheels solidify they inherently leads to chemical segregation and
unsatisfactory mechanical properties. The phase constituent of the as cast wheel are
irregular coarse grains of pearlite and island of soft phase of ferrite .The process of
upper critical temperature for hypo-eutectoid steels. The amount of free ferrite present
lowered. The criteria is being done to prevent poor physical properties. If a wheel
reaches too high a temp. and or it is held too long at temp., coarsening of the structure
will result. With the help of an optical pyrometer we can measure the temp. of surface
of a wheel in soaking furnace .The temp. of the wheel upon existing furnace should be
Cooling of the wheel from the normalizing temp. must be controlled to produce a
residual stress pattern,for this the stationary hub insulating disk, provide the additional
P a g e | 12
closing. This amount of closing or opening of the saw cut reveals the differential
cooling between the hub and tread. If hub cools slower than the tread, the saw cut will
yield a closer.
To provide the additional benefit of controlling the residual stress pattern,we use a
stationary hub insulating disks .These disks must be kept as close to the hub as possible
Under these condition, we maintained the hub temp. up to 593 0c,while discharging off
Following the initial heat treatment, the tread is sprayed with water until a uniform
hardness pattern throughout the rim section is produced. This treatment of cooing with
water jet starts while the rim section of the wheel is above the critical transformation.
The temp. of rim surface must be maintained to 788 oC , before quenching. we find that
if the temp. drops below this critical temp. at the start of the quenching operation, the
desired structure has not be obtained and the physical properties has not be enhanced
after quenching and lower hardness value be also obtained. Along with temp. we have
follow the length of time for the quenching, as well as pressure and flow rate of water.
These all parameters show a great impact on the desired properties of material.
We set these values for our requirements for BGC and BOX’N wheels. According to
the chemistry of our wheel type, we set the tmep. Of water at 13 oc to 27oC, As, too cold
water affects the wheel in such a manner that quench crack phenomenon occurs. If the
temp. of the water raises above 27 oC, it shows the affect of water vapour blanket, so we
adjust the pressure and flow rate of water in such a way that it may penetrate the water
vapour barrier.
Alignment of water nozzles also has impact on the hub or plate physical properties. We
have to adjust the nozzle in such a way that no water enters the hub or plate, and the
P a g e | 13
We then focus on the temperature of the rim, such that there temp must stabilize
between 427oC to 451oC. We find that too high stablization temp. produces a soft
wheel. Quenching time has also be maintained in such a way that after properly
quenching wheel shows a circumferential line of demarcation, about two thirds inwards
through the sprues reveals that they found better heat treatment.
Now, wheels get ready for tempering, we saw their temp. to be maintained upto 371 oC.
If quenched wheel falls below 371 oC , we have to again reprocess the wheel through the
normalizing furnace.
For tempering the wheels are entered into draw furnace for two hours at a temp of
460±11oC.
Following quenching, the wheels are tempered and we found the hardness of the wheel
Class B- Carbon-0.57 to 0.67, hardness range in between 277 HBW TO 341 HBW
For satisfactory service to be attained by cast steel wheel , we choose the heating
parameters to obtain the desired Mechanical properties. First we heat the wheels
according to set parameters of temp. in normalizing furnace for as long as 1hrs, beyond
the minimum holding time before renormalizing. This criteria is being done to prevent
poor physical properties. If is a wheel reaches too high temperature,and or it is held too
With the help of an optical pyrometer we can measure the temp. of surface of a wheel in
soaking furnace.The temp. of the wheel upon existing furnace should be minimum of
P a g e | 14
927~c.for this a test wheel with a thermocouple embedded in the thermocenter of the
Cooling of the wheel from the normalizing temp. must be controlled tproduce a residual
stress pattern,for this the stationary hub insulating disk, provide the additional benefit of
This amount of closing or opening of the saw cut reveals the differential cooling
between the hub and tread. If hub cools slower than the tread, the saw cut will yield a
closer.
To provide the additional benefit of controlling the residual stress pattern,we use a
stationary hub insulating disks.These disks must be kept as close to the hub as possible
to insure a soft hub for easy machinability. Under these condition, we maintained the
Following the initial heat treatment, the tread is sprayed with water until a uniform
hardness pattern throughout the rim section is produced. This treatment of cooing with
water jet starts while the rim section of the wheel is above the critical transformation.
The temp. of rim surface must be maintained to 788oC , before quenching. E find that if
the temp. drops below this critical temp. at the start of the quenching operation, the
desired structure has not be obtained and the physical properties has not be enhanced
after quenching lower hardness value also be obtained. Along with temp. we have
follow the length of time for the quenching, as well as pressure and flow rate of water.
These all parameters show a great impact on the desired properties of material. For
preferred.
After the rim quench has been completed, the rim section will start to pick up heat from
the rest of the wheel ,and the temp. of the rim should stabilize between 427 c to 454 c.
reveals the stress developed during quenching and imparts some toughening of the
carbide spheroidization from a lamellar microstructure , which are rather slow diffusion
process.
After tempering the inside of Hub are water cooled to produce proper stress pattern.
These are calculated with opening or closing of radial saw cut. The acceptable range of
the saw cut is 0 to 2.54 mm, closing as determined from the radial saw cut test.
Normally, a hub water quench of 2 minutes to 6 minutes will produce the proper stress
pattern. With proper adjustment, exact hub cooling time depends on type of wheels.
P a g e | 16
Chapter 3
EXPERIMENTAL DETAILS:
3.1)HEAT TREATMENT:
The two classes of wheels with associated mechanical properties are not readily
obtained in the as cast condition due to cast section design and size.Their matrix
microstructure consisting ferrite or pearlite are not homogenize and are not so adjusted
carry out the heat treatment of such cast steel wheel,then to compare the mechanical
properties.
RWP/BELA a production unit of cast steel wheel of two classes has set their heat
treatment parameters according to the wheel chemistry of two categories and to obtain
3.2)PROCESS PARAMETERS:
NORMALISING FURNACE(N.F.)
Type Zone temp. in °c Cycle time Wheel
of discha
wheel 1. 2. 3. 4. 5. 6. rge
temp.
BOXN 700± 1000± 1000± 960± 960± 960 2hrs.4 min. 920 925
10 10 10 10 10 ±10
BGC 700± 1000± 1000± 980±1 980 980 2hrs.4 min. 920 925
10 10 10 0 ±10 ±10
P a g e | 17
RIM QUENCHING(RQ)
Type of Wheel Water Cycle Cycle Air
wheel entry pressure time(water) time(Air) pressure
temp.
BOX-N 788 c(min.) 4.0 bar 5 min. 30sec. 5 bar
BGC 788 c(min.) 4.0bar 6 min. 30 sec. 5 bar
If any case water has been felled over plate area of wheel,the wheel is being
bypassed
DRAW FURNACE(D.F.)
Type Zone Zone Zone Zone Zone Zone Zone Zone Zone Wheel
of .1 2. 3. 3. 4. 5. 6. 7. 8. dischargete
whee mp.
l
rim hub
BOX 4900c 4900 4900c 490 c 490 c 490 c 490 c 490 c 490 c 470 c 480
-N c
BGC 340 c 400 c 440 c 440 c 440 c 440 c 440 c 440 c 440 c 425 c 435
c
HUB COOLING
All hub cooler shall be in working order.
Type of wheel Cycle time Water Cycle time of Air pressure
pressure air
P a g e | 18
Low Carbon Steel are primarily heat treated to create matrix microstructures and
associated mechanical properties not readily obtained in the as-cast condition. As-
both, depending on cast section size and/or alloy composition The principle
objective of the project is to carry out the heat treatment of Low carbon steel and
then to compare the mechanical properties. There are various types of heat treatment
(From low alloy carbon, cast steel wheels production unit Rail Wheel Plant Bela).
Six(04) trail batches of wheels are heat treated in NF and DF with different parameters.
heat treated cast iron specimens, now the specimens were sent to hardness test,
The first and foremost job for the experiment is the specimen preparation. The
We got the sample from plant care shop. The sample that we got was of from class A &
P a g e | 20
class B wheels.
HARDNESS TESTING:
The heat treated specimens were taken for hardness measurement. Hardness were
measured by means of Brinnel hardness testing machine. The procedure adopted can
be listed as follows:
First the hardmetal ball indenter of dia. 10 mm was inserted in the machine; the
Place the specimen on the test table and turn the nut in such a way it just touches the
Now turn the handle to apply major load for a period of dwelling time. The diameter
Table.1
P a g e | 21
The heat treated specimens were treated in UTS Machine for obtaining the %
elongation, Ultimate Tensile Strength, yield Strength. The procedures for obtaining
At first the cross section area of the specimen was measured by means of an
electronic slide caliper and then the gauge length was calculated.
Now the distance between the jaws of the UTS was fixed to the gauge l
The corresponding Load vs. Displacement diagrams were plotted by using the
software. From the data obtained the % elongation, yield strength and ultimate
Yield strength = load at 0.2% offset yield/ initial cross section area
Table.2.
SL.NO Wheel no./Heat UTS UTS ELONGATION ELONGATION
2 2
. no. (N/mm ) (N/mm ) % %
RIM PLATE
RIM PLATE
Microstructure @1000x
Grain size@100x
Chapter 4.
P a g e | 25
Results&Discussion
From the various experiments carried out following observations and inferences
were made. It was seen that the various tensile properties followed a particular
sequence:
1) More is the tempering temperature, less is the hardness or more is the softness
quenched specimen.
metallurgical inspections indicated that the surfaces of heat treated samples are
3) More is the tempering time (keeping the tempering temperature constant), more
4) This clearly implies that the UTS and also to some extent the yield strength
increases.
the UTS value and the yield strength of the specimen where as on the other hand
Chapter 5.
CONCLUSION:
From the various results obtained during the project work it can be concluded that
the mechanical properties vary depending upon the various heat treatment processes.
Hence depending upon the properties and applications required we should go for a
suitable heat treatment processes. When ductility is the only criteria tempering at
high temperature for 2 hours gives the best result among all tempering experiments
however it is simply the hardness of the low carbon steel that is desired than we
should go for low temperature tempering for 1 hour or so. However if strength is
also desired along with hardness, this should not be done. It is seen that annealing
comparing all the heat treatment processes, optimum Combination of UTS, Yield
only.
P a g e | 27
Chapter 6.
Cast steel heat treated wheels referes to a process of altering the physical
heating, holding and cooling of metal in the solid state as cast steel
Chapter 7.
References:
1) Heat Treatment: Principles and Techniques-By T.V Rajan, C.P Sharma, Ashok
Sharma
6) Indian railway std. specification for cast steel wheels. Serial no. IRS R-
19/1993(Part 111)