LASER SURFACE ALLOYING OF MIDDLE CARBON STEEL IN ORDER TO INCREASE ITS CAVITATION EROSION RESISTANCE. Marek Szkodo

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1 LASER SURFACE ALLOYING OF MIDDLE CARBON STEEL IN ORDER TO INCREASE ITS CAVITATION EROSION RESISTANCE Marek Szkodo Technical University of Gdansk, Department of Material Engineering, Gdańsk, ul. Narutowicza 11/13, Poland, Abstract In this work laser surface alloying of Mn, Ni, Cr, Nb, Mo, and Co on carbon steel (0,45 % wt. C) was carried out using a 6 kw CW CO 2 laser. The layer of Mn, Ni, Cr, Nb, Mo, and Co mixed powders were placed by pasting and melted by laser beam. A surface metal matrix composite was thus produced. Its cavitation behaviour was investigated in a rotating disc device. The investigations were performed in the incubation period of the material damage for two intensities of the cavitation loading. The microstructure, chemical composition and phase identification of the modified layer were examined using scanning electron microscopy (SEM), light microscopy (LM), energy dispersive X-ray spectroscopy (EDX) and X-ray diffractometry (XRD), respectively. The hardness profile of the alloyed layer was investigated by a Vickers hardness tester. It was found, that presence of Co and Ni in martensite increases capability of surface layer to work hardening and contributes to an increase in its erosion resistance. 1. INTRODUCTION Among many factors contributing in the decrease of lifetime of constructions, devices or tools, wear is probably the one of the highest importance. It is especially important when occurring in areas that cannot be easily inspected using conventional methods, or when high manufacturing or material cost of the device must be compensated with an increased lifetime, or repair-to-repair time. The conventional surface treatment techniques do not always give satisfactory results, as their performance is dependent on many parameters, not always controllable. In case of surfaces with a complex geometry, or if no post-treatment machining is allowed, the conventional surface improvement methods cannot be applicable. In such circumstances laser beam surface treatment, i.e. alloying, cladding, or hardening has to be taken into consideration as a promising and efficient tooling method. Cavitation erosion is a progressive loss of material from a solid due to the impact action of the collapsing bubbles or cavities in the liquid near the metal surface. The failure of pipelines, pumps, water turbine blades and other hydraulic sets can often be attributed to cavitation erosion. It was found that laser surface modification of solid body led to substantial increase in its cavitation erosion resistance [1-14]. Especially, alloying of steel surface layers with Mn, Ni, Cr, proved to be very effective method of material protection against cavitation attack. However, the problem of determining the chemical composition the best from the anticavitation protection point of view of laser modified surface is still unresolved. The topic of this paper is the research on the influence of laser surface alloying of middle carbon steel (0,45 wt. % C) on its cavitation resistance. Chemical constitution of alloyed surfaces was designed to get microstructures: martensite+austenite, martensite+carbides, or austenite+carbides. 2. EXPERIMENTAL PROCEDURES 2.1 Objects of investigations and processing procedures The investigated samples were prepared of middle carbon steel ( 0,45 wt. % carbon). Powders 1

2 of alloying elements were mixed with natrium water glass and the layer was placed by pasting. Subsequent laser surface melting of the layer gave a surface metal matrix composite. Continuous work CO 2 laser TRIUMPH TLF 6000 was used as a power source. During the experimental runs the samples were moved across the laser beam along single, 1 cm wide path. Because of differences in melting temperatures of alloying elements as well as relatively slow course of the processing, the chemical composition of the manufactured surface layers differed from that of substrate powder. The average data on the chemical constitution of the investigated samples detected by electron dispersive spectroscopy is presented in Table 1 and the result of EDX analysis for sample designated as 45_2 depicted on Fig.1. Samples were found to be cracks free. Before emplacing the samples into the rotating disk, the grinding and polishing of their surfaces were done. Table 1 Chemical composition and microstructures of the surface layers, % wt. Samples designation Actual-post processing-chemical composition wt.% Ni Cr Mn Co Mo Nb Fe C Microstructure Maximal thickness of the alloyed layers [mm] ,4 19,4 10, ,8 61,2 0,45 austenite+carbides 0, , ,4 3,1-83,4 0,45 martensite+austenite 0, ,9-5,9 1,8-88,3 0,45 martensite+carbides 0,3 Figure 1 Result of EDX analysis for sample designated Cavitation testing of the samples The processed samples were subjected to cavitation loading at the rotating disk facility [15]. The cavitation was generated there by cylinders situated in the disk surface on the circle which diameter equalled 300 mm. Test specimens were inlaid in the disk, downstream of the cavitator. Their rotation speed stand for 3000 r.p m. Resulting mean gauge pressure was 155 kpa. The water which temperature equalled 20 C was used as an active medium. The tests were performed in 3-6 min long periods following one after another for 40 minutes in total. After each run, the plastic strains on the processed surface were defined using an image 2

3 analysis [16]. This method of quantifying of the cavitation damage of the materials is equivalent to the pits counting method admitted in the incubation period of the erosion [17]. 2.2 Material investigations Scanning electron microscope Philips 30/ESEM and light microscope Leica coupled with computer, were used for visualisation of microstructures in plane normal to the processing path. Chemical composition analysis was carried out by means of electron dispersive spectroscopy EDAX. The phase identification was examined using X-ray diffractometry XRD. The measurements of the hardness were done by means of a Rockwell tester. The microhardness within the heat-processed zone was detected at the load of 2 N. 3 RESULTS AND DISCUSSION An alloying of middle carbon steel by laser beam created surface layers of good bonding to the substrate. Thickness of the alloyed layers was non uniform because of power distribution in laser beam (Fig.2a). 2a 2b Figure 2 Non uniform thickness of alloyed zone (depicted by arrow) in sample 45-2 (2a) and its microstructure (austenite and carbides depicted by arrow)- light microscope (2b) Microstructure of the sample 45-2 surface layer was composed of austenite and carbides (chromium and niobium Fig. 2b), whereas the sample 45-3 microstructure consisted of martensite and austenite (Fig. 3a). Finally martensite 45-4 and carbides (chromium and molybdenum) were revealed as microstructure of the sample (Fig. 3b) 3a 3b Figure 3 Microstructure of surface layer in samples 45-3 (martensite and austenite depicted by arrow - Fig. 3a - light microscope) and 45-4 (martensite with chromium and molybdenum 3

4 carbides depicted by arrow Fig. 3b SEM) The series of cavitation erosion curves (e.g. time variations of plastic deformation measured as a loss of reflexivity on polished surface ) are presented in Fig. 4. The results indicate, that sample 45-3 was less susceptible to deformations for low intensity of cavitation than sample For high intensity of cavitation loading sample 45-4 occurred to be less susceptible to plastic strains. It proves that cavitation resistance of materials depends not only on microstructure but also on intensity of cavitation loading. In both cases sample 45-2 was the most susceptible to deformations. Results of microhardness investigations are presented in Figure 5. Surface layer of sample 45-2 had the lowest hardness. Maximal hardness for this sample was detected 0,15-0,2 mm below steel surface. It could prove that relaxation proceeds not only by plastic strains but also plastic strain [%] [%] high low intensity of cavitation R 2 = 0,9949 R 2 = 0,9754 R 2 = 0, R 2 = 0, R 2 = 0, _2 45_2 time [min] 45_3 45_3 time [min] 45_4 45_4 Wi l (45 3) 4a 4b Figure 4 Dependence of plastic deformations on time for low intensity (4a) and high intensities (4b) of cavitation loading microhardness HV0,2 uhv0, alloyed zone martensite R 2 = 0, ferrite + pearlite HAZ ,1 0,5 0,2 0,3 1 0,4 0,51,5 0,6 45_2 distance distance below steel surface [mm] [mm] 45_3 45_4 5a 5b Figure 5 Results of microhardness investigations (Fig. 5a) and microhardness profile for sample 45-2 (Fig. 5b) by micro cracks in strengthened surface layer up to the depth 0,15 mm (Fig. 6b). Microscopic investigations of surface layer confirmed this anticipation (Fig. 6-7). Cracks start to propagate from places of grain boundary interception by the slip lines and develop mainly along grains boundaries. The alloying with Nb was expected to cause the dispersive hardening and was assumed to form stable carbides contributing to the increase in the material strength. But too 4

5 large amount of carbides led to high brittleness of this sample. Visible slip lines are linked with the strain hardening process. The properties of the heat affected zone seems to be important for constituting of the cavitation resistance of coated materials [22]. Significant influence of the substrate on erosion performance of the superficially alloyed samples is especially the case of the materials with very thin surface layers and may be linked to scattering of the elastic energy by various substrates with different intensity. For sample 45-2 thick martensitic HAZ was almost twice harder than alloyed surface layer. This could also contribute to an increase in strain hardening and susceptibility to brittle cracks. The case of samples 45-3 and 45-4 is opposite. The highest strain hardening degree was revealed for sample 45-3 (Fig. 8). Hardness of the surface layer after alloying achieved 6a 6b Figure 6 Deformations revealed on the cross section in sample 45-2 (Fig. 6a LM) and microcracks in strengthened surface layer (Fig. 6b SEM) 7a 7b Figure 7 (Fig. 7a) Hardened surface layer with microcracks (depicted by black arrow) and early stage of micro crack in place where slight lines cross grains boundary (depicted by white arrow) and failures on the sample 45-2 surface (slip lines depicted by arrow Fig. 7b) average value of 550 µhv0,2. Cavitation loading caused an increase in its hardness up to 790 µhv0,2 i.e. to value which occurred in HAZ. Part of energy from cavitation loading was changed to strain hardening and contributed an increase in cavitation resistance. Microstructure of this sample was designed to get martensite and austenite. Austenite skeleton, susceptible to work hardening, was filled with hard martensite. Co was placed into the surface layer of this sample in order to stabilize and strengthen the lattice of austenitic type and to facilitate the stresses relaxation within the material being exploited under the 5

6 strain hardening degree [%] _2 45_3 45_4 cavitation loading. Nickel, dissolved in martensite, should have improved its impact toughness. For low intensity of cavitation loading, this kind of microstructure is very erosion resistant. It is the case, because hard martensite can resist high stresses and softer austenite contributes an increase in strain hardening and high impact toughness. Deterioration of erosion resistance of completely martensitic alloys was reported in [18]. The better resistance was achieved if steel microstructures were susceptible to strain hardening [19], e.g. due to content of some amount of austenite [20], or in the complex microstructures with matrix of high impact toughness [21]. At high intensity loading, cavitation erosion starts within austenite (Fig. 9). This selective erosion is caused by lower hardness of austenite. Figure 8 Strain hardening degree for tested samples 9a 9b Figure 9 ( Fig. 9a) Crack revealed on the cross section of sample 45-3 (austenite depicted by arrow). (Fig. 9b) Crater in the HAZ (depicted by white arrow) and pits in the alloyed zone ( depicted by black arrow) on the surface layer in sample 45-3 Microstructure of the sample 45-4 consists of hard skeleton of carbides filled with softer martensite. The microstructure was the most wear resistant under high intensity loading in the early stage of cavitation. Strain hardening degree for this sample reached the level of 13 % and was even better than strain hardening in the sample It was linked to hardness of HAZ which was softer than surface layer. This hard microstructure of the surface layer (900 µhv0,2) was not very resistance to crack formation. For this alloyed surface layer, the highest 6

7 crack propagation rates occur under the loading (Fig. 10). Such microstructure does not guarantee high resistance in advanced stage of cavitation erosion. 10a 10b Figure 10 (Fig. 10a) Crack, caused by cavitation loading, developed along the boundary of grains in sample 45-4 (depicted by arrow). (Fig. 10b) Brittle cracks and splitting on the surface for sample Mechanical etching revealed blocks of martensite (depicted by arrow) - SEM 4 CONCLUSIONS 1. Microstructure formed as austenite skeleton of filled with martensite is the most susceptible to strain hardening under cavitation loading and increases cavitation resistance at low intensity of loading. 2. Microstructure formed of carbides (chromium and molybdenum) skeleton surrounding the martensite cells is the most resistant to plastics deformation for high intensity of loading in the early stage of cavitation erosion. 3. Cavitation erosion resistance of austenite contaminated with large amount of chromium and niobium carbides is the worst due to high brittleness of such microstructure. This work was done within Polish Committee for Scientific Research Project 7/T08 COIZ17 BIBLIOGRAPHY 1. KWOK C.T. etc. Laser surface modification of UNS S31603 stainless steel. Material Science and Engineering, 2000, number A290, pages DUBE D. etc. Cavitation resistance improvement of IRECA steel via laser processing. Materials Letters, 1996, number 28, pages GIREŃ B.G., SZKODO M. Cavitation erosion of chromium-manganese and chromiumcobalt coatings processed by laser beam. Inżynieria Materiałowa, 2002, number 5, pages SZKODO M., GIREŃ B.G. Dependence of cavitation performance of superficial iron alloys on the substrate, Advances in Materials Science, 2002, number 2, pages PREECE C.M., DRAPER C.W. The effect of laser quenching the surfaces of steels on their cavitation erosion resistance, Wear, 1981,Vol. 67, number 3, pages TOMLINSON W.J. etc. The effect of laser surface melting on the cavitation wear of grey cast iron, Wear, 1987, Vol. 116, pages

8 7. TOMLINSON W.J. etc. Cavitation wear of untreated and laser-processed hardfaced coatings, Wear, 1987,Vol. 117, page GADAG S.P., SRINIVASAN M.N. Cavitation erosion of laser melted ductile iron, Journal of Material Processing Technology, 1995, Vol. 51, number 1-4, pages RAO D.R. etc. The effect of laser surface melting on the erosion behaviour of a low alloy steel. Surface and Coatings Technology, 1993, Vol. 58, page KWOK C.T. CHENG F.T., MAN H.C. Laser surface modification of UNS S31603 stainless steel using NiCrSiB alloy for enhancing cavitation erosion resistance, Surface and Coatings Technology, 1998, Vol. 107, page GIREŃ B.G., SZKODO M. On the increase of cavitation resistance of A1 structure alloys processed by laser beam, Journal of Technical Physics, 1999, Vol. XL, page GIREŃ B.G. Cavitation erosion of steels processed with a laser beam and optical discharge plasma, Surface Engineering, 1998, Vol.14, page SZKODO M. GIREŃ B.G., CENIAN A. Cavitation resistance of 45 and 2Cr13 steels enriched superficially with laser deposited Hf, SiC or SiC+AlNi powders. Proceedings SPIE, 2000, Vol. 4238, pages SZKODO M., GIREŃ B. G. On the increase of cavitation resistance of the materials due to laser surface processing, Inżynieria Materiałowa, number 5, pages STELLER K., KRZYSZTOFOWICZ T., REYMANN Z. Effects of Cavitation on Materials in Field and Laboratory Conditions, American Society for Testing and Materials, Special Tech. Pub. 1975, Vol. 567, page GIREŃ B.G., SZKODO M. Methodology of cavitation erosion assessment of laser processed materials, Advances in Materials Science, 2001 Vol. 1, pages BELAHADJI B., FRANC J.P., MICHEL J.M. Analysis of the cavitation erosion pits, Trans. ASME J.Fluid Eng., 1991, Vol. 113, page LAMBERT P. etc. Cavitation erosion and deformation mechanisms of Ni and Co austenitic stainless steels, In the proceedings from the conference VII Int. Conf. on Erosion by Liquid and Solid Impact. Cambridge, 1987, pages RICHMAN R.H. Deformation-induced martensite and resistance to cavitation erosion, Journal de Physique IV, Vol. 5, number C8, 1995, pages JIANG G.B. Cavitation erosion of bainitic steel, Wear, 1998 Vol. 215, pages WU X. Rapidly solidified nonequilibrium microstructure and phase transformation of laser synthesized iron-based alloy coating, Surface & Coatings Technology, 1999, Vol. 115, pages GIREŃ B.G., SZKODO M. Cavitation erosion of some alloys manufactured on steel and iron surfaces by laser beam, Journal of Materials Processing and Technology, in print 8

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