For the first time, the influence of gas mixture on first damage resistance of a plasma nitrided DIN 18MnCrSiMo6-4 bainitic steel was investigated. Samples were nitrided at 500 °C with three different N2-H2 gas mixtures, containing 5, 24, and 76 vol.% N2. Samples were characterized concerning the resulting roughness, microstructure, compound layer’s phase composition, residual stresses in the diffusion zone, and surface hardness. Tribological ball-on-flat tests were carried out in reciprocal mode using zirconia as ball material for friction coefficient and the compound layer resistance until the first damage. The test results were evaluated statistically by analysis of variance (ANOVA). As the amount of nitrogen in the gas mixture decreases, the ε-Fe2-3(C)N content in the compound layer decreases. A γ’-Fe4N monophasic compound layer was achieved at 5 vol.% N2 gas mixture. The diffusion zone as expected presented compressive residual stresses with the highest values near the surface. In the tribological tests, better results were obtained for 5 and 24 vol.% N2 in the gas mixture as higher amounts of γ’-Fe4N were formed. The 76 vol.% N2 gas mixture led to a brittle behavior, due to the biphasic compound layer (γ’-Fe4N and ε-Fe2-3(C)N) with a predominant content of ε-Fe2-3(C)N.

In this study, the sliding wear of a DIN 18MnCrSiMo6-4 continuous cooling bainitic steel plasma nitrided with a nitrogen rich gas composition was investigated. To evaluate the influence of processing time and temperature on mechanical and microstructural characteristics of nitrided layer, the samples were nitrided at 400, 450, 500 and 550 °C for 3, 6 and 9 h. The produced nitrided layers were characterized concerning the microstructure, phase composition, microhardness and surface roughness. The samples were tested by ball-on-flat reciprocating dry sliding for friction coefficient and wear analysis. The tests were stopped after a given damage criteria involving the rapid growth of the friction coefficients and wear. The correlation of the different treatment parameters and resulting case depths and surface hardness with sliding distance at the time of microcracks formation or delamination of the surface layer was evaluated statistically by the analysis of variance (ANOVA). The plasma nitrided samples at 550 °C showed better wear performances in the ball-on-flat tests than the other groups investigated, since these samples have a thicker compound layer and diffusion zone higher than the other conditions investigated. In general, the beginning wear is slower because of the hardest region of the compound layer.

Continuous cooling bainitic steels has been widely used in industrial processes owing to its excellent mechanical properties and toughness. Although the surface properties of them are acceptable for many purposes, for their use in mechanical components like gears, it is necessary to improve their surface properties. Plasma nitriding treatments was carried out of a DIN 18MnCrSiMo6-4 steel at 500 °C, with three different nitrogen gas composition: 76, 24 and 5 vol.% nitrogen in hydrogen, for 3, 6 and 9 hours. The surfaces were characterized concerning the microstructure, microhardness, fracture toughness, nitrogen concentration and carbon composition, phase composition and residual stress states. Based on the results presented, layer growth constants (k) for different nitrogen gas composition was determined. The carbon profiles of samples indicate that there was decarburization during the plasma nitriding. The nitrided samples with thicker compound layers presented a fracture behavior dominated by the formation of Palmqvist cracks. X-ray phase analysis indicated the formation of biphasic compound layer on the surface of all nitrided samples with 76 and 24 vol.% nitrogen, while the nitrided samples with 5 vol.% nitrogen indicated the formation of monophasic compound layer. The diffusion zone presented compressive residual stresses with highest values near the surface.

Abstract The use of continuous cooling bainitic steels can provide a more energy efficient manufacturing route. However, for their use in mechanical components like gears, it is necessary to improve their surface properties without impacting the core properties to guarantee reliable mechanical performance. The effect of temperature and time on the plasma nitriding response of a DIN 18MnCrSiMo6-4 steel was investigated. The plasma nitriding was performed for 3, 6 and 9 hours, at 400, 450, 500 and 550 °C, using a gas mixture composed of 76 vol.% nitrogen and 24 vol.% hydrogen. Samples were characterized before and after plasma nitriding concerning the microstructure, hardness and microhardness, fracture toughness, phase composition and residual stress states. Based on the results presented, layer growth constants (k) for different temperatures was determined. Moreover, it could be found that 500 °C gave the best results investigated here, as higher temperature took to core and surface hardness decrease. The nitrided samples with thicker compound layers presented a fracture behavior dominated by the formation of Palmqvist cracks. X-ray phase analysis indicated the formation of biphasic compound layer on the surface of all nitrided samples. The diffusion zone presented compressive residual stresses with highest values near the surface.

RESUMO Os novos aços bainíticos de resfriamento contínuo (CCBS) são uma excelente alternativa quando se requer elevada dureza, tenacidade e resistência à fadiga. Contudo, estima-se que a taxa de desgaste dos CCBS seja insuficiente para aplicação em componentes com alta solicitação mecânica, sendo necessário aprimorar suas propriedades de superfície. O objetivo deste estudo é o de analisar os efeitos da nitretação a plasma sobre à microestrutura e propriedades de desgaste do aço bainítico de resfriamento contínuo DIN18MnCrSiMo6-4. Portanto, tratamentos com duração de 6 horas foram conduzidos com pressão de 3 mbar, mistura gasosa composta por 76% N2 + 24% H2, e temperaturas de 400, 450, 500 e 550 °C, respectivamente. As amostras foram analisadas através de microscopia eletrônica de varredura, difração de raios-X, microdureza e ensaios de desgaste por deslizamento recíproco. Nas condições investigadas, foi possível obter uma camada de compostos e atingir um aumento de até 393% na dureza superficial, entretanto, o uso de temperaturas mais elevadas durante os tratamentos favoreceu a formação de camadas mais profundas. Em todas as amostras nitretadas, constatou-se a formação predominante da fase de nitretos ε-Fe2-3N e, em menor quantidade, da fase de nitretos γ’-Fe4N. Nos ensaios de deslizamento recíproco houve diminuição do desgaste das amostras nitretadas na temperatura de 550°C.

ABSTRACT The new continuous cooling bainitic steels (CCBS) are an excellent alternative when high hardness, toughness and fatigue resistance are required. However, it is estimated that the wear rate of the CCBS is insufficient for application in highly mechanical loaded components, being necessary to improve the surface properties. The objective of this study is to analyze the effects of plasma nitriding on the microstructure and wear properties of DIN18MnCrSiMo6-4 continuous cooling bainitic steel. Therefore, treatments lasting 6 hours were conducted with a pressure of 3 mbar, a gas mixture composed of 76% N2 + 24% H2, and a temperature of 400, 450, 500 and 550 °C, respectively. The samples were analyzed by scanning electron microscopy, X-ray diffraction, microhardness and reciprocal sliding wear tests. Under the conditions investigated, it was possible to obtain a compound layer and to achieve an increase of up to 393% in surface hardness, however, the use of higher processing temperatures favored the extension of the depth layer. In all the nitrided samples, the major presence of ε-Fe2-3N nitrides phase was observed, and the γ'-Fe4N phase content was smaller. In the reciprocal sliding tests, there was a decrease in the wear of nitrided samples at temperature of 550 °C.

Resumo A introdução dos aços fabricados por processamento termomecânico controlado (TMCP) demandou maiores propriedades mecânicas e metalúrgicas das juntas soldadas sobre eles produzidas. Em função desses fatores, a energia de soldagem é estritamente limitada, e para evitar uma eventual redução da resistência mecânica da zona afetada pelo calor (ZAC), é necessário testar os procedimentos de soldagem próximos daqueles que serão usados na estrutura real. Desta forma, o objetivo deste estudo é obter dados detalhados referentes à eficiência mecânica de juntas soldadas pelo processo MAG e com diferentes energias de soldagem, sobre perfis tubulares quadrados em aço TMCP, formando um conjunto soldado coluna/viga. Portanto, seis distintas energias de soldagem e dois metais de adição foram utilizados (AWS ER80S-G e AWS ER120S-G), com as soldas posicionadas em todo o contorno do perfil. As doze estruturas soldadas foram instrumentadas e submetidas à flexão simples. Comparando-se as juntas soldadas produzidas com mesma energia de soldagem, e apesar dos efeitos similares sobre a zona afetada pelo calor (ZAC), aquelas fabricadas com o consumível AWS ER120S-G apresentaram maior resistência mecânica.

Abstract The introduction of steels made by thermomechanical controlled processing (TMCP) demanded higher mechanical and metallurgical properties of the welded joints produced on them. Given these factors, the heat input is strictly limited, and to avoid any reduction in the mechanical strength of the heat affected zone (HAZ), it is required to test welding procedures close to those that will be used in the actual structure. Therefore, the aim of this study is to obtain detailed data on the mechanical efficiency of welded joints by GMAW process and different heat inputs, on square tubular profiles in TMCP steel, disposed as a column/beam weldment. So, six different heat inputs and two filler metals were used (AWS ER80S-G and AWS ER120S-G), with welds located around the profile contour. The twelve welded structures were instrumented and subjected to simple bending. Comparing welded joints produced with same heat input, and despite similar effects on the heat affected zone (HAZ), those made with consumable AWS ER120S-G have shown higher mechanical strength.