sessi 11-12-surface treatment.ppt
DESCRIPTION
ttg perlakuan panas pada logamTRANSCRIPT
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PROSES PERLAKUAN PENGERASAN PERMUKAAN
Dr.ir.Myrna Ariati MS
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Alasan Melakukan Pengerasan Permukaan Mengeraskan lapisan permukaan (0.1mm – 5mm) Menambah ketahanan aus Menambah ketahanan permukaan terhadap beban
dan gaya mekanis (crush resistance) Tahan terhadap tegangan sisa tekan yang terjadi
dipermukaan Memperbaiki ketahanan fatique Menghasilkan bagian inti yang tangguh, tahan
impact
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Metode Pengerasan Permukaan1. Selective / Termal
Induction Flame Laser Light
2. Termokimia Carburizing Carbonitriding Nitriding Nitrocarburizing
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Selective Heat Treatment
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Selective Heat Treatment Prosedur:
Menggunakan medium dan high carbon steels Panaskan baja ke temperatur austenite Bagian dalam (core) tidak bertransformasi
menjadi austenit Dinginkan untuk membentuk martensite di
permukaan Bagian dalam tak berubah Martensit mengalami tegangan Umumnya dilakukan tempering
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Flame Hardening Dipilih dengan alasan:
komponen berukuran sangat besar sehingga tidak ekonomis dilakukan didalam dapur.
pengerasan permukaan segmen tertentu dari luas keseluruhan kompenen.
komponen yang memiliki geometri permukaan kompleks sehingga sulit mengontrol keakuratan dimensinya dengan menggunakan sistem dapur.
Biaya produksi paling murah sehingga cocok untuk jenis baja kualitas umum.
Keterbatasannya adalah sulit mengontrol over heating dan mendapatkan case depth kurang dari 1.5 mm.
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Flame Hardening Karakteristik
Menggunakan peralatan burner dan semprot air, serta campuran gas yang terdiri dari oksigen + gas asetilen / gas alam / propane.
Kedalaman kulit pengerasan (case depth) 1 - 6 mm, dengan parameter proses: intensitas nyala api, waktu pemanasan, serta kecepatan lintas.
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©2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning™ is a trademark used herein under license.
Figure 12.26 (a) Surface hardening by localized heating. (b) Only the surface heats above the A1 temperature and is quenched to martensite.
Flame HardeningPrinsip kerja flame hardening
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Flame Hardening
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Induction Hardening
Mempersingkat siklus
heat treatment Lokasi
terseleksi Efisiensi energi Proses polusi
rendah
Keunggulan
Problem • Sulit mengontrol heating time and temperature distribution
• Sifat material tak selalu linear.
• Sulit menentukan transformasi yang terjadi dan kontrol kekerasan
•Sulit mengevaluasi efek kombinasi rapat arus AC, frekwensi dan pola kekerasan akhir.
• Adanya Trial and error, sehingga ada periode perkiraan biaya
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Induction Hardening Karakteristik:
Kedalaman pengerasan tergantung frequency (induction)
Contoh: Freq: 1.000 Hz Depth: 4.5-9 mm Freq: 1.000.000 Hz Depth: 0.25-0.8 mm
Kekerasan Permukaan 50-60 HRC (martensite atau temper martensite)
Interior 10-20 HRC (pearlite-ferrite-pearlite)
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Induction HardeningPrinsip kerja induction hardening
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Arus
A.C.
A.C. Supply
Medan magnit
Arus
Induksi
Energy
Thermal
Induction Hardening
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Induction Hardening batang bahan shaft
Induction Hardening
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Thermochemical Heat Treatment
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Mudah mengontrol kedalaman pengerasan Baik untuk bentuk kompleks Biaya rendah terutama untuk produksi
massal Bahan baku low carbon steel
penghematan Struktur lebih tangguh daripada baja medium
atau high carbon steel.
Pengerasan Termokimia
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LPG : 15 % LPG : 1 %
Surface Hardening
0.1 - 0.2 mm
Nitrocarburizing
Temperature570 - 590
N2 : 49 %
Nitriding
Temperature510 - 525
N2 : 50 %
0.5 mm
NH3 : 50 %
WAKTU15 - 300 Menit
LAPISAN
NH3 : 50 %
WAKTU460 - 1440 Menit
LAPISAN0.2 - 0.3 mm
Carbonitriding
Temperature825 -875
N2 : 77 %NH3 : 8 %
WAKTU60 - 120 Menit
LAPISAN0.7 mm
N2 : 90 -85 %
WAKTU30 - 480 Menit
LAPISAN
Carburizing
870 - 950Temperature
LPG : 10-15 %
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Baja karbon rendah mudah dibentuk dan machining dibutuhkan kekerasan permukaan meningkat, bagian tengah ulet
Prinsip DifusiC-Co= (C1-Co) [1-erf (x/2Dt)]
C = kadar karbon pada kedalaman xCo = kadar karbon dasar dalam bajaC1 = Kadar karbon dipermukaanx = Kedalaman dari permukaan (cm)D = Koef diff (cm2/s)t = waktu (s)erf = error function
Carburizing
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©2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning™ is a trademark used herein under license.Figure 12.27 Carburizing of a low-carbon steel to produce a
high-carbon, wear-resistant surface.
Carburizing
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Reaksi karburisasi (pack carburizing) BaCO3BaO + CO2 (Ba carbonate sbg energizer)
CO + H2OCO2 + H2
CO2 + C 2 CO CH4 C + 2 H2
Suhu Austenisasi 900oC
Carburizing
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Pack carburizing
Carburizing
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CarburizingMikrostruktur hasil Karburisasi baja (5% nital)
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Prinsip perkiraan kekerasan
Martensite %
0 20 40 60 80 99
HRCValue
10 20 30 40 50 60
Carburizing
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2 NH3 2 Nfe + 3 H2
Permukaan lebih keras, tahan aus (adanya Nitrida paduan)
Ketahanan tempering dan kekerasan temperatur tinggi
Kekuatan fatique tinggi Meningkatkan ketahanan korosi untuk baja
yang bukan SS Kestabilan dimensi tinggi
Nitriding
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Single stage nitriding
Doble stage nitriding
NitridingStruktur permukaan nitriding
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Jarak dari permukaan
% Ni
NitridingProfil Nitrogen
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Nitriding
• Pengaruh elemen pembentuk nitrida• Membentuk senyawa nitrida dan karbonitrida (Contoh,
Aluminum, Titanium, Niobium, dan Zirconium)• Aluminum nitrida amat halus dan hanya dapat dilihat
setelah pengambilan replika yang amat halus, dengan menggunakan Transmission Electron Microscope.
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Nitriding
PENGARUH UNSUR PEMBENTUK NITRIDAPADA KEKERASAN SETELAH NITRIDING
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Nitriding
Low Al Steel
mediumAl Steel
High Al Steel
Efek Al terhadap nitride precipitates layer
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Studi Kasus
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Baja Paduan akan dikeraskan hingga 450HB Setelah dilakukan austenisasi dan quench,
kekerasan tidak naik, bahkan menjadi berkurang
Apa penyebabnya dan bagaimana mengatasinya?
Failure Analysis
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Struktur baja terdekarburisasi. Permukaan atas hampir tidak terdapat karbon, tampak terang. Fe dipermukaan cepat teroksidasi akibat tak terdapatnya karbon pada besi
Failure AnalysisSTRUKTUR PERMUKAAN BAJA TERDEKARBURISASI
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Struktur mikro jauh dari permukaan dekarburisasi, tampak ferit jauh lebih sedikit.
Failure AnalysisSTRUKTUR MIKRO BAGIAN DALAM,JAUH DARI PERMUKAAN DEKARBURISASI
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Buatlah desain perlakuan panas permukaan untuk axle dan drive gear mobil
©2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning™ is a trademark used herein under license.
Gambar axle dan drive gear
Surface Heat Treatment Design
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Surface Heat Treatment DesignThe axle might be made from a forged 1050 steel
containing a matrix of ferrite and pearlite. The axle could be surface-hardened, perhaps by moving the axle through an induction coil to selectively heat the surface of the steel above the A3 temperature (about 770oC). After the coil passes any particular location of the axle, the cold interior quenches the surface to martensite. Tempering then softens the martensite to improve ductility.
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Surface Heat Treatment DesignCarburize a 1010 steel for the gear. By performing a
gas carburizing process above the A3 temperature (about 860oC), we introduce about 1.0% C in a very thin case at the surface of the gear teeth. This high-carbon case, which transforms to martensite during quenching, is tempered to control the hardness. This high-carbon case, which transforms to martensite during quenching, is tempered to control the hardness.
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