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1
Microstructural and Torsional
Fatigue Characteristics of Single-
shot and Scan Induction Hardened
1045 and 10V45 Steels
Lee Rothleutner1, Jody Burke2, Dr. Chester J. Van Tyne1, and Robert Cryderman1
1Advanced Steel Processing and Products Research Center
Colorado School of Mines, Golden, CO 80401 USA
2Gerdau Special Steel North America, Jackson, MI 49201 USA
Additional support from Rob Goldstein of Fluxtrol Inc.
as well as Rob Madeira and Jeff Elinski of Inductoheat Inc.
2
Study Design
Induction hardened shaft ...
Performance
↑ Strength
↑ Fatigue life1. High case depth
2. Favorable case
microstructure
3. Favorable residual
stress profile
Processing
• Power
• Frequency
• Quenchant(conc. & flow rate)
• Coil design
• Scan speed
3
Study Design
Scope...
• Scan vs. Single-shot induction hardened
– Effective case depth of 44% (~70% of area)
– 1045 and 10V45 (F/P starting microstructure)
Outline...
1. Case microstructure
2. Residual stresses (near surface)
3. Torsional fatigue performance (550, 600, 650 MPa stress amplitude, R=0.1)
4
Materials – Chemistry
wt pct C Mn Si Ni+Cr+Mo V Al N P S Cu DIb (mm)
1045 0.44a 0.74 0.23 0.25 0.002 0.016 0.0068 0.010 0.006 0.26 35.6
10V45 0.47a 0.82 0.28 0.24 0.080 0.007 0.0100 0.007 0.009 0.22 45.5
Minc 0.43 0.60 --- --- --- --- --- --- --- --- ---
Maxc 0.50 0.90 --- --- --- --- --- 0.040 0.050 --- ---
a Standard Deviation of 0.01 wt pct (n = 5)b ASTM A255-10: Standard Test Methods for Determining Hardenability of Steelc ASTM A29-12: Standard Specification for General Requirements for Steel Bars, Carbon and Alloy, Hot-Wrought
Hot Rolled to 39.7 mm (1.563 in) Diameter Bar (18.8 to 1)
5
Materials – Microstructure
1045 10V45
Transverse Characteristics 1045 10V45
Pearlite (%) 83.1 ± 2.0 86.5 ± 1.5
Pearlite ILS (nm) 225 ± 6.4 207 ± 7.1
Ferrite Grain Size (µm) 6.4 ± 0.2 3.3 ± 0.1
Ferrite Grain Circularity 0.76 ± 0.01 0.82 ± 0.01
Hardness (HV1kg) 217 ± 5 281 ± 9
6
Materials – V(C,N) Precipitation
V(C,N) diameter
4.5 ± 0.3 nm
10V45 – Proeutectoid Ferrite
BF DF
𝑏 = 011 𝛼𝐹𝑒 𝑔 = 0 20 𝑉(𝐶,𝑁)
7
Materials – V(C,N) Precipitation
10V45 – Pearlitic Ferrite
V(C,N) diameter
3.3 ± 0.3 nm
DFBF
8
Torsional Fatigue Specimen
(mm)
9
Induction Hardening
Scan Single-shot
Scan Single-Shot
Power (kW) 72 128
Freq. (kHz) 196 31
Scan Rate (mm/s) 17.3 ---
UCON A Concentration 6% 2%
Flow Rate (L/min) 75 144
10
Induction HardeningMeasured at Minimum Specimen Diameter
Scan
Single-shot
11
Equivalent Hardness
𝐻𝑉𝑒𝑞 =3
𝑅3 0
𝑅
𝐻𝑉(𝑟)𝑟2𝑑𝑟
𝑑𝑟𝑟
𝑅
Tempered at 176 °C for 90 min
after induction hardening.
HVeq ∝ Torsional Strength
∝ Fatigue Life
12
Microstructure – Scan
Tempered at 176 °C for 90 min
10V45-Scan
13
Microstructure – Single-shot
10V45-Single
Tempered at 176 °C for 90 min
14
Case Microstructure
Depth from
Surface
Scan Single-shot
1045 10V45 1045 10V45
0.0 mm --- --- --- R
0.5 mm --- R + T R R + T
0.0 mm
0.5 mm
10V45...
Higher tendency for non-martensitic
transformation products both retained (R)
and transformed (T) ferrite.
No ghost pearlite was observed within
0.5 mm of surface in any condition.
10V45-Single
10V45-Single
15
Case Microstructure – PAGS
1045-Scan
10V45-Single
10V45 is not significantly different from
1045 for a given processing routine.
16
Residual Stress
10V45 is not significantly different from
1045 for a given processing routine.
17
Residual Stress
Octahedral Shear Stress
𝜎𝐻 = ±1
2𝜎12 + 𝜎2
2 + 𝜎1 − 𝜎22
−𝜏𝑥𝑦𝑟𝑒𝑠
-𝜎𝑦𝑟𝑒𝑠
-𝜎𝑥𝑟𝑒𝑠 -𝜃
𝜎1
-𝜎2
•=
10V45 is not significantly different from
1045 for a given processing routine.
35%
25%
18
Torsional Fatigue Specimen
95% of Max Shear Stress
Longitudinal Cross-section
15.5 mm
(mm)
19
Torsional Fatigue
Crack System
𝜎
𝜏
=
−𝜏𝑥𝑦𝑎𝑝𝑝
-45°
𝜎1𝑎𝑝𝑝
−𝜎2𝑎𝑝𝑝
𝜏𝜏𝑚𝑎𝑥
𝜏𝑚𝑖𝑛
𝜏𝑚
𝜏𝑎
𝑡𝑖𝑚𝑒
I
III
II
20
Torsional Fatigue – Scan
1045 10V45
650 MPa
43,100 cycles
650 MPa
46,400 cycles
1045 exhibits more ductility in case
during crack propagation then 10V45.
21
Torsional Fatigue – Scan
1045 10V45
550 MPa
122,500 cycles
550 MPa
510,000 cycles
1045 exhibits more ductility in case
during crack propagation then 10V45.
22
Torsional Fatigue – Single-shot
1045 10V45
650 MPa
128,600 cycles
650 MPa
127,100 cycles
1045 exhibits more ductility in case
during crack propagation then 10V45.
23
Torsional Fatigue – Single-shot
1045 10V45
550 MPa
240,000 cycles
550 MPa
448,000 cycles
1045 exhibits more ductility in case
during crack propagation then 10V45.
24
Torsional Fatigue
(MPa)
Scan Single-shot
1045 10V45 1045 10V45
650 --- --- --- 1/5
600 --- --- --- 4/5
550 3/5 3/5 2/5 4/5
𝜏𝑎
Sub-surface Initiations
Initiation location:
Case hardness in 10V45 is higher
then 1045 (~2 HRC).
~70%
25
Scan vs. Single-shot
Hardness Profiles:
Scan ≈ Single-shot
Case Non-martensitic Trans. Products:
Scan < Single-shot
Prior Austenite Grain Size:
Scan > Single-shot (~25%)
Near-Surface Residual Stress:
Scan < Single-shot
Fatigue Life:
Scan ≈ Single-shot (at 550 MPa)
Scan < Single-shot (~70% higher )𝜏𝑎
27
Residual Stress• Incremental Hole Drilling Method
– ASTM E837
– Type A strain gage rosette.
– Inverted cone diamond mill.
– Strain measured every 0.05
mm to 1 mm.
– H-DRILL (v3.11) software
• Prof. Gary Schajer (UBC)
Hoop
Axial
Diamond
Mill
Micrometer
Head
Air Turbine
Assembly
Light
•Vishay M-M•RS-200
X & Y
Adjustment
28
Net Stress
-𝜎𝑦𝑠
-𝜎𝑥𝑠
𝜏𝑥𝑦𝑠
Residual
Stress State
Applied
Stress State
Net
Stress StateResultant
Principal
Stresses
𝜎
𝜏
+−𝜏𝑥𝑦
𝑟𝑒𝑠
-𝜎𝑦𝑟𝑒𝑠
-𝜎𝑥𝑟𝑒𝑠 -𝜃
𝜎1
-𝜎2
=𝜏𝑥𝑦𝑎𝑝𝑝
𝜎
𝜏
+ =𝜎
𝜏
𝜎
𝜏
=
=
29
Net Stress
Maximum Reduction in Applied Stress
-𝜃𝜎1
-𝜎2
Positive throughout test.
Negative throughout test.
Between -30° (at min)
and -45° (at max).
-𝜎2
𝜎1
-𝜃
10V45 is not significantly different from
1045 for a given processing routine.
(MPa) Scan Single-shot
650 -400 -560
550 -400 -560
𝝈1
30
Torsional Fatigue