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International Journal of Application or Innovation in Engineering & Management (IJAIEM)

Web Site: www.ijaiem.org Email: editor@ijaiem.org


Volume 7, Issue 6, June 2018 ISSN 2319 - 4847

EVALUATION OF SURFACE FINISH AND


ITS EFFECT ON PACKED DIFFUSION
ALUMINISATION OF LOW ALLOY STEEL
COMPONENT
Sreenath S1, M.R. Shivakumar2

1
P.G Scholar, Department of Industrial Engineering, Ramaiah Institute of Technology, Bengaluru, Karnataka,
India.
2
Assistant Professor, Department of Industrial Engineering, Ramaiah Institute of Technology, Bengaluru,
Karnataka, India.

ABSTRACT
Medium alloy carbon steel has become the choice of material for high temperature applications due to its desirable mechanical
properties at elevated temperature and corrosive environment. The medium alloy carbon steel undergoes various types of
corrosion like carburization, oxidation based on various industrial applications. Various methods are employed to obtain
protective coating on the surface of the metal. The best suited technique among the available techniques is diffusion
aluminisation using pack cementation process .The salient feature of diffusion aluminisation process is that a diffusion as well
as deposition layer can be enriched on the metal surface. The Aluminizing coating technology is an established technique
wherein several studies and researches are being carried out to study the kinetics of aluminisation on the metal surface.
However there is lack of information and research gap regarding the role of the surface attributes and the profiles and its effect
on the anti-corrosion coating thickness of the metal.This paper aims to study the role of surface roughness (Ra )on the coating
thickness of the EN24 steel samples achieved by three different machining processes such as turning, grinding, abrasive flow
finishing machining. The paper also investigates the influence of the surface roughness (Ra )on hardening and annealing prior
to the packed diffusion aluminisation process followed by tempering of both the sets post aluminisation process. The diffusion
pack cementation process was carried out at temperature of about 500 C to 900 C. The analysis was carried out to study the
coating characteristics using optical light microscope, EDX using Scanning Electron Microscope (SEM), X-ray Powder
Diffraction (XRD) and micro hardness.
KEYWORDS – Diffusion aluminisation process, Surface roughness, Turning, Grinding, Abrasive flow finishing
machining

1. INTRODUCTION
Protective coatings are formed on the structural materials to ensure its use in harsher environments to avoid surface
degradation due to exposure to high temperature and corrosive environment.Diffusion aluminisation is an effective
surface coating technology to improve the corrosion resistance of the steel surface. Pack diffusion aluminisation is
carried out at high temperatures of above (500-900 C). In Pack cementation process the pack used for aluminisation of
the steel substrateconsists of aluminium source, aluminium filler and a halide activator. A number of investigations
have been done to study the microstructure and phase composition of the pack diffusion aluminide coating on plain
carbon steel but the role of surface finish and heat treated conditions on the growth of the aluminium on the steel
substrate have not been investigated extensively.The aim of the present paper is that EN 24 steel samples is selected
and is machined using turning, grinding and abrasive flow machining process. The aluminized layer, diffusion depth
and phases were examined upon subjecting the sample to three different heat treatment cycles to illustrate if there exits
any significant variation in the coating characteristics.

2. LITERATURE REVIEW

[1] This paper titled “Low temperature pack aluminizing of X80 Pipeline steel through addition of zinc and self nano
crystallization”[ ],authors WANG Yu,HUANG Min and XIE Xiang Xu carried out packed diffusion aluminisation

Volume 7, Issue 6, June 2018 Page 77


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org
Volume 7, Issue 6, June 2018 ISSN 2319 - 4847

carried out on pipeline X80 steel wherein the surface of the pipeline steel was modified using surface refinement
treatment and variation in the pack powder.
[2] This paper titled “A LOW TEMPERATURE ALUMINIZING TREATMENT OF HOT WORK TOOL STEEL” [ ],
author Bozidar matijevic carried out Aluminisation on X40CrMoV5-1 hot work tool steel using pack cementation
process. The Aluminizing temperature was carried out at 550°C to 620 °C. Investigation was carried out study the role
of temperature and time on the phase change and microstructure of the component.
[3] This paper titled “Pack Diffusion Aluminizing of Carbon Steel”[ ]author M.E Abd EL-AZIM,K.E
MOHAMED.....F.H HAMMAD.This paper shows that aluminisation diffusion is best achieved through pack
cementation process. The aluminisation process was carried out through the use of ferrous aluminium mixture, pure
aluminium and halide activator. Diffusion aluminisation was carried out on delta 37 steel.
[4]This paper titled “Lower temperature aluminizing and its effect on improving corrosion resistance of iron treated by
surface mechanical attrition treatment”[ ] authors Cheng Zhong,Wenbin Hu,Yiming Jiang ,the study involved use of
an Fe plate to create a nano surface finish of 28nm using surface mechanical attrition treatment. The (SMAT) samples
were analysed for their coating thicknesses using SEM, XRD. The result highlighted that the samples subjected to
SMAT process were highly corrosion resistant and the samples subjected SMAT samples achieved good coating
thickness at lower temperature.
[5] This paper titled “The aluminizing in powder technology of AISI 304 steel” [ ] authors DB baitanu,DG
Galusa...Bakri
Abdullah,this paper presents studies about the aluminisation carried out on AISI 304 steel to form protective coatings
to reduce
corrosion resitance under harsh environments. Pack cementation mixture consisted of pure aluminium powder,
aluminium oxide and an halide activator. The analysis was carried out using SEM to understand the layer composition
after aluminisation at various degrees.
[6]This paper titled “Aluminide coating on 304 Stainless steel”[ ] authors Kevin L. Smith,Armen kutyan,Shaghik
A.Abolian,…Vilupanur A.ravi,this paper studies about aluminisation were type 304 stainless steel was used under the
temperature of 650°C,750°C,850°C for time range of one to twenty five hours using pack cementation technique.

3. PROBLEM OBJECTIVE
• Selection of the protective coating process to avoid corrosion on the low alloy steel component.
• Establishing the standard cycle to achieve the desired coating characteristics.
• Selection of the desired grade of carbon steel to achieve the protective coating.
• Study and compare the influence of surface finish on the coating thickness of the material.
• Study and compare the role of surface finish and coating thickness on the hardness of the material.
• Analyse the hardness values before and after aluminisation.
• Analyse the coating parameters like strength of the chemical bond, phase’s changes in the inter-metallic layer using
SEM, XRD.
• Draw interferences and conclude from the above.

4. Experimental procedure
The EN24 samples having an outer diameter of 30 mm and inner diameter of 15mm with a thickness of 15mm was
produced using turning, grinding and abrasive flow machining process. The samples were cleaned and one set of
sample was subjected to hardening and annealing cycle according to the fig 1.The hardness were measured in the stock
condition and after hardening and annealing.All the samples(hardened and non-hardened) are aluminized according to
the cycles as shown in figure 2 .The aluminizing agents consisted of Ferro –aluminium powder, aluminium powder and
activator(NH4Cl).Upon completion of the aluminisation cycle the samples(hardened and non-hardened) are subjected
to hardening and tempering as shown in the figure3.

Volume 7, Issue 6, June 2018 Page 78


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org
Volume 7, Issue 6, June 2018 ISSN 2319 - 4847

Figure 1Heat Treatment cycle before aluminisation process

Fig 2 Heat treatment cycle for aluminisation process

Fig 3Heat Treatment Cycle after aluminisation process

The EN24 samples after the completion of the three different cycles are measured for their coating thicknesses using
optical light microscope,EDX in SEM for percentage atomic weight ,phases obtained using XRD and hardness using
micro hardness tester.

RESULTS AND DISCUSSIONS

The hardness values of the rods before hardening and after subjecting it to hardening cycle is given in the table below.
Tab 1 hardness values of the samples
Specimen Hardness Values (HRC)
Non hardened and annealed 16.22
Hardened and annealed 30.24

Volume 7, Issue 6, June 2018 Page 79


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org
Volume 7, Issue 6, June 2018 ISSN 2319 - 4847

Coating thicknesses of samples (After aluminisation process):

The coating thickness of the samples subjected to aluminisation process are measured using optical light microscope at
200X magnification. The results obtained from the instrument are tabulated below.
Tab 2 Coating thicknesses of samples after aluminisation
Sample 6 Thicknesses (µm)
Turning non hardened 85.06
Grinding non hardened 85.55
AFFM non hardened 92.68
Turning hardened 99.06
Grinding hardened 87.36
AFFM hardened 92.85

Turning non -hardenedGrinding non -hardenedAFFM non- hardened

Turning hardenedGrinding hardenedAFFM hardened

Fig 4: At 200X various sample coatings

Coating Thickness discussion


The coating thickness was measured using optical light microscope and the analyses revealed there was not much
significant difference in the coating quality of the turned, grinded and abrasive flow machined samples. The coating
results also did not show any variation and almost remained the same between the hardened and non-hardened.
Hardness measurement:
The following results contain all the hardness values measured by Vickers hardness test. This was done on EN24
material before and after coating process.The report contains micro hardness values. The hardness is measured by
Vickers hardness method. For the measurement of Vickers hardness 300gf is used.
Tab 3 Micro hardness (After aluminisation coating):
Samples Hardness values (HRC)
Turning non hardened 29.49
Grinding non hardened 30.46
AFFM non hardened 30.27
Turning hardened 31.45

Volume 7, Issue 6, June 2018 Page 80


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org
Volume 7, Issue 6, June 2018 ISSN 2319 - 4847

Grinding hardened 32.27


AFFM hardened 31.62

3 SEM, EDX ANALYSIS


The hardened and non hardened samples are analysed for their percentage compositional atomic weight using Energy
Dispersive X-ray Analysis(EDX) technique. The results of the percentage atomic weight of the various spectra are
summarized below. Tab----- compares the( EDX ) of the hardened and non hardened samples subjected to different
machining proecsses.

[a] [b]

Fig 5EDX analysis of turned samples of [a] Non-hardened sample [b] Hardened sample

[a] [b]

Fig 6 EDX analysis of grinded samples of [a] Non-hardened sample [b] Hardened sample

[a] [b]

Fig 7 EDX analysis of abrasive flow finished samples of [a] Non-hardened sample, [b] Hardened sample

Volume 7, Issue 6, June 2018 Page 81


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org
Volume 7, Issue 6, June 2018 ISSN 2319 - 4847

Tab4 EDX analysis

EDX analysis discussions


The percentage atomic weight analysis was carried out in SEM using EDX method . The comparisons exhibited that as
one moves from outer end one spectrum to the interface layer of the spectrum band the percentage atomic weight of
the alumium decreases showing no major highlighting differences in the hardened and non-hardened samples after the
aluminisation process and also the surface roughness's.

XRD ANALYSIS

Fig 8 XRD analysis of the samples


XRD analysis discussions:
Theanalysis carried out in XRD revealed that no major highlighting differences in the hardened and non-hardened
samples wherein the samples were enriched with rich phases of AlFe3 and the surface of the non-hardened sample was
containing Al2O3 .Further studies and thorough analysis needs to be carried out to differentiate highlighting differences
in the samples.

CONCLUSION
The EN24 steel is prone to corrosion like carburization, oxidation, sulfudation based on type of industrial applications
over passage of time. These undesirable effects can be avoided by incorporating protective coatings on the surface of the
steel . Various methods are employed to obtain protective coating on the surface of the metal. The area of interest is
overcome the above problem .To find a solution for the problem exhaustive literature survey has been carried out by

Volume 7, Issue 6, June 2018 Page 82


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org
Volume 7, Issue 6, June 2018 ISSN 2319 - 4847

selecting the best suited technique among the available protective coating techniques. The existing solution to overcome
the above problem is achieved by pack cementation aluminisation process. The experimental setup and procedure for
carrying out the pack cementation aluminisation process is defined. The area of focus is the role of surface finish and
heat treatment conditions on the growth and coating characteristics of the aluminized samples. The varying degree of
surface finish is produced by turning, grinding and abrasive flow finishing process. The samples are subjected to three
different heat treatment cycles to achieve the aluminium coating. The pack cementation mixtures are selected based on
exhaustive literature survey. The Aluminium coating achieved on the surface of the EN24 samples was in the range of
80-100 µm .The aluminized samples after the completion of the heat treatment samples were analysed for the coating
characteristics using optical light microscope, EDX using SEM,XRD and micro hardness. The analysis and comparison
results out of the optical light microscope, EDX using SEM, XRD and micro hardness revealed no significant
differences in the coating characteristics. It was also found that the hardened, non-hardened samples and the surface
roughness's had no effect on the aluminisation process. Further studies and researches on corrosion resistance using salt
spray technique needs to be carried to distinguish the reliability of the samples so as to conclude between the three
different machined samples.

References
[1]Y. Wang et al., "Low-Temperature Pack Aluminizing of X80 Pipeline Steel through Addition of Zinc and Surface
Self-Nano crystallization", Advanced Materials Research, Vols. 233-235, pp. 2516-2521, 2011
[2] Božidar Matijević ISSN 1333-1124 A LOW TEMPERATURE ALUMINIZING TREATMENT OF HOT WORK
TOOL STEEL UDC 621.785: 669.14.018:620.179.11
[3]Abd El Azim, M. E.Vol 12, No 1 (1994)meatallurgical sciencesand technology - ArticlesPack diffusion
aluminizing of Carbon Steel
[4] Cheng Zhong,Wenbin Hu,Yiming Jiang,Bo Deng,Jin Li,Journal of Coatings Technology and Research,January
2011, Volume 8, Issue 1, pp 107–116| C,Lower temperature aluminizing and its effect on improving corrosion
resistance of iron treated by surface mechanical attrition treatment
[5] The aluminizing in powder technology of AISI 304 steelD B Băitanu1, D G Găluşcă1, D C Achiţei1,2, M G
Minciună1,2 and Mohd Mustafa Al Bakri Abdullah2Published under licence by IOP Publishing Ltd
[6] Journal of Materials ScienceOctober 1994, Volume 29, Issue 20, pp 5424–5428| Cite asThe effect of diffusion
barrier formation on the kinetics of aluminizing in inconel-718 diffusion profiles for material like aluminium, iron
and nickel.
[7]Aluminide Coatings on 304 Stainless SteelKL Smith, A Kutyan, SA Abolian, TF Krenek… - CORROSION …,
2013 - onepetro.org, Yuki Matsuoka1, Yasuo Matsunaga1, Kiyokazu Nakagawa1, Yoshihiro Tuda1 and Shigeji
Taniguchi2 ,Growth Behavior of Coatings Formed by Vapor Phase Aluminizing Using Fe-Al Pellets of Varying
Composition 1Research Laboratory, Ishikawajima-Harima Heavy Industries Co., Ltd., Yokohama 235-8501, Japan

Volume 7, Issue 6, June 2018 Page 83

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