Wear Behavior of Austempered and Quenched and Temp
Wear Behavior of Austempered and Quenched and Temp
Wear Behavior of Austempered and Quenched and Temp
Article
Abstract: In this research, an austempering heat treatment was applied on gray cast iron using various
austempering temperatures ranging from 232 ◦C to 371 ◦C and holding times ranging from 1 min
to 120 min. The microstructure and hardness were examined using optical microscopy and a
Rockwell hardness tester. Rotational ball-on-disk sliding wear tests were carried out to investigate
the wear behavior of austempered gray cast iron samples and to compare with conventional
quenched and tempered gray cast iron samples under equivalent hardness. For the austempered
samples, it was found that acicular ferrite and carbon saturated austenite were formed in the
matrix. The ferritic platelets became coarse when increasing the austempering temperature or
extending the holding time. Hardness decreased due to a decreasing amount of martensite in the
matrix. In wear tests, austempered gray cast iron samples showed slightly higher wear resistance
than quenched and tempered samples under similar hardness while using the austempering
◦ ◦ ◦ ◦
temperatures of 232 C, 260 C, 288 C, and 316 C and distinctly better wear resistance while
using the austempering temperatures of 343 C and 371 ◦C. After analyzing the worn surface,
◦
abrasive wear and fatigue wear with the presence of pits, spalls, voids, long cracks, and wear debris
were the main mechanisms for austempered gray cast iron with a low austempering temperature.
However, only small pits and short cracks were observed on the wear track of austempered gray
cast iron with high austempering temperature. Furthermore, the graphite flakes were exposed and
ground by the counterpart surface during wear tests. Then, the graphite particles would form a
tribo-layer to protect the contact surface.
1. Introduction
Gray cast iron (GI) is one of the conventional iron-carbon alloys with a carbon content of 2.5–
4% and a silicon content of 1–3%. Its typical microstructure contains graphite flakes surrounded by
pearlite or ferrite. In terms of morphology, size, and distribution, graphite flakes are divided into
five patterns from A to E in the ASTM Standard A247 [1]. Due to its excellent machinability and
damping capacity with low production cost, GI has been broadly used in the manufacturing of
brake rotors, clutch discs, cylinder liners, and tool mounts. Most of the GI applications require superior
resistance to retard wear loss on contact surfaces. Therefore, heat treatment processes such as
austempering treatment and quenching and tempering treatment are expected to provide benefits
for the tribological properties of GI.
The austempering heat treatment was first proposed by Edgar C. Bain in the 1930s [2]. In this
process, GI is austenitized above the Acm critical temperature to convert the ferrite or pearlite into
Metals 2019, 9, 1329; doi:10.3390/met9121329 www.mdpi.com/journal/metals
Metals 2019, 9, 1329 2 of 13
unstable austenite. Then, the full austenitized GI is transferred and soaked in a salt bath furnace at
a constant temperature for a specific period. The isothermal temperatures should be between the
pearlite formation temperature and martensite formation temperature, which are similar to the bainite
formation temperatures of steel. The final microstructure of austempered gray cast iron (AGI)
consists of acicular ferrite and carbon saturated austenite. In the austempering process, a salt bath
furnace is typically used in order to eliminate or minimize surface oxidation and carburization.
A quenching and tempering treatment is one common heat treatment process applied on cast irons
and steels. Additional tempering is introduced on as-quenched materials to improve the ductility
and relieve some internal stress. The tempering temperature should be set below the eutectoid
temperature. Precise control of tempering temperature and holding duration is vital for the desired
mechanical properties. In the tempering process, the martensite formed during the quenching step
is transformed into tempered martensite by carbon precipitation and diffusion.
The tribological performance of GI has been studied by several researchers using different alloy
elements and heat treatment processes through various test configurations. Hassani et al. [3] studied
the influence of hard carbide forming elements such as vanadium and chromium on the wear properties
of GI by using a pin-on-disk rotational fixture. The presence of vanadium and chromium induced
the formation of oxidative layers to reduce the wear loss. Sarkar et al. [4] investigated the wear
behavior of copper alloyed AGI using six austempering temperatures by a block-on-roller
tribometer. Low wear resistance was obtained for high austempering temperature due to the
significant drop in hardness and tensile strength. Vadiraj [5] studied the wear resistance of
quenched and tempered gray cast iron (QTGI) on a pin-on-disk test rig. It was found that the wear
rate increased when increasing the tempering temperature. This was attributed to the softening of the
martensitic matrix with the tempering reaction. Vadiraj et al. [6] also evaluated the wear performance
of a series of alloyed AGIs using a pin-on-disk tribometer. The specific wear rate had a decreasing
trend when increasing the graphite content since more graphite could be engaged into the contact
interface as solid lubricant. Furthermore, the wear rate would increase when the ferritic laths became
thick due to the low wear resistance of the soft ferrite phase. Balachandran et al. [7] found that the
wear resistance of AGI was degraded after adding nickel alloy since the presence of nickel would
stabilize the austenite and inhibit the stress induced transformation.
Some recent studies have reported better wear resistance of AGI compared with as-cast GI [8–
10]. However, few research studies have paid attention to the comparison of the tribological
characteristics between AGI and conventional QTGI. Since it has been well known that the wear
resistance of cast irons and steels is often correlated with surface hardness, the comparison in wear
resistance is reasonable under equivalent hardness [11–14]. In the current research, AGI samples
were prepared by a wide range of austempering temperatures and holding times. Various
tempering temperatures were applied on quenched GI to match the hardness of AGI samples for the
comparison in wear performance. Wear resistance of AGI and QTGI samples was tested using a
rotational ball-on-disk sliding rig. In addition, the microstructure of AGI and QTGI produced by the
different heat treatment parameters was evaluated by optical microscopy, and the worn surface was
examined through scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy
(EDS) to analyze the potential mechanisms. The results will be helpful for the possible substitution
of traditional QTGI by AGI in existing and future applications.
Elements Percentage
Carbon, C 3.53%
Silicon, Si 2.71%
Manganese, Mn 0.74%
Chromium, Cr 0.12%
Copper, Cu 0.94%
Sulfur, S 0.03%
Phosphorous, P 0.08%
Iron, Fe Remainder
The as-cast GI samples were austenitized at a temperature of 832 ◦C for 20 min in a medium
temperature salt bath furnace (50% KCl + 20% NaCl + 30% CaCl2). The pearlite was transformed
into unstable austenite, and the alloy elements were distributed uniformly. Then, the fully
austenitized GI samples were quickly transferred to another pre-heated low temperature salt bath
furnace (50% KNO3 + 50% NaNO3) for the austempering process at various austempering
temperatures (232 ◦C, 260 ◦C, 288 ◦C, 316 ◦C, 343 ◦C, and 371 ◦C) and holding times (1 min, 2
min, 3 min, 6 min, 10 min, 20 min, 30 min, 60 min, 90 min, and 120 min). The above parameters were
selected in terms of the previous related research [6,10,15–19]. Then, the AGI samples were cooled to
room temperature by water. The austempering process diagram is displayed in Figure 2a and Table
2.
Figure 2. Heat treatment processes: (a) austempering heat treatment; (b) quenching and tempering
heat treatment.
Metals 2019, 9, 1329 4 of 13
The as-cast GI samples were first austenitized at a temperature of 832 ◦C for 20 min in a
medium temperature salt bath furnace (50% KCl + 20% NaCl + 30% CaCl2) to obtain unstable
austenite. After that, the fully austenitized GI samples were quenched by oil. Then, different
tempering temperatures (316 ◦C, 371 ◦C, 399 ◦C, 454 ◦C, 482 ◦C, 510 ◦C) with a constant holding
time of 60 min were applied on quenched GI samples to match the hardness of the AGI samples,
respectively. The tempering process was conducted using an electrical heating furnace under air
atmosphere (Lindberg-M, Thermo Scientific, Waltham, MA, USA). Finally, the tempered samples were
cooled to room temperature in oil. The quenching and tempering process diagram is displayed in
Figure 2b, and Table 2 gives the details.
surface using Si-carbide sandpaper from 240 grit to 1200 grit and polishing cloths with 0.3 µm alumina
oxide suspension. Then, coupons were thoroughly rinsed by water and etched by 3% nital solutions
for 2 s to 3 s. Metallurgical evaluation was carried out using optical microscopy (PME-3, Olympus,
Tokyo, Japan).
Figure 3. Sectional view of the rotational ball-on-disk sliding wear test fixture.
3. Results
was formed in the matrix at the austempering temperature of 371 ◦C with the holding time of 120
min. In Figure 4b,d,f,h,j, the light areas are carbon saturated austenite, which were stable at room
temperature. In addition, some researchers reported that the carbon saturated austenite would be
decomposed into the equivalent ferrite and carbide once the holding time was too long. The
formation of ferrite and carbide would degrade the mechanical properties of austempered cast irons
[21–24]. In the present research, no carbidic particles and islands could be found among the ferritic
plates when the highest austempering temperature and longest holding duration were applied, which
suggested that the carbon saturated austenite had not been decomposed into equilibrium phases.
In the microstructure analysis of QTGI samples, graphite flakes were retained, and as-
quenched martensite and retained austenite were transformed into tempered martensite containing the
cementitic and ferritic phases, as shown in Figure 5. When increasing the tempering temperatures
with the same holding time, the cementite particles continuously developed. Finally, coarse cementite
particles could be found within the ferritic matrix.
Figure 5. Metallurgical evaluation of QTGI samples produced by different tempering temperatures: (a)
◦ ◦ ◦ ◦ ◦ ◦
316 C; (b) 371 C; (c) 399 C; (d) 454 C; (e) 482 C; (f) 510 C.
Figure 6. Rockwell C hardness of AGI under various austempering temperatures and holding times.
austempering temperatures of 232 ◦C, 260 ◦C, 288 ◦C, and 316 ◦C and distinctly better wear resistance
while using the austempering temperatures of 343 ◦C and 371 ◦C. The best result with a wear loss
of around 0.44 mm3 was obtained using AGI samples with the austempering temperature of 343 ◦C,
which was 21.7% lower than that of QTGI samples. In all wear tests, the upper ceramic balls were
much harder than GI disks and had no detectable wear scars.
Table 3. Average hardness of AGI and QTGI sample groups in rotational ball-on-disk sliding wear tests.
Group Number 1 2 3 4 5 6
◦
Austempering Temperature ( C) 232 260 288 316 343 371
Hardness (HRC) 42.3 42 37.4 28.9 28.1 26.8
◦
Tempering Temperature ( C) 316 371 399 454 482 510
Hardness (HRC) 41.1 41.8 38 29.5 28.7 27.2
Figure 8. Wear volume loss of AGI and QTGI samples under equivalent hardness.
surface and sub-surface would be deformed with the substrate along the sliding direction. Graphite
flakes were then exposed and ground by the ceramic ball to produce graphite powder. The graphite
powder resulted in a tribo-layer which lowered the wear, as shown in Figure 10b.
Figure 9. Surface evaluation on wear track: (a) AGI sample in Group 1; (b) AGI sample in Group 5; (c)
elemental examination of dark spot by EDS.
Figure 10. Potential failure mechanisms on AGI Samples in sliding wear tests: (a) production of wear
debris; (b) formation of graphite tribo-layer.
4. Conclusions
In this research, AGI samples were prepared using different austempering temperatures and
holding durations. Rotational ball-on-disk sliding wear tests were carried out on AGI samples and
compared with conventional QTGI samples under similar hardness. In addition, microstructure and
hardness were evaluated using optical microscopy and a Rockwell hardness tester. Several conclusions
can be drawn: The original pearlite was transformed into acicular ferrite and carbon saturated austenite
in the austempering heat treatment. Most of the ferritic platelets nucleated around graphite flakes
due to the high potential energy. Thin needle-like ferrite became coarse after increasing the
austempering temperature or extending the holding time. The hardness of AGI samples decreased
when either increasing the austempering temperature or extending the holding time and became
nearly constant beyond a critical time (mostly between 20 min to 30 min). This critical time occurred
when the phase transformation had been fully completed in the matrix. The hardness drop was caused
by the formation of soft acicular ferrite and stable austenite rather than hard martensite. The slight
increase in hardness of QTGI samples while using the tempering temperature of 371 ◦C was
associated with the effects of tempered brittleness. In rotational ball-on-disk sliding wear tests, the
average wear volume loss of AGI samples was slightly lower than that of QTGI samples under
equivalent hardness, approximately 6%, 6.2%, 8.4%, and 6.5% while using the austempering
◦ ◦ ◦ ◦
temperatures of 232 C, 260 C, 288 C, and 316 C, respectively. In addition, excellent wear
resistance of AGI samples was found while using the austempering temperatures of 343 ◦C and 371
◦
C. The best result having a wear loss around 0.44 mm 3 was obtained using AGI samples with the
austempering temperature of 343 ◦C, which was 21.7% lower than that of QTGI samples. In the analysis
of worn tracks, AGI samples produced by low austempering temperature showed abrasive wear and
fatigue wear mechanisms with the presence of pits, spalls, voids, and long cracks on the wear track.
However, only small pits and short cracks could be detected on the wear track of AGI samples with
a high austempering temperature. It was believed the graphite flakes were ground during the wear
tests. Then, the graphite particles would form a tribo-layer to protect the contact surface.
Author Contributions: Conceptualization, B.W. and G.C.B.; methodology, B.W. and Y.P.; data curation, B.W.;
formal analysis, B.W., X.H. and Y.P.; investigation, B.W., X.H. and Y.P.; resources, G.C.B.; writing, original
draft preparation, B.W. and Y.P.; writing, review and editing, B.W. and G.C.B.; project administration, G.C.B.
Metals 2019, 9, 1329 12 of 13
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