Effect The Coated Layer of Hard Chromium On Fatigue Behavior For Aisi 1039 Medium Carbon Steel

Journal of Engineering and Sustainable Development Vol. 22, No. 2 (part-3), March 2018 www.jeasd.
org (ISSN 2520-0917)

The Fourth Scientific Engineering and First Sustainable Engineering Conference
2102‫ اّراس‬،)3-‫ (اىجضء‬2‫ اىعذد‬،22 ‫اىَجيذ‬

ISSN 2520-0917
10.31272/jeasd.2018.2.35
EFFECT THE COATED LAYER OF HARD CHROMIUM ON

FATIGUE BEHAVIOR FOR AISI 1039 MEDIUM CARBON STEEL
Dr. Zeyad Dushan Kadhim1, Dr. Mohammed Abdulraoof Abdulrazzaq2, Zahraa Naseef
Jassim3
1) Asst. Prof., Materials Engineering Department, Mustansiriyah University, Baghdad, Iraq.

2) Lecturer, Mechanical Engineering Department, Mustansiriyah University, Baghdad, Iraq.
3) Engineer, Materials Engineering Department, Mustansiriyah University, Baghdad, Iraq.
Abstract: In this paper, study the effect of fatigue behavior on AISI 1039 medium carbon steel
electroplated with hard chromium in which the electro deposition method was carried out within a period
of 10, 15, 20, 25, 30 minutes plating time, As shot peening were used in this work as a type of surface
treatment in which peening was carried out with steel balls for a period of 10 minutes. It was found that
the highest fatigue limit was 300 MPa in case of 10 minutes chromium plated shot peened steel , also it
was observed there is reduction in fatigue limit with increasing in time of electroplating. Coating
thickness increases as coating time increasing and this leading to lower the fatigue limit, where the
highest coating thickness value was 33µm with 30 minutes coating time and fatigue limit is reduced till
250 MPa. Also it was found that the coating thickness causes an increase in surface hardness of the alloy.
While as coating thickness increased the surface roughness decreased.
Keywords: Shot peening, Fatigue, Hard chromium electroplating, Coating medium carbon steel.
‫ متوسط الكاربون‬AISI 1039 ‫تأثير طبقة الطالء بالكروم المصلد على سلوك الكالل لفوالذ‬
ٌ‫ حُث ح‬،‫ اىَطيٍ باىنشوً اىَصيذ‬AISI 1039 ‫ حٌ فٍ هزا اىعَو اىبحثٍ دساست سيىك اىناله ىفىالر ٍخىسط اىناسبىُ ٍِ ّىع‬:‫الخالصة‬
‫ دقُقت مَا حٌ فُها‬30 ، 25 ، 20 ،15 ، 10 ‫اجشاء عَيُاث اىطالء بطشَقت اىخشسُب اىنهشبائٍ و حٌ فُها حغُُش صٍِ اىطالء بفخشاث‬
‫ حٌ اىخىصو اىً اّه اعيً قَُت ىيناله ماّج‬.‫ دقائق‬10 ‫اسخخذاً احذي حقُْاث اىَعاٍالث اىسطحُت واىخٍ هٍ اىقزف باىنشاث اىحذَذَت وبَذة‬
‫ حُث ميَا اصداد‬،‫ عْذ اسخخذاً حقُْت اىقزف واىطالء بعشش دقائق ٍعا حُث حٌ ٍالحظت اّه عَش اىناله َقو عْذ اىطالء‬300 MPa ‫بَقذاس‬
‫صٍِ اىطالء ٍَا َؤدٌ اىً صَادة سَل طبقت اىطالء و اُ صَادة سَل طبقت اىطالء ادي اىً اّخفاض فٍ عَش اىناله حُث ماّج اعيً قَُت‬
‫أظافت اىً رىل اّه بضَادة سَل‬. 250 MPa .‫ دقُقت واُ حذ اىناله قذ اّخفط اىً قَُت‬30 ٍِ‫ ٍاَنشو ٍخش بض‬33 ‫سَل طبقت اىطالء عْذ‬
.‫طبقت اىطالء قذ أدي اىً صَادة اىصالدة اىسطحُت ىيسبُنت‬
1. Introduction
Hard chromium plating is also known as industrial, functional, or engineering
chromium plating. The major uses of hard chromium plating are for improvement of
tool performance and tool life, wear-resistance applications and part salvage, Special
*mohammedraof415@yahoo.com
27
Journal of Engineering and Sustainable Development Vol. 22, No. 2 (part-3), March 2018 www.jeasd.org (ISSN 2520-0917)
surface properties, Protection, Appearance, mechanical and or engineering properties

[1].
Various types of tools are plated with chromium to minimize friction, reduce wear,
and/or prevent or minimize corrosion. Hard chromium plating is used to get back to
original dimensions, the worn surfaces of large crankshafts for diesel and gas engines
and for compressors [2]. Fatigue failures usually occur in three stages. First, a very
small cracks nucleates after applied the load. And the nucleation sites will be located
near the Surface, where the maximum stress well be there.
Besides that the maximum stress is also located at the surface defects or
imperfections like grain boundaries, pits and dislocation. The second stage, Crack
propagates as continuous the loading cycle. The last stage, failure or fracture will be
occurs suddenly due to the materiel cannot with stand the applied load. So the antickel
will be fail by fatigue at stress lower than the yield stress of the material and this is due
to that stress intensity is bigger than the tensile strength [3]. The reduction of the fatigue
strength of mechanical parts due to the density of cracks and high internal stresses, the
fatigue failure occurs on the surface as a result of the initiation and propagation of these
microscopic cracks from electroplating layer over the surface of the metal-coating layer
and its propagation through the original metal.
One of the surface treatments is the shot peening. This process is used to enhance the
fatigue strength of components, because this process created a compressive stresses
inside the surface layer [4, 5]. The compressive residual stresses arise by shot peening
process. These stresses will act as delaying or pinned the cracks nucleation on
propagation [6, 7]. In machining operations, the nature and distributions residual
stresses depends on tool geometry and conditions of lubrication besides, these two
variable, also it depends on other machinery parameters like, cutting speed, depth of cut
and feed rate. Indeed, the nature of residual stresses and its distributions will be effect
on properties of material and its ability to resistance for stress corrosion and fatigue [8,
9].
Voorwald et al. remarked that the fatigue strength of AISI 4340 steel decreased if
this steel electroplated with chromium layer. While this fatigue strength will increased
as the steel coated with nickel as used as an under layer. This under layer will be a
barrier for crack propagation [10]. Nakonieczny investigated the effect of shot peening
on produces some changes in stresses of the surface layer, however these changes will
be responsible for improved the fatigue strength and enhanced the fatigue life of the
treated part by shot peening process.
Also it was found that the shot peening improve the fatigue life by altering the nature
the stresses in the surface of metal [11]. Voorwald et al. it was found that the fatigue
limit for AISA 4340 52HRC steel is little higher when the steel peened with ceramic
shots than the same seal peened with steel shots [12]. Ibrahim et al. investigated the
specimens of AISA 4340 steel coated by using velocity oxygen fuel (HVOF). It was
found that the specimens which coated with this process have higher fatigue lives them
uncoated specimens [13].
27
Mosa A. M. Studied the effect tempering temperature on fatigue life of AISI 4340
steel. Samples were heat treated by oil quenching then a tempering process was done for
all samples with different tempering temperatures. First group were tempered at 200 CO,
second group were tempered at 320 CO and the last group were tempered at 650 CO. It
was remarked that the best fatigue performance was obtained from high tempered
specimens [14]. Khan L.R.A. and Aggarwal M.L. studied the effect of shot peening on
hardness, endurance limit, surface roughness and fatigue strength for nitrogen austenitic
stainless steel. It was found that is an improvement in hardness and endurance limit of
RS 561 steel. Also the surface roughness decreased without a significant change in
residual stress by using a double shot peeing. The fatigue strength improves with
primary and secondary shot peening [15]. Bonoraa et al. studied the high resistance to
wear and corrosion for AISI 4340 steel coated with hard chromium [16]. Ching, an
Huang et al shown that the hardness of a Cr-C deposit became about 1600 HV after
annealing was done at 600 CO for one hour [17]. Aiyoub Parchehbaf Jadid et al.
investigate the optimization and the effect of electroplating variables on coating brass
sheets by chromium [18].
This paper shows a comparative study among bard chromium plating peened, non-
peened steel and uncoated peened, non-peened steel. However fatigue is an important
characteristic for coated and peened component, so fatigue test were done on coated
peened, non-peened steel and un coated peened non-peened steel and S-N curves were
obtained for all samples that submitted to rotating beam fatigue tests.
2. Experimental Works
2.1. Material Selection
Medium carbon-steel (AISI 1039) was used for the present study. The chemical
composition of this alloy can be shown in table (1) below.
Table (1): The chemical composition analysis of steel

Element wt % C% Si % Mn % P% S% Fe %
STANDARD:1039 0.36- 0.44 0.4 0.7-1 ≤ 0.040 ≤ 0.050 98.47-98.94
ASTM value
Measured value 0.390 0.173 0.796 0.009 0.022 Bal.
2.2. Preparation of Fatigue Samples

Samples were prepared by using a conventional lathe (type Harrison 600, M350 and
EWD 700). The dimensions of sample can be shown as figure (1) below. Turning was
done for samples, to standard dimensions of the rotating-bending fatigue machine (High
tec. HSM 19 Rotating Fatigue device).
27
Fig.1. Fatigue sample with dimensions
3. Surface Treatment
Stress relief process was carried out for samples at 19 CO for one hour by using an
eclectic furnace [5].
3.1. Shot Peening Technique

Shot peening was performed with a spherical ball of steel with diameter 1mm. This
process was carried out for six groups of fatigue samples. Hardness of balls was 48-50
HV. While the average blasting pressure was 12 bars and ball speed 40m/s with 100%
coverage. Also the shot peening with 1:100 mm standoff [15].
3.2. Hard chromium Electroplating

3.2.1. Preparation for Electroplating
Adhesion of coating to a base metal or the substrate is an important factor for
equality work. So metal surface must be prepared before plating. Surface preparation
includes some steps as shown in figure (2).
1- Alkaline cleaning: samples must be immersed in hot solution Noah. Samples hold by
using a stainless steel wires.
2- Rinsing by using water.
3- Samples immersed in dilute HCL acid bath. to remove any oxides or rust from the
surfaces.
4- Rinsing by water.
27
Fig.2. Chart of surface preparation steps for samples
3.2.2. Hard Chromium Coating

The accelerated hard chromium had been performed by using acid solution with 200
g/L of Cr03 and 0.3- 2.5 g/L of H2504 at 50 Co- 55Co and 33 current density. The term
accelerated used for characterize the high of efficiency bath with catalyst, based on
sulphate was used. The electro deposition cell can be shown in figure (3).
Anodes made from pure chrome were used, and it dissolved completely while the
efficiency of deposition. Would be 15-35 % hence insoluble lead anodes were used.
Coating or electroplating was done with efferent times. The first group was done at 10
minutes coating time; second group has been done at 15 minutes coating time, third
group made with 20 minutes coating time, fourth group coated at 25 minutes, and the
last group electroplated at 30 minutes.
Fig.3. Electro deposition cell
3.3. Samples Conditions

The tensile test was carried for AISI 1039 medium carbon steel after stress relief
process, for type of alloy and it was obtain that value of yield stress was 510 MPa. So in
fatigue test it can used a stresses less than this value.
27
Table (2) Conditions of samples that presented in work

Group of Samples conditions
A Dry medium carbon steel (as received)

B 10 minutes shot peening medium carbon steel
C 10 Min. coating on shot peened Steel
D 15 Min. coating on shot peened Steel
E 20 Min. coating on shot peened Steel
F 25 Min. coating on shot peened Steel
G 30 Min. coating on shot peened Steel
H 30 Min. coating on dry steel
3.4. Fatigue Test

A rotating bending fatigue device which used for all samples fatigue test with
constant and variable amplitude illustrated in figure (4). The applied load was subjected
on sample from the right side and perpendicular to the axis of sample developing a
bending moment. Thus, the sample surface is under tension and compression stress as it
rotates. It can be determine the value of stress, measured by (MPa) form the relation
below:
σ (MPa) = 32 × 125 P(N))/(π × d³) (1)
Where:
P = is the applied load in newton
Arm of force = 125mm
d (mm) at minimum diameter of the specimen
Fig.4. Rotating-bending fatigue machine
22
4. Results and Discussion

4.1. Coating Thickness
Medium carbon steel (AISI 1039) was coated by electro deposition technique.
Electroplating was done with a hard chromium coating. This coating method was done
by using chromic acid and sulfuric acid with ratio of 100:1, the current density on 30
Amp/dm2 at the solution temperature between (50-55 oC). The coating thickness depend
on several variables like (plating time, current density and temperate). Table (3) shows
plating thickness and time values which obtained from this process.
Table (3): Plating thickness and time of coating for Groups of samples
Groups Plating thickness (μm) Time (min)
C 13 10
D 19 15
E 25 20
F 28 25
G 33 30
H 32 30
Figure (5) shows the effect of plating time on thickness of coating, it can be seen that
thickness of coating layer increased with increasing plating time and this is due to the
current density that effect on the rate of deposition. So the rate of deposition was high
due to use high current density. Also, the current density would be effects on plating
properties (like hardness, surface roughness of coating the specimen). However if high
current density used then a burning and rough deposit obtained while the low current
density make an uneven coating. To obtain the required hardness there must be
coordination between the temperature and the current density.
Fig. 5. Plating thickness –time curve
27
4.2. Micro Hardness of Samples

The values of samples micro hardness are shown in table (4). The relationship
between value of micro hardness and conditions for each sample can be shown in the
figure (6).
Table (4): Value of micro hardness of samples

Group Specimens Hardness value (HV)
A AISI 1039 Steel 346
B AISI 1039 steel with 10 minutes shot peened 410
C Shot peening steel coated for 10 min. 463
D Shot peening Steel coated for 15 min. 512
E Shot peening Steel coated for 20 min. 639
F Shot peening Steel coated for 25 min. 863
G Shot peening Steel coated for 30 min. 1076
H Dry steel coated for 30 min. 446
Fig. 6. Relationship between value of micro hardness and conditions for each sample
4.3. Surface Roughness of Samples

One of the coating properties is the surface roughness. It is an important property
which is effects by the current density and the temperature that is used in electroplating
process. The values of surface Roughness for tested samples is shown in table (5). The
relationship between values of surface Roughness and conditions for each sample can
be shown in the figure (7).
Table (5): Values of surface Roughness for tested samples

Group Specimens Ra (μm)
A AISI 1039 Steel 1.91
B AISI 1039 steel with 10 minutes shot peened 1.72
C Shot peening steel coated for 10 min. 1.52
D Shot peening Steel coated for 15 min. 1.44
E Shot peening Steel coated for 20 min. 1.35
F Shot peening Steel coated for 25 min. 1.29
G Shot peening Steel coated for 30 min. 1.18
H Dry steel coated for 30 min. 1.82
27
Fig. 7. Relationship between values of surface Roughness and conditions for

each sample
4.4. Rotating Bending Fatigue Tests

S-N curves for all cases carried out in this study are shown all in figure (8). From this
figure it's possible to notice that hard chromium coating is affected on reducing the
fatigue strength of 1039 medium carbon steel. However this is due to increase the
tensile residual stresses induced materials during plating.
S-N Curves
Stress(MPa)
No. of Cycles(RPM)
Fig.8. S-N curves for all groups
4.5. Effect of Technique

In shot peening process compressive residual stresses could be produced in surface
of material, some parameters that are controlled of the depth of these stresses. These
parameters are size, hardness of shot, percentage of recovering and type of materials
that are peened. These residual tensile stresses in hard chrome plating would induce a
compressive residual stresses in the material. As referenced by Horsewell who
explained that the contraction of chrome layer during the electroplating process will
78
make a high tensile stresses in the coating or plating and compression stresses in the
material.
So, micro cracks that presented in the material that coated with hard chrome, which
when submitted to external loads and tensile residual stresses, then the micro cracks will
propagates and decreased the fatigue life of material. Hardness of medium carbon steel
will be increased with hard chrome electroplating. It will be reach to a high value over
1000 HV. As plating time increased, thickness of hard chrome layer increased and it
will be 33µm within 30 minutes time of plating which leads to surface finer roughness
as shown in figure (9).
Fig. 9. SEM micrographs shows the macrostructure for medium carbon steel AISI 1039 with coating
surface for 10, 20, and 30 minutes of plating
4.6. Fatigue Fracture Surfaces

As the axial load is cycled between zero and this two- thirds value, fracture will
occur after a sufficient cycle, this is called fatigue fracture, and this is could be
recognized from the fracture surface topography. Figure (10) shows surface fracture.
78
Fig 10. Fatigue fracture surfaces for AISI 1039 steel, A: 10 min. coated SP steel, B: 15 min. coated SP steel,
C: 20 min. coated SP steel D: 25 min. coated SP steel, E: 30 min. coated SP steel, F: coated steel only
77
4.7. X-Ray Diffraction Analysis

X-ray diffraction analysis was done carried out on the tested samples which plated
with hard chromium within 30 minutes to detect chromium and chromium oxide phases
were created during the plating process as shown in figure (11).
Fig.11. :X-Ray diffraction analysis to the Cr layer on the steel substrate
5. Conclusions
1. The electroplating of steel by a hard-chromium produces an internal residual
stresses (tensile stresses).
2. Fatigue limit decreases due to promote the crack initiations. That happened because
the internal tensile residual stresses.
3. Shot peening promote the compressive residual stresses, so the maximum value of
fatigue strength was 300 MPa.
4. AISI 1039 steed electroplating by hard chromium had lower fatigue strength due
internal tensile residual stress.
5. Steed treated with shot peening and coated with hard chromium had high hardness
value over them 1000 VH.
6. As plating time increased, thickness of coating increased. The maximum thickness
of coating was 33 µm at planting time of 30 min. which gives a good surface finish
or finer surface roughness.
6. References
1. Surasit Tanthadiloke et al, (2014)" Modelling and Design a Controller for Improving
the Plating Performance of a Hard Chromium Electroplating Process " science
direct journal Volume 33.
2. Kirk-Othmer (2004)"Encyclopedia of Chemical Technology", Volume 10.
77
3. Fine Morris E. and Chung Yip-Wah (1997)"Fatigue Failure in Metals" ASM Vol.
19.
4. Alalkawi H.J., Abdul Hassan M. R., Abdu Allah F. N. (2010)"Shot peening
Treatment as a barrier to Fatigue Crack Propagation in Pure Shear for Medium
Carbon Steel " Engineering and technology Journal.
5. Higgins, Raymond A. "Engineering Metallurgy: Applied Physical Metallurgy",
volume 1, 6 Rev. edition, pp.463-297.
6. Yoshiaki A., Hidehiko K. and Sasaki T. (2009)"Effect of Residual Stresses on
Fatigue Strength of Severely Surface Deformed Steels by Shot peening" JCPDS-
International Center for Diffraction Data.
7. Blackadder Warren (2013)"Select common engineering materials" 1st edition, pp.
150,.
8. M'Saoubia R., Outeirob J.C. , Changeuxa B. , Lebruna J.L., Morao Diasb A., (1999)"
Residual stress analysis in orthogonal machining of standard and resulfurized AISI
316L steels" Journal of Materials Processing Technology 96.
9. Nascimento M. P., Torres M.A.S., Souza R.C., Voorwald H.J.C. (2002) "Effect of a
Shot Peening Pre Treatment on the Fatigue Behavior of Hard Chromium on
Electroless Nickel Interlayer Coated AISI 4340 Aeronautical Steel" Mat. Res. vol.5
no.2 São Carlos June.
10. Voorwald, H. J. C., Padilha, R. Q., Pigatin, L. W., Cioffi, M. O. H., Silva, M. P. "
Influence of Electroless Nickel Interlayer Thickness on Fatigue Strength of
Chromium Plater AISI 4340 Steel" São José dos Campos / SP / BR-CEP:1288-904,
Brazil.
11. Nakonieczny A. "Effect of Shot peening on Fatigue life of machine elements" Shot
peener library, Marsaw, Poland.
12. Voorwald, H. J. C., Silva, M. P., Costa, M. Y. P., Pigatin, L. W., Marques, B. M. F
"Influence of Shot peening on Chromium Electroplated AISI 4340 Steel Fatigue
strength " a São José dos Campos / SP / BR-CEP:1288-904, Brazil.
13. Ibrahim A., C.C. Berndt (2007)" Fatigue and deformation of HVOF sprayed WC–Co
coatings and hard chrome plating" Materials Science and Engineering a 456, 114-
119.
14. Mosa A. M. (2006) "Effect of Surface Treatment on the Fatigue Performance of AISI
Steel " AL- Taqani, Vol. 19, No .2.
15. Khan L.R.A. and Aggarwal M.L. (2010)" Effect of shot peening on hardening and
surface roughness of nitrogen austenitic stainless steel" International Journal of
Engineering Science and Technology Vol. 2(5), Pages 818-826.
16. Bonoraa R.G., Voorwalda H.J.C. , Cioffia M.O.H. , Juniora G.S. , Santosa L.F.V.
(2010) " Fatigue in AISI 4340 steel thermal spray coating by HVOF for aeronautic
application" Procedia Engineering 2, 1617–1623.
17. Huang Ch. A. , Liu Y.W., Yu Ch., Chun-Chen Y. (2011)" Role of carbon in the
chromium deposit electroplated from a trivalent chromium-based bath" Surface &
Coatings Technology 205, 3461-3466.
77
18. Jadid A. P., Pourjafar M. , Banaei A. (2014)" Optimization of Electroplating

Conditions of Chromium(VI) Using Taguchi Experimental Design Method" Anal.
Bioanal. Electrochem, Vol. 6, No. 1, 16-27.
77

Effect The Coated Layer of Hard Chromium On Fatigue Behavior For Aisi 1039 Medium Carbon Steel

Uploaded by

Copyright:

Available Formats

Effect The Coated Layer of Hard Chromium On Fatigue Behavior For Aisi 1039 Medium Carbon Steel

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Effect The Coated Layer of Hard Chromium On Fatigue Behavior For Aisi 1039 Medium Carbon Steel

Uploaded by

Copyright:

Available Formats

Journal of Engineering and Sustainable Development Vol. 22, No. 2 (part-3), March 2018 www.jeasd.

org (ISSN 2520-0917)

2102‫ اّراس‬،)3-‫ (اىجضء‬2‫ اىعذد‬،22 ‫اىَجيذ‬

EFFECT THE COATED LAYER OF HARD CHROMIUM ON

1) Asst. Prof., Materials Engineering Department, Mustansiriyah University, Baghdad, Iraq.

surface properties, Protection, Appearance, mechanical and or engineering properties

Table (1): The chemical composition analysis of steel

Measured value 0.390 0.173 0.796 0.009 0.022 Bal.

2.2. Preparation of Fatigue Samples

Fig.1. Fatigue sample with dimensions

3.1. Shot Peening Technique

3.2. Hard chromium Electroplating

Fig.2. Chart of surface preparation steps for samples

3.2.2. Hard Chromium Coating

Fig.3. Electro deposition cell

3.3. Samples Conditions

Table (2) Conditions of samples that presented in work

A Dry medium carbon steel (as received)

3.4. Fatigue Test

σ (MPa) = 32 × 125 P(N))/(π × d³) (1)

Fig.4. Rotating-bending fatigue machine

4. Results and Discussion

Fig. 5. Plating thickness –time curve

4.2. Micro Hardness of Samples

Table (4): Value of micro hardness of samples

4.3. Surface Roughness of Samples

Table (5): Values of surface Roughness for tested samples

Fig. 7. Relationship between values of surface Roughness and conditions for

4.4. Rotating Bending Fatigue Tests

Fig.8. S-N curves for all groups

4.5. Effect of Technique

4.6. Fatigue Fracture Surfaces

4.7. X-Ray Diffraction Analysis

Fig.11. :X-Ray diffraction analysis to the Cr layer on the steel substrate

18. Jadid A. P., Pourjafar M. , Banaei A. (2014)" Optimization of Electroplating

You might also like