CHAPTER 2 LITERATURE REVIEW
4 2.1 Carbon Steel
4 2.2 Heat Treatment
9 2.2.1 Annealing
10 2.2.2 Normalizing
11 2.2.3 Hardening
11 2.2.4 Tempering
12 2.2.5 Case Tempering
12 2.3 Warpage
13 2.4 External Flame Heating Process
15 2.5 Microstructure
16
CHAPTER 3 METHODOLOGY
20
3.1 Methodology Flowchart 20
3.2 Preparation of Specimen 21
3.3 Rockwell Hardness Test 24
3.4 Heat Treatment process 25
3.5 External Flame Heating Process 28
3.6 Tempering Process 30
3.7 Microstructure Analysis 31
3.7.1 Cutting 31
3.7.2 Mounting 32
3.7.3 Grinding and polishing 33
3.7.4 Etching 34
3.7.5 Microstructure 35
CHAPTER 4 RESULT
37
4.1 Rockwell Hardness Test HRD 37
4.2 Microstructure 39
CHAPTER 5 DISCUSSION
41
CHAPTER 6 CONCLUSION AND RECCOMENDATION
46 REFERENCES
48
APPENDIX A
51
APPENDIX B 52
LIST OF TABLES
NO. TITLE
PAGE
1 Types and approximate percentage of identifying
elements in standard carbon steel Source: Practical Heat Treating, 2006
3 2
UNS number and composition of selected nonresulfurized carbon steels 1.0Mn.
Practical Heat Treating 2006 6
3 The recommended temperature for types of carbon steel
Source: Gupta et al 2009 10
4 Description of samples
21 5
Processes involved for each samples 23
6 The purpose of each stage of Rockwell hardness test
25 7
Rockwell hardness test result 36
8 The microstructure image of all samples
38 9
Comparison of Structure for sample 1 and 2 41
10 Comparison for Structure of sample 3 and 4
42
LIST OF FIGURE
NO. TITLE
PAGE
1 Iron – Carbon phase diagram
Source: http:www.substech.com, 2011 7
2 Figure 3: The structure for BCC and FCC
Source: http:www-ee.ccny.cuny.edu, 2011 8
3 Example of ferrite microstructure
Source: Voort. G. F. V
, 2001
16
4 Example of microtructure of austenite
Source: Voort. G. F. V
, 2001
17
5 Example of microtructure of cementite
Source: Voort. G. F. V
, 2001
17
6 Example of microstructure of pearlite
Source: Voort. G. F. V
, 2001
18
7 Example of microstructure of martensite
Source: Voort. G. F. V
, 2001
19
8 Example of microstructure of bainite
Source: http:www.metallographic.com, 2011 19
9 Methodology Flowchart
20
10 Cutting process using band saw
22
11 A sample of material after cutting process
22
12 Figure 12: Rockwell Hardness Tester
24
13 Graph of temperature vs time for heat treatment process
26
14 The carbon steel samples on the furnace before heat treatment
26
15 Sample after soaking process and ready for quenching process
27
16 Quenching process
27
17 A sample of warped carbon steel
28
18 External heating process at the warped section of the samples
29
19 Straightening process using clamp
29
20 Temperature variation during tempering process
30
21 Progress flow for microstructure analysis
31
22 A sample that have been cut from specimen
31
23 A sample after mounting process
32
24 Automatic mounting press machine
32
25 Grinding process
33
26 Polishing process
33
27 Etching process
34
28 Microscopic examination process
34
29 Inverter microscope
35
30 Image of microstructure of heat treated sample
40 100 x magnifications
31 Image of microstructure for sample 5
43
32 Image of microstructure for sample 6
43
LIST OF SYMBOLS
SAE =
Society of Automotive Engineering AISI
= American Iron and Steel Institute
ASTM =
The American Society of Testing and Material UNS
= United Numbering System
C =
Carbon Mn
= Manganese
P =
Phosphorus S
= Sulfur
BCC =
Body- Centered Cubic FCC
= Face-Centered Cubic
Fe =
Iron Cu
= Copper
T =
Thickness L
= Length
W =
Width
LISTS OF APPENDIX
No. TITLE
PAGE A
Gantt Chart PSM I 50
B Gantt Chart PSM II
51
CHAPTER 1
INTRODUCTION
1.1 BACKGROUND
