Evaluation of boron mobility on the phases FeB, Fe2B and diffusion zone in AISI 1045 and M2 steels

The present study evaluates the growth kinetics of boride layers at the material surface on AISI 1045 and M2 steels during the paste boriding process. This surface hardening technique produces on the material two characteristic phases FeB, Fe₂B and a transition zone, denominated diffusion zone, in the layer/substrate interface. The thermochemical treatment was done at three different temperatures: 1193, 1223 and 1273 K with two treatment times: 2 and 6 h for the 1045 steel, and 1223, 1253 and 1273 K with the same treatment times for M2 steel, modifying the boron potentials in equilibrium at the substrates surfaces. Using the mass balance equation, and assuming a linear concentration profile at the interfaces, the mobility of boron was determined on both types of steels. The influence of boron potential, treatment time and temperatures is clearly observed on the growth kinetics of boride layers.     

Growth kinetics of borided layers: Artificial neural network and least square approaches

The present study evaluates the growth kinetics of the boride layer Fe₂B in AISI 1045 steel, by means of neural networks and the least square techniques. The Fe₂B phase was formed at the material surface using the paste boriding process. The surface boron potential was modified considering different boron paste thicknesses, with exposure times of 2, 4 and 6 h, and treatment temperatures of 1193, 1223 and 1273 K. The neural network and the least square models were set by the layer thickness of Fe₂B phase, and assuming that the growth of the boride layer follows a parabolic law. The reliability of the techniques used is compared with a set of experiments at a temperature of 1223 K with 5 h of treatment time and boron potentials of 2, 3, 4 and 5 mm. The results of the Fe₂B layer thicknesses show a mean error of 5.31% for the neural network and 3.42% for the least square method.     

Simulation of the growth kinetics of the (FeB/Fe2B) bilayer obtained on a borided stainless steel

The present work is an attempt to simulate the growth kinetics of the (FeB/Fe₂B) bilayer grown on a substrate made of AISI 316 stainless steel by the application of the powder-pack boriding process, and using four different temperatures (1123, 1173, 1223 and 1273 K) and five exposure times (2, 4, 6, 8 and 10 h). The adopted diffusion model solves the mass balance equation at each growth front: (FeB/Fe₂B or FeB/substrate) under certain assumptions and without considering the diffusion zone. To consider the effect of the incubation times for the borides formation, the temperature-dependent function ?(T) was incorporated in the model. To validate this model, a computer code written in Matlab (version 6.5), was developed with the purpose of simulating the kinetics of the boride layers. This computer code uses the following parameters as input data: (the boriding temperature, the treatment time, the upper and lower limits of boron concentration in each iron boride, the diffusion coefficients of boron in the FeB and Fe₂B phases as well as the ?(T) parameter). The outputs of the computer code are the parabolic growth constant at each growth front and the thicknesses of the FeB and Fe₂B layers. A good agreement was obtained between the experimental parabolic growth constants taken from a reference work [I. Campos-Silva et al., Formation and kinetics of FeB/Fe₂B layers and diffusion zone at the surface of AISI 316 borided steels, Surf. Coat Technol., 205 (2010) 403-412] and the simulated values of the parabolic growth constants (k_FeB and k₁). The present model was also able to predict the thicknesses of the FeB and Fe₂B layers at a temperature of 1243 K during 3 and 5 h.In addition, the mass gain at the material surface was also estimated as a function of the time and the upper boron content in each iron boride phase. It was shown that the simulated values of the generated mass gain are very sensitive to the increase of both temperature and the upper boron contents in the FeB and Fe₂B phases.     

Effect of boron paste thickness on the growth kinetics of polyphase boride coatings during the boriding process

The growth kinetics of FeB and Fe₂B phases forming on AISI M2 steel by paste boriding was studied using different values of paste thickness, treating temperature and exposure time. The growth of iron boride layers is described by the mass balance equation between phases in thermodynamic equilibrium, assuming that the boron concentration at the interfaces remain constant during the treatment. The experimental results show that boron mobility and growth kinetics of iron borides are considerably increased when the paste thickness is increased at constant values of temperature and exposure time.     

Characterization of AISI 4140 borided steels

The present study characterizes the surface of AISI 4140 steels exposed to the paste-boriding process. The formation of Fe₂B hard coatings was obtained in the temperature range 1123-1273 K with different exposure times, using a 4 mm thick layer of boron carbide paste over the material surface. First, the growth kinetics of boride layers at the surface of AISI 4140 steels was evaluated. Second, the presence and distribution of alloying elements on the Fe₂B phase was measured using the Glow Discharge Optical Emission Spectrometry (GDOES) technique. Further, thermal residual stresses produced on the borided phase were evaluated by X-ray diffraction (XRD) analysis. The fracture toughness of the iron boride layer of the AISI 4140 borided steels was estimated using a Vickers microindentation induced-fracture testing at a constant distance of 25 μm from the surface. The force criterion of fracture toughness was determined from the extent of brittle cracks, both parallel and perpendicular to the surface, originating at the tips of an indenter impression. The fracture toughness values obtained by the Palmqvist crack model are expressed in the form K_C(π/2) > K_C > K_C(0) for the different applied loads and experimental parameters of the boriding process.     

Computer simulation of monolayer growth kinetics of Fe2B phase during the paste-boriding process: Influence of the paste thickness

This paper deals with the effect of boron paste thickness on the study of the monolayer growth kinetics of Fe₂B phase forming on AISI 1045 steel by the paste-boriding process. A mathematical diffusion model based on the Fick's phenomenological equations was applied in order to estimate the growth rate constant at (Fe₂B/γ-Fe) interface, the layer thickness of iron boride as well as the associated mass gain depending on the boriding parameters such as time, temperature and surface boron concentration related to the boron paste thickness. The simulation results are found to be in a fairly good agreement with the experimental data derived from the literature.     

Corrosion behavior of boride layers evaluated by the EIS technique

The corrosion behavior of boride layers at the AISI 304 steel surface is evaluated in the present study. Electrochemical impedance spectroscopy (EIS) technique was used for the evaluation of the polarization resistance at the steel surface, with the aid of AUTOLAB potentiostat. Samples were treated with boron paste thickness of 4 and 5 mm, in the range of temperatures 1123 ≤ T ≤ 1273 K and exposed time of 4 and 6 h. The electrochemical technique employed 10 mV AC with a frequency scan range from 8 kHz to 3 mHz in deaerated 0.1 M NaCl solution. Nyquist diagrams show that the highest values of corrosion resistance are present in the samples borided at the temperature of 1273 K, with treatment time of 4 h and 4 mm of boron paste thickness. The values of corrosion resistance on borided steels are compared with the porosity exhibited in the layers.     

Evaluation of the tool life and fracture toughness of cutting tools boronized by the paste boriding process

The present study evaluates the tool life and the fracture toughness of AISI M2 steel cutting tools boronized by the paste boriding process. The treatment was done in selective form on the tool tips of the steels. The temperatures were set at 1173 and 1273 K with 4 h of exposure time and modifying the boron carbide paste thicknesses in 3 and 4 mm. Microindentation fracture toughness method was used on the borided tool at the temperature of 1273 K and a 4 mm paste thickness, with a 100 g load at different distances from the surface. Also, the borided cutting tools were worn by the turning process that implied the machining of AISI 1018 steel increasing the nominal cutting speed, of 55 m/min, in 10 and 25% and maintaining the feed and the depth cut constants. The tool life was evaluated by the Taylor's equation that shows the dependence of the experimental parameters of the boriding process.     

A diffusion model for describing the bilayer growth (FeB/Fe2B) during the iron powder-pack boriding

In this paper, a diffusion model is proposed for studying the bilayer growth kinetics (FeB/Fe₂B) on pure iron substrate during the powder-pack boriding in the temperature range of 1023-1273 K.This model based on Fick's laws was solved, under certain assumptions, considering a parabolic growth of iron borides.For this purpose, a computer simulation program was created for predicting the boride layer thickness as a function of process parameters (temperature, time and surface boron content). A fairly good agreement was observed between the simulation calculations and experimental data derived from the literature.     

A model for studying the kinetics of the formation of Fe2B boride layers at the surface of a gray cast iron

The present work estimates, using a kinetic model, the growth kinetics of Fe₂B boride layers generated at the surface of a gray cast iron via the powder-pack boriding considering three different temperatures (1173, 1223 and 1273 K) and four treatment times (2, 4, 6 and 8 h). By the use of the mass balance equation at the (Fe₂B/substrate) interface under certain assumptions and considering the effect of the boride incubation time, it was possible to estimate the corresponding parabolic growth constant in terms of two parameters and β(T) depending on the boron content in the Fe₂B phase and on the process temperature, respectively. The mass gain at the material surface and the instantaneous velocity of the (Fe₂B/substrate) interface were also estimated. A fairly good agreement was observed between the experimental parabolic growth constants taken from a reference work (Campos-Silva et al., Characterization of boride layers formed at the surface of gray cast irons, Kovove Mater. 47 (2009) 1-7.) and the simulated values of the parabolic growth constants. Furthermore, the boride layer thicknesses were predicted and experimentally verified for three process temperatures and four treatment times.     

Bilayer period effect on corrosion-erosion resistance for [TiN/AlTiN]n multilayered growth on AISI 1045 steel

The aim of this work is to study the electrochemical behavior, under a corrosion-erosion condition, of [TiN/AlTiN]_n multilayer coatings with bilayers periods of 1, 6, 12 and 24, deposited by a magnetron sputtering technique on Si (1 0 0) and AISI 1045 steel substrates.The TiN and AlTiN structure for multilayer coatings were evaluated via X-ray diffraction (XRD) analysis. Silica particles were used as an abrasive in the corrosion-erosion test within a 0.5 M H₂SO₄ solution at an impact angle of 30° over the surface. The electrochemical characterization was carried out using a polarization resistance technique (Tafel), in order to observe changes in the corrosion rate as a function of the bilayers number (n) or bilayer period (Λ). Corrosion rate values of 359 mpy in uncoated steel substrate and 1.016×10⁻⁶ mpy for substrate coated with [TiN/AlTiN]₂₄ under impact angle of 30° were found. This behavior was related with the mass loss curve for all coatings and the surface damage was analyzed using SEM images. These results indicate that TiN/AlTiN multilayer coatings deposited on AISI 1045 steel provide a practical solution for applications in erosive-corrosive environments.     

Kinetics of the formation of Fe2B layers in gray cast iron: Effects of boron concentration and boride incubation time

The growth kinetics of Fe₂B layers formed at the surface of gray cast iron were evaluated in this study. The pack-boriding process was applied to produce the Fe₂B phase at the material surface, and the variables included three temperatures (1173, 1223 and 1273 K) and four exposure times (2, 4, 6 and 8 h). Taking into account the growth fronts obtained at the surface of the material and the mass balance equation at the Fe₂B/substrate interface, the boron diffusion coefficient on the borided phase was estimated for the range of treatment temperatures. Likewise the parabolic growth constant, the instantaneous velocity of the Fe₂B/substrate interface, and the weight gain in the borided samples were established as a function of the parameters τ(t) and α(C), which are related to the boride incubation time (t₀(T)) and boron concentration at the Fe₂B phase, respectively. Observation of the growth kinetics of the Fe₂B layers in gray cast irons suggest an optimum value of boron concentration that is in good agreement with the set of boriding experimental conditions used in this work.     

Kinetics of electrochemical boriding of low carbon steel

In this study, the growth kinetics of the boride layers forming on low carbon steel substrates was investigated during electrochemical boriding which was performed at a constant current density of 200 mA/cm² in a borax based electrolyte at temperatures ranging from 1123 K to 1273 K for periods of 5-120 min. After boriding, the presence of both FeB and Fe₂B phases were confirmed by the X-ray diffraction method. Cross-sectional microscopy revealed a very dense and thick morphology for both boride phases. Micro hardness testing of the borided steel samples showed a significant increase in the hardness of the borided surfaces (i.e., up to (1700 ± 200) HV), while the hardness of un-borided steel samples was approximately (200 ± 20) HV. Systematic studies over a wide range of boriding time and temperature confirmed that the rate of the boride layer formation is strongly dependent on boriding duration and has a parabolic character. The activation energy of boride layer growth for electrochemical boriding was determined as (172.75 ± 8.6) kJ/mol.     

A simple model for the growth kinetics of Fe2B iron boride on pure iron substrate

The present work evaluates the growth kinetics of Fe₂B iron boride forming on iron substrate by means of a diffusion model in the temperature range 1223-1323 K. The model takes into account the effect of the boride incubation time during the formation of Fe₂B phase. The parabolic growth constant at the (Fe₂B/Fe) interface and the mass gain generated by this treatment were estimated. Likewise a simple relationship was proposed to describe the variation of the parabolic growth constant as a function of both the temperature and the boron content in the Fe₂B phase. Furthermore, the simulation results show a good agreement with our experimental results.     

Research on preparing compact bulk nanocomposite Nd2Fe14B/α-Fe magnetic materials by hot extrusion

In this paper, compact bulk nanocomposite Nd₂Fe₁₄B/α-Fe magnetic materials were prepared by hot extrusion of amorphous and nanocrystalline powders, which were prepared by high-energy ball-milling (HEBM) of the Nd₂Fe₁₄ B-type hard magnetic phase with 20 vol% of α-Fe as soft magnetic phase. The extrusion temperature has important influence on magnetic properties and microstructure of magnetic materials. The results show that the grain size of Nd₂Fe₁₄B and α-Fe phase increases steadily with increasing extrusion temperature. Furthermore, optimal extrusion temperature of 1223 K occurs, at which the highest magnetic properties and relative density can be obtained.     

Surface modifications of AISI 1045 steel created by high intensity 1064 and 532 nm picosecond Nd:YAG laser pulses

Interaction of Nd:YAG laser, operating at 1064 or 532 nm wavelength and a pulse duration of 40 ps, with AISI 1045 steel was studied. Surface damage thresholds were estimated to be 0.30 and 0.16 J/cm² at the wavelengths of 1064 and 532 nm, respectively. The steel surface modification was studied at the laser energy density of 10.3 J/cm² (at 1064 nm) and 5.4 J/cm² (at 532 nm). The energy absorbed from Nd:YAG laser beam is partially converted to thermal energy, which generates a series of effects, such as melting, vaporization of the molten material, shock waves, etc. The following AISI 1045 steel surface morphological changes and processes were observed: (i) both laser wavelengths cause damage of the steel in the central zone of irradiated area; (ii) appearance of a hydrodynamic feature in the form of resolidified droplets of the material in the surrounding outer zone with 1064 nm laser wavelength; (iii) appearance of periodic surface structures, at micro- and nano-level, with the 532 nm wavelength and, (iv) development of plasma in front of the target. Generally, interaction of laser beam with the AISI 1045 steel (at 1064 and 532 nm) results in a near-instantaneous creation of damage, meaning that large steel surfaces can be processed in short time.     

Modifications of AISI 1045 steel by picosecond Nd:YAG laser at 266 nm; comparison with 532 and 1064 nm pulses

Interaction of Nd:YAG laser, operating at 266 nm wavelength and a pulse duration of 40 ps, with AISI 1045 steel was studied. Surface damage threshold was estimated to be 0.14 J/cm². The steel surface modification was studied at the laser fluence of ∼1.0 J/cm². The energy absorbed from Nd:YAG laser beam is partially converted to thermal energy, which generates a series of effects, such as melting, vaporization of the molten material, shock waves, etc. The following AISI 1045 steel surface morphological changes and processes were observed: (i) intensive damage of the target in the central zone of irradiated area; (ii) appearance of periodic surface structures at nano-level, with periodicity in agreement with the used wavelength; (iii) reduction of oxygen concentration in irradiated area; and (iv) development of plasma in front of the target. Generally, interaction of laser beam with AISI 1045 steel (at 266 nm) results in a near-instantaneous creation of damage, meaning that large steel surfaces can be modified in short times.     

Preparation and characterization of Fe-based bulk metallic glasses in plate form

Amorphous alloys with composition (at%) Fe₄₈Cr₁₅Mo₁₄C₁₅B₆Gd₂ (alloy A) and Fe₄₈Cr₁₅Mo₁₄C₁₅B₆Y₂ (alloy B) were prepared either using pure elements (A and B1) and a commercial AISI430 steel as a base material (B2). When prepared from pure elements both alloys (A and B1) could be cast in plate form with a fixed thickness of 2 mm and variable lengths between 10 and 20 mm by means of copper-mold injection in air atmosphere. In the case of alloy B2, prepared using commercial grade raw materials, rods of 2 mm diameter were obtained.     

Influence of boron on the giant magnetocaloric effect of La(Fe0.9Si0.1)13

The influences of boron addition on the phase formation, Curie temperature and magnetic entropy change of the NaZn₁₃-type La(Fe_0.9Si_0.1)₁₃ compound have been investigated. Eight boron containing La(Fe_0.9Si_0.1)₁₃B_x samples were prepared with x=0, 0.03, 0.06, 0.1, 0.2, 0.3, 0.5 and 0.6, respectively. Experimental results show that a small amount of B addition in La(Fe_0.9Si_0.1)₁₃ forms the solid solution NaZn₁₃-type structure phase by substituting B for Si or doping B into interstitial position of the lattice, preserves its giant magnetocaloric effects due to their first-order structural/magnetic transition, as well as increase its Curie temperature T_c slightly. The maximum magnetic entropy changes in the magnetic field change of 0–1.6 T are around 20 J kg^–1 K^–1 for the samples with Boron addition less than 0.3, while improving the Curie temperatures by 2 K.     

Preparation,microstructure, and magnetic properties of a nanocrystalline Nd12Fe82B6 alloy by HDDR combined with mechanical milling

Nanocrystalline Nd₁₂Fe₈₂B₆ (atomic ratio) alloy powders with Nd₂Fe₁₄B/α-Fe two-phase structure were prepared by HDDR combined with mechanical milling. The as-cast Nd₁₂Fe₈₂B₆ alloy was disproportionated via ball milling in hydrogen, and desorption–recombination was then performed. The phase and structural change due to both the milling in hydrogen and the subsequent desorption–recombination treatment was characterized by X-ray diffraction (XRD). The desorption–recombination behavior of the as-disproportionated alloy was investigated by differential scanning calorimetry (DSC) and thermal gravimetric analysis (TGA). The morphology and microstructure of the final alloy powders subject to desorption–recombination treatment were observed by scanning electron microscopy (SEM) and transmission electron microscopy (TEM), respectively. The results showed that, by milling in hydrogen for 20 h, the matrix Nd₂Fe₁₄B phase of the alloy was fully disproportionated into a nano-structured mixture of Nd₂H₅, Fe₂B, and α-Fe phases with average size of about 8 nm, and that a subsequent desorption–recombination treatment at 760 °C for 30 min led to the formation of Nd₂Fe₁₄B/α-Fe two-phase nanocomposite powders with average crystallite size of 30 nm. The remanence B_r, coercivity H_c, and maximum energy product (BH)_max of such nanocrystalline Nd₁₂Fe₈₂B₆ alloy powders achieved 0.73 T, 610 kA/m, and 110.8 kJ/m³, respectively.