Growth kinetics of iron boride layers: Dimensional analysis

Dimensional analysis is presented as a powerful tool in the study of the paste boriding process. In particular, a dimensional method is used to study the growth kinetics of the boride layers FeB and Fe₂B. Experiments were performed in AISI 1045 steel and AISI M2 steel, to test the suggested model. Samples of 1045 steel were prepared and treated using boron paste thickness of 3-5 mm, at temperatures of 1193, 1223 and 1273 K, with 2, 4 and 6 h of treatment time. The M2 specimens had boron paste thickness of 3 and 4 mm and temperatures of 1223, 1253 and 1273 K for 2 and 6 h. Results indicate that the growth of boron layers obeys power laws of the form y = αx^β, where α and β constants are a function of the material and the interface of interest. Validation of the model was carried out using experimental data with an average error percentage of 7.6% for Fe₂B in 1045 steel, 15.8% for FeB and 3.4% for Fe₂B in M2 steel.     

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.     

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.     

The pack-boronizing of pure vanadium under a controlled atmosphere

Pack boronizing of pure vanadium was performed at 1100 °C for 4, 8, 12 and 16 h under a controlled atmosphere. Characterization of the boride formed on the surface of pure vanadium was carried out by metallographic techniques, profilometry, SEM-EDS, XRD and microhardness measurements. The metallographic studies revealed that a single boride layer with dense, compact and relatively smooth morphology was formed on the surface of pure vanadium. The interface between boride layer and base metal was wavy in nature. The formation of only the VB₂ phase on pure vanadium was confirmed by surface and cross-sectional XRD analysis. The microhardness of the boride layer was approximately 3700 HV for all boriding times. Fracture toughness of the boride layer was evaluated using Vickers indentation, giving the value of 2.1-5.9 and 1.7-3.4 MPa m^1/2 for Palmqvist and median/radial approaches, respectively. Thickness of the boride layer increased almost parabolically from about 23 to 50 μm with boriding time. Surface roughness of the coating was relatively increased from approximately 0.58 to 2.25 μm by boriding duration.     

Gradient formation of boride layers by borocarburizing

In this study borocarburizing was used for the formation of gradient boride layers. The microstructure, microhardness profiles and the low-cycle fatigue strength during radial compression of carburized, borided and borocarburized layer have been compared. The gradient borocarburized layers, formed by boriding of previously carburized substrate, are characterized by two zones in diffusion layer: iron borides zone and carburized zone. After borocarburizing the iron borides show a tendency towards a loss of the needle-like nature. The hardness gradient between iron borides and low-carbon substrate is reduced. The microhardness beneath the iron borides decreases to 900 HV in carburized zone and next gradually decreases to 400–450 HV in the core of steel. The highest resistance to low-cycle fatigue during radial compression has been observed in case of carburized and through hardened layer. The fatigue strength of gradient boride layer (borocarburized and through hardened) is a little lower. The typical borided and through hardened layer is characterized by the lowest resistance to low-cycle fatigue during radial compression. The profiles of stresses after boriding and borocarburizing have been compared. The obtained profile of stresses and the lower values of tensile stresses at the surface can be the reason for higher frictional wear resistance of borocarburized layers and for higher fatigue strength of these layers, too.     

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.     

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.     

Plasma transferred arc boriding of a low carbon steel: microstructure and wear properties

Borided coatings on AISI 1018 steel with different boron contents were produced using plasma transferred arc (PTA) melting. The thickness of the coatings ranged from 1 to 1.5 mm and their hardness from 400 to 1600 HV. Hypoeutectic or hypereutectic compositions consisting of primary ferrite or primary Fe₂B borides, respectively, and a eutectic constituent of -Fe+Fe₂B were obtained. The presence of FeB attested in coatings with the highest boron contents seems to be responsible for the intergranular cracks extending from the surface of the coatings to the substrate. Crack free coatings corresponding to the minimum quantity of eutectic and with a minor quantity of FeB were subjected to pin on disk wear testing and compared to the steel of the substrate. It was found that the wear rate of the borided coatings was about four orders of magnitude lower than the wear rate of the steel substrate. A transition from mild to severe wear was observed for the steel substrate material, but it was absent in the case of the borided coatings for the entire range of the applied loads examined. It is shown that the transition in the case of steel occurs when grooving and plastic deformation is replaced by intense cracking of the material above a critical load. In the case of the borided layer the dominant wear mechanism is delamination of the eutectic, however, the platelike borides are able to support the load and remain in the mild wear range for all the loads tested. Both borided and plain steel surfaces have the same friction coefficient after a short transition period, because both develop an oxide layer leading roughly to the same tribosystem with the alumina counterbody.     

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.