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Pack-Boriding of Pure Iron with Powder Mixtures Containing ZrB2

  • A. Calik , N. Ucar EMAIL logo , M.S. Karakas and H. Tanis
Published/Copyright: November 9, 2018
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High Temperature Materials and Processes
From the journal High Temperature Materials and Processes Volume 38 Issue 2019

Abstract

Boriding of pure iron was investigated using the powder pack method with boriding powder mixtures containing different weight fractions of ZrB2 (5 %, 10 %, 15 % and 20 %). The samples were borided in an electric resistance furnace for an exposure time of 4 h at 1,173 K temperature under atmospheric pressure. Borided samples were characterized by optical microscopy, X-ray diffraction analyses and microhardness tests. Results showed that the boride layers consisted mainly of FeB and Fe2B phases. No significant difference in boride layer thicknesses (average 140 μm) could be observed as a function of ZrB2 content. The needle-like morphology of the boride layer became more prominent with increasing weight fraction of ZrB2 in the boriding powders. The average microhardness of the boride layer decreased with increasing ZrB2 content due to changes in the morphology of the boride layer.

Keywords: boriding; boride layer; boriding agent; microhardness; ZrB2

Introduction

Iron is the second most abundant metal in Earth’s crust, after aluminium. When reduced from its ore, pure iron is soft and susceptible to corrosion. The use of surface coatings opens up the possibility for material design in iron and steel for which certain properties such as surface hardness and corrosion resistance can be improved. One such surface coating technique is boriding, a thermo-chemical surface treatment in which boron atoms diffuse into the surface of the workpiece to form hard borides with the base material. Boriding can be performed in a solid, liquid or gaseous medium and is applicable to iron-based alloys as well as to alloys of nickel, cobalt and titanium [1–10]. While showing some promise, liquid- and gas-phase boriding techniques have not become popular due to toxicity issues.

In the literature [11, 12, 13], it has been shown that borided materials exhibit significantly higher surface hardness compared to their untreated counterparts and improved abrasive and adhesive wear resistance, due to the hard boride phases grown on the surface and also due to diffusion of boron into the substrate. The composition and thickness of the boride layer formed on the surface can be significantly altered by changing certain parameters which include, but are not limited to, the boriding source, time, temperature and the chemical composition of the substrate. Corresponding to this, it has been shown that longer boriding times and higher treatment temperatures usually result in the greater coating layer thickness [14, 15, 16]. Various investigations have also shown that boriding agents and their compositions in the boriding medium can have important effects on the formation of boride layers and phases [17, 18, 19]. Calik [19] reported that the average microhardness of the boride layers can range between 1,450 and 1,651 HV, depending on the size of the powders in the boriding source. The thickness of the boride layer increases with decreasing particle size of the boriding powders and increasing boriding temperature.

Zirconium diboride (ZrB2) has attracted considerable attention due to its excellent combination of properties such as high melting point, high hardness, high thermal and electrical conductivity, high-temperature strength and thermal shock resistance. Bliznakov et al. [20] showed that the treatment of steel surfaces with ZrB2 leads to complex boridation-zirconization, resulting in enhanced hardness values in comparison to that of iron borides. Zakhariev et al. [21] reported that coatings up to 1 mm in thickness can be produced by boriding treatments involving ZrB2 as the main additive. The coatings were found to consist of ZrO2, ZrB2 and Fe2B phases. The main goal of the current study is to investigate the microstructure and morphology of boride layers grown on the surface of pure iron by pack boriding using powders containing ZrB2 in different concentrations as the boron source.

Experimental method

Pure iron samples (99.97 % purity, obtained from Alfa Aesar) were packed in boriding sources composed of 5 wt.% B4C and 5 wt.% KBF4 with varying concentrations of ZrB2 and SiC as shown in Table 1. Ekrit® powder (finely ground SiC, supplied from Bortech GmbH, Germany) was also added on top of the pack as a cover layer to prevent oxidation. The boriding process was carried out at a temperature of 1,173 K for 4 h.

Table 1:

Compositions of the different boriding sources (wt.%).

Boriding sourceZrB2SiCB4CKBF4
ZB009055
ZB158555
ZB2108055
ZB3157555
ZB4207055

Microstructural analysis of borides formed on cross-sections of the borided pure iron samples was carried out using optical and scanning electron microscopy. The presence of borides and other phases formed on the surface of the borided samples was determined by using an X-ray diffractometer (Rigaku D-MAX 2200) with CuKα radiation of 0.15418 nm wavelength. The thickness of the boride layer was measured from optical micrographs. For the measurement of boride layer thickness, only the needles which penetrate most deeply into the substrate were selected as suggested in Ref [22, 23].

To determine the hardness profiles of the borided samples, microhardness measurements were made on cross-sections perpendicular to the borided surface by means of a Vickers indenter with a load of 100 g and dwell time of 15 s. Before microhardness testing, a standard specimen was used for calibration. To ensure the reliability of the results, a minimum of five measurements were made at each depth to obtain average microhardness values.

Results and discussion

The cross-sections of optical micrographs of pure iron borided with the ZB1, ZB2, ZB3 and ZB4 powders at 1,173 K for 4 h are shown in Figure 1. As seen in the figure, the boride layers exhibit the characteristic needle-like morphology. Two distinct regions are identified in the cross-sections of the borided pure iron surfaces: the double-phase boride layer and the substrate unaffected by boron diffusion. Crack formation is present within the double-phase boride layer, which is common in borided iron and steel [24, 25, 26]. The micrographs also show that increasing the ZrB2 content in the boriding source does not result in significant difference in the thickness of the boride layers.

Figure 1: Cross-sectional optical microscopy images of pure Fe borided at 1,173 K for 4 h using (a) ZB1, (b) ZB2, (c) ZB3 and (d) ZB4 powders.
Figure 1:

Cross-sectional optical microscopy images of pure Fe borided at 1,173 K for 4 h using (a) ZB1, (b) ZB2, (c) ZB3 and (d) ZB4 powders.

The average boride layer thickness value of borided pure iron sample borided with powders containing ZrB2 additions varies between 138 and 141 μm, while it is 139 μm for the pure iron sample borided with powders without ZrB2 addition. However, when the micrographs in Figure 1 are compared, it can be seen that addition of ZrB2 tends to cause greater variation between the peaks and valleys in the double-phase boride layer. Addition of ZrB2 to the boriding powder, therefore, has a negative effect on the boriding process, hindering the diffusion of boron into the substrate.

According to X-ray diffraction (XRD) analyses, the boride layers in the borided pure iron samples are composed of FeB, Fe2B and also ZrB2 (Figure 2). The reason why ZrB2 does not appear in the optical micrographs in Figure 1 but appears in the XRD patterns in Figure 2 should be considered as due to the holding or adhesion of ZrB2 on the surface due to high boriding temperature.

Figure 2: X-ray diffraction patterns obtained from the surface of pure Fe borided at 1,173 K for 4 h using (a) ZB1, (b) ZB2, (c) ZB3 and (d) ZB4 powders.
Figure 2:

X-ray diffraction patterns obtained from the surface of pure Fe borided at 1,173 K for 4 h using (a) ZB1, (b) ZB2, (c) ZB3 and (d) ZB4 powders.

Microhardness measurements were carried out from the surface to the interior on cross-sections of the borided specimens. As seen in Figure 3, the hardness of the boride layer is approximately ten times that of the matrix. This is a consequence of the presence of hard boride phases as determined by optical microscopy and XRD analyses. On the other hand, it can be seen again from the figure that ZrB2 addition in the boriding source decreases the average hardness of the resulting boride layer. Summarizing, the results of the current study show that the presence of ZrB2 in the boriding source does not result in the formation of a surface coating with enhanced hardness compared to the hardness of iron borides, and does not have a positive influence on boride layer thickness, contrary to the results published by Bliznakov et al. [20] and Zakhariev et al. [21].

Figure 3: Change in microhardness values from boride surface to substrate for borided pure Fe.
Figure 3:

Change in microhardness values from boride surface to substrate for borided pure Fe.

Conclusions

In this study, the effect of boriding powders with varying ZrB2 contents on the boriding behaviour of pure iron was investigated. The following conclusions can be drawn:

  1. Two distinct regions were identified in the cross-sectional optical micrographs of the borided samples: The boride layer and the substrate unaffected by boron diffusion.

  2. The boride layer exhibited needle-like morphology and consisted mainly of FeB and Fe2B. ZrB2 was additionally detected through XRD analysis.

  3. No significant difference in boride layer thickness as a function of ZrB2 content was observed.

  4. The microhardness in the boride layer decreased with increasing ZrB2 content due to the hindering of boron diffusion into the surface.

Funding statement: This study was supported by the Scientific Research Projects Coordination Unit of Suleyman Demirel University (Project reference number: SDU-BAP 4128-YL1-14).

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Received: 2017-06-09
Accepted: 2018-01-19
Published Online: 2018-11-09
Published in Print: 2019-02-25

© 2019 Walter de Gruyter GmbH, Berlin/Boston

This work is licensed under the Creative Commons Attribution 4.0 Public License.

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https://doi.org/10.1515/htmp-2017-0081
Keywords for this article
boriding; boride layer; boriding agent; microhardness; ZrB2
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Articles in the same Issue

  1. Frontmatter
  2. Review Article
  3. Research on the Influence of Furnace Structure on Copper Cooling Stave Life
  4. Influence of High Temperature Oxidation on Hydrogen Absorption and Degradation of Zircaloy-2 and Zr 700 Alloys
  5. Correlation between Travel Speed, Microstructure, Mechanical Properties and Wear Characteristics of Ni-Based Hardfaced Deposits over 316LN Austenitic Stainless Steel
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  34. Structural Characteristics and Hydration Kinetics of Oxidized Steel Slag in a CaO-FeO-SiO2-MgO System
  35. Optimization of Microwave-Assisted Oxidation Roasting of Oxide–Sulphide Zinc Ore with Addition of Manganese Dioxide Using Response Surface Methodology
  36. Hydraulic Study of Bubble Migration in Liquid Titanium Alloy Melt during Vertical Centrifugal Casting Process
  37. Investigation on Double Wire Metal Inert Gas Welding of A7N01-T4 Aluminum Alloy in High-Speed Welding
  38. Oxidation Behaviour of Welded ASTM-SA210 GrA1 Boiler Tube Steels under Cyclic Conditions at 900°C in Air
  39. Study on the Evolution of Damage Degradation at Different Temperatures and Strain Rates for Ti-6Al-4V Alloy
  40. Pack-Boriding of Pure Iron with Powder Mixtures Containing ZrB2
  41. Evolution of Interfacial Features of MnO-SiO2 Type Inclusions/Steel Matrix during Isothermal Heating at Low Temperatures
  42. Effect of MgO/Al2O3 Ratio on Viscosity of Blast Furnace Primary Slag
  43. The Microstructure and Property of the Heat Affected zone in C-Mn Steel Treated by Rare Earth
  44. Microwave-Assisted Molten-Salt Facile Synthesis of Chromium Carbide (Cr3C2) Coatings on the Diamond Particles
  45. Effects of B on the Hot Ductility of Fe-36Ni Invar Alloy
  46. Impurity Distribution after Solidification of Hypereutectic Al-Si Melts and Eutectic Al-Si Melt
  47. Induced Electro-Deposition of High Melting-Point Phases on MgO–C Refractory in CaO–Al2O3–SiO2 – (MgO) Slag at 1773 K
  48. Microstructure and Mechanical Properties of 14Cr-ODS Steels with Zr Addition
  49. A Review of Boron-Rich Silicon Borides Basedon Thermodynamic Stability and Transport Properties of High-Temperature Thermoelectric Materials
  50. Siliceous Manganese Ore from Eastern India:A Potential Resource for Ferrosilicon-Manganese Production
  51. A Strain-Compensated Constitutive Model for Describing the Hot Compressive Deformation Behaviors of an Aged Inconel 718 Superalloy
  52. Surface Alloys of 0.45 C Carbon Steel Produced by High Current Pulsed Electron Beam
  53. Deformation Behavior and Processing Map during Isothermal Hot Compression of 49MnVS3 Non-Quenched and Tempered Steel
  54. A Constitutive Equation for Predicting Elevated Temperature Flow Behavior of BFe10-1-2 Cupronickel Alloy through Double Multiple Nonlinear Regression
  55. Oxidation Behavior of Ferritic Steel T22 Exposed to Supercritical Water
  56. A Multi Scale Strategy for Simulation of Microstructural Evolutions in Friction Stir Welding of Duplex Titanium Alloy
  57. Partition Behavior of Alloying Elements in Nickel-Based Alloys and Their Activity Interaction Parameters and Infinite Dilution Activity Coefficients
  58. Influence of Heating on Tensile Physical-Mechanical Properties of Granite
  59. Comparison of Al-Zn-Mg Alloy P-MIG Welded Joints Filled with Different Wires
  60. Microstructure and Mechanical Properties of Thick Plate Friction Stir Welds for 6082-T6 Aluminum Alloy
  61. Research Article
  62. Kinetics of oxide scale growth on a (Ti, Mo)5Si3 based oxidation resistant Mo-Ti-Si alloy at 900-1300∘C
  63. Calorimetric study on Bi-Cu-Sn alloys
  64. Mineralogical Phase of Slag and Its Effect on Dephosphorization during Converter Steelmaking Using Slag-Remaining Technology
  65. Controllability of joint integrity and mechanical properties of friction stir welded 6061-T6 aluminum and AZ31B magnesium alloys based on stationary shoulder
  66. Cellular Automaton Modeling of Phase Transformation of U-Nb Alloys during Solidification and Consequent Cooling Process
  67. The effect of MgTiO3Adding on Inclusion Characteristics
  68. Cutting performance of a functionally graded cemented carbide tool prepared by microwave heating and nitriding sintering
  69. Creep behaviour and life assessment of a cast nickel – base superalloy MAR – M247
  70. Failure mechanism and acoustic emission signal characteristics of coatings under the condition of impact indentation
  71. Reducing Surface Cracks and Improving Cleanliness of H-Beam Blanks in Continuous Casting — Improving continuous casting of H-beam blanks
  72. Rhodium influence on the microstructure and oxidation behaviour of aluminide coatings deposited on pure nickel and nickel based superalloy
  73. The effect of Nb content on precipitates, microstructure and texture of grain oriented silicon steel
  74. Effect of Arc Power on the Wear and High-temperature Oxidation Resistances of Plasma-Sprayed Fe-based Amorphous Coatings
  75. Short Communication
  76. Novel Combined Feeding Approach to Produce Quality Al6061 Composites for Heat Sinks
  77. Research Article
  78. Micromorphology change and microstructure of Cu-P based amorphous filler during heating process
  79. Controlling residual stress and distortion of friction stir welding joint by external stationary shoulder
  80. Research on the ingot shrinkage in the electroslag remelting withdrawal process for 9Cr3Mo roller
  81. Production of Mo2NiB2 Based Hard Alloys by Self-Propagating High-Temperature Synthesis
  82. The Morphology Analysis of Plasma-Sprayed Cast Iron Splats at Different Substrate Temperatures via Fractal Dimension and Circularity Methods
  83. A Comparative Study on Johnson–Cook, Modified Johnson–Cook, Modified Zerilli–Armstrong and Arrhenius-Type Constitutive Models to Predict Hot Deformation Behavior of TA2
  84. Dynamic absorption efficiency of paracetamol powder in microwave drying
  85. Preparation and Properties of Blast Furnace Slag Glass Ceramics Containing Cr2O3
  86. Influence of unburned pulverized coal on gasification reaction of coke in blast furnace
  87. Effect of PWHT Conditions on Toughness and Creep Rupture Strength in Modified 9Cr-1Mo Steel Welds
  88. Role of B2O3 on structure and shear-thinning property in CaO–SiO2–Na2O-based mold fluxes
  89. Effect of Acid Slag Treatment on the Inclusions in GCr15 Bearing Steel
  90. Recovery of Iron and Zinc from Blast Furnace Dust Using Iron-Bath Reduction
  91. Phase Analysis and Microstructural Investigations of Ce2Zr2O7 for High-Temperature Coatings on Ni-Base Superalloy Substrates
  92. Combustion Characteristics and Kinetics Study of Pulverized Coal and Semi-Coke
  93. Mechanical and Electrochemical Characterization of Supersolidus Sintered Austenitic Stainless Steel (316 L)
  94. Synthesis and characterization of Cu doped chromium oxide (Cr2O3) thin films
  95. Ladle Nozzle Clogging during casting of Silicon-Steel
  96. Thermodynamics and Industrial Trial on Increasing the Carbon Content at the BOF Endpoint to Produce Ultra-Low Carbon IF Steel by BOF-RH-CSP Process
  97. Research Article
  98. Effect of Boundary Conditions on Residual Stresses and Distortion in 316 Stainless Steel Butt Welded Plate
  99. Numerical Analysis on Effect of Additional Gas Injection on Characteristics around Raceway in Melter Gasifier
  100. Variation on thermal damage rate of granite specimen with thermal cycle treatment
  101. Effects of Fluoride and Sulphate Mineralizers on the Properties of Reconstructed Steel Slag
  102. Effect of Basicity on Precipitation of Spinel Crystals in a CaO-SiO2-MgO-Cr2O3-FeO System
  103. Review Article
  104. Exploitation of Mold Flux for the Ti-bearing Welding Wire Steel ER80-G
  105. Research Article
  106. Furnace heat prediction and control model and its application to large blast furnace
  107. Effects of Different Solid Solution Temperatures on Microstructure and Mechanical Properties of the AA7075 Alloy After T6 Heat Treatment
  108. Study of the Viscosity of a La2O3-SiO2-FeO Slag System
  109. Tensile Deformation and Work Hardening Behaviour of AISI 431 Martensitic Stainless Steel at Elevated Temperatures
  110. The Effectiveness of Reinforcement and Processing on Mechanical Properties, Wear Behavior and Damping Response of Aluminum Matrix Composites
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