A novel route of carburizing through microwave hybrid heating

Abstract Carburizing is a surface treatment process by diffusing carbon into the steel. These days, manufacturing industries demand highly efficient processes that consume low power. Microwave processing is a newly evolving process that consumes low power. This study proposes a novel route for carburizing mild steel (substrate) through experimental and simulation studies using a microwave heating. Charcoal powder was used as a susceptor to convert microwave energy into heat energy and to deposit carbon on the surface of the specimen. The mild steel specimens were exposed to the microwave power input of 900 W and 360 W for exposure time of 1500 s and 1980 s naming it as S2 and S3 respectively. The microstructural analysis of specimens S2 and S3 confirms the formation of pearlite structures at the surface. However, the amount of pearlite structure was significantly higher for the S3 . The higher carbon content is confirmed through energy-dispersive x-ray spectroscopy (EDS) analysis of specimen S3 . The average hardness of the S3 specimen was determined to be 220.8 HV, which shows an increase of 38.36% compared to the S1 (base metal). x-ray diffraction (XRD) results indicate the additional cementite peaks (Fe 3 C) and ferrite-confirming phase transformations for carburized samples. The wear analysis of S2 and S3 was conducted through pin-on-disk testing. The peak COF of 0.73 and 0.64 was observed for S2 and S3 respectively. The hard surface of S3 resists the penetration of the counter body to a greater extent due to the fine morphology of pearlite. From the FEM study, the maximum value of 7.96 <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" overflow="scroll"> <mml:mo>×</mml:mo> </mml:math> <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" overflow="scroll"> <mml:msup> <mml:mrow> <mml:mn>10</mml:mn> </mml:mrow> <mml:mrow> <mml:mn>3</mml:mn> </mml:mrow> </mml:msup> </mml:math> (V/m) was determined at the center region for the electric field distribution in the microwave cavity, which is the optimum value for efficient heating. The maximum temperature of the mild steel obtained during the carburization process was 900 °C in 1800 s. The microwave carburizing process requires relatively less time than the conventional carburizing process which will save energy consumption.