Surface Engineering

Subject Code: PI-607

Unit-II
(Part-I)

By
Dr. Tushar Banerjee
Assistant Professor
Production & Industrial Engineering
NIT Jamshedpur
 Laser Assisted Surface Engineering
How Laser Beam is Generated?
Light Amplification by Stimulated Emission of Radiation

Fig. Atomic Structure

Fig. Generation of Laser Beam

1. High voltage electric supply, 2. Flash tube, 3. Atoms absorbing photon energy,
getting exited and releasing photons (spontaneous emission) of particular wavelength,
4. Back and forth movement of photons, 5. Stimulated emission of photons and
strengthening of the beam, 6. Mirror, 7. Partially silvered mirror, 8. LASER Beam 2
 How Laser Beam is Generated?
1.A high-voltage electric supply makes the tube flash on and off.

2.Every time the tube flashes, it "pumps" energy into the ruby crystal. The flashes it makes inject
energy into the crystal in the form of photons.

3.Atoms in the ruby crystal (large green blobs) soak up this energy in a process called absorption.
Atoms absorb energy when their electrons jump to a higher energy level. After a very short duration
(10-5 to 10-8 s), the electrons return to their original energy level (ground state) by giving off a
photon of light (small blue blobs). This is called spontaneous emission.

4.The photons that atoms give off zoom up and down inside the ruby crystal, traveling at the speed
of light.

5.Every so often, one of these photons stimulates an already excited atom. When this happens, the
excited atom gives off a photon and we get our original photon back as well. This is
called stimulated emission. Now one photon of light has produced two, so the light has been
amplified (increased in strength). In other words, "light amplification"(an increase in the amount of
light) has been caused by "stimulated emission of radiation" (hence the name "laser", because
that's exactly how a laser works!)

6.A mirror at one end of the laser tube keeps the photons bouncing back and forth inside the crystal.

7.A partial mirror at the other end of the tube bounces some photons back into the crystal but lets
some escape.

8.The escaping photons form a very concentrated beam of powerful laser light. 3
Laser Assisted Surface Engineering

4
Laser Surface Treatment
*Laser Surface Transformation Hardening
* Laser Melting & Re-solidification
* Laser Surface Alloying
* Laser Surface Cladding
Need for Surface Treatment
To improve

 Hardness,
 Strength,
 Wear resistance,
 Corrosion resistance and
 Fatigue life
Particular parts of surfaces which are vulnerable
 Laser Surface Treatment- classifications
1) 2)

3) 4)
 Cooling Curve of Pure Iron

Fig. 2. Allotropic forms of pure iron

Fig. 1. Cooling curve of pure iron

Ref: Manufacturing Science, Ghosh & Mallick, East-West Press 3

 Iron-Carbon Equilibrium Diagram

• Ferrite: Solid solution of α-iron and

Fe3C

• Austenite: Solid solution of γ-iron and

Fe3C

• Cementite: Carbon present in steel is

in the form of Fe3C. It consists of
6.67% C. This Fe3C is called Cementite

• Pearlite: It consists of alternate layers

of ferrite and cementite and is
formed due to eutectoid reaction at
7230 C.
Fig. Iron-Carbon Equilibrium Diagram

Ref: Manufacturing Science, Ghosh & Mallick, East-West Press 4

Time-Temperature-Transformation (TTT) Diagram for Carbon Steel
• Technologically important because it help us
to determine the cooling process (i.e. cooling
temperature or rate) to get certain
microstructure (pearlite/bainite/martensite)
from austenite.

• Family of S-shaped curves at different

temperatures pertaining to growth of new
phase are used to construct the TTT diagram.
Isothermal (constant temperature)
transformations at different temperatures
below 7230 C are used.
• Dilatometer is used to use to identify start
and end of transformation (phase change
produces volume change)

Fig. TTT diagram for carbon steel 6

Ref: Manufacturing Science, Ghosh & Mallick, East-West Press

 Transformation in steel : basics
At room temperature, plain carbon steels :a mixture of a body-
centered cubic phase (Ferrite) and an iron carbide phase.
At eutectoid temperature (727 ºC): Carbides and Ferrite
dissolve into a single face-centered cubic phase called Austenite.
Austenite () Ferrite () + Cementite (Fe3C)
FCC BCC Orthorhombic
0.8 % 0.02% 6.67%

Under slow cooling conditions, high-temperature Austenite

phase reverts to the ferrite and carbide structure.
If cooling rate is more than 103-104 K/s: No
compositional
Austenite () Martensite (’) change or
FCC BCT diffusion
0.8 % 0.8%

In fast cooling Carbon tends to move- Distortion in Lattice Structure

Compressive stress at the surface: Increased Hardness
Laser Power Density: 103-5.104W/cm2 Interaction Time:1-10-2s

Beam Width,  = 5mm

Scan speed = 5m/min

Beam dwell time = 0.06s

Thermal diffusion length ,d = 0.5mm
Laser Energy coupled (, d ) ~ 50J
Rise in Temperature (Steel) =9000C
Laser Beam :High Reflection
Heating Rate ~ 9000C/ 0.06s below Melting Temperature
=1.5x104C/s
Coating: 50-100m
Cooling by Self-Quenching: Heat
* Manganese/Zinc Phosphate
dissipation in 2-3 Diffusion Length
* Graphite Spray
t = (3d)2 /4 = 0.8s * Black Paint (High pigments-
TiO2, SiO2 & Carbon black)
Cooling Rate = 9000C/0.8s ~ 103C/s
Materials Surface Hardened by Laser: Carbon Steel, Alloy Steel, Tool
Steel, Cast Iron, Copper based alloys e.g. Brass, Aluminum bronze

Micro Hardness increase: up to 2 times,

Depth: up to 2mm

Application: transformation hardening

 Automobile Sector
 Hardening of engine & drive trains,
 Components like- Cylinder liners, piston rings, Cam.
 Hardening of files
 Hardening of machine shafts
 Hardening of Gear teeth, Rails
Hardening of piton rings
Advantages of Laser Hardening
• Precise control of Heat Input to Localized Areas
• Minimum Distortion
• Hard to reach areas can be Heat Treated if a line of sight exists
• No Quenchants required- Self Quenching
• Time Efficient Process
• No post processing required

Limitation of Laser Hardening

• Limited depth of hardening : 0.1-2mm
• Not enough time to become homogenous, equilibrium at
temperature: Laser hardening-only of relatively homogeneous
materials with narrow layers
 Laser Re-solidification
Laser Surface Melting & Re-solidification at fast cooling rates improves surface
characteristics (wear, corrosion resistance) through one or more of the
following processes:
*Grain refinement : Scan rate <100cm/min
*Homogenization of microstructure : Scan rate <10cm/min
*Enhancement of solid solubility : 100-10,000cm/min
*Formation of meta-stable state / Amorphous phase i.e. surface glazing
Cooling rates: 108-1011K/s
Laser Power Density= 105-107W/cm2
Interaction Time = 10-4-10-7s
 Cast Iron, Tool Steel, Modified 316(N) Stainless Steel Weld Metal,
Al-Si alloys, Camshaft.
All advantages of Fast quenching
Laser Rapid Solidification
Cast Iron is most commonly used engineering material, it has
usually non-homogenous structure of ferrite and graphite in
various forms (flakes, spheres, etc.) .
On Remelting, This improves hardness &
improves wear resistance to
Graphite  Cementite & great extent. Service Life
Austenite Martensite increased by 2-3 times

Applications:
 Automobile Sector:
Brake Drum,
 Fillets of crank shafts.
 Hardening of shawl tips for earth moving applications.