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Martempering is a widely practiced industrial heat treatment process to harden steel parts with minimum distortion. A numerical experiment to predict hardness distribution in AISI 4140 steel cylinders of various diameters during martempering is presented in this work. Apart from the diameter (D), the effect of other process variables such as heat transfer coefficient (h), bath temperature (Tb), and residence time (tr) was also studied. The relationship between hardness distribution and the aforementioned process variables was highly nonlinear. An artificial neural network (ANN) model with a single hidden layer and 30 hidden layer neurons was thus developed to predict the hardness distribution in martempered AISI 4140 steel cylinders. The increase in bath temperature, diameter, and residence time decreased the average hardness, and an increase in the heat transfer coefficient increased the average hardness of martempered AISI 4140 cylinders. The weights of the ANN model were used to calculate the relative importance of all input variables and they followed a decreasing order of Tb>D>tr>h.

Drilling is the most common operation that is performed on the composite material to facilitate the fastening of a composite with other components in an assembly. The present investigation investigates the most significant parameter that affects the quality of the drilled hole in glass fiber-reinforced composites. Epoxy resin is used in the matrix phase. Aluminum powder is used as a filler material in the epoxy matrix to reduce delamination. Laminated composites were fabricated by the hand-layup process with 0%, 3%, and 6 vol% aluminum fillers. Holes were drilled in the composites with the help of a computer numerical controlled drilling machine equipped with a dynamometer. Spindle speeds of 1000, 3000, and 5000 rpm, and feed rates of 50, 100, and 150 mm min−1 were the variables involved in the study. The thrust force and torque experienced during the machining process were measured. An artificial neural network model was executed using python programing language. The data obtained from the model was optimized using genetic algorithm to arrive the optimized machining conditions that would result in least delamination due to drilling.

Growing concerns over the hazardous impact of mineral oil-based industrial quench media on human health and the environment have forced researchers to seek renewable and non-hazardous alternatives. Non-edible vegetable oil-based quench media are perceived to be a potential replacement for mineral-based industrial quench media. The present work focuses on assessing the cooling performance of neem oil as compared to commercial hot oil quench media. Inconel and steel probes were used to characterize the cooling performance of these quench media maintained at bath temperatures 100 °C, 150 °C and 200 °C. The heat extraction rates and uniformity of heat extraction in Inconel probes quenched in neem oil were observed to be substantially higher at all bath temperatures. The hardness of AISI 52100 steel probe quenched in neem oil at all bath temperatures was observed to be higher. The pearlitic microstructure was observed in the steel probe quenched in hot oil maintained at 200 °C bath temperature. In contrast to this, a mixture of bainite, martensite and carbide was observed in case of steel probes quenched in neem oil maintained at 200 °C. Oxidation experiments revealed that neem oil is susceptible to an increase in viscosity due to oxidation. An increase in the viscosity by about 15% was observed in the case of neem oil as compared to only 4% increase in viscosity of hot oil. However, after an initial increase, the viscosity of neem oil stabilized and further no significant change in viscosity due to oxidation were observed. Oxidation had no significant effect on the cooling performance hot neem oil quench medium, and thus, it can be considered as an effective replacement for hot oil.

The present study involved the assessment of cooling severity of molten NaNO3–KNO3 mixtures which are widely used as quench media for austempering and martempering operations. An Inconel probe instrumented with thermocouples was quenched in molten NaNO3–KNO3 binary mixtures of varying concentration maintained at different quench bath temperatures. The temperature data acquired at various locations in the Inconel probe during quenching was used to calculate the spatially dependent transient heat flux at the metal–quenchant interface. Two critical points corresponding to peak heat extraction rates during the nucleate boiling stage and transition from boiling to convection stage were identified for each quench medium. The variation of average heat flux and average surface temperature corresponding to these critical points was mapped with variation in bath temperature and composition of the quench medium. AISI 4140 steel probes were quenched in these quench media maintained at 300 and 350 °C. The average hardness values measured in steel probes agreed with the cooling performance of these quench media determined using Inconel probe. The degree of uniformity in heat transfer as indicated by the spatial variation of normalized heat energy decreased with the increase in the concentration of KNO3 in the quench medium. A mechanism of boiling heat transfer during quenching based on thermochemical decomposition of the salt was proposed.

The present work presents a comprehensive comparative study on the cooling performance of hot oil and molten 54%KNO3-7%NaNO3-39%NaNO2 eutectic mixture quench media. The study was conducted using a cylindrical Inconel probe of 12.5 mm diameter and 60 mm length. Cooling curves at different locations in the probe were acquired and were subsequently used to calculate spatially dependent transient heat flux at the metal/quenchant interface. The heat extraction mechanism in hot oil and NaNO2 eutectic mixture was found to be different. Heat transfer occurred in two stages, namely boiling stage and convective cooling stage during quenching in molten NaNO2 eutectic mixture. In the case of hot oil, apart from these two stages, third stage of cooling, namely vapor blanket stage, was observed. A detailed study was conducted to compare the magnitude and uniformity of heat extraction during each stage of quenching. Molten salt offered a higher cooling rate and more spatial uniform cooling as compared to that obtained in hot oil quench medium. The non-uniformity in surface temperature during boiling stage in Inconel probe was ten times lower in molten salt medium as compared to that observed in the hot oil medium. However, the non-uniformity in surface temperature during convective cooling stage in both the media were comparable. Based on the distribution of characteristic cooling time (t85) calculated in quenched Inconel probe, higher and uniform hardness distribution is predicted in steel parts quenched in molten NaNO2 eutectic mixture media as compared to that in hot oil.

Cooling behaviour of steels in quench media is of great importance as this controls phase transformations, heat transfer and the stress evolution. The heat extraction ability of each quenchant is different because of varying thermophysical properties and wetting behaviour. The quenchants should be selected in such a way that they provide uniform cooling of steel. In the present investigation, quenching experiments were carried out with Inconel 600, EN19, EN24, EN31 steel grades in distilled water, servo oil, carbonated distilled water and 10% PAG. The cooling curve analysis of the quenching process was carried out with temperature data recorded during quenching. This measured temperature–time data were used to estimate the heat flux by inverse modelling without considering the effect of phase transformation. The crack propensity was quantified using the quench uniformity ratio. The hardness distribution observed during quenching in carbonated distilled water was observed to be more uniform compared to other quench media.

This paper presents the results of a study on the cooling performance of hot oil and molten salt quench media. It describes the tests performed, analyzes the results, and interprets the findings. It explains how the heat extraction mechanism in hot oil differs from that of NaNO2 eutectic mixtures and how it translates to differences in cooling rate, spatial uniformity, and hardness in quenched steel parts.

Martempering is an industrial heat treatment process that requires a quench bath that can operate without undergoing degradation in the temperature range of 423 K to 873 K (150 °C to 600 °C). The quench bath is expected to cool the steel part from the austenizing temperature to quench bath temperature rapidly and uniformly. Molten eutectic NaNO3-KNO3 mixture has been widely used in industry to martemper steel parts. In the present work, the effect of quench bath temperature on the cooling performance of a molten eutectic NaNO3-KNO3 mixture has been studied. An Inconel ASTM D-6200 probe was heated to 1133 K (860 °C) and subsequently quenched in the quench bath maintained at different temperatures. Spatially dependent transient heat flux at the metal–quenchant interface for each bath temperature was calculated using inverse heat conduction technique. Heat transfer occurred only in two stages, namely, nucleate boiling and convective cooling. The mean peak heat flux (q max) decreased with increase in quench bath temperature, whereas the mean surface temperature corresponding to q max and mean surface temperature at the start of convective cooling stage increased with increase in quench bath temperature. The variation in normalized cooling parameter t 85 along the length of the probe increased with increase in quench bath temperature.

Distilled water and polyalkylene glycol (PAG)-based aqueous quenchants of 5 and 10 vol.% with and without carbonation were prepared and used as heat transfer media during immersion quenching. Cooling curves were recorded during quenching of an inconel 600 cylindrical probe instrumented with multiple thermocouples. It was observed that the vapor stage duration was prolonged and the wetting front ascended uniformly for quenching with carbonated media. The cooling data were analyzed by determining the critical cooling parameters and by estimating the spatially dependent probe/quenchant interfacial heat flux transients. The study showed significantly reduced values of heat transfer rate for carbonated quenchants compared to quenchants without carbonation. Further, the reduction was more pronounced in the case of PAG-based carbonated quenchants than carbonated distilled water. The results also showed the dependence of heat transfer characteristics of the carbonated media on polymer concentration. The effect of quench uniformity on the microstructure of the material was assessed.

Quench hardening is a process where an alloy is heated to solutionizing temperature and held for a definite period, and then rapidly cooled in a quenching medium. Selection of quenchant that can yield desired properties is essential as it governs heat extraction process during quenching. In the present work, the cooling performance of vegetable oil and mineral-vegetable oil blend quench media was assessed. The vegetable oils used in this work were olive oil, canola oil and rice bran oil. The mineral-vegetable oil blends were prepared by blending 10 and 20 vol. % of rice bran and canola oil in mineral oil. Inconel probe of 12.5mm diameter and 60mm height, instrumented with thermocouples were used to characterize quenchants. The probe was heated to 850°C and quenched in the oil medium. The cooling curves at different locations in the probe were used to study wetting kinematics. Inverse modelling technique was used to estimate spatially dependent metal-quenchant interfacial heat flux. It was found that the vegetable oils exhibited very short vapour blanket stage compared to mineral oil and blends. Faster wetting kinematics obtained with blends resulted in uniform heat transfer compared to that of mineral oil. The temperature distribution in the probe quenched in vegetable oils and blends was more uniform compared to that in mineral oil. It is expected that the parts quenched in vegetable oils and blends would lead to better hardness distribution compared to mineral oils.

The present research work is aimed at the estimation of quench severity Polyalkylene Glycol (PAG) polymer quenchants having varying concentrations. An Inconel600 probe instrumented with thermocouples was used for this purpose. The thermal history at various locations in the probe was used as an input to the inverse heat conduction model. The inverse analysis yields spatially dependent heat flux transients. The quench severity was assessed using the Grossmann technique. The wetting kinematics of quenching was studied by cooling curve analysis. The severity of quenching as measured by the Grossmann’s technique was found to be higher for polymer quenchants. However, the heat flux transients estimated by the inverse technique and rewetting times measured form the cooling curve analysis suggested comparable and uniform heat transfer with polymer quenchants compared to water quenchants.

Several industrial heat treatment processes, such as martempering and austempering, require a quench bath to be maintained at a temperature ranging between 150°C–600°C. Molten salts, molten alkali, and hot oils are the preferred quenchants for these processes. Molten salts and molten alkali are preferred over hot oil because they possess properties like wide operating temperature range, excellent thermal stability, and tolerance for contaminants. In the present work, the performance of a molten potassium nitrate (KNO3) quench bath was analyzed with an Inconel probe that measured 60 mm in height and 12.5 mm in diameter. The probe was heated to 850°C and subsequently quenched in a bath maintained at 450°C. Cooling curves at different locations of the probe were recorded using the K-type thermocouples inserted into the probe. Spatially dependent transient heat flux at the metal/quenchant interface was estimated using inverse heat conduction technique. The existence of two stages of quenching—boiling stage and convection stage—was confirmed by analyzing the heat flux. The heat transfer coefficient was calculated based on heat flux obtained by the inverse method. The nonuniformity in heat transfer along the length of the probe was quantified by calculating the range of surface temperatures at each instance. The hardness distribution in an AISI 4140 steel was predicted using the temperature distribution in the Inconel probe and obtained using inverse method. Uneven distribution of hardness predicted in the probe was attributed to the nonuniform cooling of the probe during quenching.