The possibility of decreasing water polymer concentration, decreasing alloy elements in steel, decreasing distortion of steel parts, and increasing service life of machine components and tools during quenching is widely discussed in this paper based on achievements of modern physics. Instead of quenching alloy steel in oils or high concentration of water polymer solutions, the accelerated quench process of optimal hardenability steel in water low concentration of inverse solubility polymers is proposed. Physics of the new approach and new technologies is explained by the author. The creation of a thin polymeric insulating layer during quenching steel in low concentration of inverse solubility polymers decreases initial heat flux density below its critical value that is reason for absence the film boiling process. Due to this fact, full film boiling during quenching is completely absent allowing use optimal hardenability steel instead of alloy steels containing costly alloy elements. Accelerated cooling provided by low concentration of water polymer solution results in creation of high surface compression residual stress, and super strengthening of material that in turn increases service life of machine components and tools. It is underlined in the paper that along with the use of a thin polymeric insulating layer, the resonance effect can be used for destroying the full film boiling process based on implementation different kinds of hydrodynamic emitters. The proposed new technology saves materials, increases service life of steel parts, and improves environment condition in heat treating industry. The patented technologies and processes can be used by engineers and scientists. and can bring great benefits if widely implemented in the practice.
In the paper it is shown that quenching in slow agitated water salt solution of optimal concentration and in low concentration of inverse solubility polymers is intensive quenching creating maximal temperature gradients at the beginning of cooling. The evidence to support such idea were collected by analyzing quenching process in liquid media where any film boiling process was completely absent. In this case, surface temperature at the beginning of cooling drops closely to saturations temperature of a liquid within the interval 1–2 seconds, independently on nature of water solution, and then during transient nucleate boiling process maintains at the level of boiling point of a liquid which is often called self–regulated thermal process. The computer modeling of such cooling processes provided Kondrat’ev numbered Kn which are strongly linear function of time. At the beginning of cooling Kondrat’ev number is almost equal to 1 while average Kondrat’ev number Kn≥0.8. According to US Patent, intensive quenching starts when Kn=0.8. Based on achieved results, it is possible to perform intensive quenching in slow agitated of low concentration water salt and polymer solutions, usually initiated by hydrodynamic emitters. Along with liquid agitation, emitters generate resonance wave effect which destroys film boiling processes making cooling very uniform and intensive. The proposed IQ process works perfectly when martensite starts temperature Ms>Ts. If saturation temperature Ts≥Ms, intensive austempering process via cold liquids can be successfully performed to replace slow cooling of molten salts and alkalis by intensive quenching in liquid media.
Currently, metallurgists are trying to improve mechanical properties of steel by increasing alloy elements in it that require slow cooling in oils or high concentration of water polymers solutions. The paper discusses opposite way in increasing service life of machine components by cardinal decrease alloy elements in steel and providing intensive cooling in locally agitated plain water performed by moving sprayers. The proposed new approach is based on two fundamental phenomena which include creation of high surface compressive residual stresses after quenching and obtaining super - strengthened material in surface layers after intensive cooling. These two factors compensate decrease alloy elements in steel. The paper provides methodology of calculation for achieving maximal effect in residual surface compressive stress formation and super- strengthening of material depending on martensite finish temperature of steel. Effectiveness and benefits are considerable due to saving alloy elements, energy and increasing service life of products. A team of Ukrainian leading specialists is organized to design appropriate software for governing and optimizing hardening processes with the aim of achieving above benefits and make environment clean. New steel and technology of hardening is based on UA Patents No. 109577 and No. 114174
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