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Improvement of Wear and Corrosion Resistance of the H13 Tool Steel by Using Thermal Surface Treatment

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Improvement of Wear and Corrosion Resistance of the H13 Tool Steel by Using Thermal Surface Treatment IMPROVEMENT OF WEAR AND CORROSION RESISTANCE OF THE H13 TOOL STEEL BY USING THERMAL SURFACE TREATMENT 2020 PhD THESIS MECHANICAL ENGINEERING HAMDI ABDULHAMID HASAN RAGHS Assist.Prof.Dr. M. Huseyin CETIN IMPROVEMENT OF WEAR AND CORROSION RESISTANCE OF THE H13 TOOL STEEL BY USING THERMAL SURFACE TREATMENT HAMDI ABDULHAMID HASAN RAGHS T.C. Karabuk University Institute of Graduate Programs Department of Mechanical Engineering Prepared as PhD Thesis Assist.Prof.Dr. M. Huseyin CETIN KARABUK September 2020 I certify that in my opinion the thesis submitted by Hamdi Abdulhamid Hasan Raghs titled “IMPROVEMENT OF WEAR AND CORROSION RESISTANCE OF THE H13 TOOL STEEL BY USING THERMAL SURFACE TREATMENT” is fully adequate in scope and in quality as a thesis for the degree of PhD. Assist.Prof.Dr. M. Huseyin CETİN .......................... Thesis Advisor, Department of Mechanical Engineering APPROVAL This thesis is accepted by the examining committee with a unanimous vote in the Department of Mechanical Engineering as a PhD thesis. September 2020 Examining Committee Members (Institutions) Signature Chairman : Assoc.Prof.Dr. Okan UNAL (KBU) .......................... Member : Assoc.Prof.Dr. Fuat KARTAL (KU) .......................... Member : Assist.Prof.Dr. Nuri SEN (DU) .......................... Member : Assist.Prof.Dr. Abdullah UGUR (KBU) .......................... Member : Assist.Prof.Dr. M. Huseyin CETIN (KBU) .......................... The degree of PhD by the thesis submitted is approved by the Administrative Board of the Institute of Graduate Programs, Karabuk University. Prof. Dr. Hasan SOLMAZ .......................... Director of the Institute of Graduate Programs ii “I declare that all the information within this thesis has been gathered and presented in accordance with academic regulations and ethical principles and I have according to the requirements of these regulations and principles cited all those which do not originate in this work as well.” Hamdi Abdulhamid Hasan RAGHS iii ABSTRACT Ph. D. Thesis IMPROVEMENT OF WEAR AND CORROSION RESISTANCE OF THE H13 TOOL STEEL BY USING THERMAL SURFACE TREATMENT HAMDI ABDULHAMID HASAN RAGHS Karabuk University Institute of Graduate Programs The Department of Mechanical Engineering Thesis Advisor: Assist. Prof. Dr. M. Huseyin CETIN September 2020, 203 pages In this thesis, the H13 alloy steel specimens will subject to Thermal surface treatments in order to improve and enhancing wear and corrosion resistance, and an attempt to expose H13 alloy steel samples to different experiments, and improve the length of life of H13 tool steel by increasing the hardness, toughness, impact resistance and its fatigue strength, and the ability to withstand cracking. Thus improving economic viability by limiting early failure and the ultimate goal is economic gain through delaying fail mode. To this end, we will employ a thermal treatment process to stress relieving, for the purpose of decreases stresses in H13 tool steel, which will later be heated and cooled so as to modify their physical and mechanical properties while maintaining the form and without changing the product shape, and examine elemental compositions, surface morphologies and structural properties, and tribology properties of the H13 steel in hot conditions. iv In the present thesis, powder boronizing occurs in boriding and, applying boron paste, we develop a shielding layer while treating the samples with heat so as withstand oxidation. In the meantime, boronizing with powder is is carried out under a controlled atmospheric environment to prevent oxidation, and detecting the microstructures in further detail.To determine the phases formed on the surface, all materials are examined. Accordingly, the maximum surface hardness is seen to materialize with boriding process. In this respect, boronizing is shown to offer many advantages in comparison with conventional hardening methods.The boride layer has high hardening value, and maintains this property at high temperatures along with other ideal features, namely, protection against wear, oxidation and corrosion. Moreover, microhardness measurements are carried out in various cross-sections. Additionally, Wear and corrosion resistance of the specimens was measured and checked alongside metallographic analyses of the boronized samples, later to be tested again for abrasion. The results are compared to determine the economic implications, because abrasion of these kind of materials cause financial costs, which further emphasizes the need to develop wear and corrosion resistance in such tools. In the laboratory, we used nano-silver-doped lubricants under working conditions. The boronizing process was carried out at 700, 800, and 900 °C for 2, 4, and 8 h in a nano-boron powder atmosphere. Wear tests were conducted under dry conditions and with nano-silver-doped colloidal suspension media prepared with three different ligands. Analyses of the experimental results examined the parameters of friction coefficient, weight loss, microhardness and surface roughness. According to the experimental results, an average coating thickness of 26.5 µm and hardness value of 2001 HV were obtained under conditions of 900 °C for 4 h. The nano-silver-doped colloidal suspension prepared with gelatin yielded 52% better friction coefficient, 88% better weight loss and 51.42% better surface dryness results than the dry wear conditions. It was determined that nano-silver-doped colloidal suspensions prepared with different ligands exhibited different characteristics in the wear environment, and also the corrosion rate decreases at 900 ° C for 4 hours and the corrosion resistance increases. v We selected AISI H13 tool steel in this research, because it has large application on tools production. Wear of extrusion dies has an important technological and economic significance due to cost to prevent die failure from thermal cracking, erosive wear, soldering and corrosion or a combination of these processes. The hardness, strength of H13 can be enhanced significantly through the application of compressive residual stresses around the surface area. In our attempts, Structure investigations will have performed by Corrosion test , Hardness test, Wear test , Microstructure view analysis by Scanning Electron Microscope (SEM), Ultra-violet (UV), Transmission Electron Microscopy (TEM),Energy Dispersive X-ray analysis (EDX), and XRD Analysis is used to define the mechanical properties for specimens, and also 3D topography methods were used for visual and elemental analysis of the surfaces. Thus the specimens being compared to study the change of metal, and this will help us to explain properties of the samples so as to detect all variations and changes likely to occur in the course of the experiments, and also the research has made Recommendation for future work. Keywords: Boriding, Scanning Electron Microscope (SEM), Energy Dispersive X- ray analysis (EDX), Transmission Electron Microscopy (TEM), American Iron and Steel Institute (AISI), Severe Plastic Deformation (SPD), Surface Treatment of Metals (STM), Wear resistance, Stress Corrosion Cracking (SCC),Surface Engineering (SE), Coefficient Of Friction (COF), Mechanical Properties, Surface Mechanical Attrition Treatment (SMAT), Charge Coupled Device (CCD), Corrosion resistance, XRD analysis, surface quality, Composition Structure, Erosion, Corrosion behaviour, Metal matrix composite, Mechanical surface treatments, Tribology properties, Thermal surface treatments, High temperature corrosion, Wear rate, Sliding wear, Tool steel, Micro hardness, Wear behaviour, Corrosion rate. Surface damage, Microstructure, Surface treatments, Toughness, Wear mechanisms, Structural steel. Science Code : 91419 vi ACKNOWLEDGEMENTS I want to thank my God for seeing me through this program successfully despite the all challenges along the way. The author would like to take this opportunity to thank a number of individuals who have in one way or another made the production of this thesis possible. I would like to gratefully acknowledge these assistances from all those people who offered me their help. This thesis would not be finished without their supports, and for their significant help of this work and for contributions to my academic and professional development: First, I would like to express my deepest gratitude to my supervisor, Dr. M. Huseyin CETIN, with whose guidance I finished the dissertation smoothly. He not only taught me the useful research methodology, but also has offered me valuable suggestions and criticisms with his knowledge in this topic and rich research experience, and instilled the necessary confidence for success. He was always there to provide encouragement, especially when I needed it most. Thank you for all of the constructive feedback, sharing of your experiences, and for helping me get to the finish line, I do appreciate his great help for this thesis. I would like to equally express my gratitude to the Mechanical Engineering Department and graduate college for support throughout my study. Second, I am extremely grateful to Research. Assistant. Bilgehan KONDUL in university. I cannot make this research without her supports and encouragement. In addition, Thanks are also due to my programme friends, who never failed to give me great encouragement and suggestions. vii I thank all of my colleagues and fellow students for all the help and guidance throughout my research, whether it was with lab equipment or procedures, or just research questions and discussions, you have all been
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