Wear 266 (2009) 11061112

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Wear
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Abrasive wear behavior of boronized AISI 8620 steel

M. Tabur a , M. Izciler a, , F. Gul b , I. Karacan c
a

Gazi University, Industrial Arts Education Faculty, Technology Education Department, Glbas, Ankara, Turkey
Gazi University, Tech. Education Faculty, Metal Education Department, Besevler, Ankara, Turkey
c
Karabuk University, Tech. Education Faculty Manufacturing Education Department, Karabuk, Turkey
b

a r t i c l e

i n f o

Article history:
Received 24 January 2008
Received in revised form
23 December 2008
Accepted 4 March 2009
Available online 18 March 2009
Keywords:
Boronizing
Abrasive wear
AISI 8620 steel

a b s t r a c t
In this study, AISI 8620 steel was boronized using the solid state boronizing technique. Processes were
carried out at the temperatures of 850, 900 and 950 C for 2, 4 and 6 h of treatment. Abrasive wear behavior of the samples boronized at different temperatures and treatment durations have been examined.
Using boronized and unboronized samples, abrasive tests were conducted using pin on disc test apparatus. 80 and 120 mesh aluminum oxide (Al2 O3 ) abrasive papers were used in the abrasion experiments
and the samples were subjected to abrasion under 10, 20 and 30 N loads. Boronized steels exhibited an
improvement in abrasive wear resistance reaching up to 500%. Microstructures and wear surfaces of the
samples were inspected using SEM microscopy. SEM examinations revealed that the thickness of the
boride layer on the steel surfaces changes with changing process durations and temperatures. The presence of boride formed in the borided layer at the surface of the steels were determined by XRD analysis
and microhardness values of the iron borides (FeB, Fe2 B) formed on the steel surface were found to be
over 1600 HV.
2009 Elsevier B.V. All rights reserved.

1. Introduction
Boronizing is one of the methods used on steels and iron
to improve their surface properties [1]. Boronized steel parts
exhibit excellent performance in various tribological applications
in mechanical engineering and in the automotive sector [2]. In the
past 40 years, boronizing has become an increasingly better surface
protection method [3]. Boronizing of steels is used against adhesive,
sliding and abrasive wear and is recognized as an effective method
to combat these effects [113]. The most widely known boronizing
procedure is forming iron borides on the steel surface [5]. Boronizing is one of the most widely used methods in many tribological
applications where wear and friction control are paramount [14].
The boronizing process is a chemical heat treatment that aims to
form borides with the substrate metal by diffusing the boron atoms
into the sample surface [14]. Boron is a metal that can form many
minerals and compounds [6]. Because it is a relatively small element, the process may be applied to many types of materials such as
ferrous and non-ferrous metals [15], nickel and cobalt alloys, metal
bound carbides, refractory alloys [13] and some super alloys [15].
Boronizing of ferrous products is usually conducted between 840
and 1050 C [7,14]. There are several techniques available for surface boron enrichment process [8]. The process can be carried out
employing any of the solid, liquid, gaseous state [7,14], plasma and

Corresponding author.
E-mail address: mizciler@gazi.edu.tr (M. Izciler).
0043-1648/$ see front matter 2009 Elsevier B.V. All rights reserved.
doi:10.1016/j.wear.2009.03.006

ion implantation [16] environments [17]. Pack boronizing mixtures

comprise 5% B4 C as the source, 5% KBF4 as activator and 90% SiC as
the diluting agent [7,9]. During the boronizing process, the sample
is put inside a sealed container packed with powder mix and sealed.
The container is heated up to desired temperature and kept at that
temperature for the prescribed time, and nally cooled [7].
With the diffusion of boron into the steel, iron borides (FeB,
Fe2 B) form and the thickness of the boride layer is determined by
the process temperature and time [9,17]. The crystal structure of
both layers exhibit columnar shapes oriented along the diffusion
axis [18]. Generally, saw-tooth shaped single phase (Fe2 B) layer formation is preferred over a layer with both FeB and Fe2 B [7,9]. The
boron-rich FeB phase that has approximately 16.23 wt% B is not preferred because it is more brittle compare to the Fe2 B phase that has
8.83 wt% B [19]. Boride layers adhere to the substrate material more
strongly because of the saw-tooth morphology. Brittleness of the
boronized layer increases with the layer thickness [1,20]. Also, since
the FeB and Fe2 B phases have different thermal expansion constants (TEC; FeB = 23 106 C1 , Fe2 B = 7.85 106 C1 ), crack
formations are frequently found on the FeB/Fe2 B phase interfaces in
two phase layers. These cracks frequently cause spalling and scaling
under a mechanical load [19]. By controlling the boronizing parameters, that is the boronizing powder composition, temperature and
process time, the pack boronizing method can reliably produce the
Fe2 B phase [7].
Steels surface treated using boronizing heat treatment methods
are widely used in industry. It is known that the boride layers can
exhibit surface hardness over 2000 HV and provide good abrasive

M. Tabur et al. / Wear 266 (2009) 11061112

and adhesive wear resistance [21]. Comparison of steels used in

industry treated with other surface hardening treatments such as
carburizing and nitriding with boronizing shows that the boronized
steels have superior tribological characteristics [22]. Boronized iron
and steel surfaces exhibit high hardness, excellent wear and corrosion resistance and strong chemical stability [16]. Habig reports that
the abrasive wear resistance of boronized steels is higher against
alumina abrasives than against silicon carbide abrasives. Habig concludes that this is because of relative hardness of these materials.
Richardson similarly reports that in case the hardness H value of
the material subjected to wear is higher than the hardness Ha of
the abrasive material or more appropriately in case H > 0.8Ha , wear
resistance signicantly decreases [23].
A very hard surface layer, a very low coefcient of friction, no
requirement of heat treatment after the boronizing process and a
very signicant resistance against some acids, bases, metal solutions and high temperature oxidizing are among the advantages of
boronizing over other surface hardening methods [24]. Hardness,
shape and size or roughness of abrasive material, angle of contact,
normal load applied, sliding speed and fracture toughness of the
material are all among important factors in wear mechanisms [1].
One of the most important reasons for the machinery parts to
suffer damage and fail is wear. Abrasive wear, most important type
of wear for the industrial machine parts, is important as it may cause
rapid failure in the system. Because of these, this study focuses on
the effects of boronizing treatments carried out at different temperatures and with different process durations on abrasive wear
resistance.
2. Details of the experiment
2.1. Test materials
Materials used in this study are AISI 8620 cementation steel
samples. Chemical composition of the samples is given in Table 1.
Test samples used were pin shaped with the at surfaces sliding
against the abrasive paper. Their nominal dimensions were 6 mm
(diameter) 50 mm (height).
Samples were ground using 500 mesh sandpaper before the
treatment and 200, 400, 600, 800, 1000 and 1200 mesh sandpapers
respectively and polished using 3 m diamond paste before etching in 2% Nital solution after the treatment. Cross sections of the
boronized steels were examined using a JEOL JSM-6060 LV brand
scanning electron microscope.
2.2. Boronizing process
Boronizing was conducted using the solid-state pack boronizing method. All samples were treated using a micro-processor
controlled electric resistance furnace with 1200 C temperature
limit, 5 C accuracy, a digital display and a volumetric capacity
of 200 mm 150 mm 250 mm. All samples to be boronized in the
treatment phase were packed inside stainless steel boxes with at
least 10 mm of powder mix packing thickness. The stainless steel
boxes were then securely sealed. Boronizing heat treatments were
carried out at temperatures of 850, 900, and 950 C for 2, 4 and 6 h
using Ekabor-II, a mixture with high boronizing potential. Argon
was used as the protective atmosphere. After boronizing, the samples were air cooled. The chemical composition of the Ekabor-II
mixture was; 5% B4 C, 5% KBF4 and 90% SiC. The mixture may be
Table 1
Chemical composition of AISI 8620 steel (wt%).

1107

Fig. 1. Pin-on disc abrasive test apparatus [27].

classied as high quality in regard to surface texture and is used in

low allow steel and pig iron and spero casting procedures.
2.3. Characterization and microhardness of specimen
Cross sections of the boronized steels were examined using
a JEOL JSM-6060 LV brand scanning electron microscope. XRD
analyses were performed in a Rigaku D/Max-2200/PC Model
diffractometer, with 2 varying from 20 to 100 , using Cu K radiation. Microhardness measurements of the samples were taken
using a Shimadzu brand HMV Micro Hardness Tester model apparatus. Microhardness was measured using a load of 0.1 kgf and average
of ve reading was evaluated.
2.4. Abrasion testing procedure
Abrasion tests were conducted using a pin on disc apparatus
under dry and grease-free sliding conditions at room temperature.
Abrasive tests of the boronized and unboronized were carried out
on the two-body pin on disc apparatus shown in Fig. 1 under 10,
20 and 30 N of load at the speed of 0.2 m/s using 80 and 120 mesh
aluminum oxide (Al2 O3 ) abrasive. Samples were moved in right
angle with the abrasion axis on the abrasive paper so that the samples were constantly kept in contact with new abrasive surfaces.
Total sliding distance of the samples on the abrasive surface was
10.25 m. Samples were weighed, before and after the test, using an
electronic scale with a resolution of 104 g in order to determine
wear losses as lost weight. Wear ratios of the samples with known
lost weight were calculated using the formula below [2527]. The
abrasion tests were performed three times for each sample and the
results were calculated using the mean values.
Wa =

G
mm3 /Nm
dMS

where Wa is the abrasion rate, G the mass loss, M the applied

load (force length), d the density and S is the sliding distance. The
respective densities of FeB and Fe2 B are 6.75 and 7.43 g/cm3 .
3. Results and discussions
3.1. Microstructure

Si

Mn

Cr

Mo

Ni

0.20

0.24

0.85

0.019

0.009

0.55

0.21

0.5

Scanning electron microscopy (SEM) on unboronized sample

(AISI 8620) revealed that the ferrite and pearlite phases are homo-

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M. Tabur et al. / Wear 266 (2009) 11061112

Fig. 2. Cross section SEM image of the borides formed on the surface of AISI 8620 steel with 400 magnication. (a) 850 C, 6 h; (b) 950 C, 6 h; (c) 900 C, 2 h; (d) 900 C, 6 h.

geneous throughout the matrix (Fig. 2(b)). SEM images taken from
the center of the sample boronized for 6 h at 950 C revealed that
the sample has grain growth. This is because the sample was cooled
in air after 6 h of boronizing at 950 C.
Scanning electro microscopy (SEM) examinations of the
boronized steels revealed that the borides on the surfaces of these
samples have smooth branched morphology. It was observed that
the thickness of the boride layer increased with boronizing time and
temperature [9,17]. Boronized surfaces had three distinguishable
zones. These are (i) layer with FeB and Fe2 B borides, (ii) diffusion
zone beneath the boride layer where boron makes a solid state solution with the steel and which has lower hardness than the borides
but higher hardness than the steel, and (iii) steel matrix free of
boron [14] (Fig. 2(a)(d)).
Fig. 2(a)(d) shows that increasing the boronizing temperature
and treatment duration increases the boride layer thickness. Boride
layer thickness is observed to increase more than twice depending
on boronizing time (Fig. 2(c) and (d)). Also, with increasing temperature and treatment duration, grain growth was observed; ferrite
and pearlite structures exhibited growth. Similarly, the inspection of (a) and (d) within Fig. 2 shows that the Fe2 B core formed
according to the composition of the main material and procedural
conditions is layer out along the boron gradient. Therefore, the high
stress areas and cage distortions that appears near the point of the
Fe2 B core allow the layer to grow colonically. The growth mechanism of the FeB phase show similarity to that of the Fe2 B phase.
The colonical formations between the FeB/Fe2 B layers are less than
those seen between the Fe2 B/matrix layers. The reason for this is
that the Fe2 B phase is based on a more ductile material in comparison to the FeB phase, resulting in the achievement in a harder
FeB phase [28]. Dybkov et al. indicated that the boron layer formation is not simultaneous, and that the Fe2 B phase is formed rst
[18]. Fig. 3 displays the XRD analysis used to determine the phases
formed on the samples boronized for 6 h at 950 C. Uslu et al. have
also reported in their study on P 20 steel that the Fe2 B phase is
formed before the FeB phase [29].

3.2. Microhardness and boride layer

Hardness values of the borides formed on the surfaces of the
boronized AISI 8620 steels are much higher than those of the substrate as can be seen in Fig. 4.
Change in the hardness of the AISI 8620 steel with distance from
the surface is shown in Fig. 4. Hardness of the unboronized AISI
8620 steel was found to be 220 HVN0.1. Vickers hardness values
of the boride layer and the matrix of the boronized samples are
1650 and 220 HVN0.1, respectively. As can be seen on the hardness
curves, hardness values of the borides are much higher than those
of the matrix. Hardness decreases with distance into the matrix.
This may be explained by grain growth in matrix with temperature
and treatment duration. The boride layer hardness of the sample
boronized at 950 C for 6 h was found to be 1850 HVN0.1, the boride
layer hardness of the sample boronized at 950 C for 2 h was 1710
HVN0.1, the boride layer hardness of the sample boronized at 850 C
for 6 h was 1750 HVN0.1, while the boride layer hardness of the
sample boronized at 850 C for 2 h was 1650 HVN0.1.

Fig. 3. X-ray analysis of AISI 8620 steel sample boronized for 6 h at 950 C.

M. Tabur et al. / Wear 266 (2009) 11061112

1109

Fig. 4. (a) Microhardness values of the samples boronized at 850 C for 2, 4 and 6 h; (b) microhardness values of the samples boronized at 950 C for 2, 4 and 6 h.

There are three zones present on the hardness distribution diagram; (i) borides, (ii) boron rich transition zone, and (iii) matrix [14].
Since boronizing treatment is a thermo-chemical diffusion process,
boride layer thickness increases depending both on the treatment
temperature and time. Bejar and Moreno and Uslu et al. have also
reported that the boride layer thickness increases under higher
temperatures and longer durations [13,29]. Furthermore, zdemir
et al. and Sahin have also reported that the boride layer thickness
increases together with the boronizing duration [30,31]. With the
increasing temperature, the boride layer thickness was observed
to increase. The boride layer thickness of the sample boronized at
950 C for 6 h was measured to be 250 m, the boride layer thickness of the sample, boronized at 950 C for 2 h was measured to
be 110 m, the boride layer thickness of the sample, boronized at
850 C for 6 h was measured to be 150 m while that of the sample
boronized at 850 C for 2 h was 80 m.

3.3. Wear behavior

Wear mechanism is dened as the physical and chemical phenomena that take place during wear. Abrasive wear refers to the
mechanism where two bodies rubbing against each other break
off pieces from each other. Hardness, shape and size or roughness
of abrasive material, angle of contact, normal load applied, sliding speed and fracture toughness of the material are all among
important factors in wear mechanisms [1].
Wear ratios of the samples are given in Fig. 4. Accordingly, largest
wear was exhibited by the sample boronized at 950 C for 2 h while
smallest wear was exhibited by the sample boronized at 850 C for
6 h. This is because the FeB layer formed on the sample boronized
for a longer time has a brittle and crisp [1,5,7,14,19,23] structure.
The decrease in wear on the sample boronized for 6 h at 850 C is
explained by the thickness of the boride level is increased at the

Fig. 5. (a) Wear rate of the unprocessed AISI 8620 steels with 80 and 120 mesh Al2 O3 sandpaper. Wear rate of the AISI 8620 steels boronized at 850 C for different treatment
times using (b) 80 mesh Al2 O3 sandpaper, (c) 120 mesh Al2 O3 sandpaper. Wear rate of the AISI 8620 steels boronized at 950 C for different treatment times using (d) 80 mesh
Al2 O3 sandpaper, (e) 120 mesh Al2 O3 sandpaper.

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M. Tabur et al. / Wear 266 (2009) 11061112

Fig. 6. SEM images of the worn surfaces of AISI 8620 steel at 200 magnication worn using 80 mesh sandpaper (a) side image of the sample boronized at 850 C for 2 h
under a load of 30 N; (b) side image of the sample boronized at 850 C for 6 h under a load of 30 N; (c) side image of the sample boronized at 950 C for 6 h under a load of
30 N; (d) side image of the sample boronized at 950 C at 6 h under a load of 10 N.

same temperature with the extension of the boronizing duration.

As seen in Fig. 2(a) and (d) the thickness of the FeB layer increases
at higher boronizing temperatures, leading to increased wear measured in samples boronized at higher temperatures. For this reason,

it is advantageous to boronize for longer durations at lower temperatures. Great care was taken to decrease the sliding distance
to determine the effects of these layers on wear resistance. Martini et al. in their study, Adhesive and Abrasive Wear Behavior of

Fig. 7. SEM images of the worn surfaces of AISI 8620 steel at 200 magnication worn using 120 mesh sandpaper (a) side image of the sample boronized at 850 C for 2 h
under a load of 30 N; (b) side image of the sample boronized at 850 C for 6 h under a load of 30 N; (c) side image of the sample boronized at 950 C for 6 h under a load of
30 N; (d) side image of the sample boronized at 950 C at 6 h under a load of 10 N.

M. Tabur et al. / Wear 266 (2009) 11061112

1111

Fig. 8. SEM images of the worn surfaces of unboronized AISI 8620 steel at 200 magnication. (a) Image of the surface worn under a load of 30 N and using 80 mesh Al2 O3
sandpaper; (b) image of the surface worn under a load of 30 N and using 120 mesh Al2 O3 sandpaper; (c) image of the surface worn under a load of 10 N and using 80 mesh
Al2 O3 sandpaper.

Boride Coatings, have concluded that the wear rate is very high
both under abrasive and adhesive conditions because of the brittle
outer layer with irregular crystal structure over the boride coating. Celebi et al. have observed as a result of their studies on AISI
8620 steel that the fracture toughness of the borides formed on the
steel boronized at higher temperatures is higher than those formed
at relatively lower temperatures. As for the effects of the abrasive paper mesh size on wear behavior, as can be seen in Fig. 4(a),
large grained (80 mesh) abrasive paper causes more wear than ne
grained (120 mesh) ones. All these ndings agree with the literature on this subject [13,5,13,23]. Goddard and Wilman found that
the wear behavior changes with the average grain size of the abrasive material and that the wear rate is increased with the increasing
grain size. As it can be seen in Fig. 4(a)(e), with the increasing load
applied on unit surface area, wear increases. Modi et al. reported in
their (2003) cooperative work that the wear rate exhibits changes
depending on the load and wear rate increases with increasing load
[32]. When the comparing with previous study [27], in this study,
boronizing process gives higher wear resistance than carburising
under 80 mesh abrasive paper.
When the SEM images of the worn surfaces of unboronized samples are examined, it can be seen that the wear marks in Fig. 5(a) are
larger and deeper. Least wear with the thinnest marks are observed
in (c).
Examining Fig. 6(a)(d), it is clear that the wear scars are deeper
and wider with increasing load and wear scars are getting wider and
deeper in the samples boronized at the same temperature while the
boronizing time decreases.
Examining Fig. 7(a)(d), it is clear that the wear scars are deeper
and wider with increasing load and decreasing boronizing time.
When Figs. 6 and 7 are compared, it can be seen that with the average grain size of the abrasive the wear changes; wear marks become
deeper and wider.
When the SEM images taken from wear surfaces are examined, it
can be observed from Figs. 68 that the samples unboronized have
deeper and wider wear scars than those of the boronized samples.
It is also clear that wear rate increases, with increasing load. Images
taken from the side of the sample boronized at 950 C for 6 h show
fractures because of the FeB layer. Again, from the gures, it is clear
that the wear scars are deeper and wider with increasing load.
4. Conclusions
In this study, abrasive wear behaviors and mechanical properties of AISI 8620 steels, both unboronized and boronized at different
temperatures for different treatment times were studied. Experimental results show that borides formed on the substrate exhibit a
smooth branched morphology. Microhardness values of the borides
formed on the AISI 8620 steel are much higher than that of the original substrate. Hardness of the sample boronized at 850 C for 2 h

is 1650 and that of the sample boronized at 950 C for 6 h is as

high as 1850 HVN0.1, while hardness of substrate is 220 HVN0.1.
It is clear from wear test results and SEM images that FeB layer is
harder and more brittle than Fe2 B layer. With increase in boronizing
temperature and time, it is observed that the boride layer thickness
increases too. There is a parabolic relation between treatment times
and layer thickness. It is understood that unboronized samples
exhibit inferior wear resistance compared to boronized samples.
The wear resistance of specimens increased boronizing time, at
the same boronizing temperature, grooves are much ner in sample boronized for 6 h and worn surface appear smoother. The wear
resistance of specimens decreased with increasing boronizing temperature at the same boronizing time. Grooves are much wider
and deeper for higher boronizing temperature. The wear rate is
found to be increasing with increasing load. It is also observed that
wear scars on the sample surfaces become deeper and wider with
increasing load and abrasive wear increases with increasing abrasive grain size. Finally, it is observed that the FeB layer that forms
on the sample surface exhibits a crisp and brittle structure. The
specimen boronized has higher wear resistance than the specimen
carburised.
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