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HEAT TREATMENT (THROUGH HARDENING) OF EN 24(AISI

4340) & EN36(AISI 3310) MATERIAL COMPONENTS OF


FUELLING MACHINE HEADS, SERVICE TOOLS AND
SPARES.

PROCEDURE:
1.0 SCOPE
2.0 APPLICABLE CODES & STANDARDS
3.0 EQUIPMENT USED
4.0 CALIBRATION OF FURNACES AND INSTRUMENTATION
5.0 CALIBRATION WITH REPRESENTATIVE SCRAP LOAD
6.0 WITNESS COUPONS
7.0 CLEANING AND DEGREASING
8.0 HEAT TREATMENT CYCLE FOR EN-24 (AISI 4340) MATERIAL
COMPONENTS
8.1 PREHEATING
8.2 HARDENING
8.3 OIL OR POLYMER QUENCHING
8.4 TEMPERING
9.0 HEAT TREATMENT CYCLE FOR EN-36C (AISI 3310) MATERIAL
COMPONENTS
9.1 PRE HEATING (GAS CARBURISING)
9.2 GRAIN REFINING
9.3 OIL OR POLYMER QUENCHING
9.4 CASE HARDENING
9.5 OIL OR POLYMER QUENCHING
9.6 TEMPERING
10.0 HEAT TREATMENT CYCLE FOR SS440C MATERIAL COMPONENTS:
10.1 STRESS RELIEVING:
10.2 1ST PRE HEATING & 2ND PRE HEATING
10.3 HARDENING
10.4 QUENCHING
10.5 CLEANING
10.6 STABILIZING
10.7 1ST TEMPERING & 2ND TEMPERING
10.8 INSPECTION AND TESTING OF SS440C MATERIAL
COMPONENTS
10.9 HARDNESS
10.10 MICRO STRUCTURE
11.0 INSPECTION AND TESTING OF EN-24 & EN -36C MATERIAL
COMPONENTS
12.0 RECORDS
1.0 SCOPE

This procedure is applicable for Heat treatment (Through


Hardening ) of components of F/M Head assembly(for 700 MWe) and
associated equipment of Material: EN -24(AISI-4340), EN -36C (AISI-
3310) & SS440C

2.0 APPLICABLE CODES & STANDARDS :

1. NPCIL SPEC. NO. PC-E-122 for manufacture of Fuelling Machine


Head(700 MWe)

3.0 EQUIPMENT USED

Electrically Heated forced Air Circulation Furnace, SGC Furnace /


Neutral Salt Bath Furnace and associated equipment viz.,
Thermocouples, compensating cables, temperature indicators,
controllers, recorders etc.,

4.0 CALIBRATION OF FURNACES AND INSTRUMENTATION:

4.1 The furnace instrumentation viz., temperature controllers,


indicators and temperature recorders shall be calibrated once in
three months.
4.2 Thermocouples and compensating cables shall be calibrated
once in three months

4.3 For calibration of Neutral salt bath Furnace, one calibrated


thermocouple for bath controlling and one calibrated thermocouple
for bath uniformity checking from bottom to top of the molten salt
level will be used.

Temperature variation within the working zone will be maintained


within +10 0c of the temperature set by controller.

4.4 For calibration of FAC Furnace, one calibrated thermocouple


per 0.75 cu.meter of the working zone or a minimum number of
five calibrated thermocouples shall be used. At the time of
treatment, three job thermocouples will be used.

Temperature variation within the working zone will be maintained


within +50C of the temperature set by the controller. Calibration of
F.A.C. Furnace will be done by loading of scrap metal in to the
furnace and load spread uniformly in the furnace. For calibration of
Neutral salt bath furnace, a lengthy thermocouples will be used
shifting the same to various zones. Furnace temperature uniformly
checks will be done every 6 months during execution of the order
4.5 For calibration of Gas Carburising Furnace, No. of witness
pieces will be placed at different levels in the furnace within the
working zone along with Dummy load spread uniformly in the
furnace. After carrying out Heat Treatment to the case hardening
requirements (as specified in the closed Annexure-1 for EN- 36C
Material Components),witness pieces placed at different levels
within the working will be checked for Case Hardness and effective
Case depth and conformity to the case hardening requirements on
all the witness pieces shall be the sign for valid Calibration of the
Gas Carburising Furnace.

5.0 CALIBRATION WITH REPRESENTATIVE SCRAP LOAD


Thermocouples, compensating cables, temperature controllers and
temperature recorders shall be calibrated as a whole to ensure that
these instruments indicate the temperature of the job in the furnace
within +50C. This will be ensured by loading scrap and monitoring
furnace temperature.

However if any of the thermocouples or temperature controllers or


recorders are replaced /repaired due to accidental damage or such
other reasons then they shall be recalibrated. Calibrated readings
and test results for the furnace and instruments shall be submitted
to NPCIL- QA for certifying the furnace.
Furnace temperature uniformity checks shall be done in every six
months during execution of the order.

6.0 WITNESS COUPONS:


The witness coupon will be kept in the furnace along with the
components. The size of witness coupon is given in enclosed
annexures (Annexure-1 )

7.0 CLEANING AND DEGREASING:


All parts shall be thoroughly cleaned before taking up for heat
treatment. Traces of oil, grease, dirt shall be removed using
degreasing agents like acetone or any other suitable agent Absolute
cleanliness of furnace, storage space etc., shall be maintained.

8.0 HEAT TREATMENT CYCLE FOR EN-24 (AISI 4340)


MATERIAL COMPONENTS
8.1 PREHEATING
After cleaning OF components, the components along with witness
piece shall be loaded into the Forced Air Circulation Furnace and
heated to a temperature of 6000C and holding for 45 minutes at
6000C
8.2 HARDENING
The preheated parts shall be loaded into salt bath Furnace at 8000C
and shall be stabilised for 30 minutes at 8100C-8200C. The
temperature shall then be raised to 8500C-8650C (Hardening
temperature is specified for each component in the enclosed
Annexure-I) and soaked for a period given in the enclosed Annexure-
I against each component

8.3 OIL OR POLYMER QUENCHING


The components shall be quenched either in mineral oil bath (Servo
quench grade 11) or in Polymer bath o Polymer grade p11. The
temperature of the bath should b 550 Max. After quenching the
components shall be allowed to cool and Hardness in as quenched
condition shall be checked on 10% of the components.

8.4 TEMPERING
The components shall be into Forced Air circulation tempering
Furnace and temperature shall be raised to 5500 C- 6000C
(tempering temperature ids mentioned for each component in the
enclosed Annexure-I) and shall be soaked for a period mentioned in
the enclosed Annexure-I and Air cooled.

9.0 MATERIAL COMPONENTS


9.1 PREHEATING
After cleaning of components, components will be loaded into Gas
carburising Furnace and temperature shall be raised to 4500C +
100C and soaked for a period of 1-2 hours at this temperature. The
temperature shall then be raised to 6000C and soaked for a period of
1 1.5 hours at this temperature. Then temperature shall be raised
to 9200C 9300C and components shall be held at this temperature
till required case depth is achieved. This shall be checked on witness
piece removing from the bath. After ensuring that required case
depth is achieved, Furnace is allowed to cool from 9200C to 6500C-
7000C and components shall be soaked at this temperature for 2 to 3
hours. Then temperature shall be reduced up to 450 0C by furnace cooling
and components shall be unloaded and cooled at still air

9.2 GRAIN REFINING


Components will be pre heated in Forced Air circulation Furnace to
5000C to 5500C and holding for 30 min to 1 hour at this temperature.
Components will be further heated to 8550C for 1 hour plus 10 min
either in same FAC Furnace or by shifting the components into salt
bath Furnace and heating to 8550C and soaking for a period of 1
hour + 10 min at 8550C.

9.3 OIL OR POLYMER QUENCHING


The components shall be quenched in either in mineral oil bath
(Servo Quench grade-11) or in polymer bath of polymer grade P-
11.The temperature of the bath shall be 550C max.

9.4 CASE HARDENING


The components shall be loaded into salt bath /Gas carburising
Furnace and shall be heated to 8000C -8200C and stabilised for
1hour at this temperature.

9.5 OIL OR POLYMER QUENCHING:


The components shall be quenched either in mineral oil bath
(Servo quench grade 11) or in Polymer bath of Polymer grade P11.
The temperature of the bath shall be 550C max

9.6 TEMPERING
The components shall be loaded into FAC Furnace / Gas carburising
Furnace and temperature shall be raised to 160-1700C and soaking
shall be done at this temperature for 2 hours+ 10 min followed by
Air cooling.

10.0 HEAT TREATMENT CYCLE FOR SS 440C MATERIAL


COMPONENTS

10.1 STRESS RELIEVING:


The components along with the witness coupon shall be loaded
into FAC Furnace and stress relieved at a temperature of 6000C -
6200C for 90 minutes and then furnace cooled to 2500C (min) and
subsequently cooled in air to room temperature.

10.2 1ST PRE HEATING


After cleaning, components along with the witness piece shall be
loaded into FAC Furnace and temperature shall be raised to 6000C
to 6200C for 60 min.

2nd PRE HEATING

The components shall be loaded into the salt bath Furnace


from FAC Furnace for 2nd pre heating and temperature shall be
raised to 8100C - 8300C and holding it for a period of 30 minutes.
10.3 HARDENING
The temperature of the pre heated parts shall be raised to 10250C
- 10350C and holding the temperature for 54 min.

10.4 QUENCHING
Components shall be quenched in mineral oil bath (Servo quench
grade 11). As quenched Hardness shall be checked on witness
pieces.

10.5 CLEANING:
All the components shall be cleaned thoroughly in hot water.

10.6 STABILIZING
The components shall be loaded into subzero treatment Furnace
(Hot & Cold chamber) and shall be soaked at the temperature of
-700C to -800C (-750C-+50C) for 120 minutes, within two hours after
quenching.

10.7 1ST TEMPERING


The comlponents shall be placed into FAC tempering Furnace and
temperatures shall be raised to 3500C-+100C and shall be soaked
at this temperature for 120 minutes, followed by air cooling.

2nd TEMPERING
2nd Tempering cycle will be decided / finalised at the time of
tempering the actual components, based on pre-production trail
results, ensuring Hardness of 51-56 HRC.

10.8 INSPECTION AND TESTING OF SS440C MATERIAL


COMPONENTS
All the components shall be thoroughly cleaned after tempering
and inspected visually for any damages.

10.9 HARDNESS
Hardness shall be checked after tempering. The required Hardness
shall be 51 56 HRC.

10.10 MICRO STRUCTURE


Under Microscopic examination, the structure shall be in the Matrix
of tempered Martensite.

11.0 INSPECTION AND TESTING OF EN-24 & EN-36C


MATERIAL COMPONENTS
All the components shall be cleaned thoroughly after tempering and
inspected visually for any damages.
11.1 Hardness check shall be done in 100% components on
hardness testing machine and results shall be recorded.
11.2 Mechanical testing shall be done (Tensile & Impact Testing)
applicable to EN-24 & EN36C components and shall meet the
drawing requirements as specified in the enclosed Annexure-I for
each component.
11.3 For all EN-36 C material components (Case Hardened
Components), following requirements should be met (as per clause
No.2.6.3(C) and 2.6.11 of Annexure-4 of Tender Document).

1. Case Hardness shall be 56 RC min unless otherwise


specified in the drawing.
2. Effective case depth define as depth upto which the
Hardness is more than 50 RC shall be 0.8 to 1.0 mm
exclusive of finish grinding allowance, unless otherwise
specified in the drawing. Micro hardness traverse across
the case depth shall be carried out on witness specimen
and reported.
3. Austenitic grain size shall be No:5 or finer as determined by
Mc Quid Ehn test in accordance with ASTM-E-112. Single or
Double grain orefinement shall be carried to achieve this.
4. The microstructure shall be tempered martensite and shall
not exhibit retained austenite or undissolved cementite
network.
5. Then case shall extend over all areas in contact with
mating/sliding parts and shall not have soft spots.
12.0 RECORDS
Records of Time Temperature charts for hardening & tempering
cycles, Hardness reports, Mechanical testing reports (for E-24 & EN-
36C Components), Microhardness Traverse Reports (for EN-36C
Components) and Microstructure Reports (for EN-36C and & SS 440C
components) shall be verified by MTAR-QA and NPCIL-QA for the
requirements specified in this procedure and Annexure-I for each
component and proper documentation shall be maintained.
MATERIAL : AISI 3310 (EN - 36C )

HEAT TREATMENT CONDITION : HARDENING & TEMPERING

1. EQUIPMENT : ELECTRICALLY HEATED FORCED


AIR CIRCULATION FURNACE

SGC FURNACE / NEUTRAL ALT


BATH FURNACE

2. COMPONENT DESCRIPTION: CAM SHAFT

3. DRAWING. NO.

KAPP-3&4/35221/ : 2345 / DD

4. OVERALL SIZE : 50.812 465.5

5. PREHEATED SIZE : 50.8465.5

6. COUPON SIZE FOR : 54190

TENSILE TEST SPECIMENS : 54547


WITNESS PIECE : 2 NO.S

7. TOTAL QTY. (NOS) : 7 NOS

8. CYCLE : GAS CARBURISING : 920 0C


9300C FOR 8-9 Hours.

GRAIN REFINING : 855 0


0
C 5 C FOR 60 MIN &

OIL QUENCHING

CASE HARDENING : 800 0C -8200


FOR 60 MIN&

OIL QUENCHING
TEMPERING : 160 0C -
1700C FOR 120 MIN&

AIR COOLING.

9. PROPERTIES REQUIRED ( AS CALLED UP IN DRAWING )

1. Ultimate Tensile Strength : 110 Kg/mm2

2. Yield Strength(0.2% strain) : 95 Kg/mm2

3. % Elongation : 13 (Min)

4. Impact Strength : 4.8 Kg-m(Min)

5. Hardness : 330 BHN

6. Case Hardness : 58-62 HRC

7. Case Depth : 0.6- 0.8mm

MATERIAL : AISI 4340 (EN - 24)

HEAT TREATMENT CONDITION : HARDENING & TEMPERING

1. EQUIPMENT : ELECTRICALLY HEATED FORCED


AIR CIRCULATION FURNACE,

SGC FURNACE / NEUTRAL ALT


BATH FURNACE

2. COMPONENT DESCRIPTION: BEARING HOUSING

3. DRAWING. NO.

KAPP-3&4/35222/ : 2035/ DD

4. OVERALL : 325125

5. PREHEATED SIZE : 329 101129


6. COUPON SIZE FOR : 32125

3 TENSILE TEST SPECIMENS : (3 NOS)

WITNESS PIECE 1 NO. : 3250

7. TOTAL QTY. (NOS) : 25 NOS

8. CYCLE : HARDENING CYCLE : 855 0C


50C FOR 70 MIN.

OIL QUENCHING : 55 0C

TEMPERING CYCLE : 590 0C - 6000C


FOR 150 MIN.

COOLING : AIR
COOLING.

9. PROPERTIES REQUIRED ( AS CALLED UP IN DRAWING )

1. Ultimate Tensile Strength : 100 Kg/mm2

2. Yield Strength(0.2% strain) : 80 Kg/mm2

3. % Elongation : 17 (Min)

4. Hardness : 28 -34 HRC