A New Approach for Studying Mechanical Properties of Thin Surface Layers Affected by Manufacturing Processes

[+] Author and Article Information
S. P. Moylan, S. Kompella, S. Chandrasekar, T. N. Farris

Center for Materials Processing and Tribology, Schools of Engineering, Purdue University, West Lafayette, IN 47907-1287

J. Manuf. Sci. Eng 125(2), 310-315 (Apr 15, 2003) (6 pages) doi:10.1115/1.1559161 History: Received December 01, 2000; Revised March 01, 2002; Online April 15, 2003
Copyright © 2003 by ASME
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Schematic diagram illustrating taper-sectioned cylindrical specimen comprising of a surface layer (or coating) on a substrate. (a) Plan view and (b) cross-sectional view of cylinder. The indents are made on the sectioned surface shown in (a) either in the form of a 2-D rectangular array or along line A-A inclined at an angle of ∼10° to the specimen edge. The thickness (tm) of the surface layer in the taper section is related to the real or radial thickness (t) of this layer by the formula t=tm cos α=tm w/r.
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Optical micrograph of a typical array of indents in a taper-sectioned AISI 4340 steel sample. The indenter penetration depth is 500 nm and the indent spacing in 20 μm horizontally and 10 μm vertically.
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Optical micrograph showing white layer on taper-sectioned steel. (a) 52100 steel: the white layer (WL), and the bulk microstructure are marked in the figure. Machining conditions: VBmax=300 μm, depth of cut=0.2 mm,feed=0.1 mm/rev, and cutting speed=150 m/min. (b) 4340 steel: The burn layer on the ground surface is seen as a white etching layer very similar to the WL observed on machined steel. The burn layer is seen to extend about 20 μm into the sub-surface.
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Atomic force microscope (AFM) image and AFM profile along a section of a Berkovich indentation, and (b) its associated load-displacement curve. The nominal indenter penetration depth is 500 nm and the actual residual depth of the indent as measured from the AFM line profile is 410 nm.
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Depth profile of variation in hardness along taper-sectioned surface of ground 4340 steel. The ground surface showed visible discoloration characteristic of grinding “burn.”
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Hardness results for a TiN-coated M2 steel sample obtained using the new approach. Indents 1 through 13 were identified as being entirely within the TiN coating, indents 14 through 24 were in the transition zone between the TiN coating and the M2 steel substrate, and indents 25 through 50 were within the M2 steel substrate. The depth into the substrate increases with increasing indent number.




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