Khulna University of Engineering & Technology
Department of Materials Science and Engineering
Course Title: Sessional on Physical Metallurgy of Materials
Course No: MSE 3108
Experiment No: 05
Experiment Name: Carburizing of a Low Carbon Steel sample
Submitted by
Name: Fuad Sadik
Roll: 2127016
Year: 3rd
Semester: 1st
Group: A-3
Date of performance: 17.10.2025
Date of Submission: 25.10.2025
Objectives:
➢ To perform pack carburizing of a low-carbon steel sample.
➢ To study the effect of carburizing on surface hardness and microstructure.
➢ Measuring hardness from the core to the edge of the sample and evaluate carburizing
effectiveness.
Introduction:
Carburizing is a process of addition of carbon to the surface of low carbon steels at temperatures
between 850 and 950°C (1560 and 1740 °F) at which carbon solubility in austenitic iron very high.
For hardening, the carbon diffused surface layer is quenched to form martensite so that a high
carbon martensitic case with good wear and fatigue resistance is superimposed on a tough, low
carbon steel core. After carbon diffusion up to the predetermined depth from the surface of the
component, hardening is accomplished. Through this process LCS is transformed into hard surface
and tough core steel. The amount of carbon increases at the surface that’s why surface become
hardened. The case depth depends on Diffusivity constant and Time. [Case depth ≈ K √Time]
There are different types of carburizing such as,
1. Pack Carburizing
2. Gas Carburizing
3. Vacuum Gas Carburizing
4. Plasma Carburizing
Among this process, we performed Pack Carburizing in our lab.
Pack Carburizing:
In pack carburizing, the media is in solid condition. This type of case hardening is applied where
the chemical compositions of low carbon steel (0.1-0.25%C) is changed. For the solid carburizing
the following solid ingredients may be used:
Charcoal: 30-32%
Coke: 30-32%
Sodium Carbonate: 2-3%
Barium Carbonate: 10-12%
Carburizing in solid media involves packing the workpieces into heat resisting boxes (Fig-1) by
which the distance between them is maintained at least by 50mm, whereby causing diffusion of
carbon rich material into the specimen surface by heating above the transformation temperature
range of 900-950 degree C. At this high temperature, the steel part is held in contact with a
carbonaceous material for a specific period of time.
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Fig -1: Pack Carburizing Technique
The overall chemical reactions that take place during solid carburizing method are given below:
BaCO3 = BaO + CO2
CO2+ C = 2CO
2CO + 3Fe = FeC + CO2
Through these reactions, carbon id diffused to the steel surface and cause surface hardening. As
carbon gradually accumulates on the steel surface and diffuses inward, the carbon content is
highest at the surface and decreases toward the core. Consequently, the microstructure transitions
from hypereutectoid near the surface to eutectoid, medium-carbon, and finally low carbon (core)
structures deeper inside. The microstructure from the surface to core would be looking like this
after carburizing:
Fig-2: Variation in carbon content from surface to the core of a carburized steel.
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Apparatus:
1. Furnace (for heating)
2. Insulated box
3. Tong, crucible, and gloves
4. Vickers Hardness Testing Machine
5. Polishing machine
6. Stereoscope
7. Optical microscope
8. Emery paper of various grades (120,220,400,500,800,1000,1200, and 1500)
9. Watch glass
Chemical used:
1. Charcoal (117 g)
2. Coke (70.2 g)
3. Ba2CO3 (20g)
4. Na2CO3 (26g)
5. Molasses
6. Al2O3 for polishing
7. Nital solution for etching (2% nitric acid+ 98% ethanol)
Process of Carburizing:
The pack carburizing process systematically enhances the surface properties of low-carbon
steel. The procedure involves several critical stages, each designed to ensure effective
carbon diffusion and the development of a hard, wear-resistant surface layer.
1. Sample Preparation
The low-carbon steel specimen is first cleaned to remove all surface contaminants such as
oil, rust, or scale. This step is crucial, as any residue can block the diffusion of carbon atoms,
leading to an uneven case depth.
2. Encasement in Carburizing Compound
The cleaned specimen is placed inside a heat-resistant container and completely surrounded
by a solid carburizing compound. This compound typically consists of:
• Charcoal or Coke: Serves as the primary source of carbon.
• Barium Carbonate (BaCO₃): Acts as an energizer, promoting the chemical reactions
that release carbon.
• The container is then sealed to prevent the entry of air, which could oxidize the steel
surface and inhibit the process.
3. Heating and Diffusion
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The sealed container is heated in a furnace to a temperature between 900°C and 950°C and
held for a predetermined time. During this stage, a series of chemical reactions occur:
• The energizer breaks down, releasing carbon dioxide (CO₂).
• This CO₂ reacts with the solid carbon to form carbon monoxide (CO).
• At the hot steel surface, the carbon monoxide gas decomposes, depositing atomic
carbon.
This carbon dissolves into the steel's austenitic structure and diffuses inwards, driven by the
concentration gradient. The temperature and holding time are the primary factors controlling the
depth of this carbon-enriched layer, or case depth.
4. Cooling Process
• After the carburizing period, the box was taken out from the furnace and
allowed to cool slowly to room temperature.
• The specimen was then removed from the mixture and cleaned properly.
Steps after carburizing:
1. A quenched steel sample bar was collected and started to grinding by different types
of emery paper like 120, 220, 320, 500, 600, 800, 1000, 1200, and 1500, along with
a glass plate, were prepared for surface finishing.
2. Surface grinding began with 120-grit emery paper, applied for a fixed period to
remove surface irregularities.
3. The sample was rotated 90° and then ground using 220-grit emery paper to refine
the surface.
4. This sequential grinding process was repeated with progressively finer grits (400,
500, 800, 1000, 1200, and 1500) to achieve a smooth finish.
5. Then the polished surface was further refined using a polishing machine with
alumina powder until a mirror-like finish was obtained.
6. The polished sample was cleaned thoroughly with water and a soft cloth to remove
residual abrasive particles.
7. Now, the polished surface was etched, followed by etching with a 2% Nital solution
to reveal the microstructure.
8. The etched surface was examined under an optical microscope.
9. The initial hardness of the sample was determined using a Vickers hardness tester.
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Result and Discussion:
Microstructural Analysis:
pearlite ferrite
ferrite cementite pearlite
Fig: At core (40X) Fig: At mid (40X) Fig: At edge (40X)
Hardness value:
At the core – 289.4 HV
At the middle – 320.9 HV
At the edge – 355.4 HV
Hardness (HV)
400
350
300 Surface
Middle
250 Core
200
150
100
50
0
Position
Figure : Hardness Profile after Carburization
Interpret:
• This gradual increase in hardness indicates that carbon successfully diffused from the outer
surface toward the inner regions during the carburizing process.
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• The hardness gradient is clearly shown in the bar chart, confirming the diffusion pattern.
• However, the microstructural analysis revealed cementite and pearlite in all three regions—edge,
middle, and core.
• Ideally:
• Edge: Cementite–pearlite combination (due to high carbon content)
• Middle: Mainly pearlite
• Core: Ferrite–pearlite structure
• The presence of cementite in every zone suggests poor case depth control and excessive carbon
penetration.
• This over-carburization likely occurred because of:
• Long holding time (24 hours)
• High temperature (950 °C)
• Inadequate monitoring of carbon potential within the pack
• Such conditions can cause deep carbon diffusion and even formation of continuous cementite
networks.
• These networks reduce toughness and may lead to surface brittleness.
Conclusion:
From the discussions so far, it can be concluded that:
➢ The mechanical properties of mild steels were found to be strongly influenced by the
process of carburization, carburizing temperature soaking time at carburizing temperature.
➢ The hardness value of the surface facing the carbon has higher rate of carbon diffusion and
higher carbon concentration. So, it is harder than the top side.
➢ The percentage of carbon in mild steel increased by carburizing which increase the
hardness of the steel.
References:
• Krauss G. Principles of Heat Treatment of Steel, American Society for Metals, Ohio, 1980,
pp. 209-219
• Goldstein J.I., Moren A.E. Diffusion Modeling of the Carburization Process,
Metallurgical and Materials Transactions A, 1978, 9 (11), p. 1515-1525