The Gas Carburization of Linear Cellular Alloys as a Novel Alloy Development Tool

Investigations of the production of thin-walled steel alloys through the gas carburization of structures made from reduced and sintered metal oxide powders were performed. Extrusions with low-alloy steel composition were produced successfully without the occurrence of metal dusting, yielding a novel technique for the production of thin-walled steel structures. Thin strip geometries (~200 to 300 μm final thickness) of samples with the composition of 4140 steel, without carbon, were produced through the extrusion of a paste of metal-oxide powders. Full reduction and sintering in a 10 pct H₂/90 pct Ar atmosphere yielded a metal part containing all necessary alloying elements except carbon. Gas carburization in a controlled CO/CO₂ atmosphere was then used to introduce carbon through the thickness of the structure while carburization parameters were controlled such that metal dusting was not observed. It has been shown in this study, through heat treatment and microstructural investigations, that structures with 4140 composition displaying microstructures and mechanical properties comparable with conventionally made steels can be reached in approximately 30 minutes during gas carburization. The research shows that carbon contents above the eutectoid composition can be reached in less than 30 minutes. As a result, a novel alloy development tool has been introduced.