Bainite hardening or austempering has been a developing hardening technique over the past decades and is particularly well applied in the bearings industry.Through a combination of process and cooling techniques it is possible to hone the microstructure to deliver favorable levels of hardness for some very specific applications.

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What exactly is 4140 steel? AISI 4140 grade steel material, often referred to as chromoly steel, is a low alloy steel containing chromium and molybdenum as its primary alloying elements. These elements give it distinct characteristics that make it stand out in the vast world of metals.

Depending on the cooling rate and alloy composition, austenite can transform in to different phases and structures. Martensite is a hard and brittle phase, but can be tempered to have a high toughness due to reduced residual stresses and a decrease in dislocation density. Slower cooling rates often results in pearlite, a lamellar structure of ferrite and cementite, which is formed at relatively high temperatures. Ferrite and cementite grow side by side to form pearlite, by a so-called edge growth. Pearlite is a soft and ductile structure and is not desired in high pressure applications.

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Steelhardness HRC

So, how hard is 4140 steel? The answer: it depends on its treatment. But one thing’s for sure, its versatility in hardness makes it a go-to choice for many industrial applications. If you have more questions or need further information about 4140 steel or any other steel types, don’t hesitate to drop me an email at jeremy@otaisteel.com or reach out on WhatsApp at +8613610149979. We at Otai Special Steel are always here to help!

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Bainite hardening or austempering has been a developing hardening technique over the past decades and is particularly well applied in the bearings industry.Through a combination of process and cooling techniques it is possible to hone the microstructure to deliver favorable levels of hardness for some very specific applications.

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The hardness of bainite varies from about 40 HRC for upper bainite to about Rockwell 60 HRC for lower bainite. This increase in hardness, as with pearlite, is a reflection of the decrease in size and spacing of the carbide platelets as the transformation temperature decreases.

Rockwell hardness scale

Steelhardness scale

To achieve a homogeneous structure, the material grade and the quenching ability of the quenching bath must fit to the load to allow the cooling curves to pass the pearlite and the bainite “nose” by isothermal quenching. As you can see from Figure 2B, the dwell time for fully finishing the bainitic structure could become very long. This time is increasing with increasing alloying content of the material, especially with Nickel or Molybdenum, and by lowering the salt bath temperature. To shorten the dwell time, two different strategies can be chosen: to increase the dwell temperature at the end of the bainitization or to quench the parts slightly below martensite start, create some martensite seeds and then follow the dwell time at bainitization temperature.

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Figure 2: Possible cooling strategies for bainite hardening: Continuous cooling (red), isothermal cooling with dwell time for desired hardness and structure (blue) and multi-stage process (green, orange)

Table 1 gives an example for reducing the dwell time for bainite hardening of bearing steels, which were austenized at 845 - 860°C. The variation of the austempering temperature can shorten the dwell time for 60 up to 70%:

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However, at lower temperatures (550°C down to martensite start temperature Ms), the mechanisms behind the formation of ferrite and cementite are different, resulting in a nonlamellar structure. The diffusion of carbon gets sluggish at lower temperatures, resulting in a fine and complex structure called bainite. During the transformation into bainite, ferrite is the leading growing phase, and the formation of cementite will occur when the carbon concentration, of the surrounding austenite or the ferrite phase, is high enough to allow precipitation of carbides. The growth of bainite and the mechanisms behind it have been a topic of debate for a long time. Two main theories are generally discussed: diffusionless and diffusional theory. As the names reveal, the theories explain independent mechanisms that depend on diffusion or diffusionless transformation.

Possible cooling rates are influenced by many parameters, such as quenching speed of the salt, the salt bath temperature, agitation of the quenching media, dimensions and weight of the load (or the parts), loading density, etc. Figure 2 shows a continuous (A) and an isothermal TTT-diagram (B) of SAE 52100 (= 100Cr6), the typical bearing steel. Depending on the steel grade, for bigger parts or higher wall thickness the formation of bainite cannot be avoided by continuous quenching, leading to an inhomogeneous structure (Figure 2A). This structure is caused by different types of bainite, which develop during continuous quenching.

How hard is steelMohs

The structure of bainite can vary in a wide range, depending on the temperature of the salt bath. Depending on the temperature, two different structures can be achieved: the “upper” and the “lower” bainite (Figure 1).

Now, onto the main question. The hardness of AISI 4140 steel can vary based on how it’s processed. But let’s break it down:

1. E. Claesson: Development of a heat treatment method to form a duplex microstructure of lower bainite and martensite in AISI 4140 steel, Master Thesis Department of Material Science and Engineering Royal Institute of Technology Stockholm, Sweden 2014, Accessed September 2020;2. H. Altena, K. Buchner: Process technology and plant design for bainite hardening, La Metallurgia Italiana - Nº3, 2016, p.23-26; Accessed May 2020.

Traditionally bainite hardening was always combined with salt bath technology. About 25 years ago, when the old salt bath technology lost its’ importance because of dirt, safety and ecological reasons, the interest in bainite hardening was decreasing, too. Times have changed, modern salt bath installations are completely capsuled and safe. The composition of salts was adapted to fulfil the ecological requirements and recycling of the used salts can be carried out.

You might be wondering, “Why all this fuss about hardness?” Well, the hardness of a steel determines its wear resistance and its ability to retain its shape under stress. Imagine using a soft steel for a high-stress component – it wouldn’t last long, would it? Steel that’s too hard can become brittle. So, for How Hard is 4140 Steel?, it’s more important to find the right balance.

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