Analysis of Hardened Depth Variability, Process Potential, and Measurement Error in Case Carburized Components

Hardened depth (effective case depth) measurement is one of the most commonly used methods for carburizing performance evaluation. Variation in direct hardened depth measurements is routinely assumed to represent the heat treat process variation without properly correcting for the large uncertainty frequently observed in industrial laboratory measurements. These measurement uncertainties may also invalidate application of statistical control requirements on hardened depth. Gage R&R studies were conducted at three different laboratories on shallow and deep case carburized components. The primary objectives were to understand the magnitude of the measurement uncertainty and heat treat process variability, and to evaluate practical applicability of statistical control methods to metallurgical quality assessment. It was found that similar to 75% of the overall hardened depth variation is attributed to the measurement error resulting from the accuracy limitation of microhardness equipment and the linear interpolation technique. The measurement error was found to be proportional to the hardened depth magnitude and may reach similar to 0.2 mm uncertainty at 1.3 mm nominal depth and similar to 0.8 mm uncertainty at 3.2mm depth. A case study was discussed to explain a methodology for analyzing a large body of hardened depth information, determination of the measurement error, and calculation of the true heat treat process variation.