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Tufftride Engl A
Tufftride Engl A
Technical Information
®
+ Iron
In principle all sorts of ferrous
materials, such as austenitic
steels, cast iron or sintered Iron Nitride
Fig. 1
2
As the regeneration takes place Thereafter, the treated material is ● Blasting with glass beads size
without change of bath volume, no furthermore cooled to room tem- 40 - 70 µm in diameter; to
bail out salts occur. The drag-out perature as well as cleaned within prevent edges being exces-
sively rounded, or removal of
losses caused by taking out a a well-tempered and agitated the compound layer being
treated load are supplemented by washing cascade. avoided, the pressure should
replenish salt (TUFFTRIDE®- not exceed 4 bar;
Process). Unlike gas nitriding or gas Is the surface roughness after
● Automated blasting with metal
nitrocarburizing, neither the nitrocarburization too high, pend- beads whose diameter should
replenish salt for the nitrocarburiz- ing on the seize and the shape of be less than 1 mm.
ing or the oxidation bath (see the parts, various polishing meth-
below), nor the regenerator are ods can be used.
classified as toxic or are harmful to
the environment. Intermediate treatment, however,
● Lapping with emery cloth may partly reduce the gained cor-
The oxidation treatment is per- grade 360 or finer; rosion resistance. For this reason,
formed after salt bath nitrocarbur- in many cases a second oxidative
● Polishing or continuous micro-
ization in an especially developed finishing with special polishing treatment is carried out. This com-
cooling bath at a temperature discs with the throughfeed plete sequence is shown in Fig. 2
range of 380 - 430 °C. During the method, similar to centreless for the QPQ®-Process. QPQ® com-
polishing, or on an automated prises TUFFTRIDE® treatment with
treatment a black iron oxide layer lathe fixed between centre
(magnetite) is produced on the oxidative cooling, mechanical
pieces;
surface of the treated parts, which processing and oxidative post
● Vibratory finishing; this treat- treatment, using the same salt
enhances substantially the corro-
ment is primarily used for small melt for both oxidative steps.
sion resistance. Apart from the and sheet metal components;
oxidative effect, the dimensional
stability of the quenched compo-
nent is positively influenced.
Nitrocarburizing
Post oxidation
Oxidation
Polishing
+ cooling
Time
Fig. 2
3
During the TUFFTRIDE®-process a sess by far most nitrogen offer cooling the pores are almost filled
nitrocarburized layer is formed con- the compound layers are almost with magnetite, which anchors
sisting of the outer compound layer monophase existing of ε-iron car- optimal the protecting oxide layer.
(ε-iron nitride) and the diffusion Same time, the residual compres-
bon nitride. Depending on the
sive stress in the boundary area
layer thereunder. The formation, material used, the compound layer
increases. In addition to the treat-
microstructure and properties of will have a Vickers hardness of
ment parameters (temperature,
the compound layer are significant about 800 to 1500 HV measured in
duration, bath composition), the
reliant on the base material. The the cross section
levels of carbon and alloying
formation, structure and properties
elements in the materials to be
of the compound layer are very The compound layer divides in a
treated influence the thickness of
much depending on the used basic compact part and a porous part
the obtainable layer. Although the
material. Apart from iron some which is situated directly at the
layer growth is lower, the content
alloying elements, such as Cr, Mo, surface. The latter is also called
of alloy is higher, the hardness
Al, V, Ti or W, are able to react with pore zone. It is used as lubricant
however increases to an equal
nitrogen. The so-called special reservoir and supports the good
extent. Fig. 3 shows the deter-
nitrides are formed within the com- dry-running operation properties of
mined correlation at a tempera-
pound layer as well as within the the treated parts. During oxidizing
diffusion layer.
Compound layer
While diffusing atomic nitrogen the
compound layer is formed. With
rising nitrogen absorption the solu-
bility limit of the boundary layer is
exceeded and forms iron nitrides,
Compound layer thickness after
in case of alloyed steel, addition-
TUFFTRIDE® treatment
ally special nitrides and builds a
closed compound layer. Depend- 25 Mild steel
ing on the nitrogen content it con- T = 580°C
tains either ε-iron nitrides, γ'-iron QT steel
20
nitride or a mixture of both.
Compared to the classical nitriding
Compound layer thickness in µm
0
0.5 1 2 3
Treatment time in h
Fig. 3
4
ture of 580 °C. With the usual tified metallographically from the visible darker etched area. Fig. 5
treatment time of 60 to 120 core structure, due to the impro- shows the nitriding hardness
minutes a compound layer of 10 - ved etchability. The actual nitrogen depth according to DIN 50190-3
20 µm is obtained on most penetration depth is pending on on various materials against treat-
qualities of material. the content of alloying elements ment time.
considerably higher than the
The metallographic analysis
defines clearly the compound layer
from the total layer as a slightly Formation of compound layer
etched zone, followed by the
diffusion layer (see Fig. 4).
Compound
layer: 15 µm
CL
DL
105
V = 500:1
Fig. 6
6
Core strength after hardening Guideline figures
and tempering (N/mm2) for surface hardness
Material
Tempering temperature 600 °C 90 min 580 °C
Tempering time TUFFTRIDE® treated
Material
Name number 2 hours 6 hours HV 1 HV 10 HV 30
Fig.7
Fig. 8 shows an overview in corro- As test criterion the salt spray check parts in a salt mist of 5 %
sion resistance of various galvanic test according to DIN EN ISO sodium chloride at 35 °C. Even
layers compared to a QPQ®-layer. 9227:2006 NSS was chosen to after a test period of 500 hours
there were no corrosion attacks
visible on the functional surface of
the QPQ® treated piston rods.
Corrosion behaviour of different layers
As well as after TUFFTRIDE®-treat-
500 ment (incl. oxidizing cooling) a
clear increasing of corrosion
400 resistance on components is
observed. Pending on the part
300 geometry and its surface finish a
Spray duration [h]
Fig. 8
7
One of the hardest corrosion of a comparison trial with QPQ ® Even under these conditions a
tests according to DIN EN ISO treated, impregnated piston rods QPQ® treatment results in consid-
9227:2006 is the AASS test, and hard chrome plated ones is erable better corrosion resistance.
which test solution additionally demonstrated in Fig. 9. The first of the samples showed a
contains acetic acid. The result corrosion attack after 92 hours and
the last, after 159 hours. The
average resistance was 114 hours.
However, the chrome plated piston
rods failed completely after 21
Hard chrome vs. QPQ® in AASS-test hours.
144 144
3 % sodium chloride and 0.1 %
120 120
hydrogen peroxide (H2O2) is used.
96 96
72 72
Prior to being dipped into the solu-
48 48
tion, the samples are degreased.
24 24 Fig. 10 shows the results obtained
0 on samples made from C45 treat-
Min. Max. Min. Max. ed by different surface engineering
hard chrome QPQ ® processes after a test lasting 2
10-15 μm 15-20 μm
weeks.
Fig. 10
8
Wear resistance and Many wear tests and practical running properties. Fig. 11 shows
applications confirm the advan- a gear made of C45N after service
running properties tages to other surface layers. life of 700,000 km in a com-
Structure and composition of the mercial vehicle. The removal by
Excellent sliding and running prop- compound layer (proportion N and wear from the upmost mono-
erties, as well as high wear resist- C) influence the wear resistance phase ε-compound layer was only
ance, are the well-known advan- considerably. Monophase carbon
1 - 2 µm. Even the pore zone is
tages of TUFFTRIDE®-treated com- enriched ε-compound layers, which still clearly visible.
ponents. Due to the intermetallic
exist after TUFFTRIDE® treatment,
composition of the compound
gain very good results. Layers with
layer, the friction and the tendency
low carbon or having high γ'-pro-
to weld with a metallic counter-
partner are reduced. Compared to portion were in most cases defi-
case hardening the nitride layer nitely worse.
possess a much better heat re-
sistance. The gained hardness In the outer zone of compound
increase within the diffusion layer layer occurring porosity is no evi-
remains the same even at higher dence for poor wear properties. In
temperatures. fact, better adhesion of the oil film
can often lead to more beneficial
Material: C45N
Section: tooth flank
Loss: approx. 1 - 2 µm
Compound
layer: mainly
ε-iron nitride
Fig. 11
9
Fig. 12 allows conclusions about lished by applying torque to the carried out with a disc running at
the relative wear resistance of sur- tooth flank and increasing it until 200 rpm against another disc being
face layers after hardening, nitro- seizure occurred. Nitrocarburizing fixed. Both parts were treat- ed
carburization and boriding under by the TUFFTRIDE® process raised equally. To avoid adhesive wear, a
adhesive stress. Although the the scuffing load limit of the mate- load of 5 - 30 N was applied.
borided samples had an approx. rials tested by 2 - 5 times. Under greater loads the coefficient
1000 Vickers higher surface hard- of friction increased with the load
ness as the TUFFTRIDE® treated Another interesting factor in con- but in the range of 5 - 30 N it
ones, the latter had with factor nection with the wear resistance remained constant.
800 higher wear resistance and and running properties is the
still 80-fold higher than the hard- friction coefficient of the outer The tested samples had a surface
ened samples. This investigation surface layer. The interfacial reac- roughness of around 4 µm. Only
makes it clear that the hardness of tions which occur during sliding the surfaces of the QPQ® treated
the surface layer is not the only are not so much determined by the samples were reduced to a sur-
influencing factor in respect of absolute hardness of the running face roughness of Rm = 1 µm by
wear properties. partner but by the material pairing, polishing. Fig. 14 gives an over-
their microstructural composition, view of the friction coefficient of
Also scuffing is significantly surface geometry and the lubricant different pairings under dry run-
reduced compared to other sur- used. ning conditions, and after being
face layers. Fig. 13 shows the lubricated with oil, type SAE 30.
results according to Niemann- To determine the coefficient of
Rettig of scuffing load limit tests friction, tests were performed on
on gears. These data were estab- the Amsler machine. Trials were
100
Relative wear resistance
10
0.1
0.01
C45 H+T 42CrMo4 H+T 42CrMo4 H+T
salt bath borided
nitrocarburized
Source: Habig, BAM
Fig. 12
10
Under these test conditions, of all
Scuffing load limits of gears variants the QPQ® nitrocarburized
samples had the lowest friction
coefficient.
600 600
100 100
● the level of nitrogen in the
compound and diffusion layer
0 0 ● the thickness of the diffusion
18/8 34Cr4 16MnCr5 18/8 34Cr4 16MnCr5
H+T case H+T case layer
hardened hardened
● the state of solution of the
®
TUFFTRIDE treated nitrogen on unalloyed steels
Fig. 13
Furthermore, the microstructure
and the strength of the base mate-
Under dry running conditions, nitro- dition, the hydrodynamic load has to
rial are to be taken into consider-
carburized samples have a much be taken into account. With the
ation. Whereas with unalloyed
lower coefficient of friction than exception of the QPQ® treated sam-
steels the increase in fatigue
case hardened or hard chrome plat- ples, there is more solid mass
strength is determined by the rate
ed ones. Due to the oxidation of the because of the surface roughness
of cooling, with alloyed materials, it
compound layer, the coefficient of so that the results presumably lie
has no mentionable effect. An
friction increases. In lubricated con- within the mixed friction range.
increase in fatigue strength is pos-
sible after 1 - 2 hours TUFFTRIDE®
treatment of 100 % on notched
Friction coefficient of different layers parts made from unalloyed steels.
With alloyed steels a general
not
improvement of 30 to 80 % can be
0.4 lubricated
obtained.
lubricated,
SAE 30
0.3
Friction coefficient in µ
Amsler discs
0.2 Partner same
treatment
0.1
Fig. 14
11
Applications
100
0
104 105 106 107
Load cycles
Fig. 15
12
The treatment times are, depend-
Extrusion dies for producing ing on the specification bet-ween
aluminium profiles 20 and 90 minutes. Pending on
the plant seize batches vary
between 2500 and 4000 pieces.
This way, a productivity of less
than 1 s per valve is realized. On
the basis of short treatment times
there are no big buffer capacities
necessary even at changing
geometries, steel grades or speci-
fications.
Fig. 17
13
Applications
In the motorcycle industry also loyed or low alloyed steel is used. 4 nitrocarburizing furnaces in one
various TUFFTRIDE® respective The required testing time in the treatment line allows cycle times
QPQ® treated engine and power salt spray test is mostly 144 hours of 0.5 - 0.6 s per piston rod.
transmission parts are in use. without corrosion point. In some
Fig. 18 shows parts with better cases there are even 400 hours The examples could be endlessly
corrosion resistance than gas or required, which are also reached continued. The TUFFTIRDE®-/QPQ®
plasma nitrocarburized ones. successfully. process is also used for compo-
Owing to the short treatment time nents in the aircraft, in the off-
and the high flexibility there is Fig. 19 shows gas spring piston shore technology, in the plant and
given an optimal integration into rods, which are utilized in the auto- machine construction, in energy
the production flow with the mobile and aircraft industry, for technology, in the food industry,
according cost advantage. engineering or in office chairs. By photo and computer industry as
substitution of the chrome layer well as in the manufacture of
The QPQ®-process finds constant considerable cost reductions were textile machines or hydraulic
growing application for piston achieved. The QPQ® treatment is aggregates.
rods, hydraulic cylinders or bush- performed in fully automated
ings. As material mild steel, unal- plants. The combination of up to
Drive and clutch components for Piston rods for gas springs
motor bikes and dampers
Fig. 18 Fig. 19
14
To run the TUFFTRIDE®-/QPQ® and are consequently advanced Fig. 20 shows a nitrocarburization
process it is easy compared to under the aspect of furnace of the newest generation.
other nitrocarburizing processes, It has a pneumatic closeable, iso-
because there is no complicated ● reduction of energy lated lid and offers considerable
consumption energy savings at base load opera-
plant technology required. The
treatment can be done both manu- ● process security tion. Furthermore, this furnace is
ally and in fully automated plants. equipped with external placed,
● operator friendliness
They are arranged in line in a mod- continuous working filtration
ular concept (please see Fig. 23) device for cleaning the salt melt
and also with a feed unit for
regeneration.
Features:
● Pneumatic
closable lid
● TENOCLEAN®
filtration device
● Regenerator
dosing device
Fig. 20
15
Fig. 21 shows a microprocessor For hand operated plants also State of the art are meantime
monitored capsuled plant. Bat- electronic systems are available, three to four step, heated and agi-
ches with different treatment which record all relevant parame- tated washing cascades (please
parameters are operated by com- ters and assort them to a batch see down right of Fig. 23), which
puter controlled guidance with a documentary. Compared to the perform not only very good
special software to guarantee an gaseous processes an online mon- washing results, but allow consid-
optimal batch flow. Big sliding itoring of the chemical parameters erable water savings.
doors allow easy access to the is not required due to the high sta-
individual plant components. The bility of the melt. Daily analyses
feeding of the refill salt respective are allocated to the treated
regenerator salt is done by accord- batches via computer.
ing channels from outside.
Sometimes the remaining salt
Fig. 22 shows exemplary the dia- residues on the components are
gram for the control of the nitrocar- criticized but they only arise from
burizing furnace. insufficient cleaning equipment.
Fig. 21
16
Control of the TUFFTRIDE® furnace via PC
Fig. 22
Evaporator
Wet Scrubber
Waste Water
Tank
Exhaust
Fresh Water
Cleaning Cascade
Fig. 23
17
Against overwhelming prejudices, In the year 2000 an ecological for Environment/Berlin. Fig. 25
the authorization of a new plant "in assessment of salt nitrocarburizing shows the results of this compari-
the green" is not more complicat- and gas nitrocarburizing was son. It reflects that the salt bath
ed than for other nitrocarburizing established. Failing sufficient pro- nitrocarburizing process from eco-
processes. Without any problem vided data the originally planed logical point of view tends to result
the effective environmental as well plasma process could not be con- in a better valuation than gas nitro-
as work place regulations will be sidered. For the study all for the carburizing.
met. The relevant plant compo- process comprising energy and
nents are equipped with an effi- mass flow had been taken into
cient exhaust device. Even account and set in relation to the
although in most cases the legiti- quantity of treated goods. The
mate allowance for air cleaning evaluation had been effected by
procedures is met the exhaust air giving "harm points" for the mate-
is lead through a dry filter device rial and energy input as well as for
or if applicable through a wet exhausts, waste water and wast-
scrubber device, to respect envi- age. This was done by consulting
ronmental aspects (see Fig. 23). criterion of the Federal Office
Ecobalance on Nitrocarburizing
5000
➜ Deposition space
➜ Acidification
4000
➜ Nutrient enrichment
Detriment level
Source: J. Buchgeister
Fig. 24
18
In addition to the significant Due to the characteristics of the the TUFFTRIDE®-/QPQ® is the
improvement of wear protection, process, such as most widely used nitrocarburizing
fatigue strength and sliding proper- process. The process is very easy
ties, the TUFFTRIDE® treatment ● excellent reproducibility, to carry out and does not require
plus oxidative cooling or QPQ® on high quality level complicated plant technology.
treatment produces a major Electronic monitoring and docu-
● shortest treatment times
increase in corrosion resistance. mentation of the process
Results of tests and industrial ● most negligible distortion sequence up to automated proce-
applications show that the quality dure, efficient devices for filtering
of the treated components is often ● high flexibility the melt as wells as for subse-
superior to that of electro galvanic quent cleaning of the treated parts
layers and other nitrocarburizing are state of the art today. The
processes. This opens a broad field plant itself is run effluent-free.
of application, in which expensive Environmental specifications can
materials can often be substi- be complied without difficulty.
tuted.
19
Durferrit GmbH
Industriestrasse 3
D-68169 Mannheim
Ihr Partner für Salzbadtechnologie Telefon + 49 (0) 621 / 3 22 24-0
Fax + 49 (0) 621 / 3 22 24-809
www.hef-durferrit.com E-Mail: technical-service@hef-durferrit.com
06.2017 DE www GR
The data contained in this publication are tions and tests; neither do these data without prior information and do not
based on our current knowledge and expe- imply any guarantee of certain properties, constitute the agreed contractual quality of
rience. In view of the many factors that may nor the suitability of the product for a the product. It is the responsibility of the
affect processing and application of our specific purpose. Any descriptions, recipient of our products to ensure that any
product, these data do not relieve proces- drawings, photographs, data, proportions, proprietary rights and existing laws and
sors from carrying out their own investiga- weights etc. given herein may change legislation are observed.