Ferritic Nitrocarburizing Training for Sales Staff

Presented by: Craig Zimmerman

 Ferritic Nitrocarburizing

 What is Ferritic Nitrocarburizing?

– Shallow case hardening process which yields almost no distortion

 Can also be used to increase corrosion resistance

– Works well on components that only require a thin case depth for light wear
 Sliding / rubbing wear
 Rolling wear with no heavy part-to-part contact pressures
 Alternative to chrome plating as a more environmentally friendly option
 Alternative to shallow case carburizing / carbonitriding where distortion may be a problem
 Terms and Definitions
 COMPOUND ZONE or WHITE LAYER
– Thin hard, wear resistant compound of iron and nitrogen that forms at the surface. Usually about .001”
thickness. Two types of iron nitride compounds are possible
 Epsilon iron nitride – more ductile - This is what we want after FNC processing
 Gamma prime – more brittle
 Mix of epsilon and gamma prime is most brittle type of layer. Typically what we get from nitriding.
 DIFFUSION ZONE
– Area below the compound zone that has higher hardness than the core due to extra nitrogen getting
crammed into the structure making it tougher to deform. Usually this harder zone extends from the
compound zone to about .016” deep where hardness starts out high and falls down to core hardness at
deeper depths.
 “NITRO” – “CARBURIZING”
– Diffusion of both nitrogen and carbon into the surface of the steel. More heavy on the nitrogen than carbon… NOT
THE SAME AS CARBO-NITRIDING!!!!
 Carbonitriding – High temperature process with quenching where we diffuse in a lot of
carbon plus some nitrogen to assist in boosting hardenability that allows us to quench out
and fully transform the carburized case in low alloy steels
 Nitrocarburizing – Low temperature process with no quench needed. Diffuse in a high
amount of nitrogen to form a desirable white layer called “epsilon iron nitride”. The reason
for adding some carbon is that it helps us form desirable epsilon compound layer instead of
an undesirable “gamma-prime” compound layer which we’d get if no carbon was added.
(We get bad gamma-prime compound layers in nitriding)
 “Ferritic”
– Low temperature process where core never becomes austenitized during the process. It
starts with a ferrite structure in the core which remains ferritic during the entire process
 “Austenic nitrocarburizing” or “ANC”
– Less popular process where we perform nitrocarburizing at a higher temperature which does transform the core material
to austenite. Get deeper white layer depths with sacrifice of greater distortion
– Also known as “Lindure 2”
Nitrocarburizing – Properties
Wear Performance

oxide

The compound zone

consists of
predominantly iron
epsilon nitride (Fe3N)
and is the element Compound
Layer
most responsible for
wear resistance.

diffused
layer
Results of the process

 Compound zone thickness  Diffusion zone thickness

– Typically .0003” to .0010” deep – Typically .012” to .020” deep
– Typically 500 HK hardness on plain – Not especially hard on plain carbon or low
carbon, low alloy steels (1008, 1018, alloy steels (mid-30’s HRC) at .002” deep
1117) – Good hardness on alloy steels where alloy
– May be up to 900-1000 HK hardness on nitrides form below compound zone. Mid-
alloy steels (4140, 8620, 4340) as 50’s HRC at .002” deep is possible
nitrogen combines with alloying elements – Not visible, but it is there when you take
to form alloy nitrides (chrome nitrides) that hardness measurements
are harder

Copper Plating for prep

Compound Zone

Diffusion Zone

Core Material
Hardness profiles by material

Hardness profile after Lindure

1200

1000

800
1018
Hardness (HK)

4140
1055
600
8620
1020
4130
400

200

0
0.000 0.005 0.010 0.015 0.020 0.025 0.030 0.035 0.040
Depth (in)
The FNC Family of Processes

 GASEOUS FNC – No post oxidation  SALTBATH FNC with post-oxidation

– Nitrocarburizing is performed in a gas- – Nitrocarburizing is performed in a salt bath to
atmosphere furnace to form epsilon compound form epsilon compound layer
layer – Oxidizing is performed by quenching parts in an
– Surface of compound layer is not oxidized at end oxidizing salt bath after they have been
of the process cycle which means we get limited nitrocarburized
increase in corrosion resistance – Typically able to pass a 200 hour salt spray
– May only get 24 to 48 hours salt spray resistance corrosion test
– Parts have a dark grayish-brownish-blackish-blue – Parts have BLACK finish that is cosmetically
color that is not always uniform pleasing
– AMS 2757 is industrial specification – AMS 2753 is industrial specification

 GASEOUS FNC with post-oxidation – ONE ADVANTAGE OVER GAS FNC is that we
have ability to process STAINLESS STEELS
– Nitrocarburizing is performed in a gas-  Do lose some corrosion resistance compared to their
atmosphere furnace to form epsilon compound untreated state, but much better corrosion properties than
layer nitriding / malcomizing

– Surface of compound layer is oxidized after being

nitrocarburized by controlled exposure to water
(steam) or air (oxygen) at end of cycle
– Typically able to pass a 200 hour salt spray
corrosion test
– Parts have a dark grayish-brownish-blackish-blue
color that is not always uniform
– AMS 2757 is industrial specification
Tradenames, tradenames, tradenames…

 GASEOUS FNC – No post oxidation  SALTBATH FNC with post-oxidation

– FNC – MELONITE
– LINDURE – MELONITE QPQ
– NITEMPER – SUR-SULF
– NITREG – NUTRIDE
– TRINIDE – ARCOR
– TENIFER
– TENIFER QPQ
– TUFFTRIDE
 GASEOUS FNC with post-oxidation
– CORR-I-DUR (Bodycote Europe)
– NITROTEC
– NITREG ONC
– NITROFLEX
– LINDURE OXYCOTE (never started)
Equipments and Loads

 Gaseous FNC (Lindure)

– Process in the same batch IQ furnaces used for carburizing, carbonitriding
– Rack parts in baskets or hang them on fixtures for distortion control
– Possible with FNC to more densely load randomly dumped small parts since the
process better permeates all surfaces and we aren’t worried about quenching or
cooling rates

Batch IQ furnace at Bodycote - Indianapolis

Corr-I-Dur furnace at Bodycote – Schaan, Lichtenstein

Equipment and Loads

 Salt Bath Ferritic Nitrocarburizing (Melonite)

– Parts are racked in baskets which become immersed in the molten salt baths
– Parts are racked vertically if possible to reduce distortion
– Any blind holes are racked facing down so salt drains from them when lifted out of pot
Common steps for FNC Processing

GASEOUS FNC PROCESS (LINDURE) SALT BATH FNC PROCESS (MELONITE)

1. Masking – Parts that require some areas to be 1. Rack parts into baskets – either hand stack
left with no compound zone are masked with vertically to reduce distortion or random dump
paints or copper plated. Welding is not into mesh baskets
possible on FNC processed surfaces, so 2. Preheat – to save time in Melonite pot, to bring
masking areas to be welded is common entire load uniformly to heat
practice. 3. FNC – (immerse in Melonite salt at 1075F
2. Rack parts into baskets – either hand stack temperatures, cycle times generally 30 to 120
vertically to reduce distortion or random dump minutes)
into mesh baskets 4. Oxidize – (Quench in AB-1 salt at 750F
3. Wash – to remove machining oils or temperature, cycle time of 20 minutes)
contaminants to improve cosmetics 5. Hot Wash – to remove Melonite salt and
4. Preheat – to save time in IQ furnace, to bring improve cosmetics
entire load uniformly to heat 6. Rinse – to remove Melonite salt and improve
5. FNC – (1000F to 1100F temperatures, cycle cosmetics
times generally 1 to 5 hours, atmosphere of 7. Polish – (QPQ option) – vibratory polish
66% ammonia plus 33% endo gas)
6. Cooling – 8. Requench (QPQ option) – reheat parts in
preheat furnace followed by second quench in
1. Top cool – for best cosmetics/distortion AB-1 salt and rewashing
2. Quench – for best diffusion zone hardness 9. Corrosion prevention (optional) – oil parts
7. Wash – to remove quench oil and improve before packaging so they don’t rust in
cosmetics transit/storage
8. Corrosion prevention (optional) – oil parts 10. Lab test –
before packaging so they don’t rust in
transit/storage
9. Lab test – to measure compound zone depth,
compound zone hardness, diffusion zone
depth, diffusion zone hardness, and core
hardness
Nitrocarburizing Market

 Gaseous Nitrocarburizing is a commodity process offered by many competitors

 Salt bath Nitrocarburizing is a licensed process only offered by about 12 competitors.

HEF is licensing company for all tradenames and has chosen geographically separated
partner companies to license. We purchase our Melonite salts from HEF who has
acquired rights to all processes

 Both processes are somewhat of a commodity but it is possible to differentiate ourselves

from our competition.

 Pricing
– Lindure generally sells for $0.30 to $0.80 per lb
– Nitrotec generally sells for $1.20 per lb
– Melonite generally sells for $2.00 per lb ($1.00 in Minneapolis mkt, $4.00 in Detroit mkt)

 Ways we can differentiate ourselves

– Cosmetics of parts after processing. Not all processes are the same (even within Bodycote) and oftentimes
customers require a certain appearance or cosmetic level that is difficult to maintain
– MELONITE QPQ yields a cosmetically pleasing black finish instead of non-uniform shades of gray.
– Distortion control using knowledgeable staff who can employ intelligent fixture designs or post-heat treat fixes such
as clamp tempering to meet straightness, flatness criteria.
– Delivery…. Fast turnaround times are always important to purchasing agents
– Large components (over 36” in length) may require FNC in a special furnace. Melrose Park can process in large
pits. Woodworth in Michigan has started using large retorts in carbottom furnaces to run massive loads at
discounted prices and are growing their business that way.
– Post-oxidation for corrosion properties. Some competitors offer gas processes such as Nitrotec to meet corrosion
resistance specifications. Until we install Corr-I-Dur equipment in the USA, Bodycote only has Melonite to meet
these needs which oftentimes is priced higher than Nitrotec or not geographically convenient to all customers.
Applications

 Window wiper blade

– Increased strength due to

diffusion zone hardening the
majority of the core material
allowed for thinner stock
material (weight savings)

– Compound zone wear

resistance allowed for
elimination of bushing used
resist wear

– Corrosion resistance from

Melonite process allowed for
elimination of a plating
process
Applications

 Roller track for car seats

– Compound zone yields

good surface wear
resistance that occurs as
seats are rolled back and
forth

– Diffusion zone strength

and hardness allows for
resistance to indention
where the bearings form
dents in the tracks
requiring user to wiggle
their butts to get the seat
to move.
 (Compliments of Don
Giessel’s patented “wiggle-
butt” story)
Applications

 Automotive sliding wear components

– Lightly loaded parts that see a great deal of sliding wear but no heavy pressure loading that would
require a deeper case
– Thin stampings or long, thin parts that would warp excessively if carburized and oil quenched

– Rocker arms, Valve guides, Engine Valves, Transmission/Clutch plates, Camshafts, Crankshafts,
Hydraulic cylinders, Shock rods
Nitrocarburized to strengthen
base plate
Applications

 Ball joints for steering and suspension

– Corr-I-Dur or Melonite process with post-oxidation to increase corrosion resistance

– Compound zone gives wear resistance to resist damage at surface
– Post polishing process to meet surface roughness requirements for low friction