Tufftride TF1 Process
Transcript of Tufftride TF1 Process
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TUFFTRIDE® TF 1 - Process
A thermochemical treatment which enriches the
surface of ferrous materials primarily with
nitrogen and, at the same time with small amount
of carbon.
What is Nitrocarburizing?
TF-GR 002 E
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TUFFTRIDE® QPQ
TF-GR 001 E
improves
wear resistancecorrosion resistancefatigue strengthappearance
and is a
economicalenvironmentally friendlymulti-purpose
process
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Media for Nitrocarburizing
TF-GR 021 D
TUFFTRIDE® TF 1 - Process
Salt bath
Gas
Plasma
Powder
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MediumMolten salt consisting of alkali cyanate and alkali carbonate
Basic Reaction in the Molten Salt
Nitrocarburizing ProcessCyanate (CNO- ) Nitrogen (N) + Carbonate (CO3
2- )Nitrogen (N) + Iron (Fe) Iron nitride (FexN)
Regenerating with REG 1Carbonate (CO3
2- ) + REG 1 Cyanate (CNO- )
Side ReactionCyanate (CNO- ) Cyanide (CN- ) + Oxygen (O2)
TUFFTRIDE® TENIFER®
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Structure of a TUFFTRIDE® treated surface
Compound Layer (CL)on the surface of a work piece
consists of ε - iron nitride
(in the case of alloyed steels, also of special nitrides)
Diffusion Layer (DL)area below the compound layer
nitrogen is solved atomically in the iron lattice
(with unalloyed steels and slow cooling also in the
form of iron nitride needles)
TUFFTRIDE® TENIFER®
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o = Fe• = Possible
N-positions
ε ε
γ‘
γ‘
Pore zone
TUFFTRIDE® Process
Systematic Structure of the Compound Layer
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Compound Layer
The most important influences on the thicknessof the compound layer are:
Material
Treating temperature
Bath chemistry (e.g. cyanate content)
Treating time
MELONITE® TENIFER®
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Effects of Composition of Material
An increasing content of alloying elements
with constant treatment parameters causes:
Decrease in thickness of the compound layer
Decrease in total nitration depth
Increase in surface hardness
TUFFTRIDE® TENIFER®
TF-GR 031 E
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0
5
10
15
20
Com
poun
d la
yer [
µm]
SAE 1045 SAE 4140 SAE 3115 H 11 420
Influence of various materials on the thickness of the compound layer
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Obtainable compound layer thickness in relation to the treating time
Com
poun
d la
yer t
hick
ness
in µ
m
Compound layer thickness
TUFFTRIDE TF1 580°C
Treating time in the TF 1 - bath in hrs
C15 - C45
Direct hardening alloy steel
Hot work steel12 % Cr-steel H23
25
20
15
10
5
0
0.5 1 2 3
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Total nitriding depth
TUFFTRIDE TF1 580°C
C15
C45
34Cr4
42CrMo4
50CrV4
34CrNiMo6
34CrAlMo5
X210Cr12
GGL
1,0
0,8
0,6
0,4
0,2
0
Tota
l nitr
idin
g de
pth
inm
m
0.5 1 2 3
Treating time in the TF1 bath in hrs
Total nitriding depth of various steels in relation to the treating time
TF-GR 068 E 1
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Hardness Behaviour of
Different Materials
Vick
ers
hard
ness
[HV
0.3]
Distance from Surface [mm]
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Process
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Har
dnes
s in
the
diffu
sion
laye
r [H
V 0.
05]
Nitr
ogen
pen
etre
atio
nde
pth
[mm
](a
ccor
ding
to h
ardn
ess
prof
ile)
Chrome content [%]
TUFFTRIDE® Process
Surface hardness and case depth in relation to the chrome content
1200
1000
800
600
400
200
0
1.2
0.8
0.4
00 1 2 3 4 5
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Treating Cycle
Preheating on air (350 - 400°C)
Nitrocarburizing in a TUFFTRIDE TF1 bath(usually at 580°C)
Cooling
Cleaning in a heated and agitated rinsing cascade
(Short immersion in dewatering fluid)
TUFFTRIDE® - Process
TF-GR 045 E
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TUFFTRIDE® TENIFER®
TF-GR 055 E
Preheating
ReasonOnly completely dry components should be put into the bath !Temperature in TF 1 bath should not drop below 1000°F (540°C) or the formation of the compound layer will be negatively impacted.
Influencing FactorsTemperature (normally 660-750°F) (350-400°C)Duration (usually 30-90 minutes, min. 30 minutes)
Important!Too high a temperature, or too long a time, can lead to scaling.( ⇒ Poorer nitriding quality, high sludge formation)
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Influencing Factors in Bath Performance
TUFFTRIDE® TENIFER®
TF-GR 034 E
Temperature Treating timeBath chemistry
CNO- 35-38%CN- ≤ 5%Fe ≤ 0.02%
Aeration
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compact
porous
0
5
10
15
20
25
30 60 90 120 150 180 210 240Treatment time [min]
Com
poun
d la
yer [
µm]
Influence of treatment time on the compound layer
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Highly flexible because
TF-GR 007 E
TUFFTRIDE® TENIFER®
components requiring various treating times can be treated together in the salt bath
various materials can be nitrocarburized in one charge
the treating / processing time is very short
the plants are of modular design so that fluctuations in throughput can be accommodated
cooling mediums with different cooling rates (water, AB1 bath, forced air, nitrogen or vacuum) can be used
TUFFTRIDE treatment is possible within a temperaturerange of 480°C - 630°C
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Bath Chemistry
CN- Content ( ≤ 5%)
• Dependent on throughput and sludge content• Too much reduces the lifetime of the pot and
affects the regeneration reaction• Is influenced by the aeration
TUFFTRIDE® TENIFER®
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Regenerating with REG1
1. Determine the required amount of regenerator from tables in the operating instructions
2. Measure exactly the amount of regenerator required to 100 g
3. Using a shovel, carefully add the regenerator in small portions to the aerated bath
TF-GR 058 E
TUFFTRIDE® Process
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Bath Chemistry
CNO- Content ( 35-38%)
• Maintained through addition of REG 1• Too much causes thick compound layers with too
much porosity (⇒ Lowering of wear and corrosion resistance)
• Too little reduces nitriding activity and leads to thinner compound layers
(⇒ Lowering of wear and corrosion resistance)
TUFFTRIDE® TENIFER®
TF-GR 064 E b
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Influence of Sludge Content on the Compound Layer
Iron content
C15 90 min TF1 580 °C
Poro
sity
[%]
100
75
50
25
0
TUFFTRIDE® - Process
TF-E 003 E
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Cooling Media
Water
Oxidative cooling bath (AB1 bath)
Forced air
Nitrogen
Vacuum
(Oil)
TUFFTRIDE® - Process
TF-GR 057 E
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90’ TF1 (580°C) SW
90’ TF1 (580°C) 10’ AB1 (350 °C) SW
Formation of the diffusion layer at different cooling
ratesMaterial: 1015
TF-G 007 E
TUFFTRIDE® Process
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Advantages of an AB1 Bath
TUFFTRIDE® - Process
TF-GR 012 E
Significant increase in corrosion resistance
Oxidation of salt residue from TF1 bath to carbonate
Less distortion because of gradual cooling
Better running properties
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Medium
Molten salt consisting of alkali nitrate, alkali hydroxide and alkali carbonate
Basic Reactions in the Molten Salt
Detoxification ReactionCyanide (CN- ) + Nitrate (NO3
- ) Carbonate (CO32- ) + Nitrite (NO2
- ) Cyanate (CNO- ) + Nitrate (NO3
- ) Carbonate (CO32- ) + Nitrite (NO2
- )
Oxidation of the Compound LayerIron nitride (FexN) + Nitrate (NO3
- ) Magnetite (Fe3O4) + Nitrite (NO2- )
RegenerationNitrite (NO2
- ) + Oxygen (O2) Nitrate (NO3- )
Oxidation in AB1
TUFFTRIDE® TENIFER®
TF-GR 062 E
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Temperature 660-750ºF (350-400ºC)Influences the oxidation potentialDetermines the solubility of the carbonate
Sodium Nitrate Content (NaNO3 : 8-15%)Influences the oxidation potentialIs partially reduced to sodium nitrite during the bath reaction
Sodium Carbonate Content (Na2CO3 : approx.. 30%)Formed by the oxidation of cyanide and cyanateToo much:
Makes cleaning of parts more difficultLeads to formation of a bath crust and building of sludge onbottom of pot
TUFFTRIDE® TENIFER®
TF-GR 081 E
Influencing Factors in AB 1® Bath
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TUFFTRIDE® TENIFER®
TF-GR 080 E
Influencing Factors in AB 1® Bath
AgitationNecessary for an even temperature and homogeneous bath compositionEnsures heat dissipation when load is brought in
AerationOxygen in the air oxidizes sodium nitrite (NaNO2) back to sodium nitrate (NaNO3)
Important !Too much oxidation potential ⇒ reddish colored partsToo little oxidation potential ⇒ reduced corrosion resistance
⇒ inconsistent dark coloring
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AB 1 Bath
TF-GR 082 E
TUFFTRIDE® TENIFER®
Warning signs that something is wrong !
Bath is not liquid at 750°F (400°C).
No foaming, no reaction when load is brought in.
(Brown-coloured salt melt)
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TUFFTRIDE® TENIFER®
TF-GR 033 E
Influencing Factors in the Quenching Tank
Temperature < 104ºF (< 40ºC)Higher temperatures cause reddish coloration
Salt ContentToo high AB 1® salt content⇒ Can lead to talc on parts⇒ Makes cleaning more difficult (especially in hard water)Fresh rinse water must contain some AB 1 salt (< 1%) to reduce the high surface tension(⇒ Building of gas bubbles; discoloration of the parts)
AgitationAvoids localized hot areas Improves cleaning effectiveness
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Diagram of a TUFFTRIDE® - plant
AS 020 E
DC
Fresh water
Cleaning Cascade
STT STT SWQT10 % 1.0 % 0.1 %
Cold Water Rinse
LSU
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Requirement of Washing Water
for Different Rinsing
Techniques
2 rinsing tanks
Rinsing tank
2-step washing cascade
3- step washing cascade
4- step washing cascade
Amount of waste water% litres
100 2000
20 400
2.25 45
0.65 13
0.33 6.5
Rinsing technology
Source: Dr. Rolf StiefelInstitute for Industrial Hydroeconomy and Aircleaning, Cologne
TUFFTRIDE® - Process
TF-GR 061 E
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TUFFTRIDE® TENIFER®
TF-GR 032 E
Influencing Factors in the Rinse Cascade
Temperature 140-175º F (60-80ºC )Heat increases the dissolving of salt residues
Salt ContentThe lower the salt content, the more effective the cleaning
AgitationFast water flow speeds up the dissolving of salt residuesImproves the cleaning effectiveness