High performance automotive and aircraft engine crankshafts are nitrided
for better fatigue resistance and wear properties on bearing journals.
Nitriding gears for applications ranging from heavy-duty machinery to
small automotive accessories enables lower manufacturing costs.
For one customer, this meant eliminating costly finishing operations
needed after carburizing.
FORGING / FORMING DIES
Forging and forming dies made of tool steels, alloy steels, cast steels
or cast iron are a frequent visitor in a heat treating shop. The
dies are vacuum hardened and tempered, flame hardened, flood-welded and
nitrided, as applicable, for better life.
ALUMINUM EXTRUSION DIE
Extrusion dies are nitrided and re-nitrided several times to extend
their die life. Nitriding parameters are adjusted to the expected
die duty cycle resulting in significant cost reductions and virtual
elimination of unscheduled press shutdowns.
The process control hardware is a product of extensive research and
development in process automation, and innovations in nitriding
technology. A typical system is configured in four distinct
sections which facilitate operation and maintenance of the system.
They consist of:
- Process control panel with solid state
relays, computer and color monitor
- Gas panel with atmosphere analysis,
gas mixing and electronic gas flow measuring equipment.
- Electrical panel with thyristor (SCR)
controllers, contactors, fuses and switches.
- Exhaust gas neutralizing unit.
This innovative approach
provides an unparalleled degree of accuracy in process execution,
contributing to consistency in nitriding results and offering new
possibilities in perfecting the nitriding technology.
PROCESS CONTROL DIAGRAM
The nitriding process control is carried out in a closed loop
circuit. This, coupled with advanced features, enables the process
control system to automatically respond to the changes in nitriding
conditions which occur during the process.
To adjust the process
parameters, the furnace atmosphere is continuously sampled and
analyzed. Based on the data extracted, the process computer
adjusts the incoming atmosphere, thus maintaining the preset value of
the nitriding potential as accurately as possible.