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Case Study One

Case Study Two

Case Studies


Case Study One

Automobile Gears

Material SAE M1010, C10

High speed gears require high root and flank stiffness to prevent bending fatigue, and a high surface hardness with a low coefficient of friction to resist abrasive and adhesive wear. Quiet running requires a surface hardening heat treatment that precludes dimensional distortion and loss of surface finish.


The ELTROPULS plasma nitriding process, compared to salt bath nitriding, produces a more uniform compound zone with less dimensional distortion for improved resistance to wear and for silent running.


Pretreatment: No heat treatment

Previous Treatment: Nitrided in a salt bath (18 microns +/- 4)

Present Treatment: ELTROPULS plasma nitriding

Treatment Parameters: T = 1070 F/ p = 3 mbar / t = 8 h


The following benefits can be obtained by selecting the ELTROPULS process:

  1. A compound zone thickness of 18 microns +/- 1 micron, with this uniformity extending over the entire gear profile.
  2. A surface hardness between 720 - 750 HV.05, measured both on the gear flank and at the root.
  3. No dimensional change or distortion of the gear profile from the heat treatment
  4. The elimination of salt deposits from the gear surface and, therefore, the elimination o environmentally sensitive cleaning operations after the nitriding step.


Case Study Two

Extrusion Dies

Material: AISI H13 Hot Work Steel, X40CrMoV51

Extrusion dies must operate under a large amount of thermal stress and mechanical pressure. They require high surface hardness in their bearing area to prevent loss of dimensional tolerances from erosive wear while pressing thin sectioned aluminum shapes.


ELTROPULS plasma nitriding permits the selection of the more ductile gamma prime compound zone and a diffusion zone for longer die life and increased extrusion speeds in most applications.


Pretreatment: Hardening and tempering to 36-38 HRc

Previous Treatment: Salt bath nitriding

Present Treatment: ELTROPULS plasma nitriding

Treatment Parameters: Temperature 1005 F, Time 9 hours


The following benefits are available with the introduction of the ELTROPULS process:

  1. Extrusion die life has been increased by 80%, often with higher extrusion speeds.
  2. Complex profiles, with a narrow openings to bearing surfaces, can be reliably nitrided.
  3. A uniform compound zone can be produced on all surfaces.
  4. Die surfaces can be effectively protected from both the abrasive and adhesive wear of aluminum extrusion.
  5. Molten salt can be eliminated from the heat treating operation and dies will require no cleaning inside narrow profiles after completion of the nitriding operation.




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