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  • Plasma Nitriding

    - especially in the Gear Industry

    Andreas Gebeshuber Ralph Trigueros

    Rübig GmbH & Co KG - Austria

  • CONTENT

    � Overview Ruebig Company

    � Short Introduction into Plasma Nitriding Technology

    � Gear Production

    � Trends in Gear Production

    � Process Chain in Gear Production

    � Development of Process Chains in Gear Manufacturing

    � Potential of Plasma Nitriding at Gear Manufacturing

    � Load and Stress Profiles on a Gear

    � Optimized local Properties due to Plasma Nitriding

    � Economic and Ecologic Aspects

    � Examples: especially Ring Gear (Co. Oberaigner)

  • The Rubig group has been engaged in steel technolog y for more than 60 years

    Knowledge and experience are the basis for our succ ess

    The synergetic cooperation of the three different d ivisions results in newest technologies

    • RUBIG – Die Forge

    • RUBIG – Heat Treatment

    • RUBIG – Engineering

    RUBIG GROUP OF COMPANIES

  • RUBIG – Die forge Your partner to develop forge parts also for smalle r series, up to 4 Kg part weight

    High quality management standards, we are working a ccording to TS 16949

    Mechanical machining, welding technology and heat t reatment

    RUBIG – Heat Treatment Heat Treatment certified according to ISO 9001:2000 and VDA 6.1

    Cooperation with academic institutes and steel prod ucers are the basis for our status as technology leader

    Expertise in material science drives the developmen t for newest heat treat technologies

    RUBIG – Engineering Individual solutions for Plasma assisted nitriding and coating units

    Vacuum furnaces and cleaning machines distinguish u s from the competition

    Fundamental research ensures application based solu tions

    E

    RUBIG GROUP OF COMPANIES

  • PRODUCT PORTFOLIO

    PLASNIT ® plasma nitriding

    system

    GASNIT ® gas nitriding system

  • PLASTIT ® Plasma assisted CVD coating system

    PRODUCT PORTFOLIO

    PLASNIT ® / GASNIT ® : combined plasma and gas

    nitriding system

  • PRODUCT PORTFOLIO

    MICROPULS ® plasma generators

    HPG line

    MAP line

  • PRODUCT PORTFOLIO

    RUEBIG ® vacuum hardening furnace

    HELIVAC ® helium - high pressure gas quenching system with integrated recycling unit

  • PRODUCT PORTFOLIO

    HYDROVAC ® metal parts cleaning unit

  • Argentina Australia Brazil Hong Kong India Indonesia Iran Japan Canada Korea Mexico Singapore South Africa Taiwan Thailand Turkey USA United Arab. Emirates

    OVERSEAS EUROPE

    Belgium Denmark Germany Finland France Great Britain Italy Liechtenstein Netherland Austria Poland Romania Sweden Switzerland Slovakia Slovenia Czech Republic Hungary

    EXPORT COUNTRIES RUBIG ENGINEERING

  • REFERENCES

  • a

    Nitriding Methods and basics of

    Plasma Nitriding Technology

  • NITRIDING

    Definition:

    The surface layer of the work piece is enriched with nitrogen by thermo chemical treatment.

    Process routes:

    � salt bath nitriding

    � gas nitriding

    � plasma nitriding

  • OXIDE LAYER, WHITE LAYER AND DIFFUSION ZONE

    oxide layer, 1-2 µm:

    � Running-in layer � Low friction coefficient � Corrosion resistance

    white layer, 5-20 µm:

    � Ceramic layer � Protection against abrasive and

    adhesive wear � High hardness

    diffusion zone, 10-1000 µm: � High compressive stress � High fatigue strength � Hardness higher than substrate

    oxide layer, Fe3O4

    white layer, Fe2-3N, Fe4N

    diffusion zone

  • COMMON NITRIDING AND NITROCARBURIZING METHODS

    salt bath nitriding no

    g o!

    !! gas nitiding

    plasma nitriding

  • DESIGN AND MAIN COMPONENTS OF A RUBIG PLASMA NITRIDING

    SYSTEM

    inner fan

    pump stand

    ARC detection

    PC - data recording

    CPU

    gas supply system

    measuring electronic

    MICROPULS power supply

    exhaust flap

    heating

    Inlet flap (cooling)

    fan/(cooling)

    retort

    intermediate ring

    multiple cooling system

    insulation amplifier

  • DESIGN AND MAIN COMPONENTS OF A RUBIG PLASMA NITRIDING

    SYSTEM

    process control system

    and visualization

    � simple operation � control system based on

    Siemens S7 � viszualization under Windows � process datad logged in real

    time � fully automatic and man-free

    operation � user surface in different

    languages available

  • DESIGN AND MAIN COMPONENTS OF A RUBIG PLASMA NITRIDING

    SYSTEM

    recipe administration

  • DESIGN AND MAIN COMPONENTS OF A RUBIG PLASMA NITRIDING

    SYSTEM

    trending diagram

  • OXIDE LAYER, WHITE LAYER AND DIFFUSION ZONE

    salt bath nitriding gas nitriding

    ...

    • high friction due to

    rough porous zone

    • post polishing necessary

    • very good corrosion

    resistance

    No GO (for comparison purposes only)

    • low friction due to

    smooth porous zone

    • no post polishing • good corrosion

    resistance

    plasma nitriding

  • GAS vs. PLASMA; HEALTH AND ENVORNMENT RELEVANT ASPECTS

    decreased engergy demand

    used gases not relevant for the environment

    reduced pollutant emmissions

    no greenhouse gas emmissions

    reduced cleaning expenses

    used gases not relevant for the health

    process temperature 530 – 600 °C

    process temperature 400 – 600 °C

    gas nitriding plasma nitriding

    process gases for nitriding: NH3, N2

    process gases for nitriding: N2, H2

    Gas consumption in an average furnace size: 4000 l/h

    gas consumption in an average furnace size: 400 l/h

    Carbon precursor for nitrocarburizing: CO2

    Carbon precursor for nitrocarburizing: CH4

    high influence of cleaning on nitriding result final cleaning by „sputtering“

    NH3 as Nitrogen precursor N2 as Nitrogen precursor

  • ECOLOGICAL ADVANTAGE: EMISSIONS COMPARISON FOR GAS- AND

    PLASMA NITRIDERS

    � 5.500 plasma nitriders produce less NOx than one gas nitrider

    � 2.700 plasma nitriders produce less CO/CO2 than one gas nitrider

    � The gas consumption of a Plasma nitrider is at least 10 times lower than for a gas nitrider

    Facts

    Source: T. Bell

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