Optimized plasma nitriding processes for efficient wear reduction of forging dies

Paschke, H.; Weber, Martin; Braeuer, G.; Yilkiran, Timur; Behrens, Bernd‐Arno; Brand, Helmut R.

doi:10.1016/j.acme.2012.06.001

Cited by 39 publications

(16 citation statements)

References 13 publications

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“…These treatments are applied to increase hardness as well as wear and corrosion resistance of forging tools at elevated temperatures [14][15][16]. Recent studies show the positive influence of plasma nitriding on the wear behavior of forging dies [5,8,13,18]. During these treatments nitrogen diffuses into the base material and the hardness in the edge zone increases.…”

Section: Plasma Surface Treatmentsmentioning

confidence: 99%

Increasing the Efficiency of Forging Operations Using Adjusted Tribological Surfaces Enhanced by Hard Coatings

et al. 2016

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Tools used in hot forging operations are subjected to high wear during processing due to complex load conditions with high temperatures and mechanical loads. The resulting abridged service lifetime of the dies highly restricts the cost-effectiveness of the production process. Several investigations indicate that the condition of the tool topography during several forging cycles affects the formation of wear distinctly. Thus, an enhancement of the topography in order to reduce tribologically caused wear is expected to increase wear resistance. Within this investigation an appropriate surface structure of forging dies is to be defined. For this purpose, efficient production methods like turning, milling and blasting are applied to generate distinguished die surfaces concerning topographical structures. By investigating the worn-out surfaces, the optimal surface structure can be determined, taking into account topography parameters deduced from the Abbott-Firestone graph. A mechanical stabilization of the created topography is necessary due to the high mechanical and thermal loads during hot forging leading to distinctive topography alterations. Thus, plasma duplex treatments were carried out, consisting of plasma nitriding and hard coatings produced by PECVD coating technique. It can be shown, that the created topography of the forging dies is sustainable over high amounts of forging cycles and thus leads to a reduction of wear.

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Section: Plasma Surface Treatmentsmentioning

confidence: 99%

Increasing the Efficiency of Forging Operations Using Adjusted Tribological Surfaces Enhanced by Hard Coatings

et al. 2016

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“…The author has shown in his work [14] that in the case of the application of a composite layers nitrided layer/ CrN, a greater thickness of the CrN coating effectively reduces the tempering effect of heat on the die material. The use of composite PVD coatings also makes it possible to obtain a surface layer with a microstructure consisting of nitrides of complex chemical composition [15]. Despite the progress in the field of many different surface engineering methods, currently, the most popular and best-mastered, low-cost method of increasing forging tool durability is still thermo-chemical treatment through nitriding (plasma nitriding, plasma diffusion treatment and gas nitriding), which, however, does not always provide a clear effect of durability improvement [16,17].…”

Section: Introductionmentioning

confidence: 99%

Influence of the nitrided layer thickness of dies made of two types of tool steel used in hot extrusion of valve forgings made of nickel–chromium steel on the durability of these tools

Hawryluk

Lachowicz

Janik

et al. 2021

Archiv.Civ.Mech.Eng

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The study constitutes an analysis of the durability of dies used in the first operation of producing valve forgings from chromium–nickel steel (NCF 3015) for motor trucks. The average durability of the dies (subjected to standard thermal treatment and nitriding) in this operation equals about 800 forgings. To perform an in-depth analysis of the effect of the nitrided layer thickness (0.1 mm and 0.2 mm) and the tool material (W360 and QRO90) on the possibilities of increasing the die durability, complex studies were carried out, which included: a macroscopic analysis combined with 3D scanning, microstructural examinations using a scanning microscope and a metallographic microscope, as well as hardness measurements. A minimum of three tools were tested for different variants, and for each of them, one representative die was selected for detailed examinations. The research showed the presence of abrasive wear, thermo-mechanical fatigue and traces of adhesive wear as well as plastic deformation on the surface of the working impressions. Also observed was the effect of the extruded material sticking to the tools (high friction and the presence of intermetallic phases in the extruded material) and the forging being blocked in the smallest section of the die, which is a critical factor causing a production shutdown and the necessity of tool replacement. The highest mean durability equalling 2600 forgings was obtained for the dies with a lower carbon content and a higher content of vanadium and the nitrided layer thickness at the level of 0.2 mm. The lowest mean durability (after one forging item) was recorded for the dies made of steel with a higher carbon content and a higher chromium content, forming less stable compound carbides and the thickness layer at the level of 0.1 mm.

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“…The successful implementation of many of these processes demands high performance from the forming tools. The tools have to resist rough conditions, such as the cyclic contact with the rapid-heated materials at temperatures above 1000°C, abrasive wear by hard particles like scale and oxides, in combination with adhesive wear by high pressure loading [1]. In some forming processes, the severe adhesion between the mould and the working materials becomes a major difficulty for demoulding without applying releasing agents or lubricants.…”

Section: Introductionmentioning

confidence: 99%

A State-of-the-art overview

Zhang

Dong

2014

Manufacturing Rev.

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Ever-increasing demand for severe work conditions, high-performance and long-life has been drivers for developing new low-friction and wear resistant coatings and surfaces for high temperature forming tools. This paper provides an overview on the recent development of coatings and modified surfaces to minimise friction and wear between contact surfaces in high-temperature working environments. This overview covers the major progresses in: (1) nanocomposite coatings based on transition metal nitrides and oxides, and the blending with solid lubricants such as silver and (2) multi-layered coatings with different combinations of hard and/or lubricating layers and duplex systems with solid lubricants on textured hard coatings and nanotubes. The challenges and future directions towards long-life and sustainable low-friction and wear-resistant coatings and surfaces for high-temperature forming tools are discussed.

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Optimized plasma nitriding processes for efficient wear reduction of forging dies

Cited by 39 publications

References 13 publications

Increasing the Efficiency of Forging Operations Using Adjusted Tribological Surfaces Enhanced by Hard Coatings

Increasing the Efficiency of Forging Operations Using Adjusted Tribological Surfaces Enhanced by Hard Coatings

Influence of the nitrided layer thickness of dies made of two types of tool steel used in hot extrusion of valve forgings made of nickel–chromium steel on the durability of these tools

A State-of-the-art overview

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