When processing metals, manufacturers opt for various heat treatment and surface treatment processes as they can alter the properties of workpieces. Most of these processes can improve their strength, resistance to elements, and workability, making it possible for industries to receive metal parts and products that last for a long time without any compromises.
One of the processes that manufacturers can maximise in working with metals is nitriding. It is a surface treatment process wherein nitrogen is introduced into the surface layer of a material. Generally, it can improve the mechanical, chemical, and physical properties of materials.
Nitriding can affect the microstructure and properties of materials in various ways. Depending on the nitriding process used, the material’s composition, and the desired outcome of the treatment, this surface treatment process can certainly alter the characteristics of materials.
One significant impact of nitriding on the microstructure of materials is the formation of a nitrided layer. This specific layer is formed due to the diffusion of nitrogen into the surface layer of the material. Its thickness often varies depending on the nitriding process and the composition of the material. Gas nitriding, for instance, can produce a thicker layer than plasma nitriding.
The nitrided layer’s microstructure may also vary based on the nitriding process used. For example, gas nitriding can produce a compound layer of iron nitrides. Plasma nitriding, alternatively, can produce a diffusion zone that contains a mixture of carbon and nitrogen.
The thickness and microstructure of the nitrided layer can then significantly impact the material’s properties. One of the most notable effects of nitriding on the properties of materials is the improvement of surface hardness. The nitrided layer formed during the process is often much harder than the material’s core, which improves the material’s wear resistance. The increase in surface hardness of a material is due to the formation of hard nitrides as well as the incorporation of nitrogen into the lattice structure of the workpiece.
The increase in surface hardness can then lead to an increase in the material’s fatigue strength. Nitriding can likewise improve the corrosion resistance of the material by forming a protective layer on the surface that prevents corrosion.
The effects of nitriding on the material’s mechanical properties are not limited to surface hardness. This surface treatment process can also improve the tensile strength, yield strength, and toughness of the material. The improvement in these properties is caused by the introduction of nitrogen into the material’s lattice structure, which leads to the formation of nitride precipitates and the refinement of the grain structure.
Nitriding can also reduce the material’s coefficient of friction, which makes it suitable for applications where low friction is essential. Nitriding can likewise decrease its electrical conductivity, making it useful in applications where electrical insulation is necessary.
Nitriding is a surface treatment process that can impact the microstructure and properties of materials. The nitrided layer formed during the process can improve the material’s surface hardness, fatigue strength, corrosion resistance, tensile strength, yield strength, and toughness. Nitriding can also impact the physical properties of a material, such as its coefficient of friction and electrical conductivity.
Metal parts and components utilised by different industries should undergo hydrogen de-embrittlement so they can be protected from the damaging effects of hydrogen.
Metals are often utilised by manufacturers in producing parts and components since they are durable, appealing, dependable, and long-lasting. However, some of them can easily get damaged due to their constant exposure to hydrogen.
Hydrogen, after all, can cause metals to become brittle and crack, leading to catastrophic failure in some applications. The process of hydrogen atoms diffusing into metal structures is known as hydrogen embrittlement, which must be averted to prevent failures and damages. One countermeasure for this process is hydrogen de-embrittlement or HDE.
Hydrogen de-embrittlement, as its name implies, is the process of removing hydrogen from metal structures to prevent embrittlement. It is also conducted to maintain the strength and durability of metal elements. HDE makes sure that metal parts and components can still be useful despite being exposed to environments with hydrogen.
Aside from countering hydrogen embrittlement, HDE can also help improve the fatigue life of metal components. Fatigue failure is a common issue in many industries, where components are subject to repeated loading and unloading. With HDE, the fatigue life of metal components can be improved significantly.
The process of HDE is done by exposing metal components to a heated acid bath. The acid from this bath eliminates and removes hydrogen from the metal workpieces. Once done, these things are rinsed and dried. The whole process can be repeated multiple times to make sure all hydrogen atoms are fully removed. The effectiveness of this process can only be achieved if it is done carefully as some metals might get damaged during HDE.
Many industries can take advantage of HDE as they often use metal parts and components in carrying out their daily operations.
The aerospace industry, for instance, uses HDE to protect aircraft engines from the effects of high stress and hydrogen infusion. Without HDE, these components might only cause catastrophic damage to the aircraft. Another industry that can take advantage of HDE is the automotive industry. High-strength metals are commonly utilised in the construction of automobiles. They may, however, be subject to hydrogen embrittlement. Through HDE, the hydrogen from these materials can be removed, which prevents them from failing.
Another important application of the HDE process is in the energy industry. Hydrogen embrittlement can be a huge problem in the said industry as they often maximise high-strength metals for drilling and production equipment. With the help of HDE, it can ensure that these equipment pieces will not fail due to hydrogen embrittlement and cause environmental damage.
Even the construction industry can take advantage of HDE. High-strength bolts and other fasteners are often utilised in construction projects and are often subject to hydrogen embrittlement. HDE ensures these things will not fail due to embrittlement, making them effective in maintaining the safety of structures.
Hydrogen de-embrittlement is a critical process in industries where metal components are subject to high stress and safety is critical. The process is used to remove hydrogen from the metal, preventing hydrogen embrittlement and ensuring the safe operation of the component. HDE can also improve the fatigue life of metal components.
Alpha Detroit offers a wide range of metal surface hardening processes so that metal parts and components will be protected from damaging elements. After all, these things are often utilised by various industries given their reliable strength, outstanding longevity, and astonishing appeal. Their versatility and flexibility also allow them to create various shapes, colours, and finishes.
But to ensure that they remain durable and long-lasting, a lot of them must undergo metal surface hardening processes. Metal surface hardening is a technique utilised to enhance the mechanical properties of metals. Some properties it can enhance are strength, toughness, and wear resistance. At Alpha Detroit, we make sure that any metal part or component of our clients will be durable, appealing, and long-lasting through metal surface hardening.
Various types of metal surface hardening can be carried out by our team at Alpha Detroit. Some of these types are as follows.
Flame hardening is a metal surface hardening process that can be done by directing a flame towards the metal surface to heat it to the required temperature. The metal workpiece is then quenched in water or oil to cool it down rapidly, resulting in a hardened surface layer. This process is typically used for low to medium-carbon steel and cast iron.
One great thing about flame hardening is it is quick. It can also achieve a high level of hardness on metal surfaces. It can even be utilised to harden specific areas of a metal workpiece. It can, however, result in distortion or wrapping due to uneven heating and cooling. A brittle surface layer may likewise show up, making the workpiece susceptible to cracking under high stress.
Through hardening, also known as quenching and tempering, can be done by heating a workpiece to a high temperature before rapidly cooling it through a quenching medium. The workpiece is then tempered at a lower temperature to reduce its brittleness and improve its toughness. This type of hardening can be used for medium to high-carbon steels.
Similar to flame hardening, through hardening can also produce materials with a high level of hardness, strength, durability, and toughness. Distortion, however, may still occur during this process. Without tempering correctly, workpieces can lose their ductility and toughness.
Case hardening is carried out by heating metal in a carbon-rich environment to absorb carbon into its surface layer. The metal is then quenched to cool it down rapidly, which results in a hardened surface layer with a softer, more ductile core. Low-carbon steels and alloy steels can take advantage of case hardening.
Compared to flame hardening, the process of case hardening can produce a harder surface layer over the workpieces. It can also be utilised to harden specific areas of the metal without affecting the rest of the workpiece. The process, unfortunately, can be slower and more expensive than other hardening processes. Surfaces can also be prone to chipping or cracking once the metal workpieces are under high stress.
Induction hardening can also harden the surface layer of the metal quickly and uniformly. During this process, the metal is heated using an induction coil to a high temperature, and then rapidly cooled by a quenching medium. It can work effectively on high-carbon and alloy steels.
One of the benefits of this process is it can generate a deeper hardening depth than other processes. It is also faster than case hardening. It can, however, be more costly than flame hardening. It may also cause distortion or warping due to uneven heating and cooling.
All these methods can be acquired from us at Alpha Detroit. Working with us can guarantee you parts and products with a better surface layer that matches your applications.
Heat treatment is the process of heating metals without melting them and cooling them in a controlled way. The purpose of this process is to ensure that the workpieces will acquire the desired mechanical properties of the industries. Some common properties that heat-treated metals acquire include corrosion resistance, increased ductility, and enhanced malleability.
One type of heat treatment process that is often carried out by the metalworking industry is surface hardening. Manufacturers often conduct this process to improve the hardness and wear resistance of metal component surfaces.
A popular method under surface hardening is induction hardening. It can be carried out to increase the hardness and wear resistance of metal components. Cracks, however, can form and develop on these materials, which can cause them to fail prematurely. To reduce cracking during induction hardening, here are some tips that you should follow.
The material that will be utilised for induction hardening can have a significant impact on the likelihood of cracking. And so, you must avoid materials that are more susceptible to cracking. Those with high carbon content, for instance, should not be used for induction hardening as they tend to crack more than those with low carbon content. Materials with better hardenability can also be used instead for induction hardening.
Too high heating rates can often lead to rapid expansion and contraction of the metal workpieces. These materials will then eventually crack. To reduce the likelihood of cracking, the heating rates should be controlled at a slow rate. Using lower power or longer heating times to achieve the desired temperature can be carried out during the induction hardening process rather than trying to heat the component too quickly.
Related to the previous tip, you must avoid overheating at all costs as it can cause the metal to become brittle, which then leads to the cracking of the workpiece. The component that will undergo induction hardening should be heated to the correct temperature and not overheated. This tip can be achieved by maximising accurate temperature monitoring equipment and subsequently controlling the power output of the induction heating system.
Quenching is vital to achieving the desired hardness in the metal. However, if the quenching process is carried out too quickly or with the wrong medium, the likelihood of the metals cracking can increase significantly. Maintaining slower quenching rates or utilising a different quenching medium can reduce the chances of materials getting cracks.
During induction hardening, materials may get distorted and eventually crack due to uneven heating and quenching. Therefore, you must utilise actions that can minimise distortion. To do this, you must use fixtures or jigs so that the components involved can be held in place during heating, quenching, and other vital heat treatment processes.
Cracking during induction hardening can be a common problem. However, it can be mitigated by taking appropriate precautions. You can work with us at Alpha Detroit Heat Treatment if you want to attain high-quality metal workpieces.
Many coating processes can be utilised by a wide range of industries to ensure their parts and products will remain durable over time. One of these processes is black oxide coating.
Black oxide coating is a conversion coating process used to enhance the corrosion resistance and aesthetics of ferrous metals like steel, iron, and stainless steel. The process involves the immersion of the metal part in a hot alkaline solution, which creates a black oxide layer on the metal surface. This layer is chemically bonded to the metal, generating a durable finish that does not chip, flake, or peel.
Black Oxide Coating General Steps
Different steps are associated with a black oxide coating. These steps are as follows.
Applications of Black Oxide Coating
The black oxide coating process is widely used in numerous industries, which include automotive, aerospace, and medical devices. Some applications of black oxide coating include:
Black oxide coating can swiftly provide products with a finish that is corrosion-resistant and appealing. It is also expected for the products from various industries to last for a long time.