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)

 RUBIG GROUP OF COMPANIES

The Rubig group has been engaged in steel technology for more than 60 years
Knowledge and experience are the basis for our success
The synergetic cooperation of the three different divisions 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 smaller series, up to 4 Kg part weight
High quality management standards, we are working according to TS 16949
Mechanical machining, welding technology and heat treatment

RUBIG – Heat Treatment

Heat Treatment certified according to ISO 9001:2000 and VDA 6.1
Cooperation with academic institutes and steel producers are the basis for our status
as technology leader
Expertise in material science drives the development for newest heat treat
technologies

RUBIG – Engineering
Individual solutions for Plasma assisted nitriding and coating units
Vacuum furnaces and cleaning machines distinguish us from the competition
Fundamental research ensures application based solutions

E
 PRODUCT PORTFOLIO
PLASNIT ®
plasma nitriding
system

GASNIT ®
gas nitriding system
 PRODUCT PORTFOLIO

PLASNIT ® / GASNIT ® :
combined plasma and gas
nitriding system

PLASTIT ®
Plasma assisted CVD coating system
PRODUCT PORTFOLIO

MICROPULS ®
plasma generators

MAP line

HPG 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
EXPORT COUNTRIES RUBIG ENGINEERING

OVERSEAS EUROPE
Argentina Belgium
Australia Denmark
Brazil Germany
Hong Kong Finland
India France
Indonesia Great Britain
Iran Italy
Japan Liechtenstein
Canada Netherland
Korea Austria
Mexico Poland
Singapore Romania
South Africa Sweden
Taiwan Switzerland
Thailand Slovakia
Turkey Slovenia
USA Czech Republic
United Arab. Emirates Hungary
REFERENCES
Nitriding Methods and basics of
a

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 oxide layer, Fe3O4

white layer, 5-20 µm: white layer, Fe2-3N, Fe4N

Ceramic layer

Protection against abrasive and
adhesive wear

High hardness

diffusion zone
diffusion zone, 10-1000 µm:

High compressive stress

High fatigue strength

Hardness higher than substrate
COMMON NITRIDING AND NITROCARBURIZING METHODS

plasma nitriding
salt bath nitriding

!!! gas
nitiding
go
no
DESIGN AND MAIN COMPONENTS OF A RUBIG PLASMA NITRIDING
SYSTEM

Inlet flap (cooling)

exhaust flap

multiple cooling system

retort
intermediate ring
fan/(cooling)

heating

PC - data
recording

CPU

gas supply
system

measuring
electronic

MICROPULS
power supply

ARC insulation inner fan

detection amplifier

pump stand
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 plasma nitriding

...

• high friction due to • low friction due to

No GO rough porous zone

• post polishing necessary
smooth porous zone
• no post polishing
(for comparison purposes
• very good corrosion • good corrosion
only)
resistance resistance
 GAS vs. PLASMA; HEALTH AND ENVORNMENT RELEVANT ASPECTS

gas nitriding plasma nitriding

process temperature 530 – process temperature 400 –
decreased engergy demand
600 °C 600 °C
process gases for nitriding: used gases not relevant for process gases for nitriding:
NH3, N2 the environment N2, H2

Carbon precursor for no greenhouse gas Carbon precursor for

nitrocarburizing: CO2 emmissions nitrocarburizing: CH4

Gas consumption in an average gas consumption in an average

reduced pollutant emmissions
furnace size: 4000 l/h furnace size: 400 l/h
high influence of cleaning on
nitriding result reduced cleaning expenses final cleaning by „sputtering“

used gases not relevant for

NH3 as Nitrogen precursor N2 as Nitrogen precursor
the health
ECOLOGICAL ADVANTAGE: EMISSIONS COMPARISON FOR GAS- AND
PLASMA NITRIDERS

Source: T. Bell

5.500 plasma nitriders produce less NOx than one gas nitrider

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

The gas consumption of a Plasma nitrider is at least 10 times lower than for
a gas nitrider
 W
itn
es
sr
oll
er
s (1
st Vickers Hardness [HV 0,3]
W VS
itn E
es /1
sr 2-
o ll D

650
750
850
950
1050
1150
1250
er ec
s (2
-2
00
nd 8)
W VS av
itn E g.
es /2
sr 4-
o ll F eb
er -2
s( 00
3r
W dV 9)
av
itn SE g.
es
sr /0
o ll 2-
er M ar
(ru -2
n- 00
W 23 9)
itn 88 av
es 50 g.
sr /0
o ll 6-
er M
(ru ar-
n- 20
24 09
W 79 av )
itn 84 g.
es /2
sr 5-
oll Ju
er n-
(ru 20
n- 09
W 24 )a
itn 85 vg
es 77 .
sr /0
oll 2-
er Ju
(ru l-2
n- 00
W 2 49
9)
itn 20 av
es 4 g.
sr /0
oll 9-J
er u l-
(ru 20
n- 09
W 24 )a
itn 97 vg
es 68 .
sr /1
oll 6-
er Ju
(ru l-2
n- 00
W 25 9)
av
itn 09 g.
es 39
sr /3
o ll 0-
er Ju
(ru l-2
n- 00
W 2 51 9)a
itn 41 vg
es 9/ .
sr 06
o ll -A
er ug
(ru -2
n- 00
W 25 9)
itn 18 av
es 45 g.
sr /1
o ll 3-
SH [HV0,3] at 0,10 mm

CH [HV0,3] at 0,60 mm

er Au
Spec. NDmin = 0,17mm

(ru g-
n-2 20
09
W 52 )a
itn 11 vg
es
sr
2/ .
o ll 17
er -A
(ru ug
-2
n- 00
W
25 9)a
itn 24 vg
es 21 .
sr /2
o ll 1-
er Au
g-
(ru
n- 200
W 25 9)
itn 68 av
es 18 g.
sr /0
o ll 8-
er Oc
(ru t-2
n- 00
W 25 9)
itn 80 av
es 59 g.
sr /2
o ll 0 -O
er c t-
(ru 20
n-
25 0 9)
W 85 av
itn
Spec. SHmin = 810 HV0,3

Spec. CHmin = 700 HV0,3

es 39 g.
Process Reproducibility - Homogeneity

sr /2
o ll 4-
er Oc
(ru t-2
n- 00
W 258 9)a
itn 91 vg
es
sr 7/ .
o ll 29
er -O
(ru c t-
n- 20
25 09
W 9 )a
itn 74 vg
es
sr
3/ .
o ll 06
er -N
ov
(ru -2
ND [mm]

n- 00
26 9)
03 av
33 g.
/1
2-
No
v-2
00
9)
av
g.
Spec. SHmax = 1100 HV0,3

0,10
0,12
0,14
0,16
0,18
0,20
0,22
0,24
0,26
0,28
0,30

Nitriding Depth [mm]

TECHNICAL ADVANTAGE – PLASMA NITRIDING

evaluation period 12/2008-12/2009– wittness loads 5 samples / charging level

Gear Production
a
 AUTOMOBILE – GEAR MANUFACTURING

Global gear production – regional production in mio.

2007 2013

Japan / Korea 24 27

Western Europe 18 21

North America 10 12

China 5 9

South Asia 2 5

Eastern Europe + South America 4 7
total 63 81

+ 28%

Non automotive gears are not included in the numbers (approx. 11 million gear boxes
additionally)
PROCESS CHAIN IN GEAR MANUFACTURING
Raw material

Turning

Gear cutting (soft machining)

Soft finishing

Carburizing

Hard machining

Sorting / Rejecting

Fabricated gear

Lecture of Klocke F., Weck M. at WZL Forum 1998 in Aachen: Warum

Feinbearbeitung?
DEVELOPMENT OF GEAR BOX PRODUCTION
Factory Kassel – VW Gear Manufacturing-Engineering

Percentage of Hard Machined Gears at VW

70%
60%
50%
Percentage

40%
30% 58%
49%
20%
10% 5%
0%
2000 2008 2011
Year
D. Knöppel, WZL Forum Aachen 1998: Möglichkeiten /Grenzen der Hartfeinbearbeitung bei PKW-Getrieben – VW
J. Fenstermann, Near-Net-Shape Tagung 2005: Anforderungen, Stand der Technik u. Perspektiven von Verzahnungen
J. Fenstermann, Getpro 2009: Ganzheitliche Prozessoptimierung in der Getriebefertigung bei VW
REASONS FOR HARD MACHINING

Noise reduction Maximizing of bearing capacity

Reaching the quality necessary for the application

Reduction of gearing failures Gear modifications

Angle corrections
Angle errors
Convexities
Pitch errors
Retractions
Rotation errors
Topological corrections
Reeling errors
Design optimization
(tooth root)

Impovement of surface quality

and fabrication of advantageous
surface structures

Lecture of Klocke F., Weck M. at WZL Forum 1998 in Aachen: Warum

Feinbearbeitung?
DEVELOPMENT OF PROCESS CHAINS IN GEAR MANUFACTURING
Factory Kassel – VW Gear Manufacturing-Engineering

 Material Up to 40% of production costs are

nowadays necessary to compensate the
Soft- Hard-
distortion due to the heat treatment
machining machining and to improve the surface quality.

Hardening
Passenger cars – gear box assembling
(aprox. 16.000 gear systems for passenger cars)

D. Knöppel, WZL Forum Aachen 1998: Möglichkeiten /Grenzen der Hartfeinbearbeitung bei PKW-Getrieben – VW
J. Fenstermann, Near-Net-Shape Tagung 2005: Anforderungen, Stand der Technik u. Perspektiven von Verzahnungen – V
J. Fenstermann, Getpro 2009: Ganzheitliche Prozessoptimierung in der Getriebefertigung bei VW
Potential of Plasma Nitriding
a

at Gear Manufacturing
LOAD AND STRESS PROFILE ON A GEAR
Tooth root Tooth flank

Pit Marks

Micro Pitting
DIFFERENT RECOMMENDATIONS FOR DIFFUSION DEPTH AT ROOT AND
FLANK

Case depth and nitriding depth for gears according Linke (Stirnverzahnungen, 1996):
Modulus in mm: 1,0 to 2,4 CD: 0,3 + 0,2 ND: 0,2 + 0,1
2,5 to 3,5 0,5 + 0,3 0,3 + 0,1
3,5 to 4 0,8 + 0,4 0,4 + 0,1
OPTIMIZED LOCAL PROPERTIES
Plasmanitriding offers an intelligent material / heat treatment design
 required material properties exactly were they are needed
properties on the gear tooth

white layer
thin white layer on flank
•reduces wear
•increases sliding behaviour
symbolic picture •increases pitting resistance
no / small white layer on tooth root
•increases tooth root bending strength

nitriding depth
average nitriding depth on flank
•increases pitting resistance
small nitriding depth at tooth root
•increases tooth bending strength
MICROGRAPH OF A RING GEAR, MODULUS 0,35
CORE MESSAGE

Appropriate
Material + Adequate Micropuls
Plasmanitriding

offers

The same or even better mechanical poperties than

carburized gear parts

Considerably more homogeneous fatigue values

compared to carburized gears

The material properties exactly where they are

needed and adjustable according to demands
RUBIG PLASMA NITRIDING INITIATIVE
sa mo
mp dul
us
le s 1,25 mo
dul
us
2,75

rotating bending tests

until middle 2007

RCF tests tooth root bending strength tooth flank pitting strength
until end of 2007 until end of 2009 until middle 2010
 TOOTH ROOT FATIGUE STRENGTH
Comparison case hardening and gas- / plasma nitriding
Data from DIN 3990 – Literature Data – Rübig Tests modulus
1,25 2,75

600
tooth root fatigue strength [N/mm2]

590
550 570
material
500
432 - R935
470
400 430 - 31CrMoV9
340
310 tests with shaved and
300 270 280 plasma nitrided gears,

developement
m=1,25 and 2,75; done at
heat treated steel

plasmanitrided
nitriding steel
FZG- Institute TU-Munich
nitriding steel

200 alloyd steel

carburized
heat treated

gas nitrided

2007 to 2010
gas nitrided

RÜBIG
100

0
fatigue strength value DIN 3990-5 Diss.
RÜBIG
Schlötermann
1988 actual data
 INFLUENCE OF WHITE LAYER ON TOOTH ROOT FATIGUE STRENGTH
Test results of plasma nitrided gears 31CrMoV9 modulus 5 mm

600
tooth root fatigue strength σ Flim [N/mm²]

Plasma nitriding - variants VAR 1 VAR 2 VAR 3

+ core hardness N/mm² 950 950 950

500
38 + white layer WS µm with with none
% 59
400 % nitriding temperature °C 530 520 520
nitriding time hours 60 36 36
300 case hardness HV 0,5 750 750 780
nitriding depth Nd in tooth
mm 0,4 0,3 0,4
200 root
tooth root fatigue strength
N/mm² 390 340 540
100 σFlim (DIN 3990)
72 63 100
percentage %
0 115 100 159
VAR 1 VAR 2 VAR 3
source: Schlötermann, K.: Auslegung nitrierter Zahnradgetriebe, Dissertation RWTH
Aachen, 1988 (131 Seiten) - Untersuchungen zu den Auswirkungen unterschiedlicher
Nitrierparameter auf den Werkstoffzustand und die Tragfähigkeit von Zahnrädern

E
 PITTING RESISTANCE σHlim- SITUATION
Standard- and test values of literature / data Rübig
Standard DIN 3990 values σHlim Values diss. Schlötermann, m= 5
(fatigue strength, 1% failure probability)
PN: σHlim = 1590 – 1760 N/mm2
Carburizing 1300 – 1650 N/mm²
Failure not by pitting, only by wear on
Nitriding 1120 – 1450 N/mm² the driving gear between, pitch circle
fatigue strength σHlim [N/mm2]

and tooth root (load = 8,5 * 107 )

1800
1760 1760
1600 1650
1400
1400 1450 1340
1300

case-hardened steel
1200 1220 1120

plasma nitrided
1000

case-hardened
nitriding steel

developement
nitriding steel
gas nitrided

780
800
gas nitrided
tempered

600

RÜBIG
steel

400
200
0
fatigue data according DIN 3990-5 Dissertation RÜBIG
Schlötermann Actual data
1988
APPLICATION – COATING OF GEARS

→ Increase of pitting resistance through coating: 27 %

COMMERCIAL ADVANTAGE – LESS HARD MACHINING
Today Tomorrow

Raw material / processing (forging)

Turning

Gear cutting (soft machining)

Soft finishing

Carburizing Plasmanitriding

Hard machining

Sorting/rejecting

Fabricated gear
Examples
a
EXAMPLES OF GEARS AND OTHER PARTS PERFECTLY DEDICATED FOR
PLASMA NITRIDING
EXAMPLES OF GEARS AND OTHER PARTS PERFECTLY DEDICATED FOR
PLASMA NITRIDING
 EXAMPLES OF GEARS AND OTHER PARTS PERFECTLY
DEDICATED FOR PLASMA NITRIDING
800

700
flank
hardness [HV 0,5]

600 root
500

400

300

200

100

0
0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1
Distance from surface [mm]

PN 100/180 DUO

installation in
production area

process time
20 hours.

∆T = ±3°C
COMPANY WILHELM OBERAIGNER GMBH

Founded 1977 – aprox. 80 Employees

One of the leading specialists in development and

production of automotive system components

Service offer includes also complete drive axles,
differential locks and gear drives

Company Wilhelm Oberaigner GmbH is also responsible for the development and supply of components

for the AWD-versions of Mercedes Vito/Viano (NCV2) and Mercedes Sprinter (T1N & NCV3)

The drive components for these cars are produced at Oberaigner and sent directly to the assembly lines of
the appropriate factories

Oberaigner invests essential amounts in R&D as well as in the production of new technologies like Hybrid
or Electro drives

Furthermore Oberaigner Aerospace (aircraft engines and business jets) is in development
COMPANY WILHELM OBERAIGNER GMBH
ALL-WHEEL FRONT AXLE: RING GEAR INTEGRATED INTO THE AXLE
HOUSING

 Increase of clearance height due to bevel gear (i ≈ 1,5)

 Planetary gear set in front axle (integrated in axle casing)
 speed reduction due to planetary gear set (i ≈ 2,5)
GOAL

since approx. 7 years ring gear is in use as linear/straight ring gear

Heat treatment

Carburizing + bolt hardening  reduction of distortion to increase quality concerning

homogenous case depth and to reduce hard machining (grinding,…)

However very much effort for hard machining

Goal

Noise reduction

Elimination / Reduction of hard machining

No loss in performance!
RING GEAR  SPECIFICATION

Bolt case hardening Plasma nitriding

Material: 20MnCrS5 (1.7149) Material: 31CrMoV9 (1.8519)

Surface hardness [HRc]: 58 + 4 Surface hardness [HV10]: 750 + 150

Case depth [mm]: 0,65 + 0,2 Nitriding depth [mm]: 0,2 + 0,2

Core hardness [MPa]: > 1000 Core hardness [MPa]: 1000 - 1200

Gear grade: 6-7 (Automotive)

RING GEAR  RESULTS AFTER PLASMA NITRIDING

Paramter Position Measured value

Surface hardness Tooth crest 862 HV10
Target: 750-900 HV10

Tooth flank 6,7µm

White layer
Target: 4-10µm
Tooth root 3,0µm

Tooth flank 0,27mm

Nitriding depth
Target: 0,2-0,4mm
Tooth root 0,24mm
RING GEAR  RESULTS AFTER PLASMA NITRIDING

Tooth flank 1
Nitriding depth
Tooth flank 2
900
Tooth root

800 Limit hardness

Hardness [HV0,5]

700

600

500

400

300
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70

Distance from surface [mm]

 RING GEAR – DISTORTION COMPARISON; m = 1,5, flange ∅ = 125, width = 32
Comparison Plasma Nitriding (PN) with Bolt-Case Hardening (BCH)
µm profile deviation flank deviation
8
7
6
5
4
3
2
1
0
µm
angle for m total angle for m total

60 Comparison of average difference values

50 before and after PN and BCH. Maximal
difference values are by PN and DEH
40
approximately with factor 2 higher.
30
pitch - deviation Measures at respectively ten gears - left and
20 right flank (PN and BCH). For each gear four
teeth were measured and mean value was
10
created. With these mean values the average
0 difference values were calculated and
roundne s s
flange
displayed in the charts.
total single pitch error

BCH PN
RING GEAR – COST COMPARISON
Plasma Nitriding (PN) with Bolt-Case Hardening (BCH) portion of costs in %
20MnCrS5 – 31CrMoV9 - PN
%
BCH Var. A Var. B
100
savings - 16 17

80 structure honing - 8 -

hard machining 32 - -
60 7 6 6
hardening
soft finishing 54 61 32
40
stress annealing - - 4

20 pre-machining - - 32

material 7 9 9
0
Bolt-Case Plasma Nitriding
∅
Hardening Route A Route B 125
SUMMERY & OUTLOOK
Summery

Distortion

Distortion after plasma nitriding only a fraction compared to bolt case hardening

No change of gear grade after plasma nitriding

Probably no subsequent machining necessary

Costs

Reduction of costs: 16 – 17%

Throughput time

Reduction: 8 – 14%

Outlook

First performance check positive

Currently endurance test in a 6x6 Mercedes Sprinter

 Contact: Ralph Trigueros [email protected]

Thank you
for your
attention!