LAUSR

Abstract Plasma nitrocarburizing based on active screen technology using a carbon-fiber reinforced carbon active screen was applied in an industrial-scale unit for thermochemical surface treatment of austenitic stainless steel. This concept is based on the use of a solid-carbon-source for the generation of highly reactive process gases directly in the active screen plasma. In this work, plasma nitrocarburizing of AISI 316L stainless steel was performed by means of the variation of the precursor gases H2 and N2 in the range of 0% N2 up to 100% N2 without the use of any additional carbon bearing gas. For a set of H2-N2 gas mixtures, the resulting reaction gas was monitored using infrared laser absorption spectroscopy (IRLAS). The four main stable species HCN, CH4, NH3 and C2H2 were detected. A detailed analysis of the surface microstructure resulting for each specific H2-N2 precursor gas mixture was performed. This included glow discharge optical emission spectroscopy (GDOES), optical microscopy, micro hardness measurements, as well as X-ray diffraction analysis. The concentrations of hydrocarbons CH4 and C2H2 were most abundant in case of pure hydrogen plasma, and a carbon-expanded austenite layer with hardness values up to 600 HK0.01 and smooth hardness gradient resulted. The admixture of N2 to the precursor gas significantly increased the concentrations of HCN and NH3. Due to this, a duplex structure of nitrogen-expanded austenite γN and carbon-expanded austenite γC formed. With increasing content of N2 up to 50% in the precursor gas, the resulting layer thickness increased and the hardness reached values up to 1300 HK0.01. At strong nitrogen excess in the precursor gas, the nitrogen concentration in the expanded austenite significantly increased, the Fe2–3(N, C) phase was formed, and simultaneously the layer thickness decreased. Structure and properties of the expanded austenite layer significantly changed by only varying the H2-N2 ratio of the precursor gas mixture.