Plasma Nitriding: Everything you need to know

In the field of surface engineering, numerous techniques are employed to enhance the properties of metal components. One such process gaining popularity is plasma nitriding.

This blog post will delve into the plasma nitriding process, compare it to gas and salt bath nitriding, explore the active screen plasma nitriding technique, differentiate it from ion nitriding, discuss the coating thickness, consider the cost implications, compare it to shot peening, and touch upon plasma nitriding of aluminum versus hardcoat.

Plasma Nitriding Process

Plasma nitriding is a thermochemical surface treatment that improves the hardness, wear resistance, and corrosion resistance of metals. In this process, the metal component is placed in a vacuum chamber, and a nitrogen-rich gas (often ammonia) is introduced. An electrical discharge is then created, ionizing the gas and forming a plasma. The high-energy ions bombard the metal surface, causing nitrogen atoms to diffuse into the material and form a hard nitride layer.

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Plasma Nitriding vs. Gas Nitriding:

Compared to gas nitriding, plasma nitriding offers several advantages. Plasma nitriding provides better control over the nitriding process, allowing for precise control of case depth and uniformity. It is also a faster process and can be performed at lower temperatures, reducing the risk of distortion or metallurgical changes in the base material.

Active Screen Plasma Nitriding Technique:

Active screen plasma nitriding is an advanced variation of plasma nitriding. In this technique, a specially designed screen is placed between the plasma source and the component. The screen acts as a filter, allowing only certain ions to pass through, resulting in enhanced control over the process. Active screen plasma nitriding offers improved uniformity, reduced white layer formation, and greater flexibility in achieving specific nitriding results.

Plasma Nitriding vs. Ion Nitriding:

Plasma nitriding and ion nitriding are often used interchangeably, but they are not the same. While both processes involve the use of plasma and ion bombardment, there are differences in the operating conditions and the nature of the plasma. Plasma nitriding typically operates at lower temperatures and utilizes a nitrogen-rich gas, whereas ion nitriding typically involves higher temperatures and the use of nitrogen or ammonia gas with a small percentage of hydrogen.

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Plasma Nitriding vs. Salt Bath Nitriding:

Compared to salt bath nitriding, plasma nitriding offers several advantages. Plasma nitriding is a dry process, eliminating the need for hazardous salts and reducing environmental concerns. It provides better control over the process parameters, resulting in consistent and uniform nitriding. Additionally, plasma nitriding can be performed at lower temperatures, reducing the risk of distortion or material damage.

Plasma Nitriding Coating Thickness:

The thickness of the nitride layer formed during plasma nitriding depends on various factors, including process parameters, treatment time, and material composition. Typical nitride layer thickness ranges from a few micrometers to several hundred micrometers, depending on the desired application and requirements.

Cost of Plasma Nitriding:

The cost of plasma nitriding depends on factors such as the size and complexity of the component, desired case depth, and process parameters. While plasma nitriding can be more expensive than some traditional surface treatments, it offers superior control, consistency, and enhanced performance, making it a cost-effective solution for specific applications.

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Plasma Nitriding vs. Shot Peening:

Plasma nitriding and shot peening are distinct processes with different objectives. Plasma nitriding modifies the surface chemistry by introducing nitrogen into the material, forming a hard nitride layer. Shot peening, on the other hand, is a mechanical process that involves bombarding the surface with small spherical pellets to induce compressive stresses, improving fatigue resistance. The two processes can be complementary and used in combination to achieve superior results in terms of wear resistance and component life.

Plasma Nitriding of Aluminum vs. Hardcoat:

Plasma nitriding of aluminum is not as common as hardcoat anodizing (also known as Type III anodizing). Hardcoat anodizing is a process that creates a thick and hard aluminum oxide layer on the surface, providing improved wear resistance and corrosion protection. Plasma nitriding of aluminum is a niche application and offers different benefits, such as increased hardness, reduced friction, and improved tribological properties.


Plasma nitriding is a versatile surface treatment technique that offers numerous advantages over traditional methods. It provides enhanced hardness, wear resistance, and corrosion resistance to metal components. By understanding the plasma nitriding process, comparing it to other nitriding methods, considering variations such as active screen plasma nitriding, and exploring its applications in different materials, industries can harness the benefits of this advanced surface treatment for improved component performance and durability.