Diffusion Surface Treatments
IBC utilizes a powder pack thermochemical diffusion process to apply a variety of coatings for improved wear and corrosion resistance.
During the thermochemical diffusion processes, specially formulated powders are heated up to high temperatures, vaporizing certain elements (B, V, Al, Cr) within the powder. These atoms diffuse onto and into the surface of the parts hardening the surface and creating coatings with strong metallurgical bonds to the substrate.
Benefits of Powder Pack Coatings:
- Abrasive wear resistance
- Erosion resistance
- Corrosion and oxidation resistance
- Non-line-of-site, capable of coating complex geometries
- High adhesion due to metallurgical bonding
IBC’s Equipment:
- Powder pack furnace capacity: 48” tall x 30” diameter
| Process | Process Temperature (°C) | Thickness (microns) | Thermal Stability (°C) | Hardness (HV) | CoF (Dry on Steel) | Applications | |
|---|---|---|---|---|---|---|---|
| Vanadium Carbide | VC TDH (Hot TD) | 900-1,000 | 500 | 3-10 | 2,500-3,000 | 0.5 | Stamping, forming tools, die casting |
| Boriding (Boronizing) | DHB | 760-1,000 | 650 | 10-500 | 1,400-1,900 | 0.6 | Abrasive and erosive wear, corrosion |
| Aluminizing | DHA | 870-1,000 | 1,000 | 50-150 | 250-1,000 | 0.6 | High temperature oxidation/carburization resistance |
| Chromizing | CrC TDH | 900-1,000 | 800 | 5-15 | 1,400-1,500 | 0.5 | Abrasive and erosive wear, corrosion |
Process Descriptions:
Also known as Hot TD coating, vanadium carbide coating is created when vanadium powder reacts with the carbon in the base material creating an outwardly diffused, extremely hard surface layer that is metallurgically bonded to the substrate. It is used effectively in stamping, forming, and die casting applications.
The boriding (boronizing) process consists of two separate reactions. The first reaction is a slow process between the boron and the base material that produces a very hard, thin, and corrosion resistant boride layer at the surface. The second reaction involves the diffusion of boron further into the substrate at a much quicker rate. In ferrous materials, IBC has optimized its technology to produce the tougher, more impact resistant Fe2B phase instead of the more brittle FeB phase. IBC’s unique process can also produce deep case boriding for applications experiencing extremely heavy abrasion and erosion, especially for the oil and gas, mining, and agricultural industries.
Aluminizing is a thermo-chemical diffusion process applied to carbon, alloy, and stainless steels; nickel-based alloys; and nickel-iron alloys to improve oxidation and corrosion resistance. When heated, aluminum vapors diffuse into the substrate to form an aluminum oxide layer at the surface, effectively creating a barrier against chemical attack. Aluminizing is particularly useful as a corrosion resistant coating for chemical processing applications such as refineries and gas plants.
During the chromizing process, chromium reacts with the carbon in the steel substrate, forming a strongly adhered and extremely hard chromium carbide layer on the surface. Like other powder diffusion coatings, it imparts exceptionally high abrasion and corrosion resistance to the substrate.
