FEATURE A D V A N C E D M A T E R I A L S & P R O C E S S E S | N O V E M B E R / D E C E M B E R 2 0 2 2 4 4 is a more brittle form of iron boride and deposits in random pockets. Blaze thermal boron diffusion only creates Fe2B for a uniform conversion layer with maximum performance attributes without the brittle component. The process is most beneficial on medium and low carbon steels with minimal alloying. This also provides the opportunity to manufacture components out of a “more basic” steel; even with the process cost it can net a savings and impart numerous benefits: • Extremely hard case 2200 Knoop up to 0.006-in. diffusion depth • Able to post heat treat the core material with standard processes • Low coefficient of friction reduces wear and power • Impervious to chemical and environmental corrosion • Totally green process and product • No hydrogen embrittlement • Minimal to zero dimensional change • No line of sight • Simple to selectively apply • Cost effective replacement of other high wear coatings • No post machining required • Designed to be done in house to reduce cost and lead time There is also the possibility to replace other more costly surface finishing steps, most of which are normally done as outsourced processes. As onshoring of manufacturing gains popularity most are opting to be as vertically integrated as possible. COMPARISON TO OTHER PROCESSES Boron diffusion can cost effectively replace other metal treatments such as carburization, nitriding (gas and salt bath), ferritic nitrocarburizing (FNC), and is a replacement for coatings such as electroless nickel, electrolytic nickel, chrome, high-velocity oxygen fuel (HVOF), TiN, and diamond-like carbon (DLC). Figure 2 shows ASTM G-65 results of multiple materials with and without thermal boron diffusion (Blaze). It is clear that the process significantly enhances a variety of materials. Fig. 2 — ASTM G-65 results of multiple materials with and without thermal boron diffusion. Fig. 3 — ASTM G-77 pressure wear test. 8
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