Based on a detailed analysis of the client’s requirements and project, our expert team tailors the optimal solution.

Nitrex metallurgists develop a unique process based on the requirements of the application and then proof the recipe in our test laboratory.

Our knowledge of import and export procedures, and know-how in handling special cargo, enables us to ensure stress-free delivery of projects. Project managers coordinate and execute client projects right from the start through to final acceptance, communicating with the client on an on-going basis about the status and progression of their project.

Nitrex pre-stages and tests the system in its own facility to shorten the installation time at the customer. During and after commissioning, training is included that covers operation, maintenance, and calibration procedures, as well as technology transfer.

Our portfolio of maintenance and support services includes on-site troubleshooting and new process development, as well as service contracts to ensure that equipment operates optimally while minimizing unnecessary downtime and costly repairs.

The gas nitriding / nitrocarburizing process control systems are designed to provide a fully automatic operation. The entire nitriding /nitrocarburizing process is executed in an automatic, self-adjusting and operator independent manner.

A typical system is configured in three distinct sections, which facilitate operation and maintenance of the system. They consist of:

• An electronic process control panel with I/O boards, an industrial controller and a color monitor.
• A gas control panel with: gas analyzing, flow and pressure measuring transducers, calibration and safety features.
• An electric control panel with: one SCR controller for each heating zone, transformers, contactors, fuses, and switches.

This type of set-up provides a high degree of accuracy in process execution, contributing to consistency in nitriding / nitrocarburizing results.

The Nitrex Process Control System monitors and controls automatically the following parameters and operating functions:

• Furnace heating functions such as process temperature, and overheat control with automatic emergency procedures
• Atmosphere composition and flow for a particular cycle
• Nitriding atmosphere ratios
• Nitriding Potential KN (dissociation rate, for customer defined cycles)
• Temperature for each process stage
• Gas pressure inside the retort
• Gas recirculation
• Execution of the cooling stage and shutdown
• Cooling water
• Process safety features

The operator follows simple steps to execute a process. Once the parts are cleaned, the furnace is loaded and sealed.

The desired process is selected and started from the process control panel. Thereafter, all stages of the nitriding cycle (e.g., purge, heat, process control, and cool) are automatically carried out sequentially in one uninterrupted cycle, without further operator intervention.

The nitriding process control is carried out in a closed loop circuit. This, coupled with advanced features, enables the process control system to automatically respond to the changes in nitriding conditions, which occur during the process.

To adjust the process parameters, the furnace atmosphere is continuously sampled and analyzed. Based on the data extracted, the process computer adjusts the incoming atmosphere, thus maintaining the preset value of the nitriding potential as accurately as possible.

Nitrex Gas nitriding /nitrocarburizing process control systems are supplied with several independent software packages. The software has been developed to adapt to the rigorous process control requirements for enhancing nitriding / nitrocarburizing. Troubleshooting, emergency and calibration software packages aid the operator in maintaining and operating the installation.

Visual displays allow the operator to access information on the status of important control points, while the process is being executed.

The process control system monitors all essential process variables (e.g. temperatures, flows, power output, nitriding potential, pressure, elapsed time, etc.) and displays them continuously on the process screen, in a clear and precise manner.

A simple menu allows the operator to select the desired nitriding / nitrocarburizing procedure from a library of pre-established cycles. The library contains researched and tested recipes designed to produce a specific nitrided case on a chosen material.

Each process is developed to meet specific nitriding / nitrocarburizing requirements defined by the customer. This complex procedure requires considerable expertise in the field of nitriding / nitrocarburizing. It involves taking the nitrided case requirements into consideration, and relating these to all other parameters which influence the end result.

Once established and stored in the integrated library, it can be used repeatedly to produce consistent results.

Each nitriding / nitrocarburizing cycle’s log file provides a timed account of the actual process execution, and contains all alarms, process interruptions or operator interventions which may have occurred.

The data contained in the log file can be presented in the form of diagrams, thus facilitating preparation of Statistical Process Control (SPC).