Boronizing

boronizing, also called Boriding, is the process by which boron is introduced to a metal or a metal alloy. It is a type of surface hardening thermo chemical heat treatment process. Boronizing is generally done by diffusing boron atoms into the surface of the part to be treated at high temperatures. This results in a hard, low-friction, wear-resistant boronized surface made of FeB/FeB2 . The resulting case layer has a hard, slippery surface capable of performing at higher temperatures than most surface treatments. Boronizing is used to improve the life and performance of metal components. 
The boronizing process is Suitable for a broad range of materials.

textile ring

The boron diffusion process is a two-step reaction. The first step is a reaction between the boron-yielding substance or compound and the part, which is a function of time and temperature. This results in a thin, dense boride layer. This reaction is followed by diffusion, which is a faster process. Boronizing here at Wear Cote Technologies is often used on steel, but is applicable to a variety of alloys and cermet materials,  Practically any ferrous material can be boronized, as well as many Ni, Ti & Co alloys.  However, it is important to note, the higher the content of alloy elements, the slower the diffusion rate. The micro-hardness of the diffused layer will vary depending on the base material. For example, FeB/FeB2layers will have a micro-hardness in the range of 1600-1900 HV. Other elements, such as Ni, Ti and Co, will produce a different hardness range, some even higher than FeB/Fe2B. The FeB layer, while harder, is more brittle and more prone to fracture upon impact.

The thickness of the boride layers varies according to:

WCT B-Cote boronizing literature  
  • Temperature
  • Treatment time
  • Material

·      Strengthens resistance to corrosion
·      Strengthens resistance to acid (especially Hydrochloric acid)
·      Strengthens resistance to abrasive wear
·      Decreases coefficient of friction (0.4)
·      Increases surface hardness (1500HV to 2300HV in general)



The surface boride may be in the form of either a single phase or a double phase boride layer. With ferrous materials, the boride layers attain a hardness of between 1500HV to 2300HV. Boronized metal parts are extremely wear resistant and will often last two to five times longer than components treated with conventional heat treatments such as Hardening, Carburizing, Nitriding, Nitrocarburizing.

A monophase Fe2B layer with a tooth-shaped morphology is generally suitable for industrial application because of the difference between the specific volume and coefficient of thermal expansion of boride and the substrate. Boron rich upper phase FeB (containing approximately 16. 23 wt. % B) is not desirable because FeB is more brittle and less tough than Fe2B (containing approximately 8. 83 wt. % B) . The boronizing results in some considerable improvements in the surface such as resistance to wear, fatigue, corrosion, and high temperature oxidation.

Nitriding


WCT N-Cote(MSB)


WCT N-Cote is a salt bath heat treatment process that diffuses nitrogen into the surface of a metal at sub-critical temperatures at ferritic stage to create a case hardened surface. It is predominantly used on steel, but also can be used on titanium, aluminium and molybdenum. The processes are named after the medium used to donate.
N-Cote salt bath nitriding the nitrogen donating medium is a nitrogen-containing salt such as cyanide salt. The salts used also donate carbon to the workpiece surface making salt bath a nitrocarburizing process. The temperature used is typical of all nitrocarburizing processes: 550–570 °C. The advantages of salt nitriding is that it achieves higher diffusion in the same period time compared to any other method.
nitriding These processes are most commonly used on low-carbon, low-alloy steels, however they are also used on medium and high-carbon steels.

Examples of easily nitridable steels include the SAE 4100, 4300, 5100, 6100, 8600, 8700, 9300 and 9800 series, UK aircraft quality steel grades BS 4S 106, BS 3S 132, 905M39 (EN41B), stainless steels, some tool steels (H13 and P20 for example) and certain cast irons. Ideally, steels for nitriding should be in the hardened and tempered condition, requiring nitriding take place at a lower temperature than the last tempering temperature. A fine-turned or ground surface finish is best. Minimal amounts of material should be removed post nitriding to preserve the surface hardness.

Typical applications include gears, crankshafts, camshafts, cam followers, valve parts, extruder screws, die-casting tools, forging dies, extrusion dies, injectors and plastic-mold tools. The process is used to improve three main surface integrity aspects such as scuffing resistance, fatigue properties, corrosion resistance(when followed by WCT-OXY Cote.

S*M*A*R*T Cote

SMART-COTE is a proprietary process of Wear cote technologies which helps in modifying the substrate by providing a combination of solid lubricant layer like graphite, Molybdenum Disulphide, Tungsten Disulphide, boron nitride etc. with intermolecular locking by attrition method to the substrate of up to 0.5micron of solid lubricant layer as a final process and maintains the dimensional tolerance. The proprietary equipment helps to treat different contour and shape. Smart-cote mainly reduces the coefficient of friction by up to a level of 0.05 to 0.03 to enhance a smooth running and to improve the wear resistance of the substrate. Maintains a thermal stability up to 650°C

Properties of S*M*A*R*T – COTE

 Smart-cote is a surface treatment not a spray. 
 Smart-cote is applied at ambient temperature. 
 Smart-cote cannot peel or chip. 
 Smart-cote is suitable for medical/clean room moulding. 
 Smart-cote is 0.5micron thick so needs no special engineering. 

click here to download literature 

WCT MOS2-Cote

Solid lubricants have the advantages including long life, no contamination and usage in harsh environments that liquid lubricant cannot be used. It has been very well known that MoS2, especially Nano sized MoS2, presents considerable applications in many field. Molybdenum disulphide is the inorganic compound with the formula MoS2 it is relatively unreactive and is unaffected by dilute acids and oxygen. In appearance and feel, molybdenum disulphide is similar to graphite.

Because of the weak van der Waals interactions between the sheets of sulphide atoms and due to their hexagonal lamellar structure MoS2 has a low coefficient of friction, producing its lubricating properties. It is stable up to 400°C even at oxidising environment and In dry oxygen free atmospheres it functions as a
lubricant up to 705° C.

Molybdenum Disulphide (MoS2) coatings are a dry film lubricant through resin bonding method.
Even between highly loaded stationary surfaces the lamellar structure is able to prevent contact. In the direction of motion the lamellas easily shear over each other resulting in a low friction. Because there is no vapour present between lattice plates, MoS2 is effective in high-vacuum conditions, where graphite will not work.



Properties of WCT MOS-Cote:

1. Excellent corrosion resistance compared to plating.
2. Does not pick up dirt/ dust like oils or greases.
3. Can withstand high contact loads(17500 kg/cm2) as compared to conventional oils or greases.
4. Useful for running in and noise reduction.
5. Helps in easy dismantling.
6. Reduces frictional torque.
7. Low coefficient of friction.
8. Enables storage for long periods especially suitable for Marine transportation.

Molybdenum Disulphide Coatings (MoS2 coatings) , also known as Moly Coatings are commonly used in applications where load carrying capacity, operating temperature and coefficient of friction are primary concerns it works best between 200°C to 300°C. Our propriety coating provides effective lubrication in a wide range of loads, in many cases exceeding 250,000 psi. Moly coatings lubricate sacrificially by transferring lubricant between the two mating surfaces, which helps to reduce wear and coefficient of friction. Molybdenum Disulphide (MoS2) coatings are a dry film lubricant through resin bonding method.

Anti Erosion


Anti Corrosion

india is losing Rs 80,000 crore per annum on account of corrosion in various sectors and at least 25 per cent of this can be saved by way of proper management, The sectors include manufacturing, petroleum, chemical and fertilisers, oil & gas, transportation, power, highway and railways.



Presently our concern is addressing the corrosion issue related to power plant, refineries and mills. Some of the methodology adopted at the power plant has been patented and is exhibited here with. This has given a remarkable monetary savings by means of reduced material consumption, improved efficiency and extended life.

corrosion bulk
corroded portion


severe damage of APH section
Severe damage of APH Primary air section

Air Pre Heater section
Work at APH section

Work at APH Section



















Replacement of corroded APH section using cost effective and innovative patented methodology.