AISI 420 martensitic stainless steel was treated viaconventionalplasma nitriding (PN) and cathodic cage plasma nitriding (CCPN) attemperatures ranging from 400 to 500 °C for 5 h to enhancesurface properties. X-ray diffraction and scanning electron microscopyanalyses confirmed uniform nitride layer formation, and microhardnessmeasurements showed a peak hardness of 1270 HV0.5 for PN at 500 °C. Notably, CCPN at 450 °C achieved similarhardness (1011 HV0.5) alongside excellent adhesion(HF1–HF2), highlighting the effectiveness of the cathodic cagetechnique. Electrochemical impedance spectroscopy and open-circuitpotential tests in 3.5 wt % NaCl showed improved corrosion resistancein all nitrided samples compared to the untreated steel. These resultsindicate that specific nitriding conditions, particularly PN at 450°C and CCPN at 400 °C, achieve an optimal balance of hardness,corrosion protection, and interfacial toughness while preserving thesubstrate’s inherent microstructure.

Improvement in surface properties of AISI-5160 steel by transition metal (Nb, V) nitride coating through cathodic cage plasma deposition

Cathodic Cage Plasma Deposition of Ag/Porous Silicon as a Scalable Route To SERS Substrates

This review summarizes the development of cathodic cage plasma nitriding (CCPN) and cathodic cage plasma deposition (CCPD) techniques. CCPN was introduced to eliminate issues in direct current plasma nitriding (DCPN), such as the edge effect, by isolating the sample at a floating potential and using radiative heating. The process was further adapted for CCPD, in which the cage serves as a sputtering target (e.g., Ti, graphite, Mo, Hastelloy) for the deposition of ceramic and metallic films. Combining nitriding pretreatment with CCPD resulted in duplex treatments that establish a hardness gradient and enhance film adhesion. The most recent advance is cathodic cylinder plasma deposition (CCyPD), which employs compacted powder targets (such as MoS2 or metal oxides) for composite film deposition and in situ oxide reduction. The review traces the evolution from process improvement to a versatile platform for surface engineering.

This study proposes a surface modification methodology for AISI 409 stainless steel by combining cathodic cage plasma nitriding (CCPN) and deposition (CCPD), evaluating the benefits of this duplex treatment over individual treatments. The mechanical strength, tribological behavior, and corrosion resistance of the treated surfaces were investigated in relation to processing parameters and resulting microstructures. Analyses were performed using XRD, SEM, Vickers microhardness, ball-on-disc testing, and corrosion testing in a 3.5% NaCl solution. The duplex treatment at 400 and 450 °C, consisting of CCPN followed by CCPD, promoted significant surface modifications. Nitriding resulted in a thick layer of Fe3N, Fe4N, and CrN, increasing hardness and wear resistance, with final improvements of 5.7 and 33.5 times, respectively. The subsequent VN deposition enhanced corrosion resistance, shifting the potential from -396 mV to -221 mV, indicating reduced electrochemical activity. These results confirm the treatment's potential for automotive exhaust systems, requiring lightweight, durable materials in aggressive environments.

SAE 5160 steel, classified as high-strength, low-alloy steel, is widely used in the automotive sector due to its excellent mechanical strength and ductility. However, its inherently low corrosion resistance limits its broader application. This study explores the application of the cathodic cage plasma deposition (CCPD) technique to enhance the corrosion resistance of SAE 5160 steel. The treatment was performed using a Hastelloy cathodic cage under two atmospheric conditions: hydrogen-rich (75%H2/25%N2) and nitrogen-rich (25%H2/75%N2). Comprehensive analyses revealed significant improvements in surface properties and corrosion resistance. The hydrogen-rich condition (H25N) facilitated the formation of Cr0.4Ni0.6 and CrN phases, associated with a nanocrystalline structure (37.6 nm) and a thicker coating (45.5 μm), resulting in polarization resistance over 290 times greater than that of untreated steel. Conversely, nitrogen-rich treatment (H75N) promoted the formation of Fe3N and Fe4N phases, achieving a dense but thinner layer (19.6 μm) with polarization resistance approximately 20 times higher than that of untreated steel. These findings underscore the effectiveness of CCPD as a versatile and scalable surface engineering technique capable of tailoring the properties of SAE 5160 steel for use in highly corrosive environments. This study highlights the critical role of optimizing gas compositions and treatment parameters, offering a foundation for advancing plasma-assisted technologies and alloying strategies. The results provide a valuable framework for developing next-generation corrosion-resistant materials, promoting the longevity and reliability of high-strength steels in demanding industrial applications.

Microstructure and tensile properties of plasma-nitrided TA1 titanium by cathodic cage plasma nitriding in different N2-NH3 gas mixtures

Cathodic cage plasma nitriding (CCPN) is a proficient and cost-effective technique for surface modification of metallic samples that has been in use for the last two decades. The effectiveness of CCPN depends upon different controlled parameters. The main objective of the current study was to investigate the effect of temperature on CCPN performance. Copper (Cu) samples were nitrided at various temperatures (100–400 °C) for a fixed time of 4 h. The treated samples were investigated using a micro-hardness tester, x-ray diffraction, scanning electron microscopy, energy-dispersive x-ray spectroscopy, ball-on-disc wear tester, and potentiodynamic polarization. An improvement in hardness, wear resistance, and corrosion resistance has been reported with an increase in temperature. The treated samples possessed aluminum nitride (AlN), copper(I) nitride (Cu3N), copper(I) azide (CuN3), copper(II) azide (CuN6), and AlCu4 phases with intensity increasing with temperature. The current study clarified the reactivity of the CCPN system on treated samples in a broad manner. Untreated samples have shown abrasive wear at low temperatures, whereas adhesive wear is the predominant mechanism at high temperatures. At high temperatures, a low friction coefficient has been achieved due to smoother surfaces. Nitrided samples have shown an overall increased corrosion resistance with an increase in temperature.

Cutting tools made of high-speed steel have significant economic and technological importance. To enhance their productivity, thermochemical treatments are sought to improve both surface mechanical and tribological properties. Plasma nitriding and thin film deposition are widely employed for this purpose. In this study, modifications were made to M2 high-speed steel drills through plasma nitriding at temperatures of 400°C and 450°C. Cathodic cage TiN plasma deposition was also performed, varying the dwell time at a fixed temperature of 450°C. Characterization techniques included optical microscopy, X-ray diffraction (XRD), Vickers microhardness testing, and scanning electron microscopy (SEM). Performance tests were carried out to evaluate the behavior of the drills in relation to wear when machining AISI 1020 steel. It was observed that longer deposition times promote more uniform and thicker layers, and higher nitriding temperatures result in thicker nitride layers. An increase in hardness was noticeable in all deposition and nitriding treatments, with the nitrided samples exhibiting the highest hardness. During performance tests, the cathodic cage plasma TiN deposition demonstrated greater potential for application in HSS drills, with a treatment lasting 4 h providing the best results.

Enhanced Surface Properties of 1080 Eutectoid Steel by Cathodic Cage Plasma TiN Deposition

Cotton fabrics with zinc oxide (ZnO) coating are of significant interest due to their excellent antibacterial performance. Thus, they are widely in demand in the textile industry due to their medical and hygienic properties. However, conventional techniques used to deposit ZnO on fabric require long processing times in deposition, complex and expensive equipment, and multiple steps for deposition, such as a separate process for nanoparticle synthesis and subsequent deposition on fabric. In this study, we proposed a new method for the deposition of ZnO on fabric, using cathodic cage plasma deposition (CCPD), which is commonly used for coating deposition on conductor materials and is not widely used for fabric due to the temperature sensitivity of the fabric. The effect of gas composition, including argon and a hydrogen-argon mixture, on the properties of ZnO deposition is investigated. The deposited samples are characterized by XRD, SEM, EDS, photocatalytic, and antibacterial performance against Staphylococcus aureus and Pseudomonas aeruginosa bacteria. It is observed that ZnO-deposited cotton fabric exhibits excellent photocatalytic degradation of methylene blue and antibacterial performance, specifically when a hydrogen-argon mixture is used in CCPD. The results demonstrate that CCPD can be used effectively for ZnO deposition on cotton fabric; this system is already used in industrial-scale applications and is thus expected to be of significant interest to garment manufacturers and hospitals.

This study investigated the wear resistance of AA1050 aluminum alloy coated using plasma deposition with a vanadium cathode cage and evaluated the effect of subsequently applying a plasma nitriding process to the coated sample. The treatments were carried out at 400°C for 3 hours. To evaluate the composition, thickness and wear resistance of the layers formed, X-ray fluorescence (XRF), scanning electron microscopy (SEM) and fixed ball micro-abrasive wear tests were applied. The treatments altered the wear mechanisms, with the treated samples also showing the two- and three-body wear modes, compared to the aluminium alloy, which only showed the two-body wear mode. The sample coated using only the cathodic cage deposition technique obtained a greater layer thickness (7.6 μm) and better wear resistance, with a reduction of around 83% in the worn volume compared to the 1050 aluminum alloy. However, the subsequent plasma nitriding process proved to be detrimental to the tribological properties of the coating formed, reducing the layer thickness (3.2 μm) and decreasing wear resistance.

AISI-1045 steel is a medium-carbon, medium-strength steel that usually requires surface engineering to be usable in industrial applications. Using the cathodic cage plasma deposition technique, transition metal (Nb, V, W) nitride coating is deposited on this steel using cathodic cage lids of these metals. The hardness of untreated steel (1.8 GPa) is upgraded to 11.2, 12.2, and 9.7 GPa for niobium nitride, vanadium nitride, and tungsten nitride coating, respectively. The elastic modulus, the ratio of hardness-elastic modulus (H/E, H2/E, and H3/E2), and the plasticity factor depict the improvement in mechanical and elastic properties. The sample treated with a niobium cage lid exhibits the Nb4N5 phase, the vanadium cage lid shows the VN phase (along with the Fe4N phase), and the tungsten cage lid consists of W2N3, WFeN2, and Fe4N phases. Among these coatings, the thickness of niobium nitride coating is maximum (1.87 μm), and a low deposition rate is obtained for tungsten nitride coating (0.83 μm). In addition to this coating, a nitrogen diffusion zone (∼60 μm) is also formed beneath the coating, which creates a hardness gradient between the coating and the substrate. The ball-on-disc wear tester shows that niobium nitride coating deposition reduces the wear rate from 19.5 × 10−3 to 8.8 × 10−3 mm3/N m and exhibits excellent wear performance.

Enhancement of hardness and tribological properties of AISI 321 by cathodic cage plasma nitriding at various pulsed duty cycle

Abstract In this study, we address challenges in the biocompatibility of nickel‐based (NiCr) alloys, prevalent in the dental industry, due to toxic metal ion release impacting corrosion resistance and cytotoxicity. Employing magnetron sputtering and cathodic cage plasma nitriding (CCPN), a duplex plasma treatment (DPT) is introduced to the NiCr alloy. The novel approach enhances surface morphology, notably reducing ion leakage compared with untreated samples. Specifically, the CCPN‐TiN‐treated sample significantly improves corrosion resistance and minimizes metal ion leakage. This transformative DPT emerges as a promising solution for surface modification, particularly mitigating toxic ion leaching in aggressive electrolytes. This research demonstrates a major stride in enhancing NiCr alloy biocompatibility, emphasizing the vital role of innovative surface modification techniques for biomedical applications and challenges.

Improved surface properties of AISI-420 steel by Ti[sbnd]C based coating using graphite cathodic cage with titanium lid in plasma deposition

AISI-420 martensitic steel is used in several applications due to its high corrosion resistance. A niobium nitride coating is deposited on steel by cathodic cage plasma deposition (CCPD) to upgrade the surface properties. The X-ray diffraction shows that the coating has a tetragonal Nb4N5 structure in each condition. The nano-hardness of the untreated sample (2.5 GPa) is increased up to 15.5 and 18.7 GPa at 400°C and 450°C, respectively. A ball-on-disc wear tester is applied for wear analysis, and the wear rate is found to be reduced up to six times by coating. This study shows that the CCPD can be used successfully for depositing niobium nitride coating with outstanding mechanical and tribological properties of AISI-420 steel.

Improved wear resistance of AISI-4340 steel by Ti–Nb–C–N and MoS2 composite coating by cathodic cage plasma deposition

Improved dry sliding wear behavior of TA1titanium by low-temperature plasma nitriding by CCPN method

Influence of using different titanium cathodic cage plasma deposition configurations on the mechanical, tribological, and corrosion properties of AISI 304 stainless steel