Integration of Gas Nitrocarburising and Oxidising in a Mass Production Line for Brake Pistons

The combination of wear- and corrosion resistance is a demand to a multitude of automotive parts. Several metallic coatings as hard/soft chromium or electroless nickel have been the conventional surface protection e.g. on parts as brake pistons and shock absorber or gas spring piston rods. The Corr-I-Dur(R) process - a special gasnitrocarburising and oxidising technology - has a huge potential not only in substituting those coatings but also in delivering surfaces with higher quality.The benefits of the replacement of soft chromium with Corr-I-Dur(R) and the implementation of the process in the customers production line with an annual capacity of 17 million brake pistons is described in this presentation. Starting with the demands on wear- and corrosion resistance the way of process development and the design of applicative equipment is shown. The result is a tailor-made surface solution with superior quality for deep drawn brake pistons. Two main disadvantagesoutgassing of the chromium layer and reduced corrosion resistance on the inner diameter - are eliminated by the replacement with Corr-I-Dur(R). The process-sure achievement of enhanced corrosion resistance, uniform layer thickness, negligible distortion as well as environmental and economical advantages make Corr-I-Dur(R) an excellence choice for this application.