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Nitriding : Enhancing
Fatigue Resistance
Written by Carlos Soler in Engineering, Fatigue of metals

Introduction
Fatigue is a progressive, localized, and permanent structural change in
a material subjected to repeated or fluctuating strains at low stresses
than the material’s static yield strength—often significantly lower. Over
time, fatigue can lead to crack formation and eventual fracture after a
sufficient number of stress cycles.
Fatigue damage results from the combined effects of cyclic stress,
tensile stress, and plastic strain. Without any one of these factors,
fatigue cracks cannot initiate or propagate. Cyclic stress induces
plastic strain, which initiates cracks, while tensile stress drives crack
growth. Although compressive stresses alone do not cause fatigue,
they can generate localized tensile stresses, contributing to crack
formation. Even at stress levels that appear to cause only elastic
deformation, microscopic plastic strains may still develop.
In metals without pre-existing cracks, fatigue failure begins at a
microscopic level. Small cracks form and eventually grow into larger
macrocracks, which propagate until the material’s fracture toughness
is exceeded, leading to final failure. Under typical loading conditions,
fatigue cracks tend to originate at surface irregularities such as
scratches, sharp section changes, pits, inclusions, or embrittled
grain boundaries.
Manufacturing procedures used in forming parts induce a wide variety
of microstructure, surface finish, and residual stress. Many of these
manufacturing procedures involve thermal processes such as casting,
forging, hot-rolling, extrusion, injection molding, welding, brazing,
quench and tempering, temper stress relief, flame or induction
hardening, carburizing, and nitriding. Residual stresses from these
thermal processes may be beneficial or detrimental.
As an example, of residual stress formation from inelastic axial loading
of a notched part.
(a) Stress distribution during inelastic loading.
(b) Elastic recovery during unloading.
(c) Resultant residual stress distribution after loading/unloading.
Microcracks may also form as a result of these processes, also residual
stresses from heat treatment, or strain-induced imperfections from
mechanical forming.
Even in a flawless, highly polished metal with no stress concentrators,
fatigue cracks may still develop if the alternating stress amplitude is
high enough. This stress causes long-range dislocation motion,
creating slip steps on the surface. Continued cyclic loading can initiate
fatigue cracks, or in some cases, dislocations accumulate at obstacles
like inclusions or grain boundaries, forming slip bands, cracked particles,
or areas of decohesion.
Initially, these cracks are extremely small—often just a fraction of a
micron in size—making them difficult to detect. As microcracks grow
and merge, they form larger macrocracks that continue to expand until
the material reaches its fracture limit. Even though the fatigue behavior
of materials has been the subject of continuous research for more
than 150 years, fatigue crack propagation has been widely investigated
based on numerous experimental data. In a tensile test, a ductile
material exhibits necking before fracturing, providing a visible warning
of impending failure. In contrast, fatigue fracture occurs suddenly,
without any obvious macroscopic indication.
One of the central challenges in structural integrity is linking the
atomic-scale mechanisms of material fatigue to practical engineering
design consideration.
The ongoing demand for smaller and lighter structures necessitates
reducing existing safety factors and revising the total-life concept,
which is based on the assumption of a fatigue limit.
Depending on the material’s strength, the phase of crack initiation and
microcrack propagation can account for up to 90% of the fatigue life.
The situation becomes even more complex when cycle-dependent
fatigue damage is compounded by time-dependent environmental
effects, such as corrosion fatigue or stress-corrosion cracking. At
elevated temperatures, the diffusion of corrosive species along
interfaces accelerates, reducing grain-boundary cohesion and leading
to intergranular crack propagation. (Elevated temperatures can soften
materials, which decreases their fatigue strength, while low
temperatures may increase brittleness. It makes materials more
susceptible to fatigue cracks)
In general, fatigue damage is strongly influenced by local
microstructural features, including grain size and geometry,
crystallographic orientation, and grain-boundary structure. Enhancing
the surface layer properties of machinery components can significantly
increase their load-bearing capacity. One effective method for
enhancing surface properties—such as hardness, wear resistance,
contact fatigue strength, and corrosion resistance (Corrosive
environments, such as saltwater or acidic substances, can accelerate
fatigue failure)—is chemical heat treatment, particularly nitriding.
Nitriding
Nitriding is a surface hardening technique in which atomic nitrogen is
diffused into the surface of a ferrous alloy to enhance its mechanical
properties. This process can be carried out using different methods,
including gas nitriding, plasma nitriding, and salt bath nitriding.
Unlike carburizing, nitriding does not require quenching and is
performed at relatively low temperatures, typically between 500°C and
580°C. As a result, it induces minimal distortion, allowing it to be applied
to finished components without further machining. Depending on the
process conditions, the nitrided layer formed in the material consists of
two distinct regions: the compound layer and the diffusion zone. The
compound layer, composed primarily of iron nitrides, can reach a
thickness of several tens of microns. Its presence depends on factors
such as alloy composition, processing time, and temperature. The
diffusion zone, which can extend several hundred microns, retains the
original microstructure but contains nitrogen in a solid solution along
with precipitated nitrides.
The primary benefits of nitriding include increased surface hardness,
improved wear resistance, enhanced fatigue life, and better corrosion
resistance. These advantages are primarily attributed to the formation
of the nitrided layer, which strengthens the material’s surface and
extends its service life.
Nitriding is a highly effective surface hardening process for steels,
improving their durability and resistance to wear. It works by introducing
residual compressive stresses at the surface, which help prevent crack
initiation and propagation. Additionally, solid solution strengthening
increases surface hardness, reducing direct metal-to-metal contact in
self-mated ferrous components. This reduction in contact areas
minimizes friction and wear, ultimately enhancing the material’s
performance and lifespan.
For example, nitriding gear steel will produce the desired compressive
residual stresses to inhibit crack propagation.
Certain limitations and challenges are associated with nitriding.
Althoug , The ion nitriding increases fatigue resistance of all structural
steels due to the saturation of metal surface by nitrogen and causing in
surface layer compressive stresses.
The use of nitriding for strengthening structural metallic materials
faced obstacles due to the toxicity of some earlier technological
processes. However, recent advancements have significantly
addressed these issues, enabling broader adoption of nitriding
methods for strengthening structural steels. (Liquid nitriding is
Environmentally Friendlier than Gas Nitriding).The technology has
evolved substantially, transitioning from traditional gas nitriding to more
advanced ion nitriding techniques. Today, both old and new methods of
nitriding are used, with the development of non-toxic cyanate-
containing baths further improving the process.
Currently, nitriding is more widely employed to enhance the fatigue
strength of structural metallic materials. However, in certain cases, it
can lead to negative effects. For example, nitriding high-strength
bearing steel, such as SUJ2, may result in a reduction in fatigue
strength. Additionally, fatigue failure in gas-nitrided 4140 steel can
result from a competition between surface crack initiation and
internal cracking.
High-Cycle Fatigue (HCF) vs. Low-Cycle Fatigue (LCF)
The distinction between LCF and HCF is not defined by a fixed number
of cycles but rather by the applied stress levels and the material’s
response—LCF is characterized by macroplastic deformation, while HCF
primarily involves elastic behavior.
The key difference lies in the stress magnitude and resulting
deformation: LCF occurs under high stress, leading to significant plastic
deformation, whereas HCF takes place at lower stress levels, where
deformation remains elastic.
A clear understanding of these distinctions is crucial for accurately
predicting material fatigue, designing long-lasting components, and
ensuring the reliability of structures and machinery subjected to
varying stress conditions.
In the case of low-cycle fatigue, cracks typically initiate on the surface
of specimens.

In contrast, for high-cycle fatigue, cracks tend to form in the near-

surface layer, particularly at the interface between the base metal and
the nitrided layer.

The dissolved nitrogen results in the development of

high microstresses.
The presence of hydrogen during furnaced nitriding may have an
influence on mechanical properties. Hydrogen stress cracking may be
described as brittle fracturing of a tough alloy under constant strain in a
hydrogen-containing environment. The cracking mechanism is
determined by the volatility of the hydrogen.
Advantages of nitriding
Formation of a Hardened Surface Layer
During the nitriding process, a hardened surface layer forms on the
component’s surface. This layer consists primarily of nitride
compounds, which are significantly harder than the base metal. The
increased hardness enhances wear resistance and makes crack
initiation more difficult.
Improved Mechanical Properties
Enhanced Elastic Modulus: The formation of nitride compounds
can alter the material’s elastic modulus, increasing stiffness.
Nitrided components often exhibit a higher elastic modulus than
untreated materials, which is particularly beneficial in high-cycle
fatigue applications.
Reduced Deformation: The hardened surface layer provides
greater resistance to plastic deformation, which is advantageous
for low-cycle fatigue performance.
Wear and Friction Reduction
Increased Durability: The heightened hardness of the nitrided
layer improves resistance to deformation, indentation, and surface
wear, ensuring long-term durability.
Lower Friction: The nitrided surface becomes smoother and more
polished, reducing abrasive contact, minimizing energy dissipation,
and decreasing heat generation.
Anti-Adhesion Properties: The process reduces the tendency of
foreign materials to adhere to the surface, preventing unwanted
stickiness and improving operational efficiency.
Corrosion Resistance
The iron nitrides formed during nitriding act as a protective shield,
preventing the infiltration of moisture, chemicals, and corrosive
agents (e.g., sea salt). This makes nitrided components highly
resistant to corrosion, making them ideal for applications exposed to
harsh environments.
Fatigue Resistance and Structural Integrity
Minimal Dimensional Changes: Nearly all nitrided products are
finish-machined to final tolerances before treatment. Since
nitriding occurs at relatively low temperatures compared to other
heat treatments, it introduces minimal expansion or contraction,
preserving the original shape and dimensions. This is particularly
valuable for components with tight tolerances or intricate
geometries.
Thermal Stability and Stress Relief
High Thermal Stability: The nitride layer maintains its hardness
and dimensional integrity even under elevated temperatures,
outperforming untreated steel and other surface coatings in high-
temperature applications.
Stress Relief for Welds: The nitriding process temperature can
be used to stress-relieve welds, mitigating residual stresses and
microstructural changes that might otherwise lead to distortion or
cracking.
Protection Against Fretting and Micro-Pitting
Fretting Wear Resistance: Nitriding creates a wear-resistant
layer that shields against microscopic abrasions and stresses
associated with fretting, a common failure mode in components
subjected to oscillatory motion under load.
Micro-Pitting Prevention: This process enhances the surface
integrity of gears and rolling bearings, reducing the formation of
small pits and fissures that can grow over time and lead to failure.
Environmental Benefits of Nitriding
1. Reduced Toxic Waste: Unlike some surface treatments, liquid salt
bath nitriding produces minimal hazardous waste, reducing
environmental impact.
2. Substitution for Harmful Processes: This method replaces
environmentally harmful processes such as chrome plating (which
involves toxic hexavalent chromium) and cadmium coatings.
3. Energy Efficiency: Operating at lower temperatures than
carburizing or hardening, nitriding consumes less energy and
results in lower greenhouse gas emissions.
4. Reduced Lubricant Usage: The enhanced wear resistance of
nitrided components decreases the need for lubrication,
minimizing potential environmental contamination.
5. Less Dependence on Protective Coatings: The corrosion
resistance of nitrocarburized components reduces the necessity
for additional coatings that may contain harmful chemicals.
6. Minimal Water Consumption: Unlike treatments requiring large
amounts of water for cooling or rinsing, the liquid salt bath process
uses a molten salt medium, conserving water.
7. Lower Airborne Pollutants: Compared to alternative treatments,
nitriding emits fewer volatile organic compounds (VOCs) and other
airborne pollutants.
8. Safer Work Environment: By reducing exposure to toxic
chemicals and harmful byproducts, nitriding promotes a safer
workplace with fewer health risks for workers.
References
-Fatigue and Fracture was published in 1996 as Volume 19 of
ASM Handbook
– Fatigue Crack Propagation in Metals and Alloys. Ulrich Krupp
 – Metal fatigue in engineering. Ralph i. Stephens, All fatemi, Robert r.
Stephens, Henry 0. Fuchs
– The effect of nitriding on fatigue strength of structural alloys V.F.
Terent’ev,A.G. Kolmakov, V. Kvedaras, V. Ciuplys, A. Ciuplys, J. Vilys

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