IONITECH Ltd. manufactures and sells on the world market,
the biggest range of plasma  nitriding and plasma
nitrocarburising installations.
These installations consist of the following subsystems:

• Vacuum Chamber;

• Pulsed Plasma Generator;

• System Controller;

• Vacuum System;

• Gas Supply System

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Vacuum Chambers

- Door type chambers
- Bell type chambers
- Pit type chambers
- Combined chambers loaded from the bottom and from the top

Vacuum chambers have double walls, with cooling water circulating in between. In order to decrease  the heat exchange between treated parts and the chamber walls, two stainless steel shields, separated by thermo-insulating wadding, are installed on the inside surface of the walls and the bottom.
The parts to be treated are stacked on metal plates in the bell and door type chambers. The parts hang from the top in the pit type chambers, while in the combined type, they can either be stacked or hanged.

The plates and the hanging devices are installed on supporting
insulators. The plate is electrically connected to the negative
pole of the pulse generator by means  of a cathode insulator.
The positive pole of the pulse generator is connected to the body 
of the chamber.
The plasma  process can be viewed through glass windows.
To measure the temperature of the treated parts, one or
two flexible mantle thermocouples (type K)  are installed.

Pulsed Plasma Generators 

Plasma generators excites a pulsed glow discharge with the following
characteristics:
- Voltage                                            300 - 800 V
- Max. Pulsed current                        25 - 400 Amp
- Pulse frequency                               5 - 10 kHz , adjustable
- Duty factor                                      50 - 95 % , adjustable

The plasma generator consists of a power transformer, a three
phase thyristor rectifier, a power choke, a power IGBT switch
and a number of circuit breakers, filters and contactors, assembled
for different supply voltages and mains frequencies.
The plasma generator complies with EN 60204-1: 1997

Vacuum and Gas Supply Systems

The gas vacuum system evacuates the chambers and fills them with treatment gases. It includes a vacuum pump, electro-pneumatic and electromagnetic valves, reducing valves with filters and manometers, mass flow controllers, gas mixer, manual valves, two absolute pressure gauges and vacuum connections.
The pressure gauges are mounted on the chambers bodies. The rest of the components are placed in a ventilated metal enclosure IP54. The process is carried out with a mixture of hydrogen and nitrogen. Propane or natural gas are used for nitrocarburising. After the end of the treatment, the chambers can be filled with argon, for accelerated cooling. Pressed air is used for the operation of the electro-pneumatic valves.
The gas vacuum system is switched between the chambers. The vacuum system operates continuously during the technological cycle, controlled by the System Controller, according to the preset technological program.
The pressure and gas mixture in the vacuum chamber, are regulated by the System Controller through the mass flow controllers, according to the preset technological program.
 

Control Systems

The control system consists of a master controller and slave nodes (transmitters and drivers) on a highly reliable communication network.
The controller collects data from the transmitters, executes the real
time software and directs the results to the drivers, which actuate the installation gear. The software includes data acquisition, pressure,
current and temperature regulators, input-output logic control, process variables logger, process execution, error detection and man-machine interface.The non-volatile memory of the controller holds 50
technological recipes and a history of the technological processes. The history includes the most important parameters - temperature, pressure, current, voltage,mass flows and time.
A technological recipe consists of three stages: cleaning, heating and treating.  During the cleaning stage the parts a cleaned and preheated.
During the heating stage the parts a gradually heated to the nitriding temperature and during the last stage, the parts a nitrided.
The cleaning lasts for 10 - 20 minutes, the heating last for 3 - 6 hours, depending on the load, and the treating  lasts for 8 - 20 hours,
depending on the type of steel and the layer requirements.
After charging the parts and starting the installation, the operator has 
only control functions. The process goes on automatically according to
the selected technological recipe.
IonVision software, running under Windows98/XP, establishes a
communication between a personal computer and the master controller. IonVision displays the current parameters of the installation, downloads
the technological history into a data base and views it in graphics and
tables.
 

IONITECH Ltd. produces installations for degreasing types ID-15, ID-18, ID-30, ID-42. This equipment assures the perfect technology for degreasing of details from oils, greases, waxes, etc. before plasma nitriding treatment can be applied.

The vapour degreasing process is a modern method of removing greases, fats, oils, waxes, and like materials from all types of metal and other nonporous surfaces. The chlorinated solvent is heated to boiling in a suitable tank to produce solvent vapours. The cooling coil near the top of the tank condenses the vapours and maintains a zone of clean solvent vapours for cleaning. The soiled work is suspended in the vapour zone where the solvent vapour condenses on the cool metal surface. This dissolves the greasy soil which flows off the part to the boiling solvent sump at the bottom of the tank. As the work is washed with the condensed solvent it heats up to the temperature of the vapour and dries quickly when raised above the vapour zone.
PERCHLORETHENE ( PCE ) has very good dissolve abilities  for oils, greases, wax , etc. Solvents and their vapours penetrate very quickly in holes and cracks.


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