Case Study of Nitrided Tool Wear in Hot Forging

Objective: The objective of this study is to evaluate the effect of different nitriding parameters on hot forging dies, considering variations in treatment time (12 to 30 hours), nitrogen concentration (5% to 75%) and presence or absence of white layer. Theoretical Framework: The aim was to analyze the factors causing the failures, as well as generate the information needed to develop efficient alternatives to reduce wear and damage to dies, increasing their useful life and, at the same time, contributing to an improvement in the quality of the final product obtained. Method: The analysis was conducted by comparing results from numerical forging simulation, practical tests, metallographic characterization, hardness measurements and industrial tests. Results and Discussion: The results of the study indicate that the appropriate choice of nitriding parameters can significantly extend tool life and reduce operating costs in hot forging. Research Implications: The numerical simulation showed a strong correlation with the experimental data (R² = 0,92), validating its application in wear prediction. Originality/Value: Laboratory tests, numerical simulation and industrial tests showed that nitrided tools without white layer and with greater nitriding depth presented better performance with lower wear rate and maximum depth of 0.04 mm and only 5% of the surface affected, while the configuration with shorter nitriding time suffered greater degradation (0.14 mm and 15% of the surface).