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This paper addressed the issues of both direct and indirect synthesis of Ni aluminides by pack cementation (pure Ni and IN 718 superalloy). On the Al-Ni diffusion twosome under pressure, at temperatures below and above the Al melting temperature, the appearance and evolution of diffusion porosity because of the Kirkendall–Frenkel effect manifestation was highlighted. It has been confirmed that, as the temperature rises above the Al melting temperature, the porosity decreases. Nickel-based superalloys, and in particular IN 718, significantly increase their performance by increasing the aluminides proportion in the top diffusion coating. This is made possible by changing the value of the Al and Ni weight percentage ratio in this area (noted as Al/Ni). In the case of the diffusion twosome between IN 718 and pack aluminizing mixtures, having in their composition as active components Al powder, Ferroaluminum (FeAl40) or mixtures of Al and Fe powders, at processing temperatures above the Al melting temperature, by modifying the active component of the mixture, substantial changes in the Al/Ni values were observed, as well as in the maximum %Al in the diffusion coating and of its thickness. It was found that, when switching from Al to FeAl40 or powder mixture (Al + Fe), the Al/Ni value changes between 3.43 and 1.01, from initial subunit values. The experiments confirmed that the highest %Al in the top aluminized diffusion coating, for IN 718, was obtained if the powder mixture contained 66.34 wt.% Al.

This paper discusses the issue of the effects of modifying the activity of nitriding media by diluting ammonia with nitrogen and the concomitant variation in the degree of ammonia dissociation on the layer’s growth kinetics and their phase composition. To understand and quantify the effects of the variation in the main parameters that influence the layer growth kinetics, the experimental programming method was used and mathematical models of interactions between influence and kinetics parameters were obtained for two metallic materials: Fe-ARMCO and 34CrAlMo5 nitralloy steel. It was concluded that the nitriding operating temperature and the degree of nitrogen dilution of the ammonia have statistically significant influences on the kinetics of the nitrided layer. In the same context, it was analytically proved and experimentally confirmed that the ammonia degree dissociation from the gaseous ammonia-nitrogen mixture, along with the dilution degree of the medium with nitrogen, significantly influences the nitrogen potential of the gaseous mixture used for nitriding and thus the concentration of nitrogen in balance at the medium thermochemically processed metal product interface.

Increasing the serviceability of industrial components intended for the petrochemical industry is possible through their superficial saturation with silicon (silicon cementation). Obtaining a silicon-rich surface coating results in a considerable increase in corrosion resistance, refractoriness, and wear resistance. One of the most economically convenient options for silicon cementation is pack siliconizing in powdery solid media. This paper presents the possibility of pack siliconizing that contains ferrosilicon (FeSi75C) and a thermite mixture (SiO2 + Al) as active, silicon-providing components, in P265GH grade steel, which is frequently used in the petrochemical industry. The aim of the study was to determine the most suitable active component of the two that were analyzed and at the same time identify the processing conditions in which the siliconized coating has the greatest thickness, is free of porosity, and is in direct contact with the support. The use of experimental programming methods allowed the optimization of the operation to obtain the optimal solution. It was concluded that the thermite mixture is not compatible with pack siliconizing because it results in a superficial saturation predominantly composed of aluminum. When ferrosilicon is used as the active component, it determines the particularly intense formation kinetics of the non-porous siliconized coating with its maximum thickness being reached at high processing temperature values (over 1100 °C) with a proportion of 60% FeSi75 and, simultaneously, with the lowest possible proportion of ammonium chloride (max. 3%), which is the surface activation/cleaning component.

The scholarly literature records information related to the performance increase of the cutting tools covered by the superficial layers formed “in situ” when applying thermochemical processing. In this context, information is frequently reported on the carbamide role in processes aiming carbon and nitrogen surface saturation. Sulfur, together with these elements adsorbed and diffused in the cutting tools superficial layers, undoubtedly ensures an increase of their operating sustainability. The present paper discusses the process of sulfonitrocarburizing in pulverulent solid media of high-speed tools steel (AISI T1, HS18-0-1) and its consequences. The peculiarity of the considered process is that the source of nitrogen and carbon is mainly carbamide (CON2H4), which is found in solid powdery mixtures together with components that do not lead to cyan complex formation (non-toxic media), and the sulfur source is native sulfur. The kinetics of the sulfonitrocarburizing process, depending on the carbamide proportion in the powdered solid mixture and the processing temperature, was studied. The consequences of the achieved sulfonitrocarburized layers on the cutting tools’ performance are expressed by the maximum permissible cutting speed and the maximum cut length. An interesting aspect is highlighted, namely the possibility of using chemically active mixtures. Their components, by initiation of the metallothermic reduction reaction, become able to provide both elements of interest and the amount of heat needed for the ultrafast saturation of the targeted metal surfaces.