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Masking Techniques (Part 1)

By Daniel H. Herring
April 5, 2013

Certain applications require that we protect part surfaces from oxidation or limit the areas on a component
part where a case-hardening process is to be performed. To accomplish these tasks, various masking
techniques are employed, including copper plating, stop-off paints, physical masking and leaving excess
stock allowance. It is important to understand where, why and how each method is used. Lets learn more.

One should not assume that any masking method has been properly applied or will work well for a
given application without testing and taking into consideration such factors as material, part geometry,
cleaning, application, drying, heat-treatment process, removal method, inspection and end-use
performance.

Plating
Copper, properly applied, is generally considered the best method of part protection. It is also the most
costly. Copper plating can be used in both atmosphere and vacuum carburizing. AMS 2418 Rev H (2011)
details the process requirements. A nickel strike (nickel flash) is often used as an under layer for improved
copper adhesion, especially when processing highly alloyed steels (e.g., Pyrowear 675, M50Nil, Vasco
X2). At high hardening temperatures, however, nickel has been observed to diffuse into the base metal,
which has the same appearance under the microscope as a decarburized surface layer.
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Platinum and palladium plating are also reported to work well for specialized materials (e.g., titanium)
but are extremely expensive and should only be considered if the project cost warrants such expense.

Paints
Stop-off paints are widely used throughout the heat-treat industry either as an alternative to copper plating
or for touch-up on plated surfaces that have been damaged.

Carburizing and Carbonitriding

The most commonly used stop-off paints for carburizing and carbonitriding are solvent- or water-based
coatings with copper or boron as the main ingredient. Paints containing copper are not particularly suited
for carbonitriding because of the possible chemical reaction with ammonia in the furnace atmosphere. The
biggest advantage of boron-based paints is that the residues that remain are soluble in hot water and
alkaline solutions. To a certain degree, they rinse off during quenching. These paints are the best choice
for applications where mechanical cleaning is not a viable option.
Boron-based paints go into a semi-liquid state at temperature when heated. If the coating is too thick, the
mass of the paint will cause it to run onto uncoated areas. It is for this reason that the paint thickness
should be limited to 0.2-1.0 mm (0.008-0.040 inch). Only one coat is required as long as this coating is
uniform. Thicker is not better. Two coats are only recommended for geometries prone to carburization
from two sides, such as threads.
Solvent-based paints containing boron oxide are still in common use today and are considered by many
to offer the best protection in this class of coatings.

Deep-Case Carburizing
For total case depths over 2 mm (0.080 inch), silicate-based paints are recommended over boron-based
paints (Fig. 1). Silicate-based stop-off paints are normally applied in two or three layers depending on the
required case depth. After heat treatment, the glass-like residue is not water or solvent soluble but must be
removed by blasting. An advantage of these paints is that they will not run even if the coating thickness is
excessive. Unlike water-based boron paints, they are not subject to the problem of glazing of the furnace
interior.

Vacuum Carburizing
In general, stop-off paints used for vacuum carburizing are similar (but not identical) to those used in
atmosphere carburizing, especially where acetylene is used as a hydrocarbon-gas choice. Boron paints are
used for applications requiring the paint to be washed off after heat treatment.If mechanical removal (shot
blasting) of the stop-off paint is acceptable, silicate-based copper-oxide paint should be the first choice.

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Gas Nitriding and Nitrocarburizing

Stop-off for gas nitriding and nitrocarburizing (Fig. 2) contain fine tin powder dispersed in a lacquer,
consisting of a solvent and synthetic binder or water and synthetic emulsion. The stop-off effect is based
on a layer of molten tin dispersed onto the part surface, which acts as a gastight barrier that prevents the diffusion of nitrogen. It must be noted that preheating coated parts in air must
be limited to 380C (715F) maximum. Exceeding this temperature limitation will prove detrimental to the
uniformity of the tin plating. After processing, powdery residues that can be easily removed by wiping or
brushing remain. It must be noted that there is a microscopic layer of tin left on the part surface. In the
event this is problematic, blasting or machining can remove it.

Plasma (Ion) Nitriding

For ion nitriding, the most commonly used stop-off technology is mechanical masking (shielding). If the
geometry of the part does not lend itself to this type of protection, stop-off paints are available either based
on copper (electrically conductive) or ceramic ingredients (nonconductive). The residues of these paints
are powdery and are most often removed by wiping or brushing.

Scale Prevention
Stop-off paints are available to prevent scale and oxidation in furnaces that are running processes such as
annealing, normalizing and stress relief in air or products of combustion. These paints are used for
annealing, stress relieving, normalizing and hardening. In these applications, the entire part surface is
coated to prevent scale from forming when heated up to 850C (1560F). There are also lacquers and
ceramic-based coatings available for applications up to 1200C (2200F). These coatings create a glass-like
barrier to prevent the scale from forming. Upon cooling, the coating will begin to spall off due to
differential expansion of the coating and the part surface. Mechanical removal after processing is usually
still required.

Application Methods
Brushing, although labor intensive, is perhaps the most common application method for stop-off paints.
Using a flat, clean brush with soft bristles, the paint should be applied in an even, thin layer of uniform
thickness. When applying the paint to the part, resist the temptation to put excessive pressure on the brush,
and let the paint flow off the brush in a uniform manner. If the paint rolls off the part surface and back to
the brush, there is oil or some contaminants on the surface that must be removed. If solvent-based stop-off
is used, storing brushes between coats must be done in a container with the same solvent as the paint to
ensure there is no adverse chemical reaction or paint contamination.
Dipping (part immersion) is the simplest way to coat large numbers of parts. If the area to be coated is at
the end of the part, semiautomatic or continuous coating can be achieved with minimal investment in
equipment.
Automatic dispensing and spraying can also be used if the part geometry and area to be masked are
conducive to this method. Robotics and automated handling systems can be employed for high-volume
applications (such as in the automotive industry). If spraying is used, it must be carefully controlled to
prevent overspray and misting into the air.

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Next Time
Part 2 will discuss common problems with various types of masking methods and presents valuable
lessons learned. IH

References
1. Burgdorf, Eckhard H., Manfred Behnke, Rainer Braun and Kevin M. Duffy, Stop-off Technologies for
Heat Treatment, ASM Handbook (in preparation), 2013.
2. Nssle GmbH & Co. KG, Nagold, Germany (www.burgdorf-kg.de), private correspondence.
3. Duffy, Kevin, The Duffy Company, (www.duffycompany.com), private correspondence.
4. Herring, Daniel H., Industry Practices Report, Selective Carburizing Methods, white paper, 2004.

Dan Herring is president of THE HERRING GROUP Inc., which specializes in consulting services (heat
treatment and metallurgy) and technical services (industrial education/training and process/equipment
assistance. He is also a research associate professor at the Illinois Institute of Technology/Thermal
Processing Technology Center. Tel: 630-834-3017; Email: heattreatdoctor@industrialheating.com

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