The properties of boride layers produced by a plasma boriding process are described and the residual stressesin these layers are analysed using a numerical modelling method. It has been shown that a new method combining electroless nickel deposition and plasma boriding is possible. The results of the present study show that compressive residual stresses in the (Fe,Ni)2B layers are reduced by about 1500 MPa, relative to those in the thin surface (Fe,Ni)B layers. This should reduce the brittleness of the borided case and hence improve wear resistance, as was observed in the preliminary studies reported.
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