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DC plasma is a very promising technology for processing different materials, and is becoming especially interesting when low environmental impact and high-performance treatments are needed. Some of the intrinsic characteristics of DC plasma technology, which make it suitable for powder metallurgy (PM) and powder injection molding (PIM) parts production, are lowpressure processing and plasma environment high reactivity. Moreover it can be considered as a highly competitive green technology. In this work, an overview of some of the important DC plasma techniques applied to PM and PIM parts processing is presented. Emphasis is given to the descriptions of the main characteristics and the technique potentials of plasma-assisted nitriding, plasma-assisted thermal debinding, plasma-assisted sintering, and simultaneously plasma-assisted sintering and surface alloying. The aspects presented and discussed in this paper indicate that DC plasma processes are promising and competitive techniques for PM and PIM parts processing.

Nitrogen flowing DC discharges were generated between two side-armed electrodes in a drift tube. The discharges operated at gas residence times (t) of ∼4 × 10−4 s, reduced electric fields (E/N) between 90 and 118 Td, and electron densities (ne) between 1010 and 1011 cm−3. A kinetic numerical model was elaborated to study the discharge kinetics. The model calculates the densities of 18 electronic states of nitrogen in the discharge, including the 45 vibrational levels of the N2(X1Σ+g) molecules, as functions of the gas residence time. The model is employed to describe the density profiles of neutral and excited atomic and molecular species, and nitrogen ions, along with the N2(X1Σ+g) vibrational distributions for our experimental conditions. The N2(X1Σ+g) vibrational and gas temperatures, E/N, ne, and the N2(B3Πg), N2(C3Πu), and N2+(B2Σ+u) relative densities were measured in the discharge by optical emission spectroscopy and double probes. The experimental determined gas temperature (Tg), electron density, and reduced electric field were used in the calculations of the electron energy distribution function and reaction rate constants. The vibrational temperature (Tv) and excited species densities measured were compared to the calculated values from the model. Although much attention has been devoted to the study of nitrogen DC discharges in the last few years, this work presents for the first time the N+ – N4+ and N2+(B2Σ+u) ion density distribution together with the densities of 13 atomic and molecular nitrogen states as functions of the discharge gas residence time and N2(X1Σ+g) vibrational distributions calculated for experimental conditions of low pressure DC discharges operating at short residence times.

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