A 50 Hz ac abnormal glow discharge is characterized as a function of filling pressure (1-4 mbar) using a Langmuir probe. It is found that electron temperature, electron density and electron energy distribution function decrease with the gas filling pressure. Nitriding of aluminum alloy (Al−Mg 2 −Si) is performed for various time durations (3, 6, 9 and 12 h) and pressures (1 and 2 mbar) by keeping the input power (100 W) and substrate temperature (250 • C) constant. To explore the surface properties induced by plasma, X-ray diffractometer, optical micrography, atomic force microscopy and Vickers micro-hardness tester diagnostic techniques are used. Results exhibit the formation of cubic aluminum nitride. A significant increase in surface hardness is observed when samples are exposed at 1 mbar pressure for 12 h of processing time. A rapid decrease in surface hardness values with the imposed load suggests the formation of a thin modified surface layer.