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Case-hardening steels (EN36, 16MnCr5, and AISI 4140) are used in applications demanding good surface properties such as precision gears, shafts, and cam rollers. This study explores the formation of microcoatings to improve the surface characteristics of these steels using carbonitriding, which combines the merits of carburizing and nitriding to offer surfaces with enhanced hardness and wear resistance. Taguchi’s L18 orthogonal array is used for conducting the carbonitriding trials with replications. The effects of various carbonitriding parameters like carbonitriding time, temperature, and flow rate of ammonia are studied on the treated surface characteristics (Vickers microhardness, diffusion depth, and wear loss). A novel integrated approach of principal component-based grey incidence (PGI) that combines the merits of both principal component analysis and grey incidence theory is effectively used to select the optimal carbonitriding inputs (material substrate AISI 4140, carbonitriding temperature −835°C, carbonitriding time-40 min, and flow rate of ammonia 0.4 lit/min). Microscopic images related to diffusion depths are also analyzed. This study offers the necessary guiding principles for obtaining the desired surface coating on EN36, 16MnCr5, and AISI 4140 steels.

Parameter Design in Carbonitriding of EN36, 16MnCr5, and AISI 4140 Steels Using Principal Component-Based Grey Incidence (PGI)