Final Report

THEORETICAL HEAT TRANSFER
INVESTIGATION OF DIFFERENT PROTECTIVE

COATINGS
A PROJECT REPORT
Submitted by
AATHI NARAYANAN.V 962818114001
ARAVINDH.A 962818114014
BABIN SESARIO.A 962818114018
DAVID BRAINART.S 962818114020
in partial fulfillment for the award of the degree
of
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING
UNIVERSITY COLLEGE OF ENGINEERING, NAGERCOIL
(A CONSTITUENT COLLEGE OF ANNA UNIVERSITY, CHENNAI)
NAGERCOIL-629 004
ANNA UNIVERSITY: CHENNAI 600 025
JUNE 2022
ANNA UNIVERSITY: CHENNAI 600 025
BONAFIDE CERTIFICATE
Certified that this project report “THEORETICAL INVESTIGATION

OF DIFFERENT PROTECTIVE COATINGS” is the bonafide work
of “AATHI NARAYANAN.V (962818114001), ARAVINDH.A
(962818114014), BABIN SESARIO.A (962818114018), DAVID
BRAINART.S (962818114020)” who carried out the project work
under my supervision.
SIGNATURE SIGNATURE
Dr.N.SARAVANAN M.Tech.,Ph.D ., Dr.U.ARUNACHALAM M.E.,Ph.D.,
Assistant professor Assistant professor
HEAD OF THE DEPARTMENT SUPERVISOR
Mechanical Engineering Mechanical Engineering
University College of Engineering University College of Engineering
Nagercoil-629 004. Nagercoil-629 004.
Submitted for project viva-voce examination held at University College of

Engineering Nagercoil on ………….
INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT
All praise, glory and honor be to the Lord Almighty, source of

all knowledge for his gracious presence and guidance that enabled
us to work with effort and complete the project in time.
It is indeed a great pleasure to express our sincere thanks to

Dr.V.A.NAGARAJAN, M.E., Ph.D., Dean of UCEN for his
sincere guidance and encouragement in all aspects of the project.
We also convey our thanks to Dr.N.SARAVANAN, M.Tech.,

Ph.D., Head of Department, Mechanical Engineering Department
for his encouragement and support to complete our project.
It is a great pleasure to express our sincere thanks and gratitude

to our project coordinator, Dr.U.ARUNACHALAM, M.E., Ph.D.,
and Dr. G.R. JINU, M.E., Ph.D., for his valuable guidance,
encouragement and providing us with ample time to complete our
project.
It is a pleasure to express our sincere gratitude to our project

guide, Dr.U.ARUNACHALAM, M.E., Ph.D., Assistant professor
of Mechanical Engineering Department for his guidance, support
and encouragement throughout the course of our project.
We wish to convey our sincere thanks to all the teaching and

non-teaching staffs of Mechanical Department. Our heartfelt
gratitude and thanks to our parents and friends for their perceptual
support.
ABSTRACT
This project proposed a theoretical investigation on conduction heat transfer of
difference protective coatings .The aim was to propose a mathematical model
to analyze the heat transfer behavior of various protective coatings .The
electro plating (Ni-W) ,paint coating and galvanizing coating of thickness of
50µm, 100µm, 150µm considered for the study .The paint coatings are
extensively used in the diesel engines ,pump ,compressor and other day to day
applications, where the galvanizing coatings are applied to steel or iron
structures to offer protection against rusting. The thermal barrier coatings have
many potential applications to protect engine components. Nickel-Tungsten
coatings showed good reduction even at elevated temperatures. In this micro
analyze study on conductive heat transfer was carried out with different
mentioned coatings. A significant heat reduction performance was achieved in
the developed coatings. The analysis was executed by using ANSYS
workbench software and the obtained results of different coatings were
correlated.
TABLE OF CONTENTS
CHAPTER TITLE PAGE
NUMBER NUMBER
ACKNOWLEDGEMENT
ABSTRACT
LIST OF TABLES
LIST OF FIGURES
LIST OF SYMBOLS
LIST ABBREVIATIONS
1 INTRODUCTION
1.1 General Introduction 1
1.2 Protective Coatings 3
1.2.1 Necessity of Coatings 3
1.2.2 Coating Applications 3
1.2.3 Categories in Coatings 7
1.2.4 Various Techniques in Coatings 8
1.3 Thermal Barrier Coating 13
1.3.1 Metals used for TBC 16
1.3.2 Applications of TBC 16
1.4 Paint Coating 19
1.5 Galvanizing Coating 19
1.6 Electroplating Coating 20
1.7 Closure 23
2 LITERATURE SURVEY 24
3 COATING OVER A MILD STEEL
SUBSTRATE
3.1 Introduction 31
3.2 Surface preparation 31
3.3 Coating process 32
3.3.1 Thermal Spray paint Coating process 32
3.3.2 Hot Dipping Galvanizing coating
process 33
3.3.3 Electro-deposition process 35
3.3.3.1 Bath Chemistry 36
3.4 Measurement of coating thickness 37
3.5 Closure 38
4 ANALYSIS OF VARIANT
4.1 Introduction 39
4.2 Analysis of variants involved in Conductive
Heat transfer performance 39
4.2.1 Material of the substrate 40
4.2.2 Thickness of the Coating 40
4.2.3 Thermal conductivity of the Coating 41
4.2.4 Area of the Coated layer 42
4.2.5 Material of the Source Element 42
4.2.6 Energy input 42
4.2.7 Temperature of rear side of substrate 43
4.2.8 Environmental effects 43
4.3 Analysis of variants involved in Convective
Heat transfer performance 44
4.3.1 Velocity of flowing air 45
4.3.2 Temperature of flowing air 45
4.3.3 Properties of the flowing air 45
4.3.4 Type of flow pattern 46
4.3.5 Convective heat transfer coefficient 46
4.4 Closure 47
5 HEAT TRANSFER BEHAVIOUR
5.1 Heat transfer 48
5.2 Conduction 48
5.2.1 Fourier’s law 49
5.3 Convection 49
5.4 Radiation 50
5.5 Closure 50
6 FINITE ELEMENT ANALYSIS
6.1 Introduction of ANSYS 51
6.1.1 Importance of FEA 52
6.1.2 Limitations of FEA 52
6.2 Finite element modeling 53
6.2.1 Methodology for ANSYS stimulation 54
7 RESULT AND DISCUSSION
7.1 Introduction 58
7.2 Conductive heat transfer performance 58
7.2.1 Conductive heat transfer performance
On Low Carbon Steel 58
Of paint coating on low carbon steel 60
Of galvanizing coating on low carbon
Steel 66
Of Nickel-Tungsten on low carbon
Steel 71
7.3 Closure 78
8 CONCLUSIONS
8.1 Introduction 79
8.2 Conclusion 79
8.3 Scope for future work 80
8.4 Closure 80
REFERENCES 81
LIST OF TABLES
TABLE PAGE
TITLE
NO NO
7.2.1 Conductive heat transfer performance of low 59
carbon steel
7.2.2 Achieved values of paint coating on structural 61
plate of 50µm thickness
7.2.3 Achieved values of paint coating on structural 63

Achieved values of paint coating on structural
7.2.4 64
Achieved values of galvanizing coating on
7.2.5 67
structural plate of 50µm thickness
7.2.6 68
7.2.7 structural plate of 150µm thickness 70
Achieved values of Ni-W coating on

7.2.8 structural plate of 50µm thickness 72
7.2.9 Achieved values of Ni-W coating on
structural plate of 100µm thickness 74
7.2.10 Achieved values of Ni-W coating on 75
FIGURE LIST OF FIGURES PAGE

NO TITLE NO
1.1 Schematic diagram of electroplating setup 13
1.2 Thermal spray paint coating 33
1.3 Hot dipping galvanizing coating process 34
1.4 Electro-deposition process 36
15 Simple slap diagram for conduction heat 40

transfer
1.6 Model generated by ANSYS workbench 55
1.7 Model in mesh command 56
1.8 Thermal load on uncoated surface 56
1.9 Convection applied on coated surface 57
1.10 Achieved surface temperature of 5mm

thickness low carbon steel 59
1.11 Achieved temperature of paint coating on

structural steel plate in 50µm thickness 61


1.14 Achieved temperature of galvanizing

coating on structural steel plate in 50µm 66
thickness

coating on structural steel plate in 100µm
thickness 68

coating on structural steel plate in 150µm 69
thickness
1.17 Achieved temperature of Ni-W coating on 72

structural steel plate in 50µm thickness
1.18 Achieved temperature of Ni-W coating on 73

Achieved temperature of Ni-W coating on

1.19 75
LIST OF SYMBOLS
L - Thickness of the slab, m
k - Thermal conductivity of the slab material, W/mk
dT - Temperature difference, K
Q - Heat transferred, W
T - Temperature (ºc)
q - Heat flux, W/m2
d - Density, kg/m3
Rth - Thermal resistance, K/W
LIST OF ABBREVIATIONS
TBC - Thermal Barrier coatings
FEA - Finite Element Analysis
T1 - Inner surface Temperature
T2 - outer Surface Temperature
T3 - Coated Surface temperature
CFD - Computational Fluid Dynamics
CHAPTER 1
INTRODUCTION
1.1 GENERAL INTRODUCTION
Metals have a vital role from household to industrial applications,

which includes chemical, electronic and engineering industry, construction and
medical fields. Large unique universal usefulness of steel, steel alloy and its
derivatives always have an emerging demand. Stainless steel is widely
employed in many chemical industries, because of its high corrosion resistance
in aqueous environments. From the failure analysis, we know that extremely
high working temperature, structural loading, latent defects, wear and corrosion
are some general causes of failure of metals during their uses. Recent times
have witnessed considerable efforts made towards the development of materials
to fulfill the needs of engineering and many other areas of applied sciences. It is
therefore necessary to improve the overall properties of steel or base metal by
some economically feasible technology. Attempts have been made by
researchers to improve the wear resistance of steel materials by coating
processes. Metal and alloys; as well as ceramic coatings have been widely
employed for several decades for protection at high temperatures in power
plants, gas turbines and oil refineries with great success. In industry, the plating
of mild steel and iron by metals like nickel, chromium, and zinc has been
widely used to protect them from corrosion for many years.
The main principle of these coatings is to boost the desired properties and
maintain oxidation rates at a level that increases the consistency of the
component’s working levels for several years without any significant damage to
the components. Conventional usage of protective coatings, at high
temperatures provides extension in lifetime, thereby increasing their operating
temperature and efficiency. Coating technology exhibits many advantages such
as no formation of hazardous waste, no volatile by-products, cost effective and
environmentally friendly technique. The Paint coating and Galvanizing coating
are good for environmental. Alloying and composite techniques are generally
used to enhance the mechanical and surface properties of the metals more than a
single metal. Nickel coated steel has enhanced corrosion resistance and wear
resistance. The nickel-plating process is widely used for decorative, engineering
and electroforming purpose which is used in limited temperature appliances.
But nickel coating alone doesn’t enhance the high temperature oxidation and
wear resistance to satisfy the industrial requirements. In order to enhance the
utilization of this material, various modifications can be applied such as the use
of alloys or composites instead of the pure metal. For advancement in
industries, alloying and metal composite techniques provide desirable results
such as making them harder, more protective and wear resistant with great anti-
friction property. Tungsten has not only the highest melting point of all
elements except carbon sources in scientific literature vary between 3387℃ and
3422℃ but also excellent high temperature mechanical properties and the
lowest expansion coefficient of all metals.
1.2 PROTECTIVE COATINGS

Coating is the common process to enhance or modify desired
properties of the surface of the metal. In this process thin layer of metal or non-
metal is applied over the base material to improve the consistency of the
material. Coating process generally affords protection and decoration. Coating
material is different from the substrate material and enhances some special
surface properties of the surface without changing its bulk properties. Coating
may improve tribological properties (wear and hardness) and appearance.
Coating may be done by single metal, metal matrix or alloy. It mainly depends
on the desired property to be improved.
1.2.1 Necessity of Coatings
To improve the desired property in metal many processes are readily

available like alloying, mixing, chemical reactions (both exothermic and
endothermic), and coating. Main advantage of coating is that it improves
physical, chemical and mechanical properties of the surface in a single process.
It improves the hardness of the substance, and its machinability strength. It
gives better resistance to corrosion and oxidation reaction, while improving
anti-friction properties like wear resistance. It increases the life period of the
specimen. It gives smoother and decorative appearance to the substance. It
provides high quality specimen by achieving chemically inert surface.
1.2.2 Coating Applications
Thermal spray medical device coatings can be found in electrosurgical

instruments, X-ray and MRI machines, dental and orthopedic implants,
prosthetics, and much more.
Food processing, mechanical pump seals are made up of stainless-steel

materials such as 316L SS, are coated with metal oxide ceramics such as
chromium oxide and with carbide containing materials for greatly enhanced
wear resistance. The surfaces typically coated on shafts and sleeves are either
seal or bearing surfaces. The coated surfaces can be ground to very smooth
finishes, but are typically ground to a finish of 10 - 16 micro-inch Ra to help in
lubricating the seal surfaces.
Thermal Spray Technologies offer a range of coatings for use in solar

energy applications. Because solar energy equipment is highly specialized, it is
important to protect this equipment from potential hazards. The materials
engineering expertise develops coating solutions that maximize protection and
promote peak performance. The coatings deliver a number of useful benefits,
including thermal barriers, Electro Magnetic Interference (EMI) and Radio
Frequency Interference Shielding, corrosion resistance, and more.
Requirements of the coatings for various applications
Industry Coating Requirements
Aerospace wear resistant, oxidation resistant, clearance control and corrosion

resistant.
Electronics electrically conductive, electrically insulating (dielectric),

EMI/RFI shielding and solderable.
Agriculture wear resistant and corrosion resistant.
Paper wear resistant, release (non-stick), corrosion resistant, traction and

Making coating metering.
Printing wear resistant, release, traction, ink metering and electrically

insulating.
Food wear resistant, corrosion resistant, and cavitation resistant.
Processing
Medical electrically insulating, tissue grip (non-slip), electrically

conductive, bio-compatible, wear resistant, EMI/RFI shielding, X-
ray generation and heat dissipative
Automotive wear resistant, antigalling, oxygen sensing, corrosion resistant,

electrically insulating, electrically conductive and EMI/RFI
shielding
Défense electrically insulating/electrically conductive, wear resistant,

EMI/RFI shielding, anti-galling and oxidation resistant
Power wear resistant, oxidation resistant, clearance control, corrosion

Generation resistant and oxygen diffusion (fuel cell)
(i) Corrosion Resistant/Protective Coatings
Zinc, aluminium, zinc-aluminium, and similar materials offer superb

galvanic protection against corrosion. Thermal Spray Technologies used for
corrosion resistant coatings have proven to be far more effective than paints and
other solutions for providing long-term protection. Other materials, such as
nickel-chromium, cobalt-chromium alloys, and oxide ceramics also provide
excellent corrosion resistant/protective properties. Coatings can easily be
produced that provide both corrosion resistance and wear resist
5
(ii) Dielectric Coatings
Oxide ceramics and other similar coating materials can provide

dielectric properties for electronic components. Coatings with dielectric
strengths of 40 volts-per-micrometre are routinely produced.
(iii) Electrically Conductive Coatings
Different degrees of electrical conductivity can be achieved through

various coating materials. Copper, aluminium, and molybdenum are commonly
used materials for electrically conductive coatings. For higher temperature
applications, materials such as iron-chromium-aluminium, molybdenum-
disilicate, and other alloys are often used.
(iv) Emissivity Coatings
The materials for emissivity coatings can be specially tailored to meet

the needs of a given application. Thermal Spray Technologies use pure metals,
metal alloys, and metal oxides, as well as other materials, for emissive coatings.
(v) EMI/RFI Shielding Coatings
Several metallic coatings are available that can provide protection

Against Electromagnetic Interference (EMI) and Radio Frequency Interference
(RFI). Thermal Spray Technologies (EMI/RFI) coatings can be deposited onto
nearly any substrate material, including plastic, carbon-carbon, and carbon fibre
composites.
6
(vi) Absorptive Coatings
As with emissivity coatings, coating materials for absorptive coatings

can be selected and especially suited to meet the needs of any customer
application. Thermal Spray Technologies can apply materials such as pure
metals, metal alloys, and metal oxides as absorptive coatings.
(vii) Reflective Coatings
Reflective coatings in the visible range are often mirrored surfaces,

because of the most applications require specular reflectance. Our thermal spray
techniques can be used to create first and second surface reflectors, as well as
diffuse reflective surfaces. Pure metals, metal alloys, and for certain unique
applications, ceramics are commonly used materials for reflective coatings.
(viii) Bio-Compatible Coatings
Specialized materials can help the human body accept and attach to
medical implant prosthetics, such as orthopaedic or dental implants. Thermal
spray coatings such as porous titanium and dense hydroxyapatite are commonly
used for these applications.
1.2.3 Categories in Coating
Coating is mainly classified into two major categories, based on

chemical nature. The first category is inorganic coating, which includes metallic
and inter-metallic compounds coating. (Example: Nickel, chromium plating,
gold plating, Ni alloy coating, etc.). The second category is organic coating,
which uses non- metallic compounds only. (Example: Paints, varnishes, etc.).
7
1.2.4 Various Techniques in Coating
(i) Electroless plating
Electroless plating is the process of depositing metal ions from

electrolyte solution onto the cathode, when no electric current is involved. The
plating is a result of chemical reaction occurring on the part surface. Deposits
are often less porous and thus provide better barrier corrosion protection to base
substrates. Electroless plating has been widely used in industrial fields for its
advantages of low temperature process and uniformity of the coating.
Electroless plating consumes more time than electrolytic plating and price
difference is minimum. The properties of electroless coatings can be easily
controlled by varying the electro pre-treatment, and deposition parameters, by
using different plating functional solutions and by various additives. For
example, electroless Ni–P has been applied in various kinds of industrial
applications such as electronics, computers, aircrafts, and car components, due
to its characteristics of hardness, corrosion protection, and wear resistance.
(ii) Conversion coating
Conversion coating is the process where the coating is formed as a

result of chemical reaction or electrochemical reaction which occurs in the part
of surface. The purpose is to form a continuous film, normally an oxide, which
provides a good base for painting and adhesive bonding. They are used for
corrosion protection, surface hardness and decorative purpose. Conversion
coating includes oxide coating, phosphate coating and chromium coating.
8
It could be very thin, on the order of 0.25 µm and thick coatings, up to several
millimeters thick. Conversion coatings have good resistance against hydration
and are highly stable over a wide pH range. Conversion coatings include
chromatin, phosphating, metal colouring and/or immersion plating.
(iii) Hot dipping
Hot dipping is the process of immersing the part of the metal to be

coated into a molten metal, followed by removal of the part from the metal bath,
which results in formation of the metal coating on the part surface. Hot-dip
deposition is used to increase corrosion and wear resistance. All low melting-
point metals and alloys are deposited by this process. Limitations are the
melting temperature of the coating metal, the difference in melting-points
between the coating material and the substrate, the brittleness of the coating
layers, and the shape of the substrate. This process doesn’t meet the industrial
requirements.
(iv) Physical Vapor Deposition (PVD)
In physical vapor deposition process, the coating material gets

vaporized in vacuum condition, then these metal vapors are transported to the
substrate and by condensing the vapor on the substrate surface required coating
is obtained. PVD is an environmentally friendly coating process that provides
brilliant and durable decorative finishes on household appliances, plumbing
fixtures, door hardware, jewelry, electronic components, automotive trim and
marine fittings. It involves high capital cost and the rate of coating deposition is
usually quite slow compared to other processes.
9
It is important to point out that PVD is considered to be a technique that can
provide not only metallic, but also alloyed and ceramic coatings with a virtually
unlimited range of chemical composition and therefore controlled protective,
mechanical and wear-resistant properties. The alternative for today’s low price
galvanic coatings is therefore dry and clean PVD technologies, fully supported
by legislation on environmental protection. The economics depend directly on
the substrate type and the quantity.
(v) Sputtering Deposition
Sputtering deposition is a similar method like PVD; molten metal is

sputtered and deposited over target material. Sputtered atoms ejected have a
wide energy distribution, typically up to tens of eV (100,000 K). Because of the
low substrate temperatures used, sputtering is an ideal method to deposit contact
metals for thin film transistors.
(vi) Ion Beam Deposition (IBD)
Ion Beam Deposition is a process of applying materials to a target

through the application of an ion beam. In the ion source, materials in the form
of a gas, an evaporated solid, or a solution are used for ionization. The ions are
then accelerated, focused or deflected using high voltages or magnetic fields.
(vii) Chemical Vapor Deposition (CVD)
In CVD process, the substrate is exposed to one or more volatile

precursors, which react and/or decompose. Decomposition of gas or chemical
reaction produces coating over the substrate. Chemical vapour deposition gives
high quality films with excellent exposure and morphology controllability.
10
The greatest problems with this technique that it requires high temperatures.
Major application of CVD is found in semiconductors and related devices –
integrated circuits, sensors and optoelectronic devices.
(viii) Thermal spraying
Thermal spraying techniques are coating processes in which melted

(or heated) materials are sprayed onto a surface. It is the process of deposition
of the atomized the molten metal at high temperature metal, delivered to the
substrate surface in a high velocity gas stream. Thermal sprayed coatings are
effective at increasing the component life and performance of applications.
Disadvantages of the plasma spray process are relatively high cost and
complexity of process.
(ix) Plasma Spraying
Plasma Spraying (PS) is an adaptable method to deposit powders as

dense, adherent and homogeneous coatings with low porosity. Plasma spraying
technique has a great interest in porosity, hardness, elastic modulus and residual
stress. In this process, powder is used as a coating material, which is heated to
reach a molten state. The heated material is propelled into droplets via plasma
jet at high velocities to the substrate, where they flatten and solidify rapidly
forming a coating. Plasma sprayed coating has a unique microstructure and
behaves differently from a comparable monolithic material.
(x) Powder Metallurgy
Powder coating is applied as a free-flowing, dry powder on the

substrate.
11
Electro statically the coating is applied and then it is treated under heat to form
a "skin". The powder coating does not require any suspended liquid form of
electrolytic solution. It is usually used to create a hard finish that is tougher than
conventional paint. It is not able to give a smooth and uniform surface finishing.
(xi) Laser Deposition
Laser is vaporizing the material to create plasma. The material

expands in plasma parallel to the target surface, thus forming a thin film over
the substrate. This process can occur in ultra-high vacuum or in the presence of
a background gas, such as oxygen.
(xii) Ion Implantation
In electric field, metals ions get accelerated and are impacted into
solid. The ions alter the elemental composition of the target metal. They cause
much chemical and physical change in the target metal by transferring their
energy and momentum to the electrons and atomic nuclei of the target material.
Ion implantation has wide application in semiconductor and electronic device
fabrication.
(xiii) Electroplating
The history of electrodeposition dates back to the beginning of 18th

century and continues till today. Electrodeposition is an aqueous deposition
technique. It is a feasible process used to fabricate composite coatings in a
single step. Electrodeposition technique offers both protective and luster
applications by depositing gold, silver, platinum, copper, nickel and zinc.
12
Electroplating is the process of deposition of metal ions from
electrolyte solution onto the cathode part. Electro-deposition is done on a part,
immersed into an electrolyte solution which is used as a cathode, when the
anode is made of the depositing material, which is dissolved into the solution in
the form of the metal ions, travelling through the solution and depositing on the
cathode surface. This process is carried out in the presence of electric current.
Figure 1.1 Schematic diagram of electroplating setup
Electroplating can be defined as the deposit of a very thin layer of

metal electrolytically to a base metal to enhance (or) change its appearance.
1.3 THERMAL BARRIER COATING
A wide temperature deviation between the inner and outer surfaces is

built up in materials in industrial environments. For this reason, a severe
residual stress is induced in these materials.
13
The major requirements in the designing of materials used in the above-
mentioned environments are heat resistance, high-temperature strength, thermal
shock resistance and anti-corrosion, etc. Thermal barrier coatings are usually
applied to metallic surfaces to protect the surfaces from high and prolonged heat
loads. The thermal barrier coating performs the function of insulating
components. Modern Thermal Barrier Coatings (TBC’s) are required to limit
heat transfer through the coating, it is also expected to protect the base metals
from oxidation and hot corrosion. They lower the component’s temperature and
reduce the oxidation and hot corrosion of base substrates, while simultaneously
reducing cyclic thermal strains. Application of thermal barrier coatings
increases the life of components further. Much of the research on thermal
barrier materials has been driven towards reducing thermal conductivity and
improving microstructure stability at high temperature.
Thermal barrier coating systems are duplex-type coatings which

consist of a metallic bond coat and a ceramic topcoat. The bond coat protects
the substrates from oxidative and corrosive attacks and improves the bonding
between ceramic topcoat and substrate. The ceramic topcoat has a significantly
lower thermal conductivity than the metallic substrate, and by applying an
internal cooling of the components it is possible to establish a large temperature
drop (several 100 K) across the ceramic layer. The most extensively used
ceramic metals are tungsten, tantalum, molybdenum, and columbium. For many
TBC applications, other than ceramic materials zirconates and stabilized
zirconia are preferred because of their low thermal conductivity and good
mechanical properties.
14
Thermal barrier coatings have a major application in gas turbine engines,
nuclear fusion equipment, diesel engines, jet engines, automobiles and space
shuttles. TBCs help reduce metal temperature, making engine components more
durable. Thermal barrier coatings (100 to 500 mm thickness) with internal
cooling facility, reduce the surface temperature (100° to 300°C). This has
enabled modern gas-turbine engines to operate at gas temperatures well above
the melting temperature of the metal, thereby improving engine efficiency and
performance. In gas-turbine blades nickel alloy coatings are used for oxidation
and corrosion resistance purpose. Addition of refractory materials like tantalum,
molybdenum, and tungsten in the nickel alloy increases the efficiency further by
acting as a TBC.
Thermal Barrier Coatings in diesel engines improves power density,
fuel efficiency, and multi-fuel capacity due to higher combustion chamber
temperature (900°C vs. 650°C). It also increases the engine power by 8%,
decreases specific fuel consumption by 15 - 20% and increases the exhaust gas
temperature by 200 K. The components used in nuclear fusion applications are
coated with silicon derivatives to increase the overall performance against high
temperature. Low thermal conductivity tungsten has been produced over fusion
appliances via vacuum spray process as a replacement for silicon coatings.
TBCs are generally produced by laser chemical vapor deposition,

electron beam physical vapor deposition and spray process. These processes are
not economically feasible. Further increase in the operation temperature could
be strongly dependent on the improvement of coating process and nano-
structure of thermal barrier coatings.
15
1.3.1 Metals used for TBC
TBC materials have to confirm to suggest requirements like

(i) high melting point, (ii) no phase transformation between room temperature
and operation temperature, (iii) low thermal conductivity, (iv)chemical inertness
(v) thermal expansion match with the metallic substrate, (vi) good adherence to
the metallic substrate (vii) thermodynamic stability and (viii) low sintering rate
of the porous microstructure. Thermal barrier effect not only depends on its
thermal conductivity it is also affected by thickness. In order to provide a
required thermal barrier effect, thermal barrier coatings are preferred to have
more than 0.2mm thickness. High-level requirements of TBC´s cannot be met
by a single material. Therefore, combinations of materials in the form of
multilayer systems and alloy coatings are preferred. The number of materials
that can be used as TBCs is very limited. So far, only a few materials have been
found to basically satisfy these requirements Several ceramic coatings such as
Al2O3, TiO2, mullite, CaO/MgO+ZrO2, YSZ, CeO2+YSZ, zircon and La2Zr2O7,
WC, WC-Ni, etc. have been considered as TBC materials.
1.3.2 Applications of TBC
Thermal barrier coating has an application in aero-engines, landing-

gear components, rocket thrust-chamber liners, missile engines, tools in crude
oil search installations, vessels in chemical refineries, gas-well tubing,
polymeric coatings on pipeline components , heaters, Solid-Oxide Fuel Cells
(SOFCs), thermopile devices for thermoelectric generators , boilers in power-
generation plants, stationary gas turbines , hydropower stations, MHD
Generators, dryers, tubing in boilers, marine gas-turbine engines, steam valve
stems.
16
(i) In gas turbines
Thermal resistive coating has a wide application in gas turbine

systems. Increase in efficiency, resulting in less fuel consumption and less
environmental pollution caused by CO2, NOx and other exhaust gas constituents.
One possibility for increasing efficiency is increasing the turbine inlet
temperature. But the increment in inlet temperature is limited by edifice metals
of the components. Thermal resistive coating of the hot parts (combustion
chamber tiles and rotating blades) increases their potential and resistance
against hot corrosive and oxidative environments which may result in high inlet
temperature and efficiency.
(ii) In diesel engines
Thermal resistive coatings protect pistons, valves and piston fire decks
from heat, high temperature oxidation, corrosion and thermal shock. The heat
from a coated piston reflected back to the chamber leads to higher temperatures
in a shorter time, and therefore it reduces the ignition delay on start-up, with
lower peak combustion temperatures. All of this improves the fuel efficiency.
The decisive improvement of thermal resistive coatings in diesel engines is
lower peak temperatures and decrease in NOx emission rate, together with the
steep fall of CO and particulate emission. At the same time, it also protects the
metallic substrate against the corrosive attack of fuel contaminants.
(iii) In Air Craft engines
Aircraft engine parts are exposed to severe mechanical loads, high

temperature, as well as corrosion and erosion media. Protective coatings have
been applied in those systems in order to enhance their durability.
17
In the front part of the engine, cold section, including the fan and the
compressor, the abrasion and erosion resistant coatings and seals are typically
employed. In the hot section of the engine, which includes the combustion
chamber area and the turbine, the thermal barrier coatings (TBCs) and high-
temperature seal coatings are used.
(iv) In Oil exploratory drilling
In addition to oil- and polymer-based muds, and more ester, ether and
alternative invert emulsion systems are found in circulating fluids, which
promote different forms of corrosive attack. Increased down-hole temperature
raises corrosion rates, while down-hole pressure increases can cause entrapped
corrosive gases to dissolve in the circulating fluid, increasing corrosiveness.
Thermal resistive coatings protect rotor, stator and drill head from heat, high
temperature oxidation, corrosion and thermal shock.
(v) In Solid Oxide Fuel Cell
High temperature (650°C to 850°C) Solid Oxide Fuel Cell (SOFC)

stacks comprised of alternating fuel. Air chambers, which are sealed by each
other and connected to fuel and air delivery manifolds are subject to a
demanding set of performance criteria due to the extreme operating
environment. The seals must have a low electrical conductivity, and be
chemically and mechanically stable in a high temperature reactive environment.
(vi) In Cutting tools
The addition of a TBC is credited with increasing cutting speeds of

tools and for providing deeper cuts.
18
In particular, TBC’s provide excellent wear resistance, which is necessary in the
harsh tool environment. Wear mechanisms of cutting tools; include crater,
attrition, flank, and abrasive wear. It has been shown that TBC’-s can limit the
crater and attrition wear processes.
1.3 PAINT COATING
A coating can be defined as a substance spread over a surface to

provide protection or to serve decorative purposes. This overview focuses on
paint coatings particularly industrial coatings, which are designed for protective
properties rather than for aesthetic qualities.
Paint is a mechanically bonded surface coating that provides a
barrier film between steel and the environment. A paint system involves the use
of several layer of coating, and sometimes, different formulations of paint,
depending on the type of environment in which the structure will be exposed.
Basic components of paint coatings

 Binders
 Pigments
 Solvents
 Additives
1.4 GALVANIZING COATING
Galvanization or galvanizing is the process of applying a protective

Zinc coating to steel or iron, prevent rusting. The most common methods is
Hot-dip galvanizing, in which the parts are submerged in a bath of hot, molten
zinc.
19
Types of galvanizing coatings

 Electro galvanization
 Hot - dipped galvanization
 Cold – galvanization
1.6 ELECTROPLATING COATING

A process where by a thin coat of metal is applied to a material. The
process involves placing the material to be coated in a solution containing ions
of the metal and then passing an electric current through the system, which
causes the ions to adhere to the material.
Types of electroplating
 Mass plating
 Rack plating
 Continuous plating
 Line plating
Mechanical Properties of the Metal
Strength, hardness, toughness, elasticity, plasticity, brittleness, ductility and

malleability are mechanical properties used as measurements of how metals
behave under a load. These properties are described in terms of the types of
force or stress that the metal must withstand and how these are resisted.
(i) Strength
Strength is the property that enables a metal to resist deformation under

load. The ultimate strength is the maximum strain a material can withstand.
20
Tensile strength is a measurement of the resistance to being pulled apart when

placed in a tension load. Fatigue strength is the ability of material to resist
various kinds of rapidly changing stresses and is expressed by the magnitude of
alternating stress for a specified number of cycles. Impact strength is the ability
of a metal to resist suddenly applied loads.
(ii) Hardness
Hardness is the property of a material to resist permanent indentation.

Because there are several methods of measuring hardness, the hardness of a
material is always specified in terms of the particular test that was used to
measure this property. Rockwell, Vickers, and Brinell are some of the methods
of testing. Of these tests, Rockwell is the one most frequently used. The basic
principle used in the Rockwell testis that a hard material can penetrate a softer
one. We then measure the amount of penetration and compare it to a scale. For
ferrous metals, which are usually harder than nonferrous metals, a diamond tip
is used.
(iii) Toughness
Toughness is the property that enables a material to withstand shock

and to be deformed without rupturing. Toughness may be considered a
combination of strength and plasticity.
(iv) Elasticity
When a material has a load applied to it, the load causes the material to
deform. Elasticity is the ability of a material to return to its original shape after
the load is removed.
21
Theoretically, the elastic limit of a material is the limit to which a material can
be loaded and still recover its original shape after the load is removed.
(v) Plasticity
Plasticity is the ability of a material to deform permanently without

breaking or rupturing. This property is the opposite of strength. By careful
alloying of metals, the combination of plasticity and strength is used to
manufacture large structural members. For example, should a member of a
bridge structure become overloaded, plasticity allows the overloaded member to
flow, allowing the distribution of the load to other parts of the bridge structure.
(vi) Brittleness
Brittleness is the opposite of the property of plasticity. A brittle metal

is one that breaks or shatters before it deforms. White cast iron and glass are
good examples of brittle material. Generally, brittle metals are high in
compressive strength but low in tensile strength. As an example, you would not
choose cast iron for fabricating support beams in a bridge.
(vii) Ductility and malleability
Ductility is the property that enables a material to stretch, bend, or

twist without cracking or breaking. This property makes it possible for a
material to be drawn out into a thin wire. In comparison, malleability is the
property that enables a material to deform by compressive forces without
developing defects. A malleable material is one that can be stamped, hammered,
forged, pressed, or rolled into thin sheets.
22
1.7 CLOSURE
This chapter gave an introduction of the importance of protective

coatings, their production techniques and the heat transfer behavior and
mechanical properties of the coatings employed for advanced and high
temperature applications. The next chapter presents the state-of-the-art and the
scope and objectives of the present study.
23
CHAPTER 2
LITERATURE REVIEW
Yahaya S Babatunade, Achema Felix, Ekpe E Esor, Atakpu ODennis. Heat

treatment of a low carbon steel. Heat treatment carried out on low carbon steel
is to improve the properties such as ductility,toughness,..etc .low carbon steel
with varying mechanical properties that can be utilized in different engineering
applications .Low carbon steel has carbon content of 1.5% to 4.5%.Low carbon
steel is the most common type of steel as its price is relatively low provides
material that are acceptable for many applications.
Daniyan,I.A.Mpofu,K.and Adeodu,A.O.Investigating the thermal

properties of carbon steel STKM13a for the welding assembly of rail car
suspension system. This work consider the use of numerical experiment to
investigate the effects of thermal properties of integrity on welding
structure .Welding assembly process of the rail car suspension system involve
elastic and plastic deformation over temperature ranging between room
temperature (25c) and the melting point (approximately 1500c).The analysis of
the result obtained indicate that the three parameters are critical as they affect
the welding process significantly hence should be controlled to promote safe,
reliable efficient welding process.
Yufei Lu,Jilan Yang,Jun Xu,Zhenghong Guo&Jianfeng
Gu (2019). Microstructure and mechanical properties of a low carbon

HDQ&P steel. Retained austenite (RA)in martensitic steel has been extensively
because of its complex effects on the service of components (1-7).
24
Presence of RA in martensitic steel could cause shape distortion and size
instability of components owing to the further transformation caused by external
stress. Hot rolling direct quenching and partitioning treatment was carried out to
simulate the one-line process of low carbon steel plates. Effects of the rolling
temperature and subsequent cooling manner on the microstructural evaluation
and associated mechanical properties of the steel plates were studied.
O.O.Daramola, B.O.Adewuyi and I.O.Oladele .Effects of heat treatment on

the mechanical properties of rolled medium carbon steel. Steel is an alloy of
iron and carbon, where other elements are present in quantities too small to
affects the properties. Other alloying elements allowed the plain carbon steel are
manganese (1.65% max) [13]; steel with low carbon content has the same
properties as iron, soft but easily formed. From the findings, the steel developed
by quenching + quenching + lamelarizing + tempering (Q+Q+L+T) process at a
lamelarizing temperature of 745 c has the highest ultimate tensile strength and
yield ratio of 75% with excellent combination of impact strength, ductility and
hardness which is very attractive for structural use followed by quenching +
lamerlarizing + tempering (Q+L+T) process and lamelaring + tempering(L+T)
process.
Olayide Rasaq Adetunji,Article Jan 2010.Optimizing hot galvanizing

operation of steel sheets for better quality. Hot dip galvanizing operations are
carried out using 99.8% zinc with small amount of aluminum addition at 450 c
for 10 minutes duration. Its coating in terms of luster and uniformly determine
that quality irrespective of that thickness. The withdrawal speed of 3m/m,4m/m
and 5m/m. Its coating in terms of luster and uniformly determine quality
irrespective of their thickness.
25
Thus, the overall quality of steel sheets galvanized at 450 c for one minute
immersion time was best start withdrawal speeds of 3m/m,4m/m and 5m/m for
gauges 18,22 and 28 states respectively.
NehaVerma, Assistant professor, Department of mechanical, SSIPMT,

Rajpur, IJERT. This literature survey provides huge information of
galvanization process. Its considering impact of excessive coating thickness of
this process on production cost, including zinc consumption cost, brittleness of
coating and excessive energy losses for galvanizing information of LPG or
electric energy. Also promotes the adoption of statistical method, design of
experiment for process and product.
Michal I Ojoven, published 2jul 2018.Influence of hot dip galvanized

coatings. Zincs capabilities to effectively protect steel against corrosion have
been known for over 200 years and make zinc coating widely appreciated and
used all over world. An addition of element impacts the morphology of zinc
coating in many ways. Lead, tin, or bismuth present in the zinc bath inhibit zinc
nucleation and lead to the formation of a various sizes.
Harshal S Khode, Case study papers on practical guidelines for the

inspection and repair of hot dip galvanized coatings. Hot dip galvanizing is
used as a very effective steel corrosion protection method, providing a long
service-life. The corrosion protection is dependent on the coating thickness and
environmental conditions (ASM Handbook, 1994). Zinc coated components are
also used to give a good appearance to the constructions.
26
In recent years the interest in hot dip galvanizing for the decorative and
constructional applications has increased. The difference in the field of use
determines the requirements to the coating appearance.
Gary Dallin, International Zinc Association. Galvanized sheet selecting the

proper coating mass. Galvanized sheet is a widely available product used by
many different industries, including construction, automotive, appliance,
electrical hardware, drainage and HVAC. While there is a wealth of data and
information about the corrosion rate of zinc is in myriad environment in which
these products are used.
Aaran Gane Robert, Issued February 1968.Organic coating properties,

selection and use. Preceding chapter of this publication have described its
objectives and arrangement, discussed the early history of paint and varnish
described the types of coatings that are available give the properties and uses of
all the important synthetic resins available today.
Vijay mannaric, Chintan Kumar j patel. Understanding coating raw

materials. Providing protection from damage by the external environment.
Providing specific attributes to the product. Providing aesthetic appeal or
decorative value to surface and product.
27
Arthur A Tracton. Coatings materials and surface coatings.
Application areas:
*Automotive
*Coatings for metal
*Maintenance
*Wood
*Business machines
Ashwini Asture, Varun Rawat, Chandramohan Srivastava, Dipti vaya.

Investigation of properties and application of ZnO polymer
nanocomposites. Polymer nanocomposites (PNCs) contain nanoparticles (NPs),
with at least one dimension of 10-100 A. Even though polymer have many
applications, NPs are dispersed on the polymer matrix to widen their scope
further. This leads to incremental effects on thermal, electrical and mechanical
properties. Zinc oxide (ZnO) is one of the most promising NPs.
Saeed Farrokhpay, New Developments in paint and coatings technology.

The current challenge in paint and coatings industry is to apply sophisticated
technology such as nanotechnology to achieve environmentally friendly and
durable coatings. Nanotechnology is being used in many applications in modern
paint and coating industries. It is predicted that environmentally friendly
application such as water borne system are continuing to be areas where
advances will be made.
28
Magdalena popczy, Julian kubisztal .E. Corrosion resistance of Heat
treated Ni-W alloy coatings. The C125/1173 coatings is the most resistant to
corrosion in 5wt% of NaCl solution. The reason for this is the highest tungsten
content in c125/1173 and smallest surface area of this coatings.
M.H.Allahyazadh, M.Aio fkhazraei,&A.R.Sabour rouhghdam.

Functionally graded nickel tungsten coating electro deposition, corrosion
and wear behavior. The FG coatings have a superior wear resistance compared
to pure Ni coatings. So that the wear rat decreases to 30& and COF of FG
coatings decreases approximately from 0.74 to 0.49 as sliding distance
increases.
U. Arunachalam, P. Veeramani, N. Shenbaga Vinnayaga mooorthi. A

Review on thermal behavior aspects of nickel-tungsten alloy coating. The
recent development in aerospace, missile, rockets, automobile engines
necessitate the development of thermal barrier coating to protect the costly,
precious base structural components from the heat load. Because of the
intermediate heat loads, the base materials explode due to high temperature
corrosion, alterations in grains etc. Hence, it becomes a major concern to a
provide a thermal barrier coating which has the property of being easily
applied, economical cost and durable life to protect the base material.
Pei-Jing-Teng, Chein-hung Lin, Shih-Wei Mao. Deposition Of Nickel
Tungsten Phosphours Coatings on Pure Copper in a Saline Water

Environment. Copper has been used extensively in the pipe line and electrical
industries due to its electrical and thermal conductivity, Flexibility and
Weldability. In Marine Engineering, Principal components of copper
demonstrate Performance by dissolved oxygen and chloride species.
29
A stable coating layer is critical to extensively deploy copper in oceanic

environment. This paper attempts to characterize a coated ternary NI-W-P layer
on copper matrix in corrosion and SSRT Test.
Zhimin Zhong, Sidney J.Clouser. Nickel-tungsten alloy brush plating for

engineering applications. A process for brush plating a Nickel-Tungsten alloy
has been developed. The electrolyte formulated provides a current efficiency
55-60% and it’s plated at a temperature 49-59 degree Celsius. The composition
of the alloy deposited in 40% Tungsten and 60% Nickel. Hardness of the as
plated deposit is 670 VHN. Heat treating the deposit between 190 and 500
degrees Celsius increase the hardness with the extent of increment being
proportional to the heat treatment temperature. The Nickel Tungsten has a low
friction.
30
CHAPTER 3
COATINGS OVER A MILD STEEL SUBSTRATE
3.1 INTRODUCTION
Mild steel remains an important engineering material frequently

applied in construction, chemical, power production, automobile and
electrochemical industries due to its abundance at relatively low production
cost. Above all, mild steel possesses unique and remarkable mechanical
properties such as good strength, toughness, ductility, formability and weld-
ability which confirm its suitability as a better construction material in
comparison to other engineering material. Some of these engineering
components must have strong and hard surface along with soft and tough core
for their durability, reliability and safe operations depending on the operational
conditions. The methodology and procedure adopted to produce coating over
mild steel substrate is clearly explained in this chapter.
3.2 SURFACE PREPARATION
In order to ensure good adhesion of the deposit to the substrate there

must be an intimate linkage between the atoms of both these materials. A steel
plate of size 90 mm x 45 mm x 5 mm is taken as the base metal for the coatings.
Many surface treatment methods have been developed and applied to enhance
the surface properties of components produced from the mild steel.
31
3.3 COATING PROCESS
Coatings are defined as the thin layer of solid material on the surface
that provides improved protective, decorative, or functional properties. More
specifically, they are liquid, liquefiable, or mastic composition that, after
application to a surface, is converted into a solid protective, decorative, or
functional adherent film. The existing coating methods to improve the
performance of mild steel, it is imperative to develop simple, scalable, cheap
and environmentally friendly method for the surface treatment.
3.3.1 Thermal spray paint coating process
Thermal spraying is a generic category of coating processes that apply

a consumable as a spray of finely divided molten or semi-molten droplets to
produce a coating. It is distinguished by its ability to deposit coatings of metals,
ceramics and polymers in layers of substantial thickness, typically 0.1 to 10mm,
for engineering applications. Almost any material can be deposited so long as it
melts or becomes plastic during the spraying operation. At the substrate surface,
the particles form 'splats' or 'platelets' that interlock and build up to give the
coating. It has been widely used for many years throughout all the major
engineering industry sectors for component protection.
32
Figure 1.2 Thermal spray paint coating
APPLICATIONS
(i) Thermal spray coatings are extensively used in the manufacturing of gas
turbines, diesel engines, bearings, journals, pumps, compressors and oil
field equipment, as well as coating medical implants.
(ii)Thermal spraying is principally an alternative to arc welded coatings,
although it is also used as an alternative to other surfacing processes, such
as electroplating, physical and chemical vapour deposition and ion
implantation for engineering applications.
3.3.2 Hot dipping Galvanizing Coating process
Hot dip galvanizing is the process of coating fabricated steel by

immersing it in a bath of molten zinc. There are three fundamental steps in the
hot dip galvanizing process; surface preparation, galvanizing, and inspection.
33
Figure 1.2 Hot dipping galvanizing coating process
Hot dip galvanizing provides a number of benefits to the steel it

protects. The metallurgical-bonded zinc-iron alloy layers not only create a
barrier between the steel and the environment, but also cathode protect the steel.
The cathode protection offered by zinc means the galvanized coating sacrifices
itself to protect the underlying base steel from corrosion. Finally, the zinc
coating naturally develops an impervious layer of corrosion products on the
surface, known as the zinc patina. The patina, cathode protection, complete
coverage and all of these other features, provide hot-dip galvanized steel with a
long, maintenance-free service life.
APPLICATIONS
(i) Products that are Hot Dip Galvanized such as the Pressed Steel Tank for
water storage and steel towers, Guardrails, Highway Guardrails or
Highway Safety Crash Barriers. Playground Equipment and Garden
Furniture are normally Hot Dip Galvanized and Duplex Powder
Coated for its colorful appeal.
(ii)The Petronas Twin Tower in Kuala Lumpur and the Kuala Lumpur
Tower are prestigious projects in Malaysia. For durability most steel are
Hot Dip Galvanized and Duplex coated.
34
Commonly found in the open areas are Forged Welded Gratings hot dip
Galvanized, Garden Lighting Poles Hot Dip Galvanized and Children
Play Stations all Hot Dip Galvanized coating. It is used in critical
construction areas such as coastal or marine concrete structures.
3.3.3 Electrodeposition process
Electro-deposition or electroplating technique involves the

degradation of organic pollutants at the cathode, while the heavy metals are
reduced and simultaneously electroplated or deposited at the cathode. This
method is generally used for the removal of inorganic pollutants. Based on the
principle of electrolysis, it is a process that uses electrical current to reduce the
cat-ions of a desired material from an electrolyte and coat those materials as a
thin film onto a conductive substrate surface. To begin electro-deposition, the
cathode (working electrode, W.E) immersed in the electrolyte contained in a
vessel (cell) along with the anode (counter electrode, C.E). To allow electric
current flow in the circuit, the two electrodes are connected to a battery or any
other power source. Electro-deposition is a process that assembles solid
materials from molecules, ions or complexes in a solution. These are images of
goal nanostructures produced by controlling the electro-deposition process. The
formation of the zinc-iron alloy coating depends principally on the chemical
composition of the steel that is galvanized. All common steels and irons can be
hot dip galvanized, but steels with particular silicon contents may produce a
very fast reaction between the iron and the zinc.
35
Figure 1.4 Electro-deposition process
APPLICATIONS
(i) Electrode-position or electroplating is the process of controlled deposition

of material on conducting surfaces using electric current from a solution
containing ionic species. Electro-deposition has been extensively used to
fabricate binder-free thin film for super capacitor applications.
(ii)A coatings more expensive metal onto a base metal surface in order to
improve the appearance. Applications are jewelry, furniture fittings,
builders’ hardware and tableware. Manufacture of sieves, screens, dry
shaver heads, record stamps, molds and dies.
3.3.3.1 Bath chemistry
Electroplating is commonly preferred for the deposition of tungsten over

nickel. REDOX (Reduction and Oxidation) reaction is responsible for the
plating process.
36
Plating process requires (i) plating bath filled with electrolyte solution which is
of acid or alkali for good conductivity (ii) anode or plating material (iii)cathode
or substance to be plated. These two electrodes should be immersed with
electrolyte solution to undergo REDOX reactions. By supplying DC current,
oxidation occurs in anode and ions from anode get dissolved in electrolyte. The
cations are attracted towards opposite charged electrodes. The ions get
deposited over the required surface by reduction, leading to the formation of a
thin layer of coating. Tungsten cannot be electrodeposited from an aqueous
solution of sodium tungstate or any other compound. The properties of deposits
are affected by numerous variables, including operating conditions impurities in
solution. Composition additives and more changes in processing variables affect
hardness, internal stress, crystalline structure and other properties. Changes in
nickel concentration, boric acid, chlorides (or) brighteners for example can
produce minor (or) remarkable changes in the deposit.
3.4 MEASUREMENT OF COATING THICKNESS
The heat transfer behavior studies are done on paint coating, galvanizing
coating and electroplating coatings are 50 µm, 100 µm and 150 µm thick coated
panels of each coating. By varying the process parameters, the required
thickness of the coating was obtained and it was measured by the "ELCO
METER", an instrument employed to measure the coating deposited over the
substrate which uses the eddy current principle. While machining the alloys, the
thickness at which it gives the required combinational properties is an inevitable
one hence the thickness needs to be measure.
37
3.5 CLOSURE
In this chapter, a detailed description about the cleanings and coating

procedures employed in the present research was reported. The next chapter
gives details of the employed to study the theoretical heat transfer investigation
of different protective coating panels.
38
CHAPTER 4
ANALYSIS OF VARIANTS
4.1 INTRODUCTION
This chapter discusses the various parameters involved in the system

which influence the behavior of the conductive and convective heat transfer
performance of the coating produced over a mild steel substrate theoretically.
4.2 ANALYSIS OF VARIANTS INVOLVED IN CONDUCTIVE

HEAT TRANSFER PERFORMANCE
The conduction of heat transfer is normally accomplished either by the

molecular interaction whereby the energy exchange takes place by the kinetic
motion or direct impact of molecules or by the drift of free electrons as in the
case of metallic solids. As per the Fourier law of conduction, the rate of heat
conduction is proportional to the area measured normal to the direction of heat
flow and to the temperature gradient in that direction.
The conduction heat transfer performance behavior of the different

coated panels over the mild steel-substrate depends on the following
parameters.
(i) Material of the substrate
(ii) Thickness of the coating
(iii) Thermal conductivity of coated layer
(iv) Area of the coated layer
(v) Material of the source element
(vi) Energy input (V and I)

39
(vii) Temperature of the rear side of the substrate and
(viii) Environmental effects
4.2.1 Material of the Substrate
The conductive heat transfer behavior of the coating mainly depends

on the substrate material, over which the coating was made. The thermal
conductivity value of the substrate material greatly affects heat flow and higher
thermal conductivity of the substrate enhances the heat flow and causes more
reduction in temperature in the rear side of the coatings. Normally mild steel
components are employed in engineering applications and need such kind of
thermal protective coatings.
4.2.2 Thickness of the Coating
As per the conduction law, we know that the heat flux by the
conduction mode is proportional to the temperature gradient. The temperature
gradient across the element purely depends on thickness. Thermal resistance
offered to the heat flow will be higher if the coating thickness increases.
dT
Q=
R
40
Figure 1.5 Simple slab diagram for conduction heat transfer
L - Thickness of the slab in m

k - Thermal conductivity of the slab material in W/ mK
dT - Temperature difference K (dT = T1 - T2)
Q - Heat transferred in W
Rth - Thermal resistance in K/W
4.2.3 Thermal Conductivity of the Coating
Thermal conductivity is the ability of the material to transfer heat with

unit temperature difference across unit thickness. Thermal conductivity of the
coating depends upon the material composition of the coating and the
temperature at which the coating was exposed. As the thermal conductivity of
the materials is a function of temperature and most of the metals it decreases
with increasing temperature.
41
4.2.4 Area of the Coated Layer
From the knowledge of electrical analogy, the thermal resistance

offered by the deposit to the conduction heat flow is inversely proportional to
the normal area to the heat flow direction. Therefore, the area available for heat
flow has significant impact on the temperature protective coatings. The increase
in area protects the system from exposure of heat loads and reduces the
temperature effects produced in the system.
4.2.5 Material of the Source Element
In the conductive heat transfer experiment, two kinds of source

elements (aluminum and cast iron) are utilized to study the heat transfer
performance of the coated panels. The maximum temperature exposed to the
panels depends on the source material even with constant energy input supplied
to the system. A surface temperature up to 300°C was obtained, if the source
material was aluminum and a temperature of 600°C was observed when the
source material was cast iron. The increase in temperature results in more heat
flow and varies the thermal conductivity of the substrate and the coated panel.
Therefore, this parameter is also considered while analyzing the conductive heat
transfer performance of the coatings.
4.2.6 Energy Input
A high voltage DC power system is utilized for supplying electric

power for all the experiments carried out in the present study. This unit can
deliver a wide range of power to the heater according to the heat flux
requirements. The instrument is regulated with DC power output.
42
The energy supply to the source element was varied by a varies which is a part
of a DC supply system to conduct the experiments in different heat loads and to
analyze the conduction behavior of the coatings. As we know, higher the energy
input, higher the exposure of temperature. This variable is one of the main
parameters which influence the conductive heat transfer performance of the
coating.
4.2.7 Temperature of the Rear Side of the Substrate
The source temperature applied to the front surface of the plate for a
specified energy input has a greater impact on the heat flow as per the law of
conduction. Higher the temperature, higher the heat flow and wider variation in
thermal conductivity value of the material through which the heat flows.
Therefore, this is one of the salient parameters to be analyzed carefully for this
conduction heat transfer performance study.
4.2.8 Environmental Effects
Finally, any experimental system should have the impact of

environmental effects in it. Here the loss of heat due to leakage through the gap
to the air reduces the heat transferred to the source block which in turn reduces
the exposure temperature of the mild steel substrate. The effect of ambient
temperature should have an impact on the conductive heat transfer performance
of the coated panels and these effects are nullified by the use of compensating
thermocouples.
43
4.3 ANALYSIS OF VARIANTS INVOLVED IN CONVECTIVE

HEAT TRANSFER PERFORMANCE
The convective heat transfer is possible only in the presence of fluid

medium. When a fluid flows inside a duct or over a solid body and the
temperature of the fluid and surface are different the heat transfer between the
fluid and solid surface takes place. This is due to the motion of fluid relative to
the surface. If the fluid motion is artificially enhanced or created by an external
agency like a blower or fan, the heat transfer is termed as forced convection. In
this present study, the coated and uncoated panels are exposed to a stream of hot
air and the rear side temperature is measured to study the convective heat
transfer performance of the coated panels. The following parameters are
carefully analyzed to perform the convective heat transfer behavior of the
different coated panels over the mild steel-substrate.
(i) Material of the substrate
(ii) Thickness of the coating
(iii) Area of the coated layer
(iv) Energy input (V and I)
(v) Environmental effects
(vi) Velocity of the flowing air
(vii) Temperature of the flowing air
(viii) Properties of the flowing air
(ix) Type of flow pattern
(x) Convective heat transfer co-efficient

44
The first five properties, viz, material of the substrate, thickness of the deposit,
area of the coated layer, energy input (V and I) and environmental effects have
been discussed in detail already while analyzing the conductive heat transfer
performance.
4.3.1 Velocity of Flowing Air
In order to study the convective heat transfer performance of the

coating, the rear side of the coated panel was exposed to air at different
temperatures with different velocities. The experiments were performed for
different velocities by altering valve opening positions. The variations of
velocity of the flowing air define the type of flow pattern of the air and alter the
convective heat transfer co-efficient of the flowing air. The higher velocity of
the flowing air causes the turbulent effect in air and enhances the heat transfer.
4.3.2 Temperature of Flowing Air
The temperature of the flowing air is the function of energy input and
velocity of air, which alters the properties of the air and the flow pattern. This
variation of flow pattern alters the convective heat transfer co - efficient of the
flowing air and hence better percentage reduction in temperature is obtained.
4.3.3 Properties of the Flowing Air
The Reynold’s number, Prandtl number and thermal conductivity of

the flowing air are the functions of property values of the flowing air. Reynold’s
number is a function of kinematic viscosity and Prandtl number varies in
response to dynamic viscosity, specific heat and thermal conductivity.
45
The Reynold’s number defines the kind of flow and other two properties cause
the variation in convective heat transfer co-efficient value of the flowing
medium. In practice, the systems subjected to thermos – cyclic loads experience
these kinds of variation in properties and affect the steady state of the system
and hence special care is to be taken to consider this variation used in the
system.
4.3.4 Type of Flow Pattern
The flow of any fluid system follows either laminar or turbulent

behavior depending on the magnitude of Reynold’s number. The behavior is
smooth when the flow follows laminar pattern and moderate heat transfer co-
efficient values exist in this pattern. As the Reynold’s number value increases
the flow becomes turbulent and these turbulence effects increase the convective
heat transfer rate.
4.3.5 Convective Heat Transfer Co-efficient
The Newton’s law of cooling states that the heat flux is proportional to
temperature gradient of the flowing medium and the constant of proportionality
is referred as convective heat transfer coefficient. This can be obtained from
the different Nusselt analogies applicable to the type of flow either internal or
external and with respect to the surfaces. This Nusselt number is the function of
Reynold’s number and Prandtl number. Therefore, Nusselt number of the
flowing air is the main parameter to determine the behavior of the convective
performance of the flowing air.
46
4.4 CLOSURE
In this chapter, a detailed description of all the variants that influence

the conductive and convective heat transfer performance of the different coated
panel over mild steel substrate is given. The salient features of the various
parameters are highlighted. The different statistical techniques to analyses the
variables are discussed. The next chapter deals with the detailed discussions
obtained from the experimental findings.
47
CHAPTER 5
HEAT TRANSFER BEHAVIOUR
5.1 HEAT TRANSFER
Heat transfer is the process of the movement of energy due to a

temperature difference. The calculation we are interested in typically include
determine the final temperatures of materials or how long it take for these
materials to reach this temperature. This can help inform the level of insulation
required to ensure heat is not lost from a system. Typically, heat loss is
proportional to a temperature gradient.
There are THREE ways heat can move.
Conduction – via solid material

Convection –via liquids and gases
Radiation –via electromagnetic waves
5.2 CONDUCTION
Conduction is the transfer of heat through direct contact between two
objects.
T 2 – T1
Q = KA L
Q = heat transfer (W)

A = cross sectional area (m2)
k = thermal conductivity (W/mK)
T1, T2 = temperature (ºc)
48
5.2.1 Fourier΄s Law:
The law of heat conduction, also known as Fourier΄s law, the rate of
flow of heat through a single homogeneous solid is directly proportional to the
area of the section at right angle to the direction of heat flow, and to the change
of temperature with respect to the length of the path of the heat flow
(temperature gradient).
q = -k∇ T
q – local heat flux density
-k – material conductivity
∇−¿ temperature gradient
5.3 CONVECTION
Convection is the transfer of heat due to the bulk movement of fluid. As
such convection only applies to heat transfer within a fluid or between a solid
and fluid but not the heat transfer within solid. This heat transfer is achieved by
the movement of molecules within the fluid. The term convection can refer to
either mass transfer and/or heat transfer. Typically, when referred to as
convection, heat transfer is meant.
Q = hA(T2 – T1)
Q = heat transfer ( J/hr)

A = cross sectional area (m2)
h = heat transfer coefficient (W/m2 K)
T1, T2 = temperature (ºc)
49
5.4 RADIATION
Radiation is the transfer of energy due to electromagnetic waves

when thermal energy is converted by the movement of the charge of electrons
and protons in the material. When a body radiates, the energy comes from the
entire depth of the body, not just the surface. Radiation does not require a
temperature gradient.
Q = ε σ A (T42 – T41)
5.5 CLOSURE
In this chapter, explain the heat transfer behavior. The next chapter
deals with the analysis part of the different coatings.
50
CHAPTER 4
FINITE ELEMENT ANALYSIS
6.1 INTRODUCTION TO ANSYS
Finite Element Analysis (FEA) is a computational technique used to

obtain solutions of boundary value problems in engineering. Finite Element
Analysis is a tool to obtain results for specific problem. The simple description
of Finite Element Analysis is, splitting of a structure into several elements,
describing the properties of each element, reconnecting the elements at different
points called nodes, as if they were the points of pins or droplets of glue that
held the elements together.
It can be used to calculate deflection, stress, vibration, buckling
behavior and many other phenomena. It can analyze elastic deformation, or
permanently bent out of shape' plastic deformation. The computer is required
because of the astronomical number of calculations needed to analyze a large
structure. The power and low cost of modern computers has made Finite
Elements Analysis available to many disciplines and industries.
In the finite element method, a structure is broken into many small
simple blocks or elements. The behavior of an individual element can be
described with a relatively simple set of equations. Just as the set of elements
would be joined together to build the whole structure, the equations that
describe the behavior of the whole structure. The computer can solve this large
set of simultaneous equations. From this, it can get the stress and deflection of
all the parts of the structure.
51
The stresses will be compared to allowed values of stress for the materials to be
used, to see if the structure is strong enough.
6.1.1 Importance of Finite Element Analysis
In the absence of Finite Element Analysis development of

structures must be based on the hand calculations only. For complex structures,
the simplifying assumptions required to make any calculations possible can lead
to a conservative and heavy design. A considerable factor of ignorance can
remain as to whether the structure will be adequate for all design loads.
Significant changes in designs involve risk. Designs will require prototype to be
build and field-tested. The field tests may involve expensive strain gauging to
evaluate strength and deformation.
6.1.2 Limitations of Finite Element Analysis:
Finite element methods are extremely versatile and powerful and can
enable designers to obtain information about the behavior of complicated
structures with almost arbitrary loading. In spite of the significant advances that
have been made in developing finite element packages, the results obtained
must be carefully examined before they can be used. The most significant
limitation of finite element analysis is that the accuracy of the obtained solution
is usually a function of the mesh resolution. Any regions of highly concentrated
stress, such as around loading points and supports, must be carefully analyzed
with the use of a sufficiently refined mesh. In addition, there are some
problems, which are inherently singular (the stresses are theoretically infinite).
Special efforts must be made to analyze such problems.
52
6.2 FINITE ELEMENT MODELING
ANSYS Workbench includes capability for modeling many types of

thermal and thermal stress problems of interest to practicing engineers. The
temperature distribution found at each thermal analysis node can be used with
the equivalent structural model as inputs for finding stress caused by
temperature changes
Material Properties
1. low carbon steel

Density : 7647 kg/m^3
Modulus of Elasticity : 210000 Pa
Poisson's ratio : 0.30
Thermal conductivity : 25.3 W/mK
2.Thermal spray paint

3.Galvanizing (Zinc)
Modulus of Elasticity : 210000 Pa
Poisson's ratio : 0.30
Thermal conductivity : 470 W/mK
4.Ni-W Alloy
Density : 8.8 g/cc
53
6.2.1 Methodology for ANSYS simulation
ANSYS workbench is used for our analysis purposes. we do steady

state thermal analysis in a rectangular plate for different types of thermal barrier
coating.
By applying thermal load on one surface and analyzing the
temperature on the other side. this temperature difference after applying
different coatings gives the percentage of thermal resistance made by different
coatings .by comparing the results we conclude which coating is effective for
thermal protection.
Preparation for Thermal Analysis
1. Create a folder in which the simulation has to be stored.
2. First create the geometry associated with this problem. That can be done in
ANSYS design modeler or any other solid modeling software Start ANSYS Workbench
> New simulation
3. Units > U.S. Customary (in, lbm, lbf, "F, S, V, A) verify units
4. Select Preferences->Structural Geometry Solid >Details of "Solid">

Engineering Data >add material >low carbon steel.
5. Engineering Data > add materials >paint.
6. Engineering Data >add materials >zinc.

54
7. Engineering Data >add materials >nickel-tungsten alloy
Modeling:
8. Create rectangle by, Modeling >Create >>rectangle >dimensions >generate.
9. Create plate by, Modeling >Create >extrude.
10. Create surface over plate by, Modeling >concept >add surface face >generate
Figure 1.6 Model generated by ANSYS workbench
Generate Mesh:
11. Select Mesh size by, Meshing> Mesh Tool >Element Attributes>Set
12. Meshing >Mesh Tool > select >>Mesh.

55
13. Generate Mesh by Clicking the Mesh.
Figure 1.7 Model in mesh command
Applying Thermal Loads:
14.Steady state thermal analysis >Insert >temperature >>applied on uncoated surface.
15.Steady state thermal analyses >Insert >convection >>applied on coated surface.
ANSYS
Figure 1.8 Thermal load on uncoated surface

56
Figure 1.9 Convection applied on coated surface
Solving the Analysis:1
16. Solve the Load by, Solution >Insert >Temperature >solve.
17.Solve the Load by, Solution >Insert >Heat flux >solve.

57
CHAPTER 7
RESULTS AND DISCUSSION
7.1 INTRODUCTION
This chapter considers the outcome of the theoretical findings and the
detailed analysis of the results obtained with the possible reasons for heat
transfer (conductive) behavior.
7.2 CONDUCTIVE HEAT TRANSFER PERFORMANCE
7.2.1 CONDUCTIVE HEAT TRANSFER PERFORMANCE OF A

STEEL PLATE
In the theoretical analysis of low carbon steel plate without coatings

were employed to conduct the experiments at different heat input values. The
reading obtained by the use of result were correlated with the experimental
values for the same heat input conditions. The observations were tabulated in
table 7.2.1. From the readings obtained from the analysis using ANSYS
software.
Figure 1.9 and 1.10 indicate the surface temperature achieved due to the
different temperatures and thermal conductivity applied on 5mm thick plate.
58
S. HEAT INPUT OUTPUT REDUCTION IN
N FLUX TEMPERATURE TEMPERATURE TEMPERATURE
O
(W/m2) T1 (0C) T2 (0C) (%)
1 301.21 45.12 45.06 0.14

2 671.74 63.72 63.587 0.21
3 1171 88.78 88.549 0.27
4 1819.4 120.33 120.97 0.30
5 2643.5 157.68 157.18 0.32
Figure 1.10 Acheived surface temperature of 5mm thickness steel plate
Table 7.2.1 conductive heat transfer performance of 5mm thickness mild

steel
59
Temperature Reduction in 5mm mild steel plate
0.35 0.32
0.3
0.3 0.27
% Reduction in Temperature
0.25
0.21
0.2
0.14
0.15
0.1
0.05
0
20 40 60 80 100 120 140 160 180
Inner Surface Temperature (°C)
7.2.2 CONDUCTIVE HEAT TRANSFER PERFORMANANCE OF

PAINT COATING ON A MILD STEEL
In the theoretical analysis, the paint coating was placed over the
source block which was made up of mild steel. The temperature of the coating
side surfaces was recorded. The paint coating on low carbon steel was used to
conduct the experiments at different temperature ranges. The reading obtained
by the use of result were correlated with the experimental values for the same
heat input conditions
The observations are tabulated in tables 7.2.2, 7.2.3 and 7.2.4. From the
readings obtained from the analysis part, the following was observed.
Figures 1.10, 1.11 and 1.12 indicate the surface temperature achieved
due to the different temperatures and thermal conductivity on thickness of
50µm, 100µm and 150µm paint coating on the mild steel.
60
Figure 1.11 Achieved temperature of paint coating on structural steel in
50µm thickness
S. HEAT UNCOATED COATED REDUCTION

N FLUX SURFACE SURFACE IN
O (W/m2) TEMPERATURE TEMPERATUR TEMPERATURE
T1 (0C) E (%)
T3 (0C)
1 450.93 45.12 44.25 1.92
2 1005.6 63.72 62.23 2.33
3 1753.47 88.78 86.46 2.61
4 2723.8 121.33 118.08 2.7
5 3807.35 157.68 152.83 3.07
Table 7.2.2 Achieved values of paint coating on structural plate of 50µm

61
Temperature Reduction in 50µm paint coating on mild

steel
3.5
3.07
3 2.7
2.61
2.5 2.32
1.92
2
1.5
0.5
0
20 40 60 80 100 120 140 160 180
Inner surface Temperature (°C)

100µm thickness
62
NO FLUX SURFACE SURFACE IN
(W/m2) TEMPERATURE TEMPERATURE TEMPERATURE
T1 (0C) T3 (0C) (%)
1 470.88 45.12 44.231 2
2 1089.23 63.72 62.12 2.5
3 1964.36 88.78 86.334 2.8
4 2868.56 121.33 117.89 2.83
5 4765.32 157.68 152.36 3.4

Temperature Reduction in 100µm paint coating on mild steel
3.4
3.5
3 2.8 2.83
2.5
2.5
2
2
1.5
0.5
0
20 40 60 80 100 120 140 160 180
63

150µm thickness
T1 (0C) T3 (0C) (%)
1 525.36 45.12 44.13 2.25
2 1365.17 63.72 62.52 2.82
3 2312.22 88.78 87.14 3.08
4 3522.47 121.33 118.36 3.35
5 5987.17 157.68 151.9 3.66

64
Temperature Reduction in 150µm paint coating on mild

steel
4 3.66
3.35
3.5
3.08
3 2.82
2.5 2.25
1.5
0.5
0
20 40 60 80 100 120 140 160 180
Temperature Reduction in paint coating with different
thicknesses
4
3.5
3
2.5
2
1.5
1
0.5
0
45.12 63.72 88.78 121.33 157.68
50µm 100µm 150µm
65
7.2.3 CONDUCTIVE HEAT TRANSFER PERFORMANCE OF
GALVANIZING COATING ON A STRUCTURAL STEEL
In the theoretical analysis the galvanizing coating was placed over

the source block made up of low carbon steel. The temperature of the coating
side surfaces was recorded. The galvanizing coating on structural steel was used
to conduct the experiments at different temperature ranges. The reading
obtained by the use of result were correlated with the experimental values for
the same heat input conditions
The observations are tabulated in tables 7.2.5, 7.2.6 and 7.2.7. From the
readings obtained from the controlled environment experiments, the following
was observed.
Figures 1.13, 1.14 and 1.15 indicates the surface temperature achieved
due to the different temperatures and thermal conductivity on thickness of 50 µ
m,100µm and 150µm galvanizing coating on the low carbon steel.
Figure 1.14 Achieved temperature of galvanized coating on structural plate

of 50µm
66
O (W/m2) TEMPERATURE TEMPERATURE TEMPERATURE
T1 (0C) T3 (0C) (%)
1 1190.8 45.12 42.873 5
2 2655.6 63.72 60.147 5.6
3 4629.2 88.78 83.473 6
4 7192.7 121.33 113.95 6.08
5 10150.36 157.68 147.89 6.3
Table 7.2.5 Achieved values of galvanizing coating on structural plate of

50µm
Temperature Reduction in 50µm Galvanizing coating on
mild steel
7
6.3
6 6.08
6 5.6
5
5
0
20 40 60 80 100 120 140 160 180
67

of 100µm

T1 (0C) T3 (0C) (%)
1 1360.45 45.12 42.785 5.17
2 2965.78 63.72 60.119 5.7
3 4756.83 88.78 83.428 6.02
4 7354.25 121.33 113.88 6.14
5 10581.69 157.68 147.47 6.58

100µm
68

mild steel
7 6.58
6.02 6.14
6 5.7
5.17
0
20 40 60 80 100 120 140 160 180
of 150µm
69
O (W/m2) TEMPERATURE TEMPERATUR TEMPERATURE
T1 (0C) E (%)
T3 (0C)
1 1585.21 45.12 42.735 5.3
2 3580.84 63.72 60.095 5.7
3 5621.3 88.78 83.365 6.1
4 7865.24 121.33 113.81 6.2
5 11875.32 157.68 147.04 6.85

150µm
mild steel
8
6.85
7
6.1 6.2
5.7
6 5.3
5
0
20 40 60 80 100 120 140 160 180
70
Temperature Reduction in Galvanizing coating with dif-

ferent thicknesses
8
7
6
5
4
3
2
1
0
45.12 63.72 88.78 121.33 157.68
50µm 100µm 150µm

7.2.4 CONDUCTIVE HEAT TRANSFER PERFORMANCE OF
NICKEL-TUNGSTEN COATING ON A LOW CARBON STEEL
In the theoretical analysis the nickel-tungsten coating were placed

over the source block made up of low carbon steel. The temperature of the
coating side surfaces was recorded. The nickel-tungsten coating on low carbon
steel was used to conduct the experiments at different temperature ranges. . The
reading obtained by the use of result were correlated with the experimental
values for the same heat input conditions
The observations are tabulated in tables 7.2.8, 7.2.9 and 7.2.10. From
the readings obtained from the controlled environment experiments, the
following was observed.
Figure 1.16, 1.17 and 1.18 indicate the surface temperature achieved
due to the different temperatures and thermal conductivity on thickness of
50µm,100µm and 150µm nickel-tungsten coating on the low carbon steel.
71
Figure 1.17 Achieved temperature of Nickel-tungsten coating on structural

plate of 50µm

O (W/m2) TEMPERATURE TEMPERATURE TEMPERATURE
T1 (0C) T3 (0C) (%)
1 27649.34 45.12 41.672 7.64
2 30124.25 63.72 58.567 8.08
3 33675.14 88.78 81.541 8.15
4 35681.39 121.33 111.16 8.4
5 42912.21 157.68 142.95 9.34
Table 7.2.8 Achieved values of Nickel-tungsten coating on structural plate

of 50µm
72
Temperature Reduction in 50µm Ni- W coating on mild

steel
10 9.34
9 8.15 8.4
8.08
7.64
8
7
6
5
4
3
2
1
0
20 40 60 80 100 120 140 160 180
plate of 100µm
73
T1 (0C) T3 (0C) (%)
1 28835.01 45.12 41.512 8
2 30694.56 63.72 58.34 8.44
3 34125.39 88.78 81.01 8.8
4 36263.27 121.33 110.54 8.9
5 43164.03 157.68 142.55 9.6
Table7.2.9 Achieved values of Nickel-tungsten coating on structural plate
of 100µm
Temperature Reduction in 100µm Ni-W coating on mild

steel
10
9.6
9.5
8.9
9 8.8
8.44
8.5
8
8
7.5
7
20 40 60 80 100 120 140 160 180
74

plate of 150µm
T1 (0C) T3 (0C) (%)
1 30375.56 45.12 41.387 8.3

2 31465.28 63.72 58.62 8.94
3 35284.06 88.78 80.549 9.27
4 37307.21 121.33 109.83 9.47
5 44219.55 157.68 141.78 10.1
Table 7.2.10 Achieved values of Nickel-tungsten coating on structural plate
of 150µm
75
Temperature Reduction in 150µm Ni-W coating on mild

steel
12
10.1
10 9.27 9.47
8.94
8.3
8
0
20 40 60 80 100 120 140 160 180
Temperature Reduction in Ni-W coating with different
thicknesses
12
10
0
45.12 63.72 88.78 121.33 157.68
50µm 100µm 150µm
76
Temperature Reduction in different coatings on mild steel

at 50µm coating thickness
10 9.34
9 8.15 8.4
8.08
8 7.64
7 6.3
6 6.08
6 5.6
5
5
4
3.07
3 2.61 2.7
2.33
1.92
2
1
0
45.12 63.72 88.78 121.33 157.68
Paint Coating Galvanizing Coating Electroplating

at 100µm coating thickness
12
10 9.6
8.8 8.9
8.44
8
8
6.58
6.02 6.14
6 5.7
5.17
4 3.4
2.5 2.8 2.83
2
2
0
45.12 63.72 88.78 121.33 157.68
77

at 150µm thickness
12
10.1
10 9.27 9.47
8.94
8.3
8
6.85
6.1 6.2
6 5.3 5.7
4 3.35 3.66
2.82 3.08
2.25
2
0
45.12 63.72 88.78 121.33 157.68

7.3 CLOSURE
In this chapter are presented the results and comprehensive discussion
of the heat transfer performance of the different protective coatings over a low
carbon steel substrate. The next chapter describes the major outcome of the
present study and the scopes for future work.
78
CHAPTER 8
CONCLUSION
8.1 INTRODUCTION
The heat transfer performance studies on paint coatings, galvanizing

coatings and nickel-tungsten coatings over mild steel substrate were carried out
successfully and the major conclusions derived in this chapter.
8.2 CONCLUSION
The conductive heat transfer studies of the protective coatings on low

carbon steel were carried out theoretically by using ANSYS software. The
conductive heat transfer on low carbon steel plate offered temperature reduction
of 0.14% to 0.35% in 5mm thickness plate.
The conductive heat transfer of 50µm thickness paint coatings,

galvanizing coatings and nickel-tungsten coating on low carbon steel plate
offered temperature reduction is a value 3.07, 6.3% and 9.34% respectively.

offered temperature reduction is a value 3.4%, 6.58% and 9.6% respectively.
79
offered temperature reduction is a value 3.66%, 6.85% and 10.1% respectively.
The paint and galvanizing coatings are used only for corrosive
resistance protection. Those are not with stand the high temperature resistance.
The nickel-tungsten coating can be used for the high temperature resistance
applications. So we analyze the conductive heat transfer performance of paint,
galvanizing and nickel-tungsten coatings on low carbon steel in theoretically.
8.3 SCOPE OF FUTURE WORK
The convective heat transfer experiments were conducted by exposing

the protective coating panels to the different environments to suit various
applications with different pressure levels.
The conductive heat transfer studies of the nickel -tungsten coatings are
conducted to at higher temperature levels by employing other source materials
like high carbon steel, brass, bronze etc.
8.4 CLOSURE
This chapter presented the salient conclusions of this study on heat

transfer behavior of the paint coating, galvanizing coating and nickel-tungsten
coating and finally the scope for the future work was also presented.
80
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83

Final Report

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THEORETICAL HEAT TRANSFER

INVESTIGATION OF DIFFERENT PROTECTIVE

AATHI NARAYANAN.V 962818114001

BABIN SESARIO.A 962818114018

DAVID BRAINART.S 962818114020

in partial fulfillment for the award of the degree

UNIVERSITY COLLEGE OF ENGINEERING, NAGERCOIL

(A CONSTITUENT COLLEGE OF ANNA UNIVERSITY, CHENNAI)

ANNA UNIVERSITY: CHENNAI 600 025

Certified that this project report “THEORETICAL INVESTIGATION

Submitted for project viva-voce examination held at University College of

INTERNAL EXAMINER EXTERNAL EXAMINER

All praise, glory and honor be to the Lord Almighty, source of

It is indeed a great pleasure to express our sincere thanks to

We also convey our thanks to Dr.N.SARAVANAN, M.Tech.,

It is a great pleasure to express our sincere thanks and gratitude

It is a pleasure to express our sincere gratitude to our project

We wish to convey our sincere thanks to all the teaching and

This project proposed a theoretical investigation on conduction heat transfer of

difference protective coatings .The aim was to propose a mathematical model

to analyze the heat transfer behavior of various protective coatings .The

electro plating (Ni-W) ,paint coating and galvanizing coating of thickness of

applications, where the galvanizing coatings are applied to steel or iron

many potential applications to protect engine components. Nickel-Tungsten

coatings showed good reduction even at elevated temperatures. In this micro

mentioned coatings. A significant heat reduction performance was achieved in

the developed coatings. The analysis was executed by using ANSYS

workbench software and the obtained results of different coatings were

1.1 General Introduction 1

1.2 Protective Coatings 3

1.2.1 Necessity of Coatings 3

1.2.2 Coating Applications 3

1.2.3 Categories in Coatings 7

1.2.4 Various Techniques in Coatings 8

1.3 Thermal Barrier Coating 13

1.3.1 Metals used for TBC 16

1.3.2 Applications of TBC 16

1.4 Paint Coating 19

1.5 Galvanizing Coating 19

1.6 Electroplating Coating 20

3.2 Surface preparation 31

3.3 Coating process 32

3.3.1 Thermal Spray paint Coating process 32

3.3.2 Hot Dipping Galvanizing coating

3.3.3 Electro-deposition process 35

3.3.3.1 Bath Chemistry 36

3.4 Measurement of coating thickness 37

7.2.3 Achieved values of paint coating on structural 63

Achieved values of Ni-W coating on

FIGURE LIST OF FIGURES PAGE

1.2 Thermal spray paint coating 33

1.3 Hot dipping galvanizing coating process 34

1.4 Electro-deposition process 36

15 Simple slap diagram for conduction heat 40

1.6 Model generated by ANSYS workbench 55

1.7 Model in mesh command 56

1.8 Thermal load on uncoated surface 56

1.9 Convection applied on coated surface 57

1.10 Achieved surface temperature of 5mm

1.11 Achieved temperature of paint coating on

1.12 Achieved temperature of paint coating on

1.13 Achieved temperature of paint coating on

1.14 Achieved temperature of galvanizing

1.15 Achieved temperature of galvanizing

1.16 Achieved temperature of galvanizing

1.17 Achieved temperature of Ni-W coating on 72

1.18 Achieved temperature of Ni-W coating on 73

Achieved temperature of Ni-W coating on

k - Thermal conductivity of the slab material, W/mk

q - Heat flux, W/m2

Rth - Thermal resistance, K/W

FEA - Finite Element Analysis

T1 - Inner surface Temperature

T2 - outer Surface Temperature

T3 - Coated Surface temperature

CFD - Computational Fluid Dynamics