Surface Engineering

Alokesh Pramanik
School of Civil and Mechanical Engineering
Curtin University
Office: 204.530
Ph: 9266 7981
Email: [email protected]

Contents adapted from Dr. Mobin Salasi and Dr Yu (Roger) Dong with Courtesy
4
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Do not remove this notice

5
 Overview of Today’s Lecture
1. Surface Treatments vs Surface Coatings
2. Surface Treatments – Mechanical
3. Surface Coatings
 Mechanical/Thermal
 Thermal-sprayed
 Thin Coatings (PVD, CVD, Ion implanted, Diffusion)
 Electroplating, Electroforming, Electroless plating
 Conversion
 Ceramic
 Porcelain Enamels; Organic; Painting (not included in Final Exam)
4. Surface Cleaning

6
 Component Mechanical Properties
Elasticity, strength, ductility, toughness
Bulk vs Surface
Affected by: Affected by:
• Chemical composition  Chemical composition
• Microstructure (phases, grain size)  Microstructure (phases, grain size)
• Processing (casting, forming, heat  Processing (surface treatments,
treatment, etc.) surface coatings, surface texture)

http://www.sv.vt.edu/classes/ https://en.wikipedia.org/wiki/Blisk www.appliedalloys.com.au/hard-facing-weldoverlays.htm

MSE2094_NoteBook
7
 Surface Treatments vs Surface Coatings
Change in: Change in:
• Surface properties (hardness;  Surface chemistry (a
residual stresses) different material layer
• Surface microstructure deposited)
(phase; grain size)  Surface properties (e.g.
No Change: corrosion resistance,
• Surface chemistry fatigue life, wear resistance,
friction, adhesion)

Purpose:
 Technical and functional reasons
 Aesthetic reasons

8
 Mechanical Surface Treatments
Surface properties are improved/modified using
mechanical means (forces/pressure)

Modification/improvement Typical processes

• Plastic deformation of top surface Depth < 1 mm
layers  Shot Peening
• Compressive residual stresses  Laser Peening
develop  Water-jet Peening
• Fatigue life increases  Ultrasonic Peening
• Resistance to stress corrosion  Roller Burnishing
improves
Depth > 1 mm
• Chemical composition unchanged
 Explosive Hardening
9
 Peening – Principle
peening - striking, bombarding, beating, impacting

https://cwst.com/shot-peening/overview/

How it works
• Surface deformed plastically (crater, dimple)
• Compressive stresses develop underneath (material tries to
revert to the undeformed state)
• Compressive layer slows crack development and growth
• All properties that are sensitive to crack presence are improved

10
 Shot Peening
 Workpiece surface is impacted repeatedly
with cast steel, glass or ceramic shot
(0.125-5 mm diameter spheres)
 Compressive residual stresses develop
 Average depth 0.12-0.25 mm (shallow)
 Delay of crack initiation and propagation
 Gravity peening
 Larger shot sizes, fewer impacts
 Lower extend of plastic deformation
 Economical
 Used on shafts, gears, springs, oil-well
www.icsp9.iitt.com www.ferroecoblast.com

https://www.youtube.com/watch
drilling equipment ?v=AgPsxoZnEa0
11
 General information

January 2013, Oxidation of Metals 79(1-2)

In LCF, roughness seems to be the

dominant parameter that controls fatigue
life improvement while the presence of
International Journal of FatigueVolume 110, May 2018, Pages 10-21
significant residual stresses is the
controlling factor in HCF (nucleation site is
subsurface).

12
 Laser Peening
 Also called laser shock peening
 Workpiece surface subjected to planar
laser shocks (pulses) from high-power
lasers
 Compressive residual-stress layer 1-1.5 mm
deep (deeper than in shot peening)
 Low-amplitude surface waviness
 Ra mostly unchanged
 Jet-engine fan and rotor blades, Ti and
Ni alloys
 Disadvantage: high cost of high-power
lasers
https://www.youtube.com/watch?v=LOO8yN1_RdI www.lsptechnologies.com

13
 Water-jet Peening
 Water jet at high pressure impinges on the workpiece surface
 Surface pressures as high as 1,000 MPa due to collapsing cavitation
bubbles induce compressive stresses
 Most successful underwater peening method for reactors
 Improved stress corrosion resistance
 Used on steels and Al alloys

http://www.jsm.or.jp/eja
m/Vol.1.No.2/NT/7/article.
html]

14
 Ultrasonic Peening
 Hand tool based on the piezoelectric
transducer
 Shot or pins driven by ultrasonic vibrations
transmitted from the transducer
 Typical frequency 22 kHz
 Variety of heads for different applications
 Typical applications: welds, aerospace,
automotive www.jsm.or.jp/ejam/Vol.2.No.2/GA/13/article.html

Pin-type head Ball-type head

www.toyoseiko.co.jp/english/product/product07.html

15
 Roller Burnishing
 Also called surface rolling
 Workpiece surface is cold worked by a hard and
highly polished roller or a set of rollers
 Improves mechanical properties and surface finish
 Used on various flat, cylindrical, or conical
surfaces
 Applications: seals, valves, spindles, fillets on
shafts http://www.cogsdill.co.uk/products/burnishing/

[Ref 1]

Shaft fillet Conical surface Flat surface

16
 Explosive Hardening
 High pressures through detonation of
explosive sheet placed on the surface
 Shock wave work-hardens the surface
 Contact pressures 10-50 GPa for 2-3 µs
 Increases in surface hardness but little
change in shape www.eurenco.com/content/explosives/rail-hardening/

 Deformation depth 20-100 mm

 Applications:
 Railroad crossings (Hadfield steel ‘frogs’;
USA, India)
 Mining and excavation equipment

http://www.slideshare.net/informaoz/c
raig-bishop-vae-railway-systems

17
 Mechanical Surface Treatments - Useful links
1. http://cwst.com/shot-peening/overview/
2. http://cwst.com/laser-peening/overview/
3. http://www.lsptechnologies.com/questions/
4. https://www.mnes-us.com/nuclear-services/water-jet-peening
5. https://www.youtube.com/watch?v=B6YxFxMCKkQ

18
 Mechanical/Thermal Surface Coatings
Change to both mechanical and
chemical properties of surface

Modification/Improvement Typical processes

• Chemical composition changes Mechanical
• Corrosion resistance improves  Mechanical plating
• Compressive residual stresses  Cladding
often develop Thermal
• Fatigue life increased  Hard Facing
• Wear resistance improves  Spark hardening
 Case Hardening
19
 Mechanical Plating
 Also called mechanical
coating, impact plating or
peen plating
 Fine ductile metal particles
are compacted over surface
by rotary means (tumbling)
using glass or ceramic beads
 Cold-welding of metal particles
(Zn, Sn, Cd, Pb) to surface
 Thickness usually 5- 75 µm www.tolkmit-
industries.de/e_mechanical_plating.htm
 Used for hardened-steel parts
(e.g. fasteners, automobiles
parts) for corrosion protection
 No hydrogen embrittlement www.alzin.com.au/mechanically-plated-coatings

20
 Cladding
 Also called clad bonding
 Layer (1.5-5 mm) of corrosion-
resistant ductile metal or alloy is
bonded to surface through pressure www.emsclad.com

 Pressing, rolling, extrusion; Cold rolling

usually followed by heat treatment
 Using explosives; advantage good bonding
 Examples:
 Alclad aluminium alloy; steel and Al clad
with stainless steel; steel wire clad with Cu
 Simple shapes: sheet, plate, tube

www.emsclad.com
21
 Hard Facing (Hardfacing)
 Thick layers (0.75-2.5 mm) of hard metal
(weld overlays) are deposited on the
surface by fusion welding
 Consumable electrodes in MiG welding, filler
rods in oxyacetylene and TiG welding
 Metallurgical (fusion) bonding provided
 Recall information on fusion welding from
Manufacturing Processes unit
www.thefabricator.com/article/cuttingweldprep/freq
 Enhances wear and corrosion resistance uently-asked-questions-about-hardfacing

 New components
 Repair of worn parts
 Applications: tools, dies, mining,
earthmoving and agricultural equipment
www.appliedalloys.com.au/hard-facing-weldoverlays.htm
22
Example hard facing microstructure

http://www.titanovalaser.com/hardfacing.html

23
 Spark Hardening
 Also called electric spark hardening or
electrospark deposition
 Hard coatings of tungsten, chromium or
molybdenum carbides deposited by
electric sparks
 Hard-facing alloys used as consumable
electrodes, rods or powder
 Short-duration high-current pulses generate
http://www.stt-inc.com/images/electro_spark/e-spark_05a.jpg

plasma in the electrode-workpiece gap

 Electrode melts and deposits molten drops
on the workpiece
 Layer typically 250 µm thick (thinner than
weld overlays; also called micro-welding)
 Applications: valve seats, oil-well drilling
tools, dies for hot metalworking, casting
and injection moulds
 Particularly suitable for repair of small and http://www.twi-global.com/news-
shallow defects events/connect/2002/september-october-2002/new-
mechanised-system-for-electro-spark-deposition/
24
 Surface Hardening (Case Hardening)
 Traditional processes (discussed
already in Engineering Materials 100
unit):
 For steels >0.3%C regarded as surface
treatment
 Flame hardening and induction hardening
 New heat sources: electron and laser
beams
grako-1483.wbk.kit.edu/english/200.php

 Carburizing, nitriding, carbonitriding

(diffusion surface coatings)
 Formation of martensite during case
hardening causes compressive
residual stresses on surface
 Fatigue life improved
 Wear resistance improved http://www.brighthubengineering.com/manufacturing-
technology/95554-selective-induction-softening/
25
 Induction Surface Hardening
Examples from Automotive Industry
Robot-type crankshaft hardening Camshaft hardening

https://i.ytimg.com/vi/igYqVEOJTHI/hqdefault.jpg
Gear hardening
https://www.youtube.com/watch?v=igYqVEOJTHI
(induction hardening)
https://www.youtube.com/watch?v=dzw5qQo-i4Y (flame
hardening)

http://chassissuspension.automotive-business-
review.com/suppliers/efd-induction1_11
26
 Mechanical/Thermal Surface Coatings
Useful links
1. http://www.tolkmit-industries.de/e_mechanical_plating.htm
2. http://corrosion-doctors.org/MetalCoatings/Cladding.htm
3. http://www.thefabricator.com/article/cuttingweldprep/frequently-
asked-questions-about-hardfacing
4. http://www.twi-global.com/technical-knowledge/faqs/process-
faqs/faq-what-is-electrospark-deposition-esd/

27
 Thermal-sprayed Surface Coatings
 Thick coatings (0.05 -2.5 mm) applied by spray gun
 Metal, alloys, carbides, ceramics, and polymers deposited
 Coating material in form of wire, rod, or powder
 Heating: oxyfuel flame, electric arc, plasma arc
 Temperatures 3000-8000°C; velocity 40-1000 m/s

Coating Characteristics Typical processes

• Hard and wear resistant  Combustion Spraying
• Corrosion and oxidation resistant • Flame, HVOF, D-Gun
• High porosity for some processes  Electrical Spraying
• Mechanical bonding and local • Arc Spraying
fusion • Plasma Spraying
28
 Thermal Spraying - Principles

Common Steps:
1. Heating feed stock
• Melting (or semi-melting), atomizing
2. Accelerating droplets
3. Striking the surface
• Deformation, rapid solidification
• Mechanical bond, local fusion
http://www.globalspec.com/learnmore/contract_manufacturing_fabrication/coating_services_finishing_services/coating_services
29
 Combustion (Flame) Spraying
 Thermal wire (flame) spraying
 Oxyfuel flame melts wire
 Compressed gas atomises and deposits molten droplets on the surface
 Thermal metal-powder (flame) spraying
 Oxyfuel flame melts metal powder
 Materials such as ceramics can be sprayed
 Both processes are inexpensive; the bond is medium strength,
coatings have porosity

Wire flame spraying Powder flame spraying

[Ref 1]

30
A modern flame spraying

31
 Combustion Spraying
 Detonation gun (D-Gun) spraying
 Repeated explosions using oxyfuel–gas mixture and powder metal
 High bond strength and density of coating https://www.youtube.co
 High-velocity oxyfuel-gas spraying (HVOF) m/watch?v=2mviEf4_x2
A
 Internal combustion generates supersonic flame jet for heating and
accelerating powders
 High density coating but often low deposition rates
 Less expensive than D-Gun; very good for carbide–based coatings

D-Gun spraying HVOF spraying

www.advanced-coating.com/english/spraying-detonation.htm

32
HVOF Microstructure examples

SEM microstructures of WC-CoCr coatings

Journal of Thermal Spray Technology
obtained at different temperature-velocity 23(6):1009-1018, 2014
combinations

33
 Electrical Spraying
 Twin-wire arc (arc spray)
 Arc is formed between two consumable conducting wire electrodes
 Compressed gas (air) atomizes and propels the droplets
 Plasma
 Plasma gas heats (8000°C) and sprays metal or ceramic powder
 High bond strength and low porosity level; low surface oxides in
vacuum plasma spray or low-pressure plasma spray
(mostly Zn, Al)

Arc spraying Plasma spraying

[Ref 1]
www.advanced-coating.com/english/spraying-detonation.htm

34
 Plasma spraying

Ar, Ar + H2,
Ar + N2 , Ar +
He

35
 Thermal Spraying - Examples

Resistance to high-
Resistance to high- temp oxidation
Purpose Resistance to wear corrosion and abrasion
temp corrosion

Application

Valve flange seat Step cone sprayed with Boiler tubes plasma
Spraying
powder flame sprayed WC/Co using HVOF sprayed with
method
with Ni superalloy refractory metal
http://aws.org/wj/amwelder/11-00/abc.html

https://www.youtube.com/watch?v=ah9kLdUFDQY (summary of thermal spraying)

36
 Thermal-sprayed Surface Coatings
Useful links
1. http://www.thermalspray.org/index.php?option=com_content&task
=view&id=50&Itemid=92/
2. http://www.advanced-coating.com/english/spraying.htm

37
 Vapour Deposition Surface Coatings
 Thin coatings (thin films), from nanometers to microns
 Metals, alloys and ceramics (compounds) can be deposited
 Typical applications: medical, electronics, cutting tools, dies

Chemical Vapour Deposition (CVD) Physical Vapour Deposition (PVD)

 High temperature process  High to low vacuum or plasma
 Coating from reactions or  Temperature 100-500°C
decomposition in gaseous state;  Coating particles in vapour form
interaction with substrate condense onto substrate
 Coatings usually thicker than PVD Basic categories of PVD
 Process cycle long 1. Vacuum evaporation
2. Sputtering
CVD historically older than PVD
3. Ion plating
38
 Chemical Vapour Deposition (CVD) - Principle

http://www.azonano.com/ar
ticle.aspx?ArticleID=3428

Thermochemical process (at elevated temperature)

 Precursors are introduced to chamber as gases
 Adsorbed precursors react and/or decompose on the substrates
 By-products are removed
 Conformal homogenous elemental or compound coatings with
good thickness control are produced
39
 Chemical Vapour Deposition (CVD)
Processing Equipment
 Atmospheric CVD
 High temperature
 Low-pressure CVD (LPCVD)
 Special pump to create partial
vacuum
 Lower temperature deposition; http://www.azonano.com/article.
aspx?ArticleID=3428
fast; good control over
composition and structure
 Plasma-enhanced CVD (PECVD)
(newer)
 Higher deposition rate at lower
temperature (100-300°C)
 Example: deposition of Si3N4 for
integrated circuits
http://www.dowcorning.com/content/etronics/etronicschem/etronics_newcvd_tutorial3.asp
40
Example: CVD TiN Coatings on Cutting Tools
 Titanium tetrachloride (a vapour), hydrogen, and nitrogen
are introduced into chamber and adsorb on the substrate
 Chemical reactions will form titanium nitride coating
2TiCl4 + 2H2 + N2 → 2TiN + 4HCl

TiN-coated carbide
[Ref 1]
tool inserts

41
Physical Vapour Deposition (PVD) - Principle
Three common steps:
 Evaporation of coating material (thermal, sputtering)
 Transportation of vapour to workpiece/substrate surface
 Condensation on workpiece/substrate surface

https://qph.ec.quoracdn.net/main-qimg- http://www.sigmaaldrich.com/materials-science/material-
0c8b984a2043d29c30c605507624eaec?convert_to_webp=true science-products.html?TablePage=108832720

42
 PVD - Vacuum Evaporation (VE)
 Coating material (target) is first evaporated and then
condenses on substrate
 Resistive heating (older)
 Electron beam
 Arc deposition - coating material is evaporated by arc evaporators
 Pulsed-laser deposition – coating evaporated by laser
 Applications: functional (electronics, optics), decorative

www.atl.semtechsol
utions.com/node/59
[Ref 1] /sample-preparation

Arc deposition system Coatings on SEM samples

43
 PVD - Sputtering DC or magnetron
sputtering
 Electric field ionizes an inert gas (Ar)
 Positive plasma ions bombard the
coating material (cathode) and cause
sputtering (ejection) of its atoms
 Atoms condense on substrate (anode)
 In reactive sputtering the inert gas is [Ref 1]
mixed with a reactive gas
 Oxides, nitrides, polymeric coatings
 Radio-frequency (RF) sputtering is
used for nonconductive materials TiN coated milling cutters
 Plasma-enhanced magnetron
Sputtering (PEMS) - auxiliary plasma AlTiN coated punch
source is used TiCN coated broach
https://www.youtube.com/watch?v=8mVK5dwyoEY www.richterprecision.com/pvd-coatings.html

44
Evaporation vs Sputtering
Comparison

http://www.mrsec.harvard.edu/education/ap298r2004/Erli%20chenFabrication%20II%20-%20Deposition-1.pdf

45
 PVD - Ion Plating
 Combined processes of sputtering
and vacuum evaporation
 Best coverage and adhesion
 Plasma (Ar+) cleans the substrate
(cathode) and bombards the
growing coating
 Compressive stresses [Ref 1]

 Improved adhesion Ion-plating apparatus with plasma

 Ion-beam-enhanced (assisted)
deposition (IBED or IBAD) IBED/IBAD
 Low temp vacuum system; ions for
bombardment formed in separate ion
gun
 Target evaporated or sputtered
 Variety of semiconductor, optical and
http://www.4waveinc.com/tech
tribological good-quality coatings nology/ion-assisted-
evaporation/

46
Example: Diamond Coatings
 Substrates:
 Metals, ceramics, plastics
 Deposition processes:
 CVD, plasma-assisted chemical vapour
deposition, ion-beam enhanced deposition
 Examples of applications:
https://www.vin.bg.ac.rs/050/images/Laseri/Sl.3.jpg

 scratchproof windows, sunglasses, cutting tools,

surgical knives, razors, fuel-injection nozzles,
sensors
 Freestanding diamond films (~1mm thick)
can be laser cut to desired shapes and
brazed onto cutting tools
 Also used in MEMS devices due to its
favourable friction and wear characteristics http://www.diamondtc.com/toolscoated/end
mills_tooltest.html

47
Example: Diamond-like Carbon (DLC) Coatings
 A few nanometers in thickness produced by a low-
temperature (150-300°C) plasma-assisted CVD (PACVD) and
ion-beam-enhanced deposition processed (IBED)
 Less expensive than diamond coatings but with similar
properties
 High hardness, low friction, chemical inertness, smoothness
 Examples of applications:
 Tools, dies, bearings, MEMS, engine components

http://mustangvac.com/applications/tribological/dlc/ http://www.hefusa.net/pvd_coating/DLC-coatings.html

48
 Ion Implantation and Diffusion Coatings
Purpose
Introduction of foreign atoms or ions into top surface layer

Ion Implantation Diffusion Coatings

 Accelerated foreign ions implant  Foreign atoms diffuse into surface
into surface in vacuum  Atoms from solids, liquids, gasses
 Very thin (<1µm)  Depth depends on diffusion time
 Room temperature process  High temperature process
 Improved resistance to friction,
wear, corrosion
 Change in electronic properties
 Precise process, masking often
used

49
 Ion Implantation
 Ions (charged atoms) are accelerated and
implanted into substrate
 Altered layer < 1µm
 Used on cutting and forming tools, dies and
moulds and metal prostheses
 Doping process for semiconductors
 Advantages:
 Room temperature process en.wikipedia.org/wiki/Ion_implantation
 Good control of ions density; good
reproducibility;
 Gradual interface
 Disadvantages:
 Damage to the crystal structure
 Line of sight deposition
 Expensive http://www.thin-film.de/en/technology/pbii-plasma-based-ion-implantation.html

50
 Diffusion Coating (Thermal)
 Alloying elements are diffused Example:
into the surface of the substrate Cr and Al coating on Ni superalloy
and alter its surface properties:
 Precursor form: solid, liquid, 30%Cr; 8%Al
gaseous
NiAl + Cr precipitates
 Concentration of foreign atoms
decreases with depth Cr-rich

 Typical applications: Ni superalloy

 Surface hardening: carburizing,
nitriding, boronizing
 Doping of semiconductors (now
usually superseded by ion
implantation) http://www.poweronline.com/doc/chromium-aluminum-diffusion-coating-0001

 Increasing corrosion resistance:

Aluminizing, siliconizing

51
 Thin Coatings
CVD, PVD, Ion implantation, Diffusion
Useful links
1. https://www.efunda.com/processes/surface/thinfilm_coatings.cfm
2. http://www.csiro.au/en/Research/MF/Areas/Chemicals-and-
fibres/Materials-for-industry-and-environment/Coatings-and-
surfaces/Thin-film-coating-technologies

52
 Electroplating, Electroless Plating and
Electroforming
 Thickness 1-500 µm Electroplating
 Substrates  Electrolytic Deposition
 Substrate conductive
 Metallic, ceramic, polymeric
 Properties Electroless Plating
 Resistance to corrosion  Chemical reaction without
 Resistance to wear external electricity
 High electrical conductivity  All substrates
 Better appearance
 Reflectivity Electroforming
 Principle similar to electroplating
 Thick coating becomes the formed
part

53
 Electroplating (Electrochemical plating)
 The workpiece (cathode) is plated with a different metal (Cr, Cu, Ni,
Cd, Zn, Sn, Ag) from salt solutions or sacrificial anode
 1-500 µm
 Metal at the anode is oxidized; positive metal ions in solution are
attracted to the cathode where they reduce forming a coating
 Long process, slow deposition rate
Volume = ECIt

V= plated volume [mm3]

I = current [A]
t = time
C = constant
E = cathode efficiency

[Ref 1]
Process of electroplating Cu Electroplated parts
54
 Electroplating Characteristics
 3 main methods of electroplating:
Problems
 Rack plating (large, heavy parts)
 Barrel plating (small parts in a batch)
 Reel-to-reel (coil material)
 Typical examples:
 Chromium plating (chrome plate) is done by
plating the metal with copper, nickel and Uneven plating of sharp corners
chromium
 Hard chromium (~50µm)plating is done on
the base metal and results in a high surface
hardness (70HRC)
 Nickel plating for corrosion resistance and
decoration
 Zinc plating on steel for corrosion resistance
 Silver plating of electrical connections [Ref 1]

55
 Electroless Plating
 Plating by chemical reaction, no external current
 Most common electroless Ni plating (and its alloys Ni-P, Ni-
Co)
 Nickel chloride in solution reduced to Ni and deposited on substrate
 Can be subsequently heat treated to 1000HV
 Excellent wear and corrosion resistance
 Cavities, recesses, and inner surfaces can be plated
 Advantages over electroplating:
 Can be used with nonconductive materials (polymers, ceramics)
 Uniform thickness on complex part
 Disadvantages:
 Limited metals can be electroless plated : Ni, Cu, Ag, Au, Co
 More expensive than electroplating; very slow

56
 Electroforming
Mandrel or pattern
 Metal fabrication process
 Metal is electrodeposited on a
mandrel (mould, matrix or pattern)
 Mandrel is removed, coating becomes
the product
 Thickness higher than electroplating
 Slow process Steps in electroforming
 Production rates can be increased using
multiple mandrels
 Used for aerospace, electronics, and
electro-optics applications
 Moulds for CDs and DVDs, Cu foil

[Ref 1]

57
 Conversion Coatings
Chemical-reaction priming
 Process of producing a non-metallic compound coating that
grows on metal surfaces as a result of chemical or
electrochemical reaction
 2 common methods of coating are:
 Chemical treatments (Immersion, spraying)
 Electrochemical treatments (Anodizing)
 Phosphates, chromates and oxalates are used to produce
chemical conversion coatings
 Chromates<0.0025mm, on Al, Mg, Zn, Cu
 Phosphates 0.0025-0.05 mm, on steel and Zn
 Corrosion protection, pre-painting, decoration, lubricant carrier
 Equipment depends on the method of application, the type of
product and quality considerations
58
 Anodizing
 Anodic oxidation (electrochemical)
process
 Workpiece (anode) surface converted to
a hard and porous oxide layer
 Corrosion resistance, decorative finish,
base for painting
 Thickness 0.0025-0.075mm http://www.globalspec.com/learnmore/contract_manufacturing_fabr
ication/coating_services_finishing_services/cleaning_surface_prepara

 Hard anodizing - thick (up to 0.25mm)

tion_services

oxide on aluminium (Al)

 Typical substrates:
 Al and magnesium; also used for titanium
and zinc
 Typical applications:
 Al furniture and utensils, architectural
shapes, automobile trim, keys, sporting Anodised Al Space station
goods trusses and handrails
http://www.anodizing.org/Anodizing/applications.html
59
 Colouring
 Altering the colour of metals, alloys
and ceramics using conversion
coatings
 Surfaces are converted into
coloured compounds (oxides,
chromates, phosphates) by Coloured Anodised Ti
chemical, electrochemical or http://www.danco.net/page-photos/TITANIUM-COLORS2.jpg

thermal means
 Examples:
 Blackening of iron and steels due to a
lustrous, black oxide film (magnetite)
on surfaces
 Coloured anodizing
Coloured Anodised Al
http://www.anodizing.org/Anodizing/environment.html

60
 Hot Dipping
 The workpiece is dipped
into a bath of molten metal
(see DVD)
 Common coating metals:
 Zn (galvanizing)
 Al (aluminizing)
 Sn (tinning)
 Pb-Sn (terne plate)
 Typical example:
 Galvanizing of steel pipes
and pluming supplies with
0.04-0.09 mm of Zn
 Long-term corrosion [Ref 1]

resistance Continuous hot-dipped galvanizing of sheet

steel (see also DVD)
61
 Plating and Conversion Coatings
Useful links
1. http://www.efunda.com/processes/surface/electroplatings.cfm
2. https://www.youtube.com/watch?v=OxhCU_jBiOA
3. http://nzic.org.nz/ChemProcesses/metals/8G.pdf
4. http://www.efunda.com/processes/surface/electrolessplatings.cfm
5. http://www.efunda.com/processes/surface/conversion_coatings.cfm

62
 Other Coatings

Ceramic (inorganic) Polymer (organic) Paints

 Oxides (e.g. Al2O3,  Polyurethane  Enamels
ZrO2)  Solid lubricants  Lacquers
 Porcelain Enamels (PTFE)  Water-based
Purpose Purpose Purpose
 Thermal protection  Corrosion  Chemical resistance
 Wear resistance resistance
 Appearance
 Electrical insulation  Abrasion resistance
 Abrasion resistance
 Chemical protection  Appearance
 Decorative

63
 Ceramic Coatings (inorganic)
 Applied by various techniques:
 Thermal spraying, PVD, CVD (see also relevant slides on the methods)
 Applications:
 Thermal barriers to hot-extrusion dies, turbine blades and diesel-engine
components
 Electrical insulators
 Wear resistant parts (especially at high temperatures)

[Ref 1]

64
 Porcelain Enamels
not included in Final Exam
 Glassy inorganic coatings that consist of various metal
oxides
 Applied to steel, cast iron, aluminium
 Enameling involves fusing the coating material to the
substrate by heating both of them at 425-1000°C
 Dipping, spraying, flow coating, electrodeposition
 0.075-2 mm thick
 Viscosity can be controlled using binders
 Process shown in DVD
 Applications:
 Protective coatings on jet-engine components, household
appliances, chemical-processing equipment
 Glazing is the glassy coating on ceramic wares
 Decorative finish, resistance to moisture
65
 Organic Coatings (Polymers)
not included in Final Exam
 Applied to metallic surfaces to improve appearance and
corrosion resistance
 Typical thickness 0.0025-0.2mm
 Coating properties:
 Flexibility, durability, hardness, resistance to abrasion and chemicals,
colour, texture, and gloss
 Applications:
 Appliance housings, shelving and panelling, gutters, metal furniture
 Also for protection of naval aircraft
 Coating example:
 Polyurethane coating with epoxy primer for aluminium structures

66
 Painting
not included in Mid Sem test
 Classification:
 Enamels
 Lacquers (film formed by solvent evaporation)
 Water-based paints
 Characteristics: good resistance to abrasion, temperature
extremes, fading, easy to apply and dry quickly
 Paint application: dipping, brushing, rolling, spraying

[Ref 1]

67
 Other Coatings
Useful links
1. http://www.porcelain-industries.com/porcelain-enameling-101
2. http://www.engineershandbook.com/MfgMethods/polyurethanecoa
tings.htm

68
 Industrial Cleaning of Surfaces

Types of cleaning Cleaning Fluids Purpose

methods  Alkaline  Surface
 Mechanical  Emulsions preparation for
 Electrolytic coating, painting
 Solvents
 Chemical  Reliable
 Hot vapours
functioning
 Acids, salts,
 Food safety
organic mixtures

69
 Cleaning of Surfaces
 Cleaning (industrial) involves the removal of solid, semisolid, or
liquid contaminants and residues from a surface
 Essential for:
 Effective application of coatings, painting, adhesive bonding, welding,
soldering
 Reliable functioning of parts; food and beverage containers
 Detrimental effects of cleaning:
 Increase tendency for adhesion and galling; enhanced corrosion
 2 simple and common tests for cleanliness:
 Wiping the surface and observing any residues on the white cloth
 Observing whether water continuously coats the surface of a plate

70
 Three Types of Cleaning Methods
1. Mechanical Cleaning (to remove rust, scale and other solids)
 Wire brush, abrasive or steam jets, tumbling or vibratory finishing with
abrasives
 De-burring and improving surface finish at the same time
2. Electrolytic Cleaning
 Cleaning by a scrubbing action of gas bubbles (H2, O2) evolving on the
surface (electrode)
3. Chemical Cleaning (to remove oil or grease; dissolve oxides)
 Solution (dirt dissolves in cleaning solution)
 Saponification (oil converted to water-soluble soap)
 Emulsification (dirt suspended in emulsion)
 Dispersion (concentration of dirt decreased by cleanser)
 Aggregation (dirt removed as large particles by cleanser)

71
 Common Cleaning Fluids
1. Alkaline solutions
 Least expensive, most widely used, spraying and rinsing with water;
remove oil and grease
2. Emulsions
 Kerosene and oil-in water; remove grease, wax, adhesives
3. Solvents (petroleum, chlorinated hydrocarbons)
 Hand-wiping, immersion, spraying; remove oil and grease
4. Hot vapours of solvents (chlorinated solvents)
 Known as vapour degreasing; remove oils and grease
5. Acids, salts, and mixtures of organic compounds solutions
 Remove oils, scale and rust

Treatment and disposal of cleaning fluids are very important

considerations for environmentally safe manufacturing operations,
minimizing pollution and health hazards.
72
 DVDs
1. Plating and Surface Coatings, Fundamental Manufacturing
Processes, SME DVD
 Robertson Library, AV 667.9 PLA (Level 2 Reserve – High Demand)
 Script and Study Guide at
https://www.sme.org/ProductDetail.aspx?id=22323

2. Painting and Powder Coating, Fundamental Manufacturing

Processes, SME DVD
 Robertson Library, AV 667.9 PAI (Level 2 Reserve – High Demand)
 Script and Study Guide at
http://www.sme.org/ProductDetail.aspx?id=22203

73
 Textbook Reading
Serope Kalpakjian, Steven R Schmid, Manufacturing Engineering
and Technology, Robertson Library (Level 6, 670.42 KAL)
 7th edition (2014); Chapter 34, pp. 985-1006 (1 copy Level 2, Reserve
(High Demand), 670.42 KAL; 2 copies Level 6, 670.42 KAL)
 6th edition (2010); Chapter 34, pp. 973-995
 5th edition (2006); Chapter 34, pp. 1059-1083

74
 References (in lecture slides)
1. S. Kalpakjian, S.R. Schmid, Manufacturing Engineering and
Technology, 6th ed., Pearson Prentice Hall, 2010.

75