SURFACE TREATMENT & COATING

UNIT 4 : SURFACE TREATMENT & COATING

4.1 INTRODUCTION

After a part is manufactured, some of its surfaces may have to be processed

further in order to ensure certain properties and characteristics. It may be
necessary to perform surface treatments in order to
 Improve resistance to wear, erosion, and indentation (in machine-tool
ways, wear surfaces of machinery, and shafts, rolls, cams, and gears).
 Control friction (on the sliding surfaces of tools, dies, bearings, and
machine ways).
 Reduce adhesion (electrical contacts).
 Improve lubrication (surface modification to retain lubricants).
 Improve resistance to corrosion and oxidation (on sheet metals for
automobiles, gas turbine components, and medical devices).
 Improve fatigue resistance (bearings and shafts with fillets).
 Rebuild surfaces on worn components (worn tools, dies, and machine
components).
 Modify surface texture (appearance, dimensional accuracy, and
frictional characteristics).
 Impart decorative features (colour).

This chapter describes the methods used to modify the surface's structure,
properties, and textures in order to impart desirable characteristics. We begin
with surface hardening techniques, which involve mechanical or thermal
means, and continue with descriptions of different types of coatings that are
applied to surfaces using various means.

Finally, we describe techniques used to clean manufactured surfaces before

the components are processed further and are assembled, and before the
product is placed in service. Environmental considerations regarding the
fluids used and the waste material from various surface treatment processes
are one of the important factors we will also consider.

BPLK 66 DMV 4242

SURFACE TREATMENT & COATING

4.2 LEARNING OUTCOMES

After completing the unit, students should be able to:
1. State the reasons for surface treatment and coating
2. Describe surface treatments and coatings methods.
3. Distinguish case hardening to hard facing
4. Explain thermal spraying processes and types
5. Describe two major vapour deposition processes
6. Explain the working principle of ion implantation
7. Explain the reason and types of plating
8. Describe anodizing, conversion coating and hot dipping processes
9. Describe porcelain enamelling, ceramic coatings and organic coatings
processes

BPLK 67 DMV 4242

SURFACE TREATMENT & COATING

4.3 MECHANICAL SURFACE TREATMENT AND COATING

Reason: to mechanically improve the surface properties of finished com-
ponents. Common method of mechanical surface treatment and coating are:

4.3.1 SHOT PEENING

 the workpiece surface is hit repeatedly with a large number of
cast steel, glass, or ceramic shot (small balls),
 which make overlapping indentations on the surface. This
action causes plastic surface deformation, at depths up to 1.25
mm, using shot sizes that range from 0.125 mm to 5 mm in
diameter.
 Because the plastic deformation is not uniform throughout the
part's thickness, shot peening causes compressive residual
stresses on the surface, thus improving the fatigue life of the
component.
 This process is used extensively on shafts, gears, springs, oil-
well drilling equipment, and jet-engine pans (such as turbine
and compressor blades).

4.3.2 WATER-JET PEENING

 relatively new process,
 a water jet at pressures as high as 400 MPa impinges on the
surface of the workpiece,
 inducing compressive residual stresses and surface and
subsurface hardening at the same level as in shot peening.
 The water-jet peening process has been used successfully on
steels and aluminum alloys.
 The control of process variables (jet pressure, jet velocity, and
the design of the nozzle and its distance from the surface) is
important in order to avoid excessive surface roughness and
surface damage.

4.3.3 LASER PEENING

 developed in the early 1990s,
 the workpiece surface is subjected to laser shocks from high-
powered lasers.
 This surface-treatment process produces compressive residual
stress layers that are typically 1 mm deep.
 applied successfully to jet-engine fan blades and materials
such as titanium and nickel alloys.
 Laser intensities necessary for this process are on the order of
100 to 300 J/cm2, and have a pulse duration of about 30
nanoseconds.
 limitation of this process for industrial, cost-effective
applications is the expense of high-power lasers (up to 1 kW)
that must operate at energy levels of 100 J/pulse.

BPLK 68 DMV 4242

SURFACE TREATMENT & COATING

4.3.4 ROLLER BURNISHING

 also called surface rolling,
 the surface of the component is cold-worked by a hard and
highly polished roller or rollers
 This process is used on various flat, cylindrical or conical
surfaces (Figure 4.1 and 4.2).
 Roller burnishing improves surface finish by removing
scratches, tool marks, and pits.
 Consequently, corrosion resistance is also improved, since
corrosive products and residues cannot be entrapped.

FIGURE 4.1 Roller burnishing of the fillet of a stepped shaft

to induce compressive surface residual stresses for improved
fatigue life.

FIGURE 4.2 Examples of roller burnishing of (a) a conical

surface and (b) a flat surface and the burnishing tools used.
Source: Sandvik, Inc.

Internal cylindrical surfaces are burnished by a similar process, called

ballizing or ball burnishing. A smooth ball, slightly larger than the
bore diameter, is pushed through the length of the hole.

Roller burnishing is used to improve the mechanical properties of

surfaces, as well as their surface finish. It can be used either by itself
or in combination with other finishing processes, such as grinding,
honing, and lapping. All types of metals, soft or hard, can be roller-
burnished. Roller burnishing is typically used on hydraulic-system
components, seals, valves, spindles, and fillets on shafts.

BPLK 69 DMV 4242

SURFACE TREATMENT & COATING

4.3.5 EXPLOSIVE HARDENING

 the surfaces are subjected to high transient pressures through
the placement and detonation of a layer of explosive sheet
directly on the workpiece surface.
 The contact pressures that develop as a result can be as high
as 35 GPa, and can last about 2-3 µS.
 Major increases in surface hardness can be affected using this
method, with very little change (less than 5%) in the shape of
the component.
 Railroad rail surfaces can be hardened by this method.

4.3.6 CLADDING (CLAD BONDING)

 metals are bonded with a thin layer of corrosion-resistant metal
through the application of pressure, using rolls or other means.
 A typical application is cladding of aluminum (Alclad), in which
a corrosion-resistant layer of aluminum alloy is clad over
aluminum-alloy body (core), usually in sheet or tubular form.
 The cladding layer is anodic to the core and usually has a
thickness which is less than 10% of the total thickness;
examples are as follows:
a. 2024 aluminum clad with 1230 aluminum.
b. 3003, 6061, and 7178 aluminum clad with 7072
aluminum.
 Other applications are steels clad with stainless steel or nickel
alloys. The cladding material may also be applied using dies
(as in cladding steel wire with copper) or explosives. Multiple-
layer cladding is also utilized in special applications (Figure
4.3)

FIGURE 4.3 Schematic illustration of the roll bonding, or

cladding process

BPLK 70 DMV 4242

SURFACE TREATMENT & COATING

4.3.7 MECHANICAL PLATING

 also called mechanical coating, impact plating, or peen plating
 fine metal particles are compacted over the workpiece
surfaces by glass, ceramic, or porcelain beads that are
propelled by rotary means.
 The process is used typically for hardened steel parts for
automobiles, with plating thickness usually less than
0.025 mm.

BPLK 71 DMV 4242

SURFACE TREATMENT & COATING

4.4 CASE HARDENING AND HARD FACING

Reason:
 to improve frictional and wear properties,
 resistance to indentation, erosion, abrasion, and corrosion
by thermal means and induces residual stresses on the surfaces

4.4.1 CASE HARDENING

 Traditional methods of case hardening (carburizing,
carbonitriding, cyaniding, nitriding, flame hardening, and
induction hardening) were described in Table 4.2.
 In addition to common heat sources (gas and electricity), a
laser beam can be used as a heat source in surface
hardening of both metals and ceramics.
 Principle - induces residual stresses on surfaces. The
formation of martensite during case hardening causes
compressive residual stresses on surfaces. Such stresses are
desirable because they improve the fatigue life of components
by delaying the initiation of fatigue cracks.

4.4.2 HARD FACING

 a relatively thick layer, edge, or point of wear-resistant hard
metal is deposited on the surface using any of the welding
techniques (cold welding, ultrasonic welding, friction welding,
resistance welding, explosion welding and diffusion bonding
(welding)).
 Numerous layers are usually deposited (weld overlay).
 Hard coatings of tungsten carbide, or chromium and
molybdenum carbides, can also be deposited using an electric
arc (spark hardening).

Hard-facing alloys can be used as electrodes, rod, wire, or powder.

Typical applications for these alloys are valve seats, oil-well drilling
tools, and dies for hot metalworking. Worn parts are also hard-faced
for extended use.

BPLK 72 DMV 4242

SURFACE TREATMENT & COATING

TABLE 4.1 Outline of heat treatment processes for surface hardening

BPLK 73 DMV 4242

SURFACE TREATMENT & COATING

4.5 THERMAL SPRAYING

In thermal spraying processes, coatings (various metals and alloys,
carbides, and ceramics) are applied to metal surfaces by a spray gun with
a stream of oxyfuel flame, electric arc, or plasma arc. The coating
material can be in the form of wire, rod, or powder, and the droplets or
particles impact the surfaces at speeds in the range of 100 to 1200 m/s.

The surfaces to be sprayed are first cleaned and roughened to improve

bond strength (which depends on the particular process and techniques
used). The coating has a layered structure of deposited material, and may
have porosity (as high as 20%) due to entrapped air and oxide particles
because of the high temperatures involved.

The earliest applications of thermal spraying (in the 1910s) involved metals;
hence, the term metallizing has also been used. Typical applications
include aircraft engine components (such as in rebuilding worn parts),
structures, storage tanks, tank cars, rocket motor nozzles, and components
which require resistance to wear and corrosion.

BPLK 74 DMV 4242

SURFACE TREATMENT & COATING

FIGURE 4.4 Schematic illustrations of thermal spray operations, (a)

Thermal wire spray, (b) Thermal metal-powder spray, (c) Plasma
spray.

There are several types of thermal spraying processes:

a. Thermal wire spraying (Figure 4.4a), in which the oxyfuel flame melts
the wire and deposits it on the surface. Its bond is of medium strength,
but the process is relatively inexpensive.
b. Thermal metal-powder spraying (Figure 4.4b), similar to (a) but using
metal powder instead of the wire, (see also Chapter 3).
c. Plasma, either conventional, high-energy, or vacuum (Figure 4.4c). It
produces temperatures on the order of 8300 °C, and results in very
good bond strength with very low oxide content.
d. Detonation gun, in which a controlled explosion takes place using an
oxyfuel gas mixture. The detonation gun has a performance similar to
that of plasma.
e. High-velocity oxyfuel gas spraying (HVOF), which produces a similarly
high performance as the detonation gun, but is less expensive.
f. Wire arc, in which an arc is formed between two consumable wire
electrodes. The bond has bond strength and the process is the least
expensive.

BPLK 75 DMV 4242

SURFACE TREATMENT & COATING

4.6 VAPOR DEPOSITION

Vapor deposition is a process in which the substrate (workpiece surface) is
subjected to chemical reactions by gases that contain chemical
compounds of the material to be deposited. The coating thickness is
usually a few µm, which is much less than the thicknesses that result from
the techniques described in section 4.2 and 4.3.

The deposited materials can consist of metals, alloys, carbides, nitrides,

borides, ceramics, or oxides. Control of coating composition, thickness, and
porosity are important. The substrate may be metal, plastic, glass, or paper.
Typical applications for vapor deposition are the coating of cutting tools,
drills, reamers, milling cutters, punches, dies, and wear surfaces.

There are two major vapor deposition processes:

 physical vapor deposition and
 chemical vapor deposition.

4.6.1 PHYSICAL VAPOR DEPOSITION

The three basic types at physical vapor deposition (PVD) processes

are
(a) vacuum or arc evaporation,
(b) sputtering, and
(c) ion plating.

These processes are carried out in a high vacuum and at

temperatures in the range of 200 °C - 500 °C. In physical vapor
deposition, the particles to be deposited are carried physically to the
workpiece, rather than carried by chemical reactions, as in chemical
vapor deposition.

Vacuum evaporation.
 the metal to be deposited is evaporated at a high temperature
in a vacuum and is deposited on the substrate, which is
usually at room temperature or slightly higher.
 Coatings of uniform thickness can be deposited, even on
complex shapes.
 In arc evaporation (PV/ARC), the coating material (cathode)
is evaporated by several arc evaporators (Figure 4.5), using
highly localized electric arcs.
 The arcs produce highly reactive plasma which consists of
ionized vapor of the coating material.
 The vapor condenses on the substrate (anode) and coats it.

Applications for this process are both functional (oxidation-resistant

coatings for high temperature applications, electronics, and optics)
and decorative (hardware, appliances, and jewellery).

BPLK 76 DMV 4242

SURFACE TREATMENT & COATING

FIGURE 4.5 Schematic illustration of the physical deposition

process. Source: Cutting Tool Engineering.

Sputtering.
 an electric field ionizes an inert gas (usually argon).
 The positive ions bombard the coating material (cathode) and
cause sputtering (ejecting) of its atoms.
 These atoms then condense on the workpiece, which is
heated to improve bonding (Fig. 4.6).

FIGURE 4.6 Schematic illustration of the sputtering process.

Source: ASM International.

BPLK 77 DMV 4242

SURFACE TREATMENT & COATING

In reactive sputtering,
 the inert gas is replaced by a reactive gas, such as oxygen, in
which case the atoms are oxidized and the oxides are
deposited.
 Carbides and nitrides are also deposited by reactive
sputtering.
 Very thin polymer coatings can be deposited on metal and
polymeric substrates with a reactive gas, causing polymer-
ization of the plasma.

Radio-frequency (RF) sputtering is used for nonconductive

materials such as electrical insulators and semiconductor devices.

Ion plating
 is a generic term that describes the combined processes of
sputtering and vacuum evaporation.
 An electric field causes a glow discharge, generating plasma
(Figure 4.7). The vaporized atoms in this process are only
partially ionized.

FIGURE 4.7 Schematic illustration of an ion-plating apparatus.

Source: ASM International.

Dual ion-beam assisted deposition

 is a recently-developed hybrid coating technique that
combines physical vapor deposition with simultaneous
ion-beam bombardment.
 This technique results in good adhesion on metals, ceramics,
and polymers. Ceramic bearings and dental instruments are
examples of its applications.

BPLK 78 DMV 4242

SURFACE TREATMENT & COATING

4.6.2 CHEMICAL VAPOR DEPOSITION

Chemical vapor deposition (CVD) is a thermochemical process

(Figure 4.8). In a typical application, such as coating cutting tools with
titanium nitride (TiN), the tools are placed on a graphite tray and
heated to 950°C - 1050°C at atmospheric pressure in an inert
atmosphere. Titanium tetrachloride (a vapor), hydrogen, and nitrogen
are then introduced into the chamber. The chemical reactions form
titanium nitride on the tool surfaces. For a coating of titanium carbide,
methane is substituted for the gases.

FIGURE 4.8 Schematic illustration of the chemical vapor deposition

process.

Deposited coatings are usually thicker than those obtained using PVD.
A typical cycle for CVD is long, consisting of
(a) three hours of heating,
(b) four hours of coating, and
(c) six to eight hours of cooling to room temperature.

The thickness of the coating depends on the

(a) flow rates of the gases used,
(b) the lime, and
(c) the temperature.

The types of coatings and workpiece materials allowable are fairly

unrestricted in CVD. Almost any material can be coated and any
material can serve as a substrate, although bond strength may vary.
The CVD process is also used to produce diamond coatings (Section
4.13) without using binders, unlike polycrystalline diamond films,
which use 1% to 10% binder materials.

A recent development in chemical vapor deposition is medium-

temperature CVD (MTCVD). This technique results in a higher
resistance to crack propagation than CVD coatings.

BPLK 79 DMV 4242

SURFACE TREATMENT & COATING

4.7 ION IMPLANTATION

Principle:
 ions (charged atoms) are introduced into the surface of the workpiece
material.
 The ions are accelerated in a vacuum to such an extent that they
penetrate the substrate to a depth of a few µm.
 Ion implantation (not to be confused with ion plating) modifies surface
properties by increasing surface hardness and improving resistance to
friction, wear, and corrosion.
 This process can be accurately controlled, and the surface can he
masked to prevent ion implantation in unwanted locations.

Application:
 effective on materials such as aluminum, titanium, stainless steels,
tool and die steels, carbides, and chromium coatings.
 This process is typically used on cutting and forming tools, dies and
molds, and metal prostheses such as artificial hips and knees.
 When used in specific applications, such as semiconductors (Chapter
5), this process is called doping, meaning alloying with small amounts
of various elements.

4.8 DIFFUSION COATING

Diffusion coating is a process in which an alloying element is diffused into the
surface of the substrate, thus altering its properties. The alloying elements
can be supplied in solid, liquid, or gaseous states. This process has different
names, depending on the diffused element (as can be seen in Table 4.2.
which describes the diffusion processes of carburizing, nitriding, and
boronizing).

BPLK 80 DMV 4242

SURFACE TREATMENT & COATING

4.9 ELECTROPLATING, ELECTROLESS PLATING, AND

ELECTROFORMING
Plating, as with other coating processes, imparts the properties of resistance
to wear and corrosion, high electrical conductivity, and better appearance and
reflectivity, as well as similar desirable properties.

4.9.1 ELECTROPLATING

In electroplating, the workpiece (cathode) is plated with a different metal

(anode), while both are suspended in a bath containing a water-base
electrolyte solution (Figure 4.9).

FIGURE 4.9 Schematic illustration of the electroplating process.

Although the plating process involves a number of reactions, basically the

process consists of the following:
1) The metal ions from the anode are discharged using the potential
energy from the external source of electricity,
2) The metal ions combine with the ions in the solution, and
3) They are deposited on the cathode.

Chemical cleaning and degreasing and thorough rinsing of the workpiece

prior to plating are essential. The parts are placed on racks or in a barrel
(bulk plating) and lowered into the plating bath. All metals can be
electroplated; electroplate thicknesses range from a few atomic layers to
a maximum of about 0.05 mm. Complex shapes may have varying plating
thicknesses. Some design guidelines for electroplating are shown in
Figure 4.10.

BPLK 81 DMV 4242

SURFACE TREATMENT & COATING

FIGURE 4.10 (a) Schematic illustration of nonuniform coatings (exaggerated) in

electroplated parts, (b) Design guidelines for electroplating. Note that sharp
external and internal corners should be avoided for uniform plating thickness.
Source: ASM International.

Chromium, nickel, cadmium, copper, zinc, and tin are common plating
materials. Chromium plating is done by plating the metal, first with
copper, then with nickel, and finally with chromium. Hard chromium
plating is done directly on the base metal and results in a hardness of
up to 70 HRC. This method is used to improve the resistance to wear
and corrosion of tools, valve stems, hydraulic shafts, and diesel- and
aircraft-engine cylinder liners—and it is also used to rebuild worn
parts.

Electroplating is used in copper-plating aluminum wire and phenolic

boards for printed circuits, chrome-plating of hardware, tin-plating
copper electrical terminals (for ease of soldering), and components
that require resistance to wear and corrosion and a good appearance.
Metals such as gold, silver, and platinum are important electroplating
materials in the electronics and jewelry industries.

Plastic such as ABS, polypropylene, polysulfone, polycarbonate,

polyester, and nylon can also be electroplating substrates. Because
they are not electrically conductive, plastics must be preplated using
such processes as electroless nickel plating (Section 4.8). Parts to be
coated may be simple or complex, and size is not a limitation.

BPLK 82 DMV 4242

SURFACE TREATMENT & COATING

4.9.2 ELECTROLESS PLATING

Electroless plating is done by chemical reaction and without the use of

an external source of electricity. The most common application utilizes
nickel, although copper is also used.

In electroless nickel plating,

1. nickel chloride (a metallic salt) is reduced, using sodium
hypophosphate as the reducing agent, to nickel metal,
2. which is then deposited on the work-piece.
3. The hardness of nickel plating ranges between 425 HV and
575 HV, and can subsequently be heat-treated to 1000 HV.
4. The coating has excellent wear and corrosion resistance.
5. Cavities, recesses, and the inner surfaces of tubes can be
plated successfully.
6. This process can also be used with nonconductive materials,
like plastics and ceramics.

Electroless plating is more expensive than electroplating. However,

unlike that of electroplating, the coating thickness of electroless plating
is always uniform (see Figure 4.10).

4.9.3 ELECTROFORMING
 Is a variation of electroplating which actually is a metal
fabricating process
 Metal is electrodeposited on a mandrel (also called mold or
matrix), which is then removed;
 thus, the coating itself becomes the product.
 Both simple and complex shapes can be produced by
electroforming with wall thicknesses as small as 0.025 mm.
 Parts may weigh from a few grams to as much as 270 kg.
 Production rates can be increased through the use of multiple
mandrels.

Mandrels
 are made from a variety of materials: metallic (zinc or
aluminum) or non-metallic (which can be made electrically
conductive with the proper coatings).
 should be able to be physically removed without damaging the
electroformed part.
 They may also be made of low-melting alloys, wax, or plastics,
which can be melted away or dissolved with suitable
chemicals.

The electroforming process is particularly suitable for low production

quantities or intricate parts (such as molds, dies, waveguides,
nozzles, and bellows) made of nickel, copper, gold, and silver. It is
also suitable for aerospace, electronics, and electrooptics
applications.

BPLK 83 DMV 4242

SURFACE TREATMENT & COATING

4.10 ANODIZING

 is an oxidation process (anodic oxidation) in which the workpiece

surfaces are converted to a hard and porous oxide layer that provides
corrosion resistance and a decorative finish.
 The workpiece is the anode in an electrolytic cell immersed in an acid
bath, which results in chemical adsorption of oxygen from the bath.
 Organic dyes of various colors (typically black, red, bronze, gold, or
gray) can be used to produce stable, durable surface films.

Typical applications for anodizing are aluminum furniture and utensils,

architectural shapes, automobile trim, picture frames, keys, and sporting
goods. Anodized surfaces also serve as a good base for painting, especially
on aluminum, which otherwise is difficult to paint.

4.11 CONVERSION COATING

 also called chemical reaction priming
 is the process of producing a coating that forms on metal surfaces as
a result of chemical or electrochemical reactions.
 Various metals, particularly steel, aluminum, and zinc, can be
conversion-coated.
 Oxides that naturally form on their surfaces area form of conversion
coating.

Material used for coating:

 Phosphates,
 chromates, and
 oxalates.
Purposes
 corrosion protection,
 prepainting and
 decorative finish.
Application
 to serve as lubricant carriers in cold forming operations.

The two common methods of coating are

 immersion and
 spraying.

The equipment required depends on the method of application, the type of

product, and quality considerations.

BPLK 84 DMV 4242

SURFACE TREATMENT & COATING

As the name implies, coloring involves processes that alter the color of
metals, alloys, and ceramics. It is caused by the conversion of surfaces (by
chemical, electrochemical, or thermal processes) into chemical compounds
such as oxides, chromates, and phosphates. An example is blackening of
iron and steels, a process that utilizes solutions of hot caustic soda and
results in chemical reactions that produce a lustrous, black oxide film on
surfaces.

4.12 HOT DIPPING

 workpiece (usually steel or iron) is dipped into a bath of molten metal,

 molten metal can be
o zinc (for galvanized-steel sheet and plumbing supplies),
o tin (for tinplate and tin cans for food containers),
o aluminum (aluminizing) and
o terne (lead alloyed with 10% to 20% tin).
 Hot-dipped coatings on discrete parts provide long-term corrosion
resistance to galvanized pipe, plumbing supplies, and many other
products.

A typical continuous hot-dipped galvanizing line for steel sheet is shown in

Figure 4.11.
 The rolled sheet is first cleaned electrolytically and scrubbed by
brushing.
 The sheet is then annealed in a continuous furnace with controlled
atmosphere and temperature and dipped in molten zinc at about
450 °C.
 The thickness of the zinc coating is controlled by a wiping action from
a stream of air or steam, called an air knife (similar to air-drying in car
washes).
 Proper draining, for the removal of excess coating materials, is
important.

The coating thickness is usually given in terms of coating weight per unit
surface area of the sheet, typically 150 to 900 g/m2. Service life depends on
the thickness of the zinc coating and the environment to which it is exposed.
Various precoated sheet steels are used extensively in automobile bodies.

BPLK 85 DMV 4242

SURFACE TREATMENT & COATING

FIGURE 4.11 Flowline for continuous hot-dip galvanizing of sheet steel.

The welder (upper left) is used lo weld the ends of coils to maintain
continuous material flow. Source: American Iron and Steel Institute.

BPLK 86 DMV 4242

SURFACE TREATMENT & COATING

4.13 PORCELAIN ENAMELING, CERAMIC COATING, AND

ORGANIC COATINGS

Reason coating with a variety of glassy (vitreous) coatings:

 to provide corrosion and electrical resistance,
 and to provide protection at elevated temperatures.
These coatings are usually classified as porcelain enamels, and generally
include enamels and ceramics. (The word enamel is also used for glossy
paints, indicating a smooth, hard coating.)

Porcelain enamels are glassy inorganic coatings that consist of various metal
oxides. Enameling, which was a fully developed art by the Middle Ages,
involves fusing the coating material to the substrate by heating them both to
425 °C-1000 °C to liquefy the oxides. The coating may be applied by dipping,
spraying, or electrodeposition and thicknesses are usually 0.05 mm-0.6 mm.
Depending on their composition, enamels have varying resistances to alkali,
acids, detergents, cleansers, and water: they are also available in various
colors.

Typical applications for porcelain enameling are for household appliances,

plumbing fixtures, chemical processing equipment, signs, cookware, and
jewelry. Porcelain enamels are also used as protective coatings on jet-engine
components. Metals coated are typically steels, cast iron, and aluminum.
Glasses are used as a lining, for chemical resistance, and the thickness is
much greater than that of enameling. Glazing is the application of glassy
coatings on ceramic wares to give them decorative finishes and to make them
impervious to moisture.

Ceramic coatings, such as aluminum oxide or zirconium oxide, are applied at

room temperature. using binders, to the substrate. Such coatings act as
thermal barriers, and have been applied (usually by thermal spraying
techniques) to hot extrusion dies, turbine blades, and diesel-engine
components, to extend life of these parts.

Metal surfaces can be coated or precoated with a variety of organic coatings,

films, and laminates to improve appearance, eye appeal, and corrosion
resistance. Coatings are applied to the coil stock on continuous lines, with
thicknesses generally of 0.0025 mm-0.2 mm.

Such coatings have a wide range of properties: flexibility, durability, hardness,

resistance to abrasion and chemicals, color, texture, and gloss. Coated sheet
metal is subsequently formed into various products, such as TV cabinets,
appliance housings, paneling, shelving, residential building siding, gutters,
and metal furniture.

More critical applications involve, for example, naval aircraft, which are
subjected to high humidity, rain, sea water, pollutants (such as from ship
exhaust stacks), aviation fuel, deicing fluids, and battery acid, and which are
also impacted by particles such as dust, gravel, stones, and deicing salts.

For aluminum structures, organic coatings consist typically of an epoxy primer

and a polyurethane topcoat, with a lifetime of four to six years. Primer

BPLK 87 DMV 4242

SURFACE TREATMENT & COATING

performance is an important factor in the durability of the coating;

consequently, a lot of research is being conducted to develop improved
coating materials.

Example 4.1: Ceramic Coatings for High Temperature Applications

Certain product characteristics, such as wear resistance and thermal and
electrical insulation (particularly at elevated temperatures), can be imparted
through ceramic coatings rather than imparting these properties to the base
metals or materials themselves. Selecting materials with such bulk properties
can be expensive and may not meet the structural strength requirements in a
particular application.

For example, a wear-resistance component does not have to be made

completely from a wear-resistant material, since the properties of only a thin
layer on its surface are relevant to wear. Consequently, coatings have
important applications. Table 4.3 shows various ceramic coatings and their
typical applications at elevated temperatures. These coatings may be applied
either singly or in layers, as is done in multiple-layer coated cutting tools;

TABLE 4.3 Various ceramic coatings and their typical application at

elevated temperature

BPLK 88 DMV 4242

SURFACE TREATMENT & COATING

4.14 DIAMOND COATING

The properties of diamond that are relevant to manufacturing engineering are
described as
 cutting-tool material, as a single crystal or in poly crystal line form
 abrasive in grinding wheels, for grinding hard materials
 dressing of grinding wheels (i.e., sharpening of the abrasive grains);
 dies for drawing wire less than 0.06 mm in diameter; and
 coatings for cutting tools and dies

Important advances have been made in the diamond coating of metals, glass,
ceramics, and plastics, using various techniques, such as chemical vapor
deposition (CVD), plasma-assisted vapor deposition, and ion-beam-enhanced
deposition.

Examples of diamond-coated products are:

 scratchproof windows (such as those used in aircraft and missile
sensors for protection against sandstorms),
 sunglasses,
 cutting tools (such as inserts, drills, and end mills),
 wear faces of micrometers and callipers, surgical knives, razors,
electronic and infrared heat seekers and sensors, light-emitting
diodes,
 diamond-coated speakers for stereo systems,
 turbine blades, and
 fuel-injection nozzles.

Techniques have also been developed to produce free-standing diamond

films on the order of 1 mm thick and up to 125 mm in diameter; these include
smooth, optically clear diamond film, unlike the hazy gray diamond film
formerly produced. The film is then laser cut to desired shapes and brazed
onto, for example, cutting tools.

The development of these techniques, combined with the important properties

of diamond (hardness, wear resistance, high thermal conductivity, and
transparency to ultraviolet light and microwave frequencies), have enabled
the production of various aerospace and electronic parts and components.

Studies are also continuing into the growth of diamond films on crystalline
copper substrate by the implantation of carbon ions. An important application
is in making computer chips (Chapter 5). Diamond can be doped to form n-
and p-type ends on semiconductors to make transistors, and its high thermal
conductivity allows closer packing of chips than would be possible with silicon
or gallium-arsenide chips, significantly increasing the speed of computers.

BPLK 89 DMV 4242

SURFACE TREATMENT & COATING

Diamond-Like Carbon
A more recent development is diamond-like carbon (DLC) coatings, a few
nanometers in thickness, which use a low-temperature, ion-beam-assisted
deposition process. Less expensive than diamond films but with similar properties
(such as low friction, high hardness, and chemical inertness, as well as a smooth
surface), DLC has applications in such areas as engine components, tools and
dies, gears, bearings, micro-electromechanical systems, and microscale probes.

BPLK 90 DMV 4242

SURFACE TREATMENT & COATING

4.15 SUMMARY
In this unit we have studied that
1. Surface treatment is an important aspect of all manufacturing
processes. It is used to impart specific physical and mechanical
properties, such as appearance, and corrosion, friction, wear and
fatigue resistance. Several techniques are available for modifying
surfaces.
2. The processes used include mechanical working and coating of
surfaces, heat treatment, deposition, plating, and coatings, such as
enamels, non- metallic materials, and paints.
3. Clean surfaces can be important in further processing and use of the
product (e.g., coating, painting, or welding). Cleaning can have a
significant economic impact on manufacturing operations. Various
mechanical and chemical cleaning methods may be utilized.

4.16 SELF TEST

1. State few reasons for surface treatment and coating
2. List common method of mechanical surface treatment and coating
3. Give the reason for case hardening and hard facing
4. List two major vapor deposition processes:
5. What is anodizing? How it is done?
6. Explain electroplating process. Sketch basic schematic of the
electroplating process.
7. List common applications of thermal spraying
8. Explain sputtering process with aid of diagram.
9. List the applications of Diamond Coating.
10. What is electroless plating? How it is done?

BPLK 91 DMV 4242

SURFACE TREATMENT & COATING

4.17 REFERENCES

Serope Kalpakjian, Steven R. Schmidt (2001). Manufacturing Engineering

and Technology, (4th Edition), state: Prentice Hall.
Mikell P. Groover (2002). Fundamentals of Modern Manufacturing Materials,
Processes, and Systems, (2nd Edition), state: John Wiley & Son, Inc.
John A. Schey, (year). Introduction to Manufacturing Processes, (3rd Edition),
state: Mc Graw Hill.
E. Paul Degarmo, J T. Black, Ronald A. Kohser (2003). Materials and
Processes in Manufacturing, (9th Edition), state: John Wiley & Son, Inc.

BPLK 92 DMV 4242

SURFACE TREATMENT & COATING

4.18 ANSWER
1. State few reasons for surface treatment and coating
 Improve resistance to wear, erosion, and indentation (in
machine-tool ways, wear surfaces of machinery, and
shafts, rolls, cams, and gears).
 Control friction (on the sliding surfaces of tools, dies,
bearings, and machine ways).
 Reduce adhesion (electrical contacts).
 Improve lubrication (surface modification to retain
lubricants).
 Improve resistance to corrosion and oxidation (on sheet
metals for automobiles, gas turbine components, and
medical devices).
 Improve fatigue resistance (bearings and shafts with
fillets).
 Rebuild surfaces on worn components (worn tools, dies,
and machine components).
 Modify surface texture (appearance, dimensional
accuracy, and frictional characteristics).
 Impart decorative features (colour).

2. List common method of mechanical surface treatment and coating

 Shot Peening
 Water-jet Peening
 Laser Peening
 Roller Burnishing
 Explosive Hardening
 Cladding
 Mechanical Plating

3. Give the reason for case hardening and hard facing

 to improve frictional and wear properties,
 resistance to indentation, erosion, abrasion, and
corrosion by thermal means and induces residual
stresses on the surfaces

4. List two major vapor deposition processes:

 physical vapor deposition and
 chemical vapor deposition

5. What is anodizing? How it is done?

Anodizing is an oxidation process (anodic oxidation) in which the
workpiece surfaces are converted to a hard and porous oxide
layer that provides corrosion resistance and a decorative finish.
During the process, workpiece is the anode in an electrolytic cell
immersed in an acid bath, which results in chemical adsorption
of oxygen from the bath.
Organic dyes of various colors (typically black, red, bronze, gold,
or gray) can be used to produce stable, durable surface films.

BPLK 93 DMV 4242

SURFACE TREATMENT & COATING

6. Explain electroplating process. Sketch basic schematic of the

electroplating process.
In electroplating, the workpiece is made cathode while the plating
metal is made anode.
Both are suspended in a bath containing a water-base electrolyte
solution as shown in figure below.

Schematic illustration of the electroplating process.

Due to chemical reaction:

1) The metal ions from the anode (plating metal) are discharged
using the potential energy from the external source of
electricity,
2) The metal ions combine with the ions in the solution, and
3) They are deposited on the cathode (workpiece).

7. List common applications of thermal spraying

Typical applications include aircraft engine components (such
as in rebuilding worn parts), structures, storage tanks, tank
cars, rocket motor nozzles, and components which require
resistance to wear and corrosion.

8. Explain sputtering process with aid of diagram.

 an electric field ionizes an inert gas (usually argon).
 The positive ions bombard the coating material (cathode)
and cause sputtering (ejecting) of its atoms.
 These atoms then condense on the workpiece, which is
heated to improve bonding (Fig. 4.6).

BPLK 94 DMV 4242

SURFACE TREATMENT & COATING

Schematic illustration of the sputtering process. Source: ASM

International

9. List the applications of Diamond Coating.

 scratchproof windows (such as those used in aircraft and
missile sensors for protection against sandstorms),
 sunglasses,
 cutting tools (such as inserts, drills, and end mills),
 wear faces of micrometers and callipers, surgical knives,
razors, electronic and infrared heat seekers and sensors,
light-emitting diodes,
 diamond-coated speakers for stereo systems,
 turbine blades, and
 fuel-injection nozzles.

10. What is electroless plating? How it is done?

Electroless plating is done by chemical reaction and without the
use of an external source of electricity. The most common
application utilizes nickel, although copper is also used.

In electroless nickel plating,

1. nickel chloride (a metallic salt) is reduced, using sodium
hypophosphate as the reducing agent, to nickel metal,
2. which is then deposited on the work-piece.
3. The hardness of nickel plating ranges between 425 HV and
575 HV, and can subsequently be heat-treated to 1000 HV.
4. The coating has excellent wear and corrosion resistance.
5. Cavities, recesses, and the inner surfaces of tubes can be
plated successfully.
6. This process can also be used with nonconductive materials,
like plastics and ceramics.

Electroless plating is more expensive than electroplating.

However, unlike that of electroplating, the coating thickness of
electroless plating is always uniform.

BPLK 95 DMV 4242