Surface treatments with respect automotive industry

1. Surface Treatment for Automotive
Components
Materials and Manufacturing Processes for Automobiles (AME 2513)
Module Leader Dr. Srikari S
Department Dept. of AAE
Santosh S BBB0912001
Pruthvi VJ BBB0912004
Bharath IG BBB0912005
Raj Bharath M BYB0912007
Submitted by : Rajbharath.M(BYB0912007)
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2. Introduction
Manufacturing
Surface
Treatment
Finished
Product
Figure 1: Different stages of product development [Author]
 Need for surface treatment
 Benefits of surface treatment
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3. Types of Surface Treatment
Surface
Treatment
Surface Surface  Surface hardening - Top surface layer
Hardening Coating infused with dopants.
 Surface coating - New layer is coated
Case hardening, Chemical vapour on the surface.
Mechanical deposition,
surface treatment. Plating.
Figure 2: Types of Surface Treatment [Author]
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4. Case Hardening
 Chemical structure manipulation by diffusing the atoms of
alternate elements.
 Different types includes:
Figure 3: Different case hardening techniques [1]
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5. Nitriding
 Nitrogen is diffused into the surface of the component being treated.
 Nitriding Temperature: 500-600°C [2]
 2NH3 ▲ 2N + 3H2 [2]
Figure 4: Schematic diagram of nitriding apparatus [2] Figure 5: Microstructure of nitrided component [3]
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6. Figure 6: Effect of case depth on hardness [4] Figure 7: Effect of nitriding time on case depth [2]
Process Capabilities [5]
 Nitriding was adopted to increase the
strength of the crank shaft.
Figure 8: Nitrided crank shaft [5]
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7. Carburizing
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8.  Carburization produces a hard, wear resistant layer on the surface.
 Typically, case hardens low carbon steel.
Figure 9: Carburizing process [6]
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9. Quenched microstructure [6]
Carbon Ferrite
Etching: Carburized gear
Figure 10: carbon diffusion [6]
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10. Applications
Fig 11: Carburized Steering Pinion [7] Hydraulic power steering
Fig 12: Carburized spur gear [13]
Transmission
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11. Induction hardening
Fig 14: Process overview [8]
Eddy current Fig 15: Quenching[12]
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12. Applications
Fig16:Simultaneous dual frequency
Fig 17: Sprocket – under induction hardening [10]
(SDF) – Green Hardening (for
gears). [9]
 Induction hardening is characterized by precise energy metering.
 Ultra low power consumption.
 Short process times.
 Targets surface layer alone.
 Save energy and reduce rework effort. SDF
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13. Mechanical Surface Treatment
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14. Shot Peening
 Overlapping indentations are produced on the surface.
 The surface of the component is plastically deformed, which induces
the compressive stress on the surface.
 Fatigue strength increases by 25% - 50%.
Figure 18 Shot peening Process [14]
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15. Case Study
Gear tooth Bending fatigue on a AXOD of Ford Taurus (1981)
Figure 19 Weibull analysis of Life v/s Failure [15]
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16. Laser Peening
 The surface of the work piece is subjected to laser shocks.
 As a result of which compressive stress is induced in the component,
thus improving the fatigue life.
 Specifications: Laser intensity - 100-300 J/cm2
Pulse duration - 30 seconds
Figure 20 Laser Peening Working [16]
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17. Case Study
Laser Peening emerging applications for Engine Components
 Reduce material cross-section and improve fuel efficiency.
 Retard erosion inside fuel injector tip and reduce emissions.
Fuel injector tip Figure 21 Comparison of Laser peening [17]
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18. Surface Coating
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19. Electroplating
 Electroplating is carried out to impart properties such as wear
resistance, corrosion resistance and other similar properties.
 Chromium, nickel, cadmium, copper, zinc and tin are commonly
plated materials.
 Anodizing, galvanizing, chrome plating.
Figure 22 : Chrome plating [18]
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20. Galvanization process
Figure 23: Galvanization process [19]
 Cathodic protection
Figure 24: Cathodic protection [20]
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21. Figure 25: Anti-corrosion treatment for BIW [21]
Anti-corrosion treatment for BIW
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22. Benefits / Enhancement
Possible enhancements in the components manufactured:
 Improved fatigue endurance limit.
 Better wear resistance.
 Higher strength.
 Ability to withstand bending loads for a longer time.
 Better corrosion resistance.
 Better surface finish delays crack propagation.
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23. Queries
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24. References
[1] Anon., Surface Treatment, Coating and Cleaning,
http://www.ielm.ust.hk/dfaculty/ajay/courses/ieem215/lecs/9_surfacetreatment.pdf,
retrieved on 29.12.2012.
[2] Kenneth G. Budinski and Michael K. Budinski., (2009) Engineering Materials: Properties
and Selection, 9th edition, Prentice Hall Publishers.
[3] Mumin Sahin, Ceyhun Sevil., (2011) "Investigation of properties of ion-nitrided AISI 304
austenitic-stainless steel", Industrial Lubrication and Tribology, Vol. 63 Iss: 5, pp.359 – 366.
[4] Anon., Heat Treatment Properties, http://www.tohokusteel.com/en/pages/kirin1.htm,
retrieved on 29.12.2012.
[5] Anon., Double the Strength, http://www.nitriding.co.uk/double-strength-please!,
retrieved on 29.12.2012.
[6] Hiroshi Yamagatta – “Science and technology of materials” [pg 180 onwards].
[7] “Hardness and case depth analysis through optimization techniques”
http://shodhganga.inflibnet.ac.in/bitstream/10603/1259/12/12_chapter%203.pdf
[8] Induction hardening - http://www.ustudy.in/node/4157
[9] Mark davis – “Gear hardening goes green”
http://www.eldec.de/fileadmin/00_Dateien/PDF/Veroeffentlichungen/0909_GearSolutions.p
df
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25. [10] Daewei hating machine co., ltd - http://www.dw-inductionheating.com/hardening-
induction-heating-applications.html/hardening-induction-heating, retrieved on
29.12.2012
[12] Industrial heating -
http://directories.industrialheating.com/Articles/Cover_Story/d08079c356cb7010Vgn
VCM100000f932a8c0, retrieved on 29.12.2012
[13] Thermex metal treating ltd - http://www.thermexmetal.com/carburizing-
carbonitriding, retrieved on 29.12.2012
[14] Mordern Mechanical Surface treatment.,(2006) Volker Schulze, Wiley-VCH
[15] Adam J. Vahratian, Robert P. Garibay., Application of Statistically capable Shot
Peening Automotive Components Design,
http://www.shotpeener.com/library/pdf/1993146.pdf, retrieved on 29.12.2012.
[16] Laser-assisted materials processing lab
https://engineering.purdue.edu/LAMPL/research_peening.html, retrived on
29.12.2012
[17] H.L.Chen, Lawrence Livermore National Laboratory , “Laser Peening - A Means
to Strengthen Metals”
[18] Anon., Chrome plating alternatives, http://www.rowantechnology.com/Tech-
Info.htm, retrieved on 30.12.2012
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26. [19] Anon., Zinc coatings and thin organic coatings, Coating process,
http://www.arcelormittal.com/automotive/saturnus/sheets/catalogue.pl?id_
sheet=N&language=EN, retrieved on 30.12.2012
[20] Anon., Zinc coatings protecting steels, Cathodic protection [pg. 7],
http://www.galvanizingasia.com/pdfs/ZincCoatingProtectingSteel.pdf,
retrieved on 30.12.2012
[21] Anon., “The inside story of how BMW's are made...” ,
http://www.usautoparts.net/bmw/bmw/assembly/painting.htm,
retrieved on 30.12.2012
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27. Thank You
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