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1. Surface Engineering Introduction

2.  What is Surface Engineering
 Surface engineering is the sub-discipline of materials science which deals with the surface of solid matters.
 Solids are composed of a bulk materials covered by surface. The surface which bounds the bulk material is
called the surface phase.
 The surface phase of a solid interacts with the surrounding environment this interaction can degrade the
surface phase over time.
 Surface engineering involves altering the properties of the surface phase in order to reduce the degradation
over time.
 This is an accomplished by making the surface robust to the environment in which it will be used.
 Surface engineering refers to a wide range of technology designed to modify the surface properties of
metallic & non-metallic components for decorative or functional purpose.
 Include improving corrosion & wear resistance to extend component
life making items more visually attractive & giving special properties
such as lubricity enhancement, non-stick surface etc.
INTRODUCTION

3.  History
 Surface engineering can be traced as far back as Thomas Edison in 1900 with the planting of
gold films.
 In 1983 Berghaus was among the 1st to develop plasma & ion modification of surface to
improve surface properties & surface vacuum deposited coatings.
 The ion planting process developed in the early 1960’s was a significant step forwarding in
plasma assisted coated deposition.
 Ion planting was the 1st true industrial surface engineering process.
 After the early 1970’s the history of surface engineering intimately connected to the
development of thin film deposition & plasma processes.

4.  An engineering component usually fails when its surface cannot adequately withstand the
external forces or environment to which it is subjected.
 The choice of a surface material with the appropriate thermal, optical, magnetic and
electrical properties & sufficient resistance to wear, corrosion & degradation is crucial to its
functionality.
 Improving the functionality of an existing product is only one aim of surface engineering.
 Surface engineering, provides additional functionality to solid surfaces, involves structures
and compositions not found naturally in solid, is used to modify the surface properties of
solids, and involves application of thin film coating, surface functionalization and
activation, and plasma treatment.
WHY SURFACE ENGINEERING

5. Surface modification processes are applicable to control friction, improve surface wear and corrosion
resistance and change the physical or mechanical properties of the component.
 The Traditional
 Painting
 Electroplating
 Galvanizing
 Thermal and plasma spraying
 Advanced coating technologies
 Physical vapor deposition (PVD)
 chemical vapor deposition (CVD)
 Ion implantation
 Ion-beam assisted deposition (IBAD)
 Ion-beam mixing
 Laser treatment
SURFACE COATING PROCESS & TECHNIQUES

6.  The Traditional
• Painting:
 Painting is the practice of applying paint, pigment, color or other
medium to a surface.
 The medium is commonly applied to the base with a brush, but
other implements, such as knives, sponges, & airbrushes can be
used.
 The support for paintings includes such surfaces as walls, paper,
canvas, wood, glass, lacquer, clay, leaf, copper & concrete, and
the painting may incorporate multiple other materials sand, clay,
paper, plaster, gold leaf, as well as objects

7.  Electroplating:
 Electroplating is a process that uses electric current to
reduce dissolved metal cations so that they form a
coherent metal coating on an electrode.
 Electroplating is primarily used to change the surface
properties of an object but may also be used to build
up thickness on undersized parts or to form object by
electroforming
 The process used is electroplating is called
electrodeposition.

8. Technical Seminar Presentation 2017
Example:
• We want copper plating in iron.
• We have copper anode & Iron
cathode.
• And copper sulphate solution.
Types of coating:
Gold, Silver, Platinum, Rhodium,
Aluminum, Chromium, Tin, Nickel,
Tin-Lead, Copper

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• Galvanizing:
 Galvanization is the process of
protective zinc costing to steel
prevent rusting.
 The most common method
applying a
or iron, to
is hot-dip
galvanization, in which parts are submerged in
a bath of molten zinc.
Galvanizing protects in two way
 It forms a coating of corrosion resistance zinc
which prevents corrosive substances from
reaching the more delicate part of the metal.
 The zinc serves as a sacrificial anode so that
even if the coating is scratched, the exposed
steel will still be protected by the remaining
zinc.

10.  Thermal and plasma spraying:
 Thermal spraying techniques are coating processes in which
melted (or heated) material are sprayed onto a surface.
 The “feedstock” (coating precursor) is heated by electrical
(plasma or arc) or chemical process (combustion flame).
 Thermal spraying can provide thick coating (approx. 20
micrometers) over a large area at high deposition rate as
compared to other coating process such as electroplating,
physical, & chemical vapor deposition.
 Coating materials Alloys, Ceramics, Plastics & Composites

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Process:
 They are fed in powder or wire form,
heated to a molten or semi molten state and
accelerated towards substrates in the form of
micrometer-size particles.
Disadvantages of the plasma spray process
are relative high cost and complexity of
process.

12.  Advanced coating technologies
 Physical vapor deposition (PVD):
 A type of vacuum deposition process where a material is
vaporized in a vacuum chamber, transported atom by atom
across the chamber to the substrate, and condensed into a film
at the substrate’s surface.
 Hybrid physical-chemical vapor deposition (HPCVD) is a thin-
film deposition technique that combines physical vapor
deposition (PVD) with chemical vapor deposition (CVD).
 It is generally used to improve hardness, wear resistance &
oxidation resistance used in Aerospace, Automotive, Surgical,
Dies, & molds for all manner of material cutting tools, firearms,
optics & watches.

13.  Chemical vapor deposition (CVD):
 Chemical vapor deposition is a chemical
process used to produce high quality high
performance, solid materials.
 The process is often used in the
semiconductor industry to produce thin films.
 In typical CVD, the wafer (substrate) is
exposed to one or more volatile precursors,
which react and/or decompose on the
subtract surface to produce the desired
deposit frequently, volatile by-products are also
produced, which are remove by gas flow through
the reaction chamber.
 It is used in various forms including
Monocrystalline, polycrystalline, amorphous, and
epitaxial.

14. Parala
Maharaja
Engineering
College
Technical Seminar Presentation 2017

15.  Ion implantation:
 Ion implantation is a material engineering process by
which ions of a material are accelerated in an electrical
field and impacted into a solid.
 This process is used to change the physical, chemical,
or electrical properties of the solid.

16.  Ion-beam assisted deposition (IBAD):
 In ion-assisted deposition (IAD), the substrate is
exposed to a secondary ion beam operating at a
lower power than the sputler gun.
 NASA used this technique to experiment with
depositing diamond films on turbine blades in
1980’s.
 It is used in other important industrial application
such as creating tetrahedral amorphous carbon
surface coating on hard disk platters and hard
transition metal nitride coating on medical implants.

17.  Ion-beam mixing:
 Ion beam mixing is the atomic intermixing &
interface
during ion
alloying that can occur at the
separating two different materials
irradiation.
 It applied as a process for adhering two
multilayers, especially, a substrate & deposited
surface layer.

18.  Laser treatment:
 Laser coating, also refers as “laser cladding” or
“laser spraying” (Note: In this paper the process is
called laser coating), is an advanced coating
technology for improving surface properties of
various components & equipment.
 Laser coating are used to provide surface
resistance against abrasive, erosive & adhesive
wear, wet corrosion, high temp. Oxidation &
corrosion.

19.  Surface engineering techniques are being used in the automotive, aerospace, missile, power,
electronic, biomedical, textile, petroleum, petrochemical, chemical, steel, power, cement, machine
tools and construction industries including road surfacing.
 Almost all types of materials, including metals, ceramics, polymers, and composites can be coated
on similar or dissimilar materials. It is also possible to form coatings of newer materials (e.g., met
glass. beta-C3N4), graded deposits, multi-component deposits etc.
 Sports Industry Applications -Surface engineering of titanium oxide for motor sports has proved to
be an effective modification to optimize the properties of engine parts, thus enhancing the
performance of racing cars.
APPLICATION OF SURFACE ENGINEERING

20.  Lower manufacturing cost.
 Reduced life cycle cost.
 Extended maintenance intervals.
 Enhanced recyclability of materials.
 Reduced environmental impact.
Surface modification process are applicable to control friction, improve surface
wear and corrosion resistance, and change the physical or mechanical
properties of the component.
ADVANTAGES

21. CONCLUSION
 Surface engineering provides one of the most important means of engineering products
differentiation in terms of quality, performance and life-cycle cost.
 The surface characteristics of engineering material have a significant effect on the serviceability and
life of a component, thus it cannot be neglected in design Engineering environment are severe.
 Surface engineering can help dal with these circumstances to improve the service life, and to
enhance to overall performance of the component.
 In a word, surface engineering technology provides effective solution to extreme application.

22. REFERANCE
 Frainger, S., Blunt, J., Engineering Coatings – Design and Application, 2nd edition,Abington
Publishing, Abington, England, 1998.
 http://www.iom3.org/divisions/surface/secforesight.pdf.
 Cost of Corrosion, corrosion cost in USA, http://www.corrosioncost.com/. Accessed 20 March,
2004. [4] Bell, T., and Dong, H., “Surface engineered titanium: material of the 21st century” In:
Foresight in surface Engineering, Surface Engineering Committee of the Institute of Materials,
October 2000. Figure 15. Shearography fringe patterns of defects 13
 http://www.arrowprecision.co.uk/coatings1.html.
 Information Documents and Technical Specifications, Castolin Eutectic Company.
 John, V., Testing of Materials. Macmillan, London, 1992.
 Joenathan, C., Speckle Photography, Shearography, and ESPI. In P. K. Rastogi, ed. Optical
 Measurement Techniques and Applications, Attech House, pp.151- 182, 1997.
 Steinchen, W., Yang, L. X., Digital Shearography - Theory and Application of Digital Speckle
Pattern Shearing Interferometry. SPIE Press, Washington, USA, 2003.