2. Introduction
Surface modification of materials-
• Act of modifying the surface of a material by bringing physical,
chemical or biological characteristics different from the ones
originally found on the surface of a material.
• Simply, this process, affect either a thin layer on the surface of the
part itself, or add a thin layer on top of the surface of the part.
Why we use surface treatment?
• Improves hardness and durability
• Rebuild surface
• Controls friction, reduces, adhesion, improves lubrication
• Improves corrosion resistance
• Improves aesthetics(beauty)
3. Surface modification of material-
Types-
1) Mechanical hardening of the surface
2) Case Hardening
3) Thermal spraying
4) Vapor deposition
5) Electroplating
6) Electroless plating
7) Anodizing
8) Painting
4. Mechanical hardening of the surface-
Mechanical hardening of the surface is a surface treatment which
creates a plastically deformed strain hardened layer of material
itself, by the application mechanical impulses (e.g.- light
hammering).
This process include:-
a) Shot peening
b) Water peening
c) Laser peening
d) Explosive hardening
5. a) Shot peening-
(Uses tiny balls of metal or ceramic)
• The surface get plastically deformed.
• Make the surface harder.
6. b) Water jet peening-
(uses a jet of water at high pressures e.g.- 400MPa)
• Uses cavitation impacts in the same way as shot peening.
• Used to improve fatigue strength and/or to introduce compressive
residual stress.
• In the case of cavitation peening, cavitation is generated by
cavitating jet.
7. c) Laser peening-
(surface is hit by tiny impulses from a laser)
• 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.
• Specification-
Laser intensity- 100 to 300 J/cm2
Pulse duration- 30 sec
9. d) Explosive hardening-
(Layer of explosive roated on the surface is blasted)
• The explosion hardening technique can obviously increases the
hardness of metals by several plastic deformation caused by the
shock wave.
Explosive hardening application-
The most common application
of explosive shock hardening
is to cost high-mega steel rail
frogs and switching.
10. Case Hardening-
• Basically, the component is heated in an atmosphere containing
elements (such as C/N/B) that alter the component, microstructure
and properties of surface. (Doping)
• The duration and temperature control the concentration anddepth
of the doping.
• Mostly this process is used to harden steel and other iron alloys,
including low carbon steels, alloy steels, tool steels.
13. Thermal Spraying-
• Metal is melted in a specially designed spray gun.
(using oxy-fuel, plasma, or other means to heat the sprayed metal till
it melts)
• High pressure gas then sprays the liquid metal
• depositing a layer on top the part (similar to a painting process).
14. Types of thermal spraying-
A. Thermal wire spray
B. Thermal metal powder spray
C. Plasma spray
15. Thermal wire spray-
• The feed stock is in wire or rod form.
• Metal droplets atomized by air jets using acetylene or hydrogen,
which mixed with oxygen and burned at the nozzle's face.
• Coating texture- 200micro inch to 800micro inch
• Commonly sprayed materials- Zn,Al
16. Thermal metal powder spray-
• Powder feed instead of wire
• Oxyacetylene torch modified for powder feed
• No high pressure air to assist atomization: low deposition rate
• Easy method for materials that cannot be made into wire.
17. Plasma spray-
• The material to be deposited(feedstock) is introduced into the
plasma jet, emanating from a plasma torch.
• In the jet, where the temperature is of the order of 10,000K, the
material is melted and propelled towards a substrate.
• There, the molten droplets flatten, rapidly solidify and form a
deposit.
18. Vapor Deposition-
They are of two types-
1) Physical vapor deposition(PVD)
2) Chemical vapor deposition(CVD)
Physical vapor deposition(PVD)
Family of processes in which a material is converted to its vapor
phase in a vacuum chamber and condensed onto substrate surface as a
very thin film.
• Coating materials: metals, alloys, ceramics and other inorganic
compounds, even some polymers
• Substrates: metals, glass, and plastics
• Very versatile coating technology
o Applicable to an almost unlimited combination of coatings and
substrate materials
19. Applications of PVD-
of magnesium fluoride (MgF2) onto
• Antireflection coatings
optical lenses
• Depositing metal to form electrical connections in integrated
circuits
• Coating titanium nitride (TiN) onto cutting tools and plastic
injection molds for wear resistance
20. Chemical vapor deposition(CVD)
Involves interaction between a mixture of gases and the surface of a
heated substrate, causing chemical decomposition of some of the gas
constituents and formation of a solid film on the substrate.
• Reactions occur in enclosed reaction chamber
• Reaction product nucleates and grows on substrate surface to form
the coating
• Most CVD reactions require heat
• Variety of coating and substrate materials
21. Application of CVD-
• Industrial metallurgical processes
• Coated carbide tools
• Solar cells
• Refractory metals on jet engine turbine blades
• Integrated circuit fabrication
Photomicrograph of cross
section of a coated
carbide cutting tool using
CVD and PVD
22. Sputtering-
• An electrical field ionizes an inert gas(Ar).
• Ions are generated and directed at a target.
• The ions sputter target atoms.
• The ejected atoms are transported to the substrate.
• Atoms condense and form a thin film.
23. Electroplating-
• Electroplating is the process of depositing one metal onto another
metal.
• Electrons travel from the negative end of the battery through the
cathode, through the solution, up through the anode, and into the
positive end of the battery.
• The positively charged ion form the solution are attracted to the
negatively charged cathode.
• These ions attached themselves to the cathode.
Electroplating can enhances-
Chemical properties- increase corrosion
resistance
Physical properties- increase thickness
of part
Mechanical properties- increase tensile
strength & hardness
24. Electroless plating-
• Part is submerged into an aqueous bath filled with metal salts ,
reducing agents and catalysts.
• Catalysts reduce metal to ions to form the coating.
• This process can be used to plate non conducting parts with a layer
of metal.
• Excellent for complex geometries as deposition is uniform across
surface regardless of geometry (except very sharp corners ( 0.4 mm
radii)
25. Anodizing-
• The process uses the metal as an anode, by electrolytic process a
layer of hard metal oxide is formed at the anode i.e. on the surface of
the part.
• The coating provided on the metal surface may be of different colors
(usually black, red, blue)
• Electrolytic treatment produces a stable oxide layer on the metallic
surface
• Applications: Aluminium, Magnesium, zinc, titanium, and other
metals
• Dyes can be incorporated into anodizing process to create a wide
variety of colors
• Especially common in aluminium anodizing
• Functions: primarily decorative; also corrosion protection
26.
27.
28. INTRODUCTION
• PAINT is a solution of a pigment in
water, oil, or organic solvent, used to
cover wood or metal articles either for
protection from moisture and termites
etc.
• For different surfaces different types
of paints from different companies are
used. Some of the leading companies
of India are Asian paints, Nerolac,
berger, nippon etc.
29. Paints are of three types:
A. Enamel: oil-based paints that produce a smooth surface and glossy
appearance
B. Lacquers: these are resin based paints that dry to a thin coat after
the solvent evaporates out. Common examples are varnish used in
painting wood.
C. Water-based paints: common examples include several wall paints
and home-interior paints.
Lacquers Water-based
