Surface finishing is a broad range of industrial processes that alter the surface of a manufactured item to achieve a certain property.[1] Finishing processes may be employed to: improve appearance, adhesion or wettability, solderability, corrosion resistance, tarnish resistance, chemical resistance, wear resistance, hardness, modify electrical conductivity, remove burrs and other surface flaws, and control the surface friction.[1][2] In limited cases, some of these techniques can be used to restore original dimensions to salvage or repair an item. An unfinished surface is often called mill finish
Surface finishing processes alter the surface of materials for aesthetic or functional purposes. Grinding is the most common abrasive machining process, using abrasive grits to cut material. Anodizing increases the thickness of the natural oxide film on aluminum, producing a corrosion-resistant and durable surface. Lapping uses loose abrasives to remove material within tight tolerances. Honing uses an abrasive tool that both rotates and reciprocates to smooth bore surfaces. These finishing techniques improve appearances, functionality, and sales value of products.
This document discusses sheet metal processes. It begins by defining sheet metal working as a chipless manufacturing process that forms various components from sheet metal using punching and other forming operations. It then discusses various sheet metal cutting operations like blanking and punching as well as forming operations like bending, drawing, and coining. Specific processes like fine blanking, deep drawing, and springback compensation techniques are also covered. The document provides examples of applications for sheet metal working and discusses concepts like tooling dimensions, forces, and developed lengths.
Burnishing is a cold-working process that finishes and hardens metal surfaces through pressure contact with a hardened tool. Lapping rubs two surfaces together with abrasive in between by hand or machine. Honing removes a small amount of stock from internal or external surfaces to improve flatness and finish using abrasives at low speeds of 85 to 300 sf/min.
This document contains lecture notes on manufacturing processes and metal cutting theory. It begins with definitions of manufacturing and an overview of various manufacturing processes. It then describes machine tools and their functions in metal cutting. Key sections cover classifications of manufacturing processes, cutting parameters like speed, feed and depth of cut, and characteristics and types of cutting tools materials. In summary, the document provides a comprehensive introduction to manufacturing processes, metal cutting theory, and machine tools.
Sheet metal is a thin piece of metal between 0.006 and 0.25 inches thick. Sheet metal can be cut, bent, and stretched into various shapes through forming and cutting operations. Common forming operations include bending, deep drawing, and roll forming. Common cutting operations include shearing, blanking, punching, notching, and slitting. Sheet metal workers use tools like dies and presses to perform these operations and shape the metal.
Sheet metal characteristics – shearing, bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods –special forming processes-Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning– Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro forming.
The document discusses various metal forming processes used to change the shape of metal workpieces through plastic deformation exceeding the metal's yield strength, including bulk deformation techniques like rolling, forging, and extrusion that involve significant shape changes with lower surface area to volume ratios, and sheet metalworking techniques like bending, drawing, and shearing that are performed on metal sheets or strips with higher surface area to volume ratios. Metal forming is an important manufacturing method that allows for net or near-net shape production, high production rates, profitability, and improved material properties.
The document discusses surface coatings and corrosion. It defines corrosion as the deterioration of metals due to reaction with the environment. It then describes several types of coatings used to protect metals from corrosion, including conversion coatings like anodizing which form protective metal oxide layers, thermal coatings like flame spraying, electrochemical coatings like galvanization, and vapor deposition methods like PVD and CVD. The document emphasizes that coatings provide barrier protection and extend the lifetime of metal substrates.
Surface finishing processes alter the surface of materials for aesthetic or functional purposes. Grinding is the most common abrasive machining process, using abrasive grits to cut material. Anodizing increases the thickness of the natural oxide film on aluminum, producing a corrosion-resistant and durable surface. Lapping uses loose abrasives to remove material within tight tolerances. Honing uses an abrasive tool that both rotates and reciprocates to smooth bore surfaces. These finishing techniques improve appearances, functionality, and sales value of products.
This document discusses sheet metal processes. It begins by defining sheet metal working as a chipless manufacturing process that forms various components from sheet metal using punching and other forming operations. It then discusses various sheet metal cutting operations like blanking and punching as well as forming operations like bending, drawing, and coining. Specific processes like fine blanking, deep drawing, and springback compensation techniques are also covered. The document provides examples of applications for sheet metal working and discusses concepts like tooling dimensions, forces, and developed lengths.
Burnishing is a cold-working process that finishes and hardens metal surfaces through pressure contact with a hardened tool. Lapping rubs two surfaces together with abrasive in between by hand or machine. Honing removes a small amount of stock from internal or external surfaces to improve flatness and finish using abrasives at low speeds of 85 to 300 sf/min.
This document contains lecture notes on manufacturing processes and metal cutting theory. It begins with definitions of manufacturing and an overview of various manufacturing processes. It then describes machine tools and their functions in metal cutting. Key sections cover classifications of manufacturing processes, cutting parameters like speed, feed and depth of cut, and characteristics and types of cutting tools materials. In summary, the document provides a comprehensive introduction to manufacturing processes, metal cutting theory, and machine tools.
Sheet metal is a thin piece of metal between 0.006 and 0.25 inches thick. Sheet metal can be cut, bent, and stretched into various shapes through forming and cutting operations. Common forming operations include bending, deep drawing, and roll forming. Common cutting operations include shearing, blanking, punching, notching, and slitting. Sheet metal workers use tools like dies and presses to perform these operations and shape the metal.
Sheet metal characteristics – shearing, bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods –special forming processes-Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning– Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro forming.
The document discusses various metal forming processes used to change the shape of metal workpieces through plastic deformation exceeding the metal's yield strength, including bulk deformation techniques like rolling, forging, and extrusion that involve significant shape changes with lower surface area to volume ratios, and sheet metalworking techniques like bending, drawing, and shearing that are performed on metal sheets or strips with higher surface area to volume ratios. Metal forming is an important manufacturing method that allows for net or near-net shape production, high production rates, profitability, and improved material properties.
The document discusses surface coatings and corrosion. It defines corrosion as the deterioration of metals due to reaction with the environment. It then describes several types of coatings used to protect metals from corrosion, including conversion coatings like anodizing which form protective metal oxide layers, thermal coatings like flame spraying, electrochemical coatings like galvanization, and vapor deposition methods like PVD and CVD. The document emphasizes that coatings provide barrier protection and extend the lifetime of metal substrates.
This document summarizes various surface treatment techniques including mechanical processes like shot peening and deep rolling that modify the surface without changing chemistry, thermal processes like electron beam treatment and laser treatment, and thermo-chemical processes like carburizing, nitriding, and carbonitriding that diffuse elements like carbon or nitrogen into the surface. It provides details on the mechanisms, advantages, and applications of these different surface modification methods.
CHEMICAL MACHINING - NON TRADITIONAL MACHININGSajal Tiwari
The chemical machining processes include those wherein material removal is accomplished by a chemical reaction, sometimes assisted by electrical or thermal energy applications. This group includes chemical milling, photochemical machining, and thermo-chemical machining.
Advanced Manufacturing Processes PDF Full book by badebhauEr. Bade Bhausaheb
This document provides a syllabus for an advanced manufacturing processes course. The syllabus covers 6 units: 1) metal forming processes, 2) advanced welding, casting and forging, 3) advanced material processing techniques, 4) micro machining processes, 5) additive manufacturing processes, and 6) measurement techniques for micro machining. Some key processes discussed include roll forming, hydroforming, electromagnetic forming, friction stir welding, vacuum die casting, and additive manufacturing methods like powder bed fusion. Contact information is also provided.
The document discusses the CO2 casting process. In this process, CO2 gas is used to harden sand molds. When CO2 gas comes into contact with sodium silicate in the sand mixture, it forms a stiff gel that strengthens the mold. The CO2 is forced into the packed mold at pressure. This process produces dimensionally accurate castings with a fine surface finish more quickly than green sand casting. However, it is not as economical. The molds also cannot be easily reclaimed.
GMT started manufacturing lapping & polishing machine in 1971. It was built for in-house use and until then hand lapping process was used for finishing surface plates. Critical parts for our workholding devices required a finishing and buffing machine. There was demand in the market for valve lapping and lapping plates. Since GMT had a captive ferrous foundry, castings for lap plate and lapping machine were easier to source.
Since then GMT has become one of India's largest lapping machine manufacturers and suppliers with over 350 installations throughout India mainly to the valve and pump industry. When a buyer in Japan wanted a super finishing machine for lapping large granite plates, GMT designed and supplied a 3000mm dia flat lapping machine.
Pump manufacturers, electronic industries, valve manufacturers, etc., have found a sure way of obtaining positive sealing.
This document discusses different types of cutting tool materials and their properties. It covers seven main types of toolbit materials including high-speed steel, cast alloys, cemented carbides, ceramics, cermets, cubic boron nitride and polycrystalline diamond. The key properties for cutting tools are hardness, wear resistance, shock resistance, shape/configuration. Cemented carbides are widely used and offer high hardness, wear resistance and can operate at high speeds without losing sharpness. Coatings like titanium carbide and nitride and aluminum oxide are used to improve wear resistance at different speeds. Tool geometry including side relief, side clearance, rake angles and nose radius are also covered.
Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained.
Chemical machining or chemical milling uses acidic or alkaline solutions to dissolve materials in a controlled manner for milling or blanking parts. Maskants that are chemically resistant are used to protect surfaces that should not be machined. Etchants like FeCl3 or HNO3 dissolve metals into metallic salts. Process parameters like the selection of etchant and maskant are important. Chemical machining allows for complex contours and hard materials to be machined with a high surface finish and low tooling costs but the process is generally slow. Applications include undercuts, eliminating recast layers, and thinning materials.
Broaching is a machining process that uses a toothed tool called a broach to remove material in a single pass. Broaching was first used in the 1850s and was commonly used to rifle gun barrels during World War 1. Broaching machines can perform horizontal, vertical, continuous, and rotary broaching. Broaching tools are designed based on the material, size and shape of the cut, required tolerances, and production rates. Broaching provides high production rates and accuracy for complex hole shapes and surfaces.
Fettling is the process of preparing castings for use by removing unwanted material like gates, risers, fins, and imperfections. It involves several steps and techniques. First, dry sand cores are knocked out and gates and risers are removed through chipping, cutting, sawing, or abrasive machining depending on the material. Then fins and other projections on the casting surface are chipped off. Finally, the casting is cleaned through tumbling, shot blasting, or other modern blasting processes to produce a smooth, finished part meeting specifications. Fettling transforms crude castings into functional, high quality components through various removal and cleaning operations.
The document summarizes the rolling process. It defines rolling as plastically deforming metal by passing it between rolls. Rolling provides close dimensional control and high production. There are two main types: hot rolling and cold rolling. The document describes various rolling terminologies, mill products, defects, and different rolling processes like hot rolling, cold rolling, shaped rolling, and thread rolling. It also discusses factors like angle of contact, forces involved, and how to control flatness.
This document discusses single point cutting tools. It describes the types of tools, tool geometry including angles and designations. It explains the effects that varying the back rake angle, side rake angle, relief angle, cutting edge angle, and nose radius have on machining. Finally, it lists common tool materials and provides brief conclusions and references.
The document discusses surface finish, which is the process of altering a surface to enhance appearance or functionality. Surface finish is important for protection, durability, and aesthetics. It is defined by factors like roughness, lay, waviness, and flaws. The specific surface finish requirements depend on the application.
MILLING MACHINE PPT 1: WORKING PRINCIPLE ,MILLING METHODS AND SPECIFICATIONS ...POLAYYA CHINTADA
Milling machines are used to remove materials from a workpiece via a revolving cutting tool. There are two types of milling: up-milling and down-milling. Up-milling involves cutting against the workpiece movement, resulting in varying cutting forces. Down-milling cuts in the same direction as workpiece movement, generating less heat and allowing for a better surface finish. Milling machines can cut flat, curved, or angled surfaces using multiple tooth cutters mounted on an arbor or spindle. They are suitable for machining surfaces, contours, threads, and other cross-sections.
Chapter 2 constructional feature of cnc machineRAHUL THAKER
This document discusses the constructional features of CNC machines. It classifies CNC systems according to the type of machine into point-to-point, straight-cut, and continuous path systems. It also categorizes them based on programming method as absolute or incremental, and by control system type as open-loop or closed-loop. Point-to-point systems move in straight lines for operations like drilling. Continuous path systems enable contouring for milling complex profiles. Programming specifies tool movements, and feedback loops help verify final positions match programs. Common machine elements include motors, ball screws, and feedback devices.
Capstan and turret lathes are production lathes used to manufacture large quantities of identical parts quickly. Unlike engine lathes, they do not have tail stocks and can hold multiple tools that operate simultaneously. Capstan lathes have hexagonal turrets mounted on slides that move longitudinally, while turret lathes have stationary hexagonal turrets mounted directly on the saddle. Both types of lathes are suited for machining bars and irregular workpieces, with turret lathes able to accommodate heavier work. Common tooling includes box, flanged, and slide tool holders that mount to the turrets.
Chemical machining involves controlled chemical dissolution of a workpiece material using an acidic or alkaline etchant. The process includes preparing the workpiece, applying a maskant to protect areas, etching the exposed material using an etchant, removing the remaining mask, and finishing. It allows for producing pockets and contours and removing material from high strength parts. The main steps are preparing the workpiece through cleaning, applying a masking material, etching the exposed areas using an etchant, and removing the remaining mask. Chemical machining provides advantages like weight reduction and avoiding stresses but has disadvantages like difficulty achieving sharp corners and limited thickness machining.
Chemical machining (ChM) is a process that uses chemicals to remove material from a workpiece. It involves masking areas not to be etched, then immersing or spraying the workpiece with a corrosive chemical etchant. ChM provides advantages like weight reduction, stress-free material removal, and low tooling costs. The process involves part preparation through masking, etching with chemicals, mask removal, and finishing. Precise shapes can be produced using photoresist masks and photoetching. ChM finds applications for aerospace, electronics, and other precision parts.
Milling is a machining process that uses rotary cutters to remove material from a workpiece by feeding the workpiece into a spinning tool. There are two main types of milling machines: horizontal and vertical. Horizontal milling machines have a horizontally mounted spindle and cutter above the worktable, while vertical milling machines have a vertically oriented spindle and cutter that can plunge to cut the workpiece. The type of milling machine used depends on factors like the shape, size, and number of sides needing machining of the workpiece.
The document discusses various mechanical and chemical preparation processes used before electroplating. It describes processes like blast finishing, shot peening, mass finishing, polishing, buffing, alkaline cleaning, solvent cleaning, acid cleaning, and ultrasonic cleaning. It emphasizes that cleaning is a critical process and any discontinuity or poor cleaning can negatively impact the plating process and result in defects like non-adherent deposits or peeling of the coating film. Proper pre-baking and preheating are also important before certain plating baths.
Surface preparation is critical for coating performance and longevity. It involves cleaning the surface of contaminants like mill scale, rust, grease and dirt. The level of cleaning depends on factors like the substrate material and coating system. Common preparation methods include solvent cleaning, abrasive blasting and chemical treatments. Proper surface preparation can increase coating adhesion and the protective life of a paint system by over 80%.
This document summarizes various surface treatment techniques including mechanical processes like shot peening and deep rolling that modify the surface without changing chemistry, thermal processes like electron beam treatment and laser treatment, and thermo-chemical processes like carburizing, nitriding, and carbonitriding that diffuse elements like carbon or nitrogen into the surface. It provides details on the mechanisms, advantages, and applications of these different surface modification methods.
CHEMICAL MACHINING - NON TRADITIONAL MACHININGSajal Tiwari
The chemical machining processes include those wherein material removal is accomplished by a chemical reaction, sometimes assisted by electrical or thermal energy applications. This group includes chemical milling, photochemical machining, and thermo-chemical machining.
Advanced Manufacturing Processes PDF Full book by badebhauEr. Bade Bhausaheb
This document provides a syllabus for an advanced manufacturing processes course. The syllabus covers 6 units: 1) metal forming processes, 2) advanced welding, casting and forging, 3) advanced material processing techniques, 4) micro machining processes, 5) additive manufacturing processes, and 6) measurement techniques for micro machining. Some key processes discussed include roll forming, hydroforming, electromagnetic forming, friction stir welding, vacuum die casting, and additive manufacturing methods like powder bed fusion. Contact information is also provided.
The document discusses the CO2 casting process. In this process, CO2 gas is used to harden sand molds. When CO2 gas comes into contact with sodium silicate in the sand mixture, it forms a stiff gel that strengthens the mold. The CO2 is forced into the packed mold at pressure. This process produces dimensionally accurate castings with a fine surface finish more quickly than green sand casting. However, it is not as economical. The molds also cannot be easily reclaimed.
GMT started manufacturing lapping & polishing machine in 1971. It was built for in-house use and until then hand lapping process was used for finishing surface plates. Critical parts for our workholding devices required a finishing and buffing machine. There was demand in the market for valve lapping and lapping plates. Since GMT had a captive ferrous foundry, castings for lap plate and lapping machine were easier to source.
Since then GMT has become one of India's largest lapping machine manufacturers and suppliers with over 350 installations throughout India mainly to the valve and pump industry. When a buyer in Japan wanted a super finishing machine for lapping large granite plates, GMT designed and supplied a 3000mm dia flat lapping machine.
Pump manufacturers, electronic industries, valve manufacturers, etc., have found a sure way of obtaining positive sealing.
This document discusses different types of cutting tool materials and their properties. It covers seven main types of toolbit materials including high-speed steel, cast alloys, cemented carbides, ceramics, cermets, cubic boron nitride and polycrystalline diamond. The key properties for cutting tools are hardness, wear resistance, shock resistance, shape/configuration. Cemented carbides are widely used and offer high hardness, wear resistance and can operate at high speeds without losing sharpness. Coatings like titanium carbide and nitride and aluminum oxide are used to improve wear resistance at different speeds. Tool geometry including side relief, side clearance, rake angles and nose radius are also covered.
Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained.
Chemical machining or chemical milling uses acidic or alkaline solutions to dissolve materials in a controlled manner for milling or blanking parts. Maskants that are chemically resistant are used to protect surfaces that should not be machined. Etchants like FeCl3 or HNO3 dissolve metals into metallic salts. Process parameters like the selection of etchant and maskant are important. Chemical machining allows for complex contours and hard materials to be machined with a high surface finish and low tooling costs but the process is generally slow. Applications include undercuts, eliminating recast layers, and thinning materials.
Broaching is a machining process that uses a toothed tool called a broach to remove material in a single pass. Broaching was first used in the 1850s and was commonly used to rifle gun barrels during World War 1. Broaching machines can perform horizontal, vertical, continuous, and rotary broaching. Broaching tools are designed based on the material, size and shape of the cut, required tolerances, and production rates. Broaching provides high production rates and accuracy for complex hole shapes and surfaces.
Fettling is the process of preparing castings for use by removing unwanted material like gates, risers, fins, and imperfections. It involves several steps and techniques. First, dry sand cores are knocked out and gates and risers are removed through chipping, cutting, sawing, or abrasive machining depending on the material. Then fins and other projections on the casting surface are chipped off. Finally, the casting is cleaned through tumbling, shot blasting, or other modern blasting processes to produce a smooth, finished part meeting specifications. Fettling transforms crude castings into functional, high quality components through various removal and cleaning operations.
The document summarizes the rolling process. It defines rolling as plastically deforming metal by passing it between rolls. Rolling provides close dimensional control and high production. There are two main types: hot rolling and cold rolling. The document describes various rolling terminologies, mill products, defects, and different rolling processes like hot rolling, cold rolling, shaped rolling, and thread rolling. It also discusses factors like angle of contact, forces involved, and how to control flatness.
This document discusses single point cutting tools. It describes the types of tools, tool geometry including angles and designations. It explains the effects that varying the back rake angle, side rake angle, relief angle, cutting edge angle, and nose radius have on machining. Finally, it lists common tool materials and provides brief conclusions and references.
The document discusses surface finish, which is the process of altering a surface to enhance appearance or functionality. Surface finish is important for protection, durability, and aesthetics. It is defined by factors like roughness, lay, waviness, and flaws. The specific surface finish requirements depend on the application.
MILLING MACHINE PPT 1: WORKING PRINCIPLE ,MILLING METHODS AND SPECIFICATIONS ...POLAYYA CHINTADA
Milling machines are used to remove materials from a workpiece via a revolving cutting tool. There are two types of milling: up-milling and down-milling. Up-milling involves cutting against the workpiece movement, resulting in varying cutting forces. Down-milling cuts in the same direction as workpiece movement, generating less heat and allowing for a better surface finish. Milling machines can cut flat, curved, or angled surfaces using multiple tooth cutters mounted on an arbor or spindle. They are suitable for machining surfaces, contours, threads, and other cross-sections.
Chapter 2 constructional feature of cnc machineRAHUL THAKER
This document discusses the constructional features of CNC machines. It classifies CNC systems according to the type of machine into point-to-point, straight-cut, and continuous path systems. It also categorizes them based on programming method as absolute or incremental, and by control system type as open-loop or closed-loop. Point-to-point systems move in straight lines for operations like drilling. Continuous path systems enable contouring for milling complex profiles. Programming specifies tool movements, and feedback loops help verify final positions match programs. Common machine elements include motors, ball screws, and feedback devices.
Capstan and turret lathes are production lathes used to manufacture large quantities of identical parts quickly. Unlike engine lathes, they do not have tail stocks and can hold multiple tools that operate simultaneously. Capstan lathes have hexagonal turrets mounted on slides that move longitudinally, while turret lathes have stationary hexagonal turrets mounted directly on the saddle. Both types of lathes are suited for machining bars and irregular workpieces, with turret lathes able to accommodate heavier work. Common tooling includes box, flanged, and slide tool holders that mount to the turrets.
Chemical machining involves controlled chemical dissolution of a workpiece material using an acidic or alkaline etchant. The process includes preparing the workpiece, applying a maskant to protect areas, etching the exposed material using an etchant, removing the remaining mask, and finishing. It allows for producing pockets and contours and removing material from high strength parts. The main steps are preparing the workpiece through cleaning, applying a masking material, etching the exposed areas using an etchant, and removing the remaining mask. Chemical machining provides advantages like weight reduction and avoiding stresses but has disadvantages like difficulty achieving sharp corners and limited thickness machining.
Chemical machining (ChM) is a process that uses chemicals to remove material from a workpiece. It involves masking areas not to be etched, then immersing or spraying the workpiece with a corrosive chemical etchant. ChM provides advantages like weight reduction, stress-free material removal, and low tooling costs. The process involves part preparation through masking, etching with chemicals, mask removal, and finishing. Precise shapes can be produced using photoresist masks and photoetching. ChM finds applications for aerospace, electronics, and other precision parts.
Milling is a machining process that uses rotary cutters to remove material from a workpiece by feeding the workpiece into a spinning tool. There are two main types of milling machines: horizontal and vertical. Horizontal milling machines have a horizontally mounted spindle and cutter above the worktable, while vertical milling machines have a vertically oriented spindle and cutter that can plunge to cut the workpiece. The type of milling machine used depends on factors like the shape, size, and number of sides needing machining of the workpiece.
The document discusses various mechanical and chemical preparation processes used before electroplating. It describes processes like blast finishing, shot peening, mass finishing, polishing, buffing, alkaline cleaning, solvent cleaning, acid cleaning, and ultrasonic cleaning. It emphasizes that cleaning is a critical process and any discontinuity or poor cleaning can negatively impact the plating process and result in defects like non-adherent deposits or peeling of the coating film. Proper pre-baking and preheating are also important before certain plating baths.
Surface preparation is critical for coating performance and longevity. It involves cleaning the surface of contaminants like mill scale, rust, grease and dirt. The level of cleaning depends on factors like the substrate material and coating system. Common preparation methods include solvent cleaning, abrasive blasting and chemical treatments. Proper surface preparation can increase coating adhesion and the protective life of a paint system by over 80%.
Surface Processing Operation includes material surface cleaning and surface treating processes which is physically and/or chemically to alter surface texture, Mechanical properties, Physical properties, Chemical Properties etc, to have a better material.
Surface engineering involves modifying the surface properties of materials without changing the bulk composition. This is done to improve performance, service lifetime, aesthetics or cost. There are three main categories of surface engineering processes: 1) modifying the surface texture or metallurgy without chemical changes, 2) altering surface chemistry through diffusion or interstitial processes, and 3) adding new material as a coating. The selection of a surface engineering process depends on the desired properties, substrate characteristics, thickness required, production throughput, and economics.
The document discusses surface preparation methods for bonding with industrial adhesives. It emphasizes that surface preparation is critical for achieving a strong bond, as the adhesive must adhere well to the substrates. The types of surface preparation depend on the expected performance requirements, service conditions, and cost considerations. Common preparation methods include degreasing to remove oils and greases, abrading to increase surface area, and special pretreatments like plasma treatment or chemical etching. Thorough cleaning without contamination is important for optimal bonding.
Araldite Preparacion superficial y pretatamientos. Antala Industria (Spain).Antala Industria
El éxito en las uniones depende de una combinación de múltiples factores, tales como mecánicos, químicos o electrostáticos. La unión es una cuestión de interfaz, ya que el adhesivo tiene que adherirse bien a los sustratos a unir. Por lo tanto, las condiciones de la superficie de las piezas a unir son un factor esencial en el logro de una unión de calidad.
Los Adhesivos industriales Huntsman son adhesivos de alto rendimiento que se adhieren firmemente a la mayoría de los materiales.
Se pueden obtener altas tasas de resistencia después de la eliminación de grasa y partículas sueltas, por ejemplo, óxido, de las superficies a unir.
Sin embargo, cuando se requiere la máxima resistencia y durabilidad a largo plazo. Se recomienda encarecidamente un pretratamiento superficial.
El tipo de preparación de la superficie se lleve a cabo antes de la unión depende de las prestaciones previstas (Figuras 18, 19 y 20), las condiciones de servicio de la unión y consideraciones económicas (relación costes / beneficios).
+34 93 474 66 66 | antala@antala.es
www.antala.es
Araldite surface preparation and pretreatments. Antala Ltd.Antala Ltd.
+44 161 494 1345 | info@antala.co.uk
www.antala.co.uk
Bonding performances are always a combination of multiple
factors, such as mechanical, chemical or electrostatic
interactions. Bonding is a matter of interface, as the adhesive
has to adhere well to the substrates to be bonded. Therefore,
the surface conditions of the parts to be bonded are a critical
factor in achieving a dependable quality bond.
Huntsman industrial adhesives are high performance
adhesives which adhere firmly to most materials. High
strength bonds can be obtained after removal of grease and
loose particles, e.g. rust, from the surfaces to be joined.
However, when maximum strength and long-term durability
are required, a more thorough mechanical or a chemical
surface pretreatment is highly recommended.
The type of surface preparation to be carried out prior to
bonding depends on the expected performances (Figures
18, 19 and 20), the service conditions of the assembly and
economic considerations (ratio costs / benefits).
Anodizing is an electrochemical process that converts the metal surface of aluminum to aluminum oxide. It produces a coating that is very durable, corrosion resistant, and maintains the metallic appearance of the aluminum. The anodizing process involves racking parts for processing, cleaning, etching, anodizing in an acid bath using electricity, coloring or sealing the pores, and testing to quality check the coating. Anodized aluminum has advantages like durability, low maintenance, and an environmentally friendly process.
The document discusses various surface coating techniques. It begins by defining corrosion and describing how it occurs in different metals and environments. It then discusses several coating methods including conversion coatings like oxidation, anodizing, phosphate and chrome coatings which form protective surface layers via chemical reactions. Vapor deposition techniques like physical vapor deposition and chemical vapor deposition are also summarized. Thermal coating processes involve diffusion, carburizing, nitriding and metal plating via heat. The document provides an overview of the purposes, processes and applications of various surface coating methods.
1. The document provides an overview of coating techniques used by Technip Singapore including for offshore pipeline installation, offshore structure installation, fabrication services, and diving.
2. It discusses the instructor's background and contact information, as well as Technip Singapore's capabilities in areas like shallow to deep water pipelay, rigging of pipes, and installation of platforms and subsea structures.
3. Abbreviations commonly used in coating projects are defined.
This document discusses various methods for surface modification of materials, including mechanical, thermal, electrochemical, and chemical processes. Mechanical methods like shot peening, laser peening, and explosive hardening introduce compressive stresses to strengthen surfaces. Thermal techniques involve spraying molten metals, while electrochemical approaches plate surfaces through electrolysis or chemical reduction. Vapor deposition methods like PVD and CVD coat surfaces with thin films through physical or chemical reactions in vacuum chambers. Surface treatments can improve properties like hardness, corrosion resistance, and wear resistance.
These processes are sometimes referred to as post-processing. They play a very important role in the appearance, function and life of the product. Broadly, these are processes that 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. There are different coating and surface treatments processes, with different applications, uses, etc. The important uses include:
• Improving the hardness
• Improving the wear resistance
• Controlling friction, Reduction of adhesion, improving the lubrication, etc.
• Improving corrosion resistance
• Improving aesthetics
9.1. Mechanical hardening of the surface
These methods apply mechanical impulses (e.g. light hammering) on the surface of a metallic part. This hammering action causes tiny amount of plastic flow on the surface, resulting in the work-hardening of the surface layer due to the introduction of compressive residual stresses. Examples of these processes include Shot peening (uses tiny balls of metal or ceramic), Water-jet peening (uses a jet of water at high pressures, e.g. 400 MPa), or Laser peening (surface is hit by tiny impulses from a laser) – an expensive process used to improve fatigue strength of jet fan blades and turbine impellers.
Another method is explosive hardening, where a layer of explosive coated on the surface is blasted – the resulting impact results in tremendous increase in the surface hardness. This method is used to harden the surface of train rails.
9.2. Case hardening
This is a very common process that is used to harden the outer surface of parts such as gear teeth, cams, shafts, bearings, fasteners, pins, tools, molds, dies etc. In most of these types of components, the use involves dynamic forces, occasional impacts, and constant friction. Therefore the surface needs to be hard to prevent wear, but the bulk of the part should be tough (not brittle); this is achieved best by case hardening. There are several types of case hardening: in most cases, the chemical structure of the metal is changed by diffusing atoms of an alternate element which results in alterations to the micro-structure on the crystals on the surface.
A brief knowledge about surface treatment, which is a process applied to the surface of a material to make it better in some way, for example by making it more resistant to corrosion or wear. Shot peening is a surface treatment in which small hard pellets are shot against the surface of a metal to make it more resistant to fatigue.
Emission & Air Pollution | Study On Emission | Study On Air PollutionMd Rakibul Hassan
The document discusses emissions and air pollution from internal combustion engines. It describes how engine combustion produces emissions that contribute to problems like global warming, acid rain, and health issues. The major emissions are hydrocarbons, carbon monoxide, oxides of nitrogen, sulfur, and particulate matter. It outlines various strategies to reduce emissions, including secondary catalytic reactions in the exhaust, adding thermal converters to increase reaction temperatures, and using catalytic converters containing precious metals to reduce the temperature needed for oxidation reactions to occur.
Experimental Study on Surface Roughness by Using Abrasive ParticlesIJERA Editor
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Surface finishing
1. SURFACE PROCESSING
OPERATIONS
1. Industrial Cleaning Processes
2. Diffusion and Ion Implantation
3. Plating and Related Processes
4. Conversion Coating
5. Vapor Deposition Processes
6. Organic Coatings
7. Porcelain Enameling and Other Ceramic Coatings
8. Thermal and Mechanical Coating Processes
2.
3. Overview of Industrial Cleaning
Almost all workparts must be cleaned one or more
times during their manufacturing sequence
Processes used to clean the work surfaces
Chemical cleaning methods - use chemicals to
remove unwanted contaminants from the work
surface
Mechanical cleaning - involves removal of
contaminants by various mechanical operations
4. Reasons Why Parts Must be
Cleaned
Prepare surface for subsequent processing, such
as a coating application or adhesive bonding
Improve hygiene conditions for workers and
customers
Remove contaminants that might chemically
react with the surface
Enhance appearance and performance of the
product
5. Factors in Selecting a
Cleaning Method
Contaminant to be removed
Degree of cleanliness required
Substrate material to be cleaned
Purpose of cleaning
Environmental and safety factors
Size and geometry of the part
Production and cost requirements
6. Contaminant to be Removed
Various contaminants build up on part surfaces, either
due to previous processing or factory environment
Principal surface contaminants found in factory
Oil and grease, e.g., lubricants in metalworking
Solid particles such as metal chips, abrasive grits,
shop dirt, dust, etc.
Buffing and polishing compounds
Oxide films, rust, and scale
7. Degree of Cleanliness
Refers to the amount of contaminant remaining after a
given cleaning operation
A simple test is a wiping method, in which the surface
is wiped with a clean white cloth
Amount of soil absorbed by the cloth is observed
Non quantitative but easy to use‑
8. Other Factors in Selection
The substrate material must be considered
So that damaging reactions are not caused by the
cleaning chemicals
Aluminum is dissolved by most acids and
alkalis
Steels are resistant to alkalis but react with
virtually all acids
Cleaning methods and associated chemicals should
be selected to avoid pollution and health hazards
10. Alkaline Cleaning
Uses an alkali to remove oils, grease, wax, and various
types of particles (metal chips, silica, light scale) from
a metallic surface
Most widely used industrial cleaning method
Alkaline solutions include sodium and potassium
hydroxide (NaOH, KOH), sodium carbonate (Na2CO3),
borax (Na2B4O7)
Cleaning methods: immersion or spraying followed by
water rinse to remove residue
11. Emulsion Cleaning
Uses organic solvents (oils) dispersed in an aqueous
solution
Suitable emulsifiers (soaps) results in a two phase‑
cleaning fluid (oil in water), which functions by‑ ‑
dissolving or emulsifying the soils on the part surface
Used on either metal or nonmetallic parts
Must be followed by alkaline cleaning to eliminate all
residues of the organic solvent prior to plating
12. Solvent Cleaning
Organic remains such as oil and grease are removed
from a metallic surface by chemicals that dissolve the
soils
Common application techniques: hand wiping,‑
immersion, spraying, and vapor degreasing
Vapor degreasing (a solvent cleaning method)
uses hot vapors of chlorinated or fluorinated
solvents
(such as kerosene, naphtha, and mineral spirits), chlorinated hydrocarbons (such as
methylene chloride and trichloroethylene)
13. Acid Cleaning
Removes oils and light oxides from metal surfaces
using acid solutions combined with water miscible‑
solvents, wetting and emulsifying agents
Common application techniques: soaking, spraying,
or manual brushing or wiping carried out at ambient
or elevated temperatures
Cleaning acids include hydrochloric (HCl), nitric
(HNO3), phosphoric (H3PO4), and sulfuric (H2SO4)
14. Acid Pickling
More severe acid treatment to remove thicker oxides,
rusts, and scales
Distinction between acid cleaning and acid pickling is
a matter of degree
Generally results in some etching of the metallic
surface which serves to improve organic paint
adhesion
15. Ultrasonic Cleaning
Mechanical agitation of cleaning fluid by high frequency‑
vibrations (between 20 and 45 kHz) to cause
cavitation (formation of low pressure vapor bubbles
that scrub the surface)
Combines chemical cleaning and mechanical
agitation of the cleaning fluid
Cleaning fluid is generally an aqueous solution
containing alkaline detergents
Highly effective for removing surface contaminants
16. Mechanical Cleaning
Physical removal of soils, scales, or films from the work
surface by abrasives or similar mechanical action
Often serves other functions also, such as deburring,
improving surface finish, and surface hardening
Processes:
Blast finishing
Shot peening
Mass finishing processes
17.
18. Blast Finishing
High velocity impact of particulate media to clean and
finish a surface
Media is propelled at the target surface by
pressurized air or centrifugal force
Most well known method is‑ sand blasting, which uses
grits of sand as blasting media
Other blasting media:
Hard abrasives such as Al2O3 and SiC
Soft media such as nylon beads
19. Shot Peening
High velocity stream of small cast steel pellets (called
shot) is directed at a metallic surface to cold work
and induce compressive stresses into surface layers
Used primarily to improve fatigue strength of metal
parts
Purpose is therefore different from blast finishing,
although surface cleaning is accomplished as a
byproduct of the operation
20. Mass Finishing
Finishing parts in bulk by a mixing action in a container,
usually in the presence of an abrasive media
Mixing causes parts to rub against media and each
other to achieve desired finishing action
Parts are usually small and therefore uneconomical
to finish individually
Processes include:
Tumbling
Vibratory finishing
21. Tumbling
Use of a horizontally oriented barrel of hexagonal or
octagonal cross section in which parts are mixed by
rotating the barrel at speeds of 10 to 50 rev/min
Finishing by "landslide" action - media and parts rise
in the barrel as it rotates, then top layer tumbles
down due to gravity
Drawbacks: slow, noisy, and large floor-space
required
22. Diagram of tumbling (barrel finishing) operation
showing "landslide" action of parts and abrasive media
Tumbling (Barrel Finishing)
23. Vibratory Finishing
Alternative to tumbling
Vibrating vessel subjects all parts to agitation with the
abrasive media, as opposed to only the top layer as
in barrel finishing
Processing times for vibratory finishing are
significantly reduced
Open tubs permit inspection of parts during
processing, and noise is reduced
24. Typical preformed media shapes: (a) abrasive media
for finishing, and (b) steel media for burnishing
Media Shapes in Mass Finishing
25. Processes to Alter Surface
Chemistry
Two processes that impregnate the surface of a
substrate with foreign atoms
Diffusion
Ion implantation
26. Diffusion
Alteration of surface layers of material by diffusing
atoms of a different material (usually an element) into
surface, usually at high temperatures
Surface still contains a high proportion of substrate
material
Diffused element has maximum percentage at the
surface and rapidly declines with distance below
surface
Applications: metallurgy and semiconductor
manufacture
27. Characteristic profile of
diffused element as a
function of distance
below surface in
diffusion
Plot given here is for
carbon diffused into
iron
Profile of Diffused Element
28. Metallurgical Applications of
Diffusion
Surface treatments to increase hardness and wear
resistance
Carburizing, nitriding, carbonitriding, chromizing, and
boronizing
Surface treatments to increase corrosion resistance
and/or high temperature oxidation resistance‑
Aluminizing - diffusion of aluminum into carbon steel,
alloy steels, and superalloys
Siliconizing – diffusion of silicon into steel surface
29. Semiconductor Applications
Diffusion of an impurity element into the surface of a
silicon chip to change the electrical properties at the
surface to create devices such as transistors and
diodes
Called doping in semiconductor processing
30. Ion Implantation
Embedding atoms of one (or more) foreign element(s)
into a substrate surface using a high energy beam of‑
ionized particles
Results in alteration of the chemistry and physical
properties of layers near the substrate surface
Produces a much thinner altered layer and different
concentration profile than diffusion
Alternative to diffusion when the latter is not feasible
due to high temperatures required
31. Profile of surface chemistry
using ion implantation
Shown here is a typical plot
for boron implanted in silicon
Note the difference in profile
shape and depth of altered
layer compared to diffusion
coating
Profile of Surface Chemistry
32. Advantages and Applications of
Ion Implantation
Advantages
Low temperature processing
Good control and reproducibility of impurity
penetration depth
Solubility limits can be exceeded without
precipitation of excess atoms
Applications
Modifying metal surfaces to improve properties
Fabrication of semiconductor devices
33. Some General Comments on
Coating of Engineering Materials
Metal products are almost always coated by‑
painting, plating, or other process
Exceptions: stainless steel, brass
Nonmetallic materials are sometimes coated
Plastic parts to give metallic appearance
Antireflection coatings on glass lenses
Coating and deposition processes used in the
fabrication of semiconductor chips and printed
circuit boards
34. Principal Reasons for Coating
Metal Parts and Products
Corrosion protection
Enhance product appearance
Add color and/or texture
Wear resistance and/or friction reduction
Increase electrical conductivity or resistance
Prepare metallic surface for subsequent processing
Rebuild surfaces worn or eroded during service
35. Plating and Related Processes
Coating thin metallic layer onto the surface of a
substrate material
Substrate is usually metallic, although methods are
available to plate plastic and ceramic parts
Processes:
Electroplating (most common plating process)
Electroforming
Electroless plating
Hot dipping
36. Electroplating
Electrolytic process in which metal ions in an electrolyte
solution are deposited onto a cathode workpart
Also called electrochemical plating
Anode is generally made of the plating metal and
serves as source of the plate metal
Direct current from an external power supply is
passed between anode and cathode
Electrolyte is an aqueous solution of acids, bases, or
salts
38. Theoretical Electroplating
Equation
Faraday’s laws can be summarized:
V = C I t
where V = volume of metal plated, mm3
(in3
); C =
plating constant which depends on electrochemical
equivalent and density, mm3
/amp s;‑ I t (current x
time) = electrical charge, amps-s
C indicates the amount of plating material deposited
onto the cathodic workpart per electrical charge
39. Principal Electroplating Methods
Barrel plating - performed in rotating barrels - suited
to plating many small parts in a batch
Rack plating – racks of copper wire formed into
shapes to hold parts and conduct current to them -
used for parts that are large, heavy, or complex
Strip plating – continuous strip is pulled through the
plating solution by means of a take up reel – suited to‑
high production
40. Common Coating Metals
Zinc - plated on steel products such as fasteners,
wire goods, electric switch boxes, and sheetmetal
parts as a sacrificial barrier to corrosion
Nickel - for corrosion resistance and decorative
purposes on steel, brass, zinc die castings, etc.
Also used as base coat for chrome plate
Tin - widely used for corrosion protection in "tin cans"
and other food containers
41. More Coating Metals
Copper - decorative coating on steel and zinc, either
alone or alloyed as brass
Also important in printed circuit boards
Chromium - decorative coating widely used in
automotive, office furniture, and kitchen appliances
Also one of the hardest electroplated coatings
for wear resistance
Precious metals (gold, silver) - plated on jewelry
Gold is also used for electrical contacts
42. Hot Dipping
Metal substrate (part) is immersed in a molten bath of a
second metal; when removed, the second metal is
coated onto the first
Common substrate metals: steel and iron
Coating metals: zinc, aluminum, tin, and lead
Primary purpose is corrosion protection
43. Hot Dipping Processes
Galvanizing - zinc coated onto steel or iron
Most important hot dipping process
Aluminizing - coating of aluminum onto a substrate
Excellent corrosion protection, in some cases five
times more effective than galvanizing
Tinning - coating of tin onto steel for food containers,
dairy equipment, and soldering applications
44. Conversion Coatings
Family of coating processes in which a thin film of
oxide, phosphate, or chromate is formed on a
metallic surface by chemical or electrochemical
reaction
Immersion and spraying are the two common
methods of exposing metal surface to the reacting
chemicals
Common metals treated: steel (including galvanized
steel), zinc, and aluminum
45. Conversion Coating Processes
Chemical conversion coatings - chemical reaction
only
Phosphate and chromate conversion coatings
are the common treatments
Anodizing - oxide coating produced by
electrochemical reaction
Anodize is a contraction of anodic oxidize
Most common on aluminum and its alloys
46. Anodizing
Electrolytic treatment that produces a stable oxide layer
on a metallic surface
Applications: aluminum and magnesium common
Also zinc, titanium, and other metals
Dyes can be incorporated into anodizing process to
create a wide variety of colors
Especially common in aluminum anodizing
Functions: primarily decorative; also corrosion
protection
47. 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
Applicable to an almost unlimited combination of
coatings and substrate materials
48. Applications of PVD
Decorative coatings on plastic and metal parts such
as trophies, toys, pens and pencils, watchcases, and
interior trim in automobiles
Antireflection coatings of magnesium fluoride (MgF2)
onto 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
49. Processing Steps in PVD
All physical vapor deposition processes consist of
the following steps:
1. Synthesis of coating vapor
2. Vapor transport to substrate
3. Condensation of vapors onto substrate surface
These steps are generally carried out in a vacuum
chamber, so evacuation of the chamber must
precede PVD process
50. Physical Vapor Deposition
Setup for vacuum
evaporation, one
form of PVD,
showing vacuum
chamber and
other process
components
51. 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
53. Applications of CVD
Industrial metallurgical processes
Mond process to reduce nickel from its ore
Coated carbide tools
Solar cells
Refractory metals on jet engine turbine blades
Integrated circuit fabrication
Other applications for resistance to wear, corrosion,
erosion, and thermal shock
55. Organic Coatings
Polymers and resins (natural or synthetic) usually
formulated to be applied as liquids that dry or harden
as thin surface films on substrate materials
Advantages:
Wide variety of colors and textures available
Capacity to protect the substrate surface
Low cost
Ease with which they can be applied
56. Ingredients in Organic Coatings
1. Binders - give the coating its properties
2. Dyes or pigments - provide color to the coating
3. Solvents - dissolve the polymers and resins and add
proper fluidity to the liquid
4. Additives
57. Dyes and Pigments
Provide color to the coating
Dyes - soluble chemicals that color the coating liquid
but do not conceal surface beneath
Coatings generally transparent or translucent
Pigments - solid particles of microscopic size
dispersed in coating liquid but insoluble in it
Not only color the coating, but also hide the
surface below
Since pigments are particulate, they also tend
to strengthen the coating
58. Application Example:
Automobile Car Body
Typical sequence applied to sheet metal car body in
mass production of automobiles:
1. Phosphate coat applied by dipping car body
2. Primer coat applied by dipping car body
3. Color paint coat applied by spray coating
4. Clear coat (for high gloss and added
protection) applied by spraying
59. Porcelain Enameling
Porcelain coatings are valued for:
Beauty and color
Smoothness and ease of cleaning
Chemical inertness and general durability
Porcelain enameling is the name given to the
technology of these ceramic coating materials and
the processes by which they are applied
60. Materials and Products
Porcelain = a ceramic made from kaolin, feldspar,
and quartz
Substrates: steel, cast iron, and aluminum as a
vitreous porcelain enamel
Products: sinks, bathtubs, lavatories, ranges, water
heaters, washing machines, dishwashers, jet engine
components, automotive mufflers, and electronic
circuit boards