https://www.twi-global.

com/technical-knowledge/faqs/faq-what-are-the-main-surface-
engineering-processes

This module covers the aspects of surface engineering, to develop fundamental

understanding and the role of materials to allow surface selection for mechanical contacts
and their surrounding environmental conditions.
The module will explore a range of surface treatments and advanced coatings that are
designed minimise wear, friction and surface oxidation / corrosion. Applications and
economics of surface treatments will be addressed by means of industrial case studies.

Aims and Objectives

Learning Outcomes

Knowledge and Understanding

Having successfully completed this module, you will be able to demonstrate knowledge and
understanding of:

 Pros and cons of different approaches in surface engineering.

 Fundamentals of tribology and related contact mechanics.
 Introduction to corrosion and corrosion protection.
 Principles of coating deposition methods
 Fundamental coating properties and their relationship.

Subject Specific Practical Skills

Having successfully completed this module you will be able to:

 Possess the basic skills to work in surface engineering and related industry or the
government.

Subject Specific Intellectual and Research Skills

Having successfully completed this module you will be able to:

 Analyse advantages and limitations of surface engineering methods

 Compare different coating technologies from various perspectives.
 Write an essay on a technical topic.
 Search and critically review technical literature.

Transferable and Generic Skills

Having successfully completed this module you will be able to:

  Think, observe, communicate, evaluate information and data, analyse and solve
problems

Syllabus

In this module, the emphasis will be on the performance of surface engineered materials
and matching these to service conditions. Topics to be covered will include:

 Tribologically induced stress, Hertz, dynamic Hertz, residual stresses, etc.

 Stress field and wear interactions.
 Measurement of surface / coating properties.
 Wear mechanisms, including lubricated wear, wear-corrosion and erosion.

Surface engineering processes.

(1) Erosion resistant coatings deposited by Chemical Vapour Deposition, Physical Vapour
Deposition, High Velocity Oxy-Fuel (thermal spray), and weld overlay.
(2) Plating and nano-composite coatings/surfaces.
(3) Corrosion resistant surfaces/high temperature.
(4) Surface modification: induction hardening, ion- implantation, carburising, carbo-
nitriding, nitriding and nitro-carburising.
The lectures will draw on examples from applications within the marine, oil and gas, power
generation, aerospace and biomedical sectors. Emphasis will be placed on gaining
sustainability through correct surface engineering technology. Engineering assessment of
each failure problem is described and the associated micromechanical failure modes. The
economics of surface selection
will be discussed for various examples, e.g. machine tool coatings, thermal barrier coatings
and hard chromium replacement for aerospace.

Learning and Teaching

Teaching and learning methods

The teaching methods to be employed in the delivery of this module include:

 36 lectures (three 45 minute sessions per week) which develop the themes
described in this module. Skeleton notes are given out at the start of the course,
which means you only have to note down the key points during the lecture, but still
have a full set of notes to work from. These will also be made available on
Blackboard.
 Additional research review papers are provided to give an overview of the themes of
the course.
 Formative online quizzes on Blackboard.
 Solutions to assigned problems
  Demonstrations and video materials where and when appropriate.

The learning activities include:

 Individual reading of background materials and course texts, plus work on examples.
 Example sheets and solutions.

Study time
Study time
Type
Completion of assessment task
Lecture
Revision
Wider reading or practice
Follow-up work
Preparation for scheduled sessions
Total study time

Resources & Reading list

General Resources

Other Materials. Copies of reference textbooks and dvds of surface engineering processes to
be made available by the lecture team
https://www.futurelearn.com/courses/research-project/21/todo/71568

TEXT BOOKS:

 Stand Grainger engineering coatings – design and application jaico publishing House,
1994.

REFERENCES:

 Parthasarathy. N.V., Electroplating Handbooks, Prentice Hall, 1992

 Metals Hand Book vol.2 8th Edition, American society of metals 1994
 Gabe. D.R., “Principles of Metal surface treatment and protection”, Pergamon, 1990
 Niku-Lavi, “Advances in surface treatments”, Pergamon, 1990