BTI1133

Manufacturing Processes
LECTURE 18 – SURFACE TECHNOLOGY: SURFACE TREATMENTS, COATINGS
AND CLEANING

Reference: Kalpakjian, S. & Schmid, S. Chapter 34: Manufacturing Engineering Technology in SI Units, 7th Edition

Ann Suhaimi, Semester I 2022/2023

Chapter Outline
1. Introduction
2. Mechanical Surface Treatments
3. Mechanical Plating and Cladding
4. Case Hardening and Hard Facing
5. Thermal Spraying
6. Vapor Deposition
7. Ion Implantation and Diffusion
Coating
8. Laser Treatments
9. Electroplating, Electroless Plating
and Electroforming
10. Conversion Coatings
11. Hot Dipping
12. Diamond Coating and Diamond-like
Carbon
13. Surface Texturing
14. Painting
15. Cleaning of Surfaces
Introduction
Importance of surface treatments:
1. Improve resistance to wear, erosion, and indentation
2. Control friction
3. Reduce adhesion
4. Improve lubrication
5. Improve resistance to corrosion and oxidation
6. Improve fatigue resistance
7. Rebuild surfaces
8. Modify surface texture
9. Impart decorative features
Mechanical Surface Treatments
Shot Peening
Workpiece surface is impacted repeatedly with a cast steel, glass
or ceramic shot
Process would causes compressive residual stresses on the
surface
It improve the fatigue life of the component by delaying the
initiation of fatigue cracks
Extent of deformation can be reduced by gravity peening which
involves larger shot sizes
Used on shafts, gears and springs
Mechanical Surface Treatments

Laser Shot Peening

Workpiece surface is subjected to planar laser shocks (pulses)
from high-power lasers
Surface-treatment process produces compressive residual-
stress layers
Mechanical Surface Treatments

Water-jet Peening
A water jet at high pressure impinges on the surface of the
workpiece
Induce compressive residual stresses on the surface and
subsurface

Ultrasonic Peening
Based on a piezoelectric transducer
Mechanical Surface Treatments

Roller Burnishing
Surface of the component is cold worked by a hard and highly
polished roller or set of rollers
Used on various flat, cylindrical, or conical surfaces
Used to improve the mechanical properties of surfaces and
surface finish
Mechanical Surface Treatments

Explosive Hardening
Surfaces are subjected to high pressures through the placement
and detonation of explosive sheet surface
Increases in surface hardness but little change in the
component shape
Mechanical Plating and Cladding

Mechanical Plating
Metal particles are compacted over the workpieces’ surfaces
by rotary means
Used for hardened-steel parts for automobiles
Cladding
Metals are bonded with a layer of corrosion-resistant metal
through pressure
Laser cladding consists of the fusion of a different material
over the substrate
Case Hardening and Hard Facing

Case Hardening
Case hardening induces residual stresses on surfaces
Formation of martensite during case hardening causes
compressive residual stresses on surface
Hard Facing
Wear resistant hard metal is deposited on the surface by the
fusion-welding
Enhances wear resistance of the materials
Case Hardening and Hard Facing

Spark Hardening
Hard coatings of tungsten, chromium or molybdenum carbides
is deposited by an electric arc
Applications valve seats, oil-well drilling tools and dies for hot
metalworking
Thermal Spraying
Thermal spraying is a series of processes where coatings are
by a spray gun using oxyfuel flame, an electric arc or a plasma
arc
Coating is hard and wear resistant
Coating can have a high porosity due to entrapped air and
oxide particles
Applications include aircraft engine components
Thermal Spraying
Combustion Spraying
Thermal wire spraying
Oxyfuel flame melts the wire and deposits it on the surface
Thermal metal-powder spraying
Uses a metal powder
Detonation gun
By oxyfuel–gas mixture
High-velocity oxyfuel-gas spraying (HVOF)
Similar to that of the detonation gun
Thermal Spraying
Combustion Spraying
Thermal Spraying
Electrical Spraying
Twin-wire arc
Arc is formed between two
consumable wire electrodes
Plasma
High bond strength and low
porosity level and surface
oxides
Vapor Deposition
Vapor deposition is where substrate is subjected to chemical
reactions by gases
Deposited materials can consist of metals, alloys, carbides,
nitrides, borides, ceramics, or oxides
Substrate may be metal, plastic, glass, or paper
2 major vapor-deposition processes: physical vapor
deposition and chemical vapor deposition
Vapor Deposition:
Physical Vapor Deposition
3 basic types of physical vapor deposition (PVD) processes:
1. Vacuum deposition or arc evaporation
2. Sputtering
3. Ion plating
Vapor Deposition:
Physical Vapor Deposition
Vacuum Deposition
Metal is evaporated at a high
temperature in a vacuum and is
deposited on the substrate
In arc deposition, the coating
material is evaporated by arc
evaporators using highly localized
electric arcs
Vapor Deposition:
Physical Vapor Deposition
Sputtering
An electric field ionizes an inert gas (argon) in the process
Positive ions bombard the coating material (cathode) and cause
sputtering (ejection) of its atoms
Radio-frequency (RF)
sputtering is used for
nonconductive materials
Vapor Deposition:
Physical Vapor Deposition
Ion Plating
Ion plating is a generic term describing various combined
processes of sputtering and vacuum evaporation
An electric field will cause a glow generating a plasma
Ion-beam-enhanced (assisted) deposition is capable of
producing thin films as coatings
Dual ion-beam deposition is combining of PVD with
simultaneous ion-beam bombardment
Vapor Deposition:
Physical Vapor Deposition
Ion Plating
Vapor Deposition:
Chemical Vapor Deposition
Chemical vapor deposition (CVD) is a thermochemical
process
Titanium tetrachloride (a vapor), hydrogen, and nitrogen are
introduced into the chamber
Chemical reactions will form titanium nitride on the tool
surfaces
Ion Implantation and Diffusion Coating

Ions (charged atoms) are introduced into the surface of the

workpiece material
Ion implantation will increase surface hardness and improving
resistance to friction, wear and corrosion
Used on cutting and forming tools, dies and molds and metal
prostheses

Diffusion Coating
Alloying element is diffused into the surface of the substrate
and alter its surface properties
Laser Treatments

Lasers are having increasingly broader applications in

manufacturing processes and surface engineering
Electroplating, Electroless Plating and
Electroforming
Plating imparts the properties of:
1. Resistance to wear
2. Resistance to corrosion
3. High electrical conductivity
4. Better appearance
5. Reflectivity
Electroplating, Electroless Plating and
Electroforming
Electroplating
The workpiece is plated with a different metal which is
transferred through a water-based electrolytic solution
Electroplating, Electroless Plating and
Electroforming
Electroplating
The volume of the plated metal can be calculated from
I = current in amperes
t = time
c = constant

3 main forms of electroplating:

1. Rack plating
2. Barrel plating
3. Brush processing
Electroplating, Electroless Plating and
Electroforming
Electroplating
The rate of film deposition depends on the local current
density
Chromium plating is done by plating the metal with copper,
nickel and chromium
Hard chromium plating is done on the base metal and results
in a surface hardness
Electroplating, Electroless Plating and
Electroforming
Electroless Plating
Carried out by a chemical reaction and without the use of an
external source of electricity
Cavities, recesses, and the inner surfaces of tubes can be plated
Also can be used with nonconductive materials
Electroplating, Electroless Plating and
Electroforming
Electroforming
Metal is electrodeposited on a mandrel and is removed where
the coating becomes the product
Production rates can be increased using multiple mandrels
Used for aerospace, electronics, and electro-optics applications
Conversion Coatings

Conversion coating is the process of producing a coating that

forms on metal surfaces
Phosphates, chromates and oxalates are used to produce these
coatings
2 common methods of coating are immersion and spraying
Equipment depends on the method of application, the type of
product and quality considerations
Conversion Coatings

Anodizing
Workpiece surfaces are converted to a hard and porous oxide
layer that provide corrosion resistance and a decorative finish
Anodized surfaces serve as a good base for painting, especially
on aluminum
Coloring
Alter the color of metals, alloys and ceramics
Application for blackening of iron and steels
Hot Dipping

The workpiece is dipped into a bath of molten metal

Provide long-term corrosion resistance to galvanized pipes and
plumbing supplies
Diamond Coating and Diamond-like Carbon

Examples of diamond-coated products are scratchproof

windows, sunglasses and cutting tools
Freestanding diamond films can be laser cut to desired
shapes and brazed onto cutting tools
Also used in MEMS devices due to its favourable friction and
wear characteristics
Diamond Coating and Diamond-like Carbon

Diamond-like Carbon
A few nanometers in thickness produced by a low-temperature,
ion-beam-assisted deposition process
Less expensive but with similar properties with diamond
coatings
Surface Texturing

Surface texturing consist of the following techniques:

1. Etching
2. Electric arcs
3. Lasers
4. Atomic oxygen
Painting

Paints are classified as:

1. Enamels
2. Lacquers
3. Water-based paints
Paints are available with good resistance to abrasion,
temperature extremes, fading, easy to apply and dry quickly
Painting

Common methods of applying paint are dipping, brushing,

rolling and spraying
Cleaning of Surfaces

A clean surface will have beneficial and detrimental effects

Surface not clean may reduce the tendency for adhesion and
galling
Cleaning involves the removal of solid, semisolid, or liquid
contaminants from a surface
2 simple and common tests:
1. Wiping the surface and observing any residues on the cloth
2. Observing whether water continuously coats the surface of a
plate
Cleaning of Surfaces
The type of cleaning process required depends on the type of metal
working fluid residues and contaminants to be removed
3 types of cleaning methods:
1. Mechanical Cleaning
2. Electrolytic Cleaning
3. Chemical Cleaning
🗉 Solution
🗉 Saponification
🗉 Emulsification
🗉 Dispersion
🗉 Aggregation
Cleaning of Surfaces

Cleaning Fluids
Common cleaning fluids:
1. Alkaline solutions
2. Emulsions
3. Solvents
4. Hot vapors
5. Acids, salts, and mixtures of organic compounds
Cleaning of Surfaces

Design Guidelines for Cleaning

Some design guidelines are:
1. Avoid deep, blind holes
2. Make several smaller components
3. Provide appropriate drain holes in the parts to be cleaned
Treatment and disposal of cleaning fluid are important
considerations for environmentally safe manufacturing
operations