SEMESTER: MONSOON/WINTER, SESSION: 2022-2023

EXAMINATION & SEMESTER: B.TECH./M.TECH./Ph.D. I|SEMESTER

Max. Marks: 100 Subject: Surface Engineering (MED 554) Time:3 hrs.

Instruction: Answer all questions.

6
1 (a) Arough surface has a profile of sinusoidal nature with a maximum amplitude of 5 um. Evaluate
the Ra value of the profile.

1 (b) Aceramic ballof radius 5 mm is pressed into a hemispherical recess of 10 mm radius in a steel
plate. Elastic modulus, Poisson's ratio and hardness of ceramic material and steelare 450 GPa
and 200 GPa, 0.3 and 0.3, 20 GPa and 5 GPa, respectively. Considering hardness is 3 times of
the yielding stress, estimate the normal load necessary to initiate yielding in steel plate. Also,
estimate the radius of the contact area.

6
1 (c) Two hard conical sliders of semi-angles 75° and 80° are slid across a metal surface, and the
measured friction coefficients are in the ratio 11:10. Find the two components of friction
coefficients (i.e. adhesive and abrasive) in both cases.

2 (a) In a wear test, a brass annulus having an outside diameter of 30 mm and an inside diameter of
15 mm is placed with its flat face resting on a flat carbon steelplate under anormal load of 15
Nandrotated about its axis at 60 rpm for 50hr. As aresult, the mass losses of the brass and
steel are 15 mg and 0.75 mg. Calculate the totalwear depths by taking hardness and density
for steel and brass as 2.5 GPa, 0.8 GPa, 7.5 g/cm² and 8.5 g/cm², respectively. Also, calculate
the wear coefficients of both materials.

2 (b) A steel coupon with an anode surface area of 1000 cm² is placed in an electrolyte. The 6
corrosion current is measured to be 1 mA. What mass of steel will be lost in 6 hours? What is
the corrosion rate in MPY? Takethe gram atomicweight of steel as 55.847, density as 7.5
g/cm, and valance as 2.

2 (c) Derive the relationship for estimating the required time to deposit a certain coating layer 6

thickness in the electroplating process.

3 (a) Briefly classify the Surface Modification Processes with deposition techniques. Make a 3+3
comparison between Surface Modification Processes based on 'Atomic nucleation & growth'
and 'Direct attachment, agglomeration &consolidation of solid and/or liquid particles'.

3 (b) What is the working principle of CVD? Explain it with an example of an exchange reaction. How
2+3+
the reaction rate and feasibility of reaction in the forward direction are determined? Discuss 3

the required chemical reactions in CVD for the deposition of TiC coating on the WC tool.

3 (c) What is Sputtering? Explain the working principle of Magnetron Sputtering using a schematic 2+4

diagram.
 comparisons
What are the pre-processing requirements for Thermal Spray Deposition? Make
2+6
4 (a) HVOF
among the three Spray Deposition methods, i.e. arc wire, air plasma spray, and
limitations.
What is the selective Laser Surface Hardening process? Discuss its advantages and
2+3
4 (b)
cladding with powder 2+3+
4 (c) What are the important parameters of Laser cladding? How Laser
Differentiate between Laser 2
blowing through a coaxial nozzle makes this process efficient.
cladding and Laser alloying.
3+4
5(a) What is Resolution and depth of field of a microscope?
in the visible spectrum.
Calculate the resolution and depth of field limit of red and blue light
respectively; the
Consider, the wavelength of red light and blue light are 700 nm and 475 nm,
500%
refractive index is 1; Magnification/NA of the microscope is 0.90

(SEM)? In which principle is 3+4

5 (b) What is the working principle of Scanning Electron Microscope topography and material
SEM capable of creating images having information about surface
compositions?

in TEM? Explain this using 3+3

5 (c) How 'Mass-density contrast' and 'Diffraction contrast 'are created
simple diagrams.

Some complicated formulas: "

36WE2 1_1-ri+ 1-i
Cmax = Vn3R2 E1 Ez

kWx 0.612
3 3WR R= ;NA= usina
a=
V 4E* =cote NA