Surface Technology

Part 1
Introduction

Professor Kenneth W Miller

Office A108
Phone 0841 9348 0324

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 Topics for Today
• Course Syllabus
• Introductions
– My background
– What is your background
– What are your areas of interest
• Automobile Parts of Interest
• Materials of Interest
• What is Not Covered
• Fundamentals of Materials Science
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 Automotive Parts of Interest
• Body in White
• Suspension Components
• Brake Components
• Steering Components
• Space Frames
• Accessories
– Mirrors
– Antenna

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 Enemies List
• Metal to metal contact
• Sun
• Water
• Salt
• Rocks
• Grocery carts
• Time

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 Body and Frame Functions
• Strength
– Frame
– A, B, and C Pillars
– Suspension and Steering Components
– Braking Components
• Cosmetic
– Body panels
– hood

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Automotive Materials of Interest
• Steel • Composites
– Carbon Steel
– HSLA
– Stainless Steel
– New Alloys
• Aluminum
• Magnesium
• Polymers

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 What is Not Covered
• Engine and engine components
• Tires
• Polymers will get limited coverage
– underbody impact protection
– body parts

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 Summary
• Body in White is the Primary Topic
• Steel is the Primary Material
• Aluminum is Becoming Significant
• Magnesium is of Limited Interest
• What are the factors in material selection?

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 Material Structure
Atomic Level
• Patterns of Atoms
• Unit Cells
• Body-Centered Cubic (BCC)
• Face-Centered Cubic (FCC)
• Hexagonal Close Pack (HCP)

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 Material
Structure -
FCC

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Material Structure -BCC

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Material Structure - HCP

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 Energy and Packing
• Non dense, random packing
Energy

typical neighbor
bond length

typical neighbor r
bond energy

• Dense, regular packing Energy

typical neighbor
bond length

typical neighbor r
bond energy
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2
 Material Structure - APF
• Atomic Packing Factor
• APF = Volume of atoms / Volume of cell
• APF = 0.74 for FCC
• APF = 0.68 for BCC
• APF = 0.74 for HCP

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 Material Structure
Coordination Number
• Nearest neighbors and touching atoms
• Coordination Number = 12 for FCC
• Coordination Number = 8 for BCC
• Coordination Number = 12 for HCP

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 Material Structure - FCC
Metal Atomic Radius (nm)
Aluminum 0.1431
Copper 0.1278
Gold 0.1442
Nickel 0.1246
Platinum 0.1387
Silver 0.1445
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 Material Structure - BCC
Metal Atomic Radius (nm)
Chromium 0.1249
Iron (α) 0.1750
Molybdenum 0.1363
Tantalum 0.1430
Tungsten 0.1371
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 Material Structure - HCP
Metal Atomic Radius (nm)

Cadmium 0.1490

Cobalt 0.1253

Titanium (α) 0.1445

Zinc 0.1332
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 Strength of Materials
• Determined by bond strength
• Limited by slip planes
• Slip planes and dislocations
• Split planes and inclusions
• Atomic separation (distances)

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Crystalline Defects

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Bond Strength

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 Energy and Packing
• Non dense, random packing
Energy

typical neighbor
bond length

typical neighbor r
bond energy

• Dense, regular packing Energy

typical neighbor
bond length

typical neighbor r
bond energy
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2
 Granular Structure
• Pure metals are rarely used
• Practical limits to crystalline structure
• Can create anisotropy
• Reflects heterogeneous composition
• Caused and changed through
– Forming operations such as casting
– Working operations e.g. rolling, drawing
– Heat treatment
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Granular Structure
Polycrystalline
lead ingot

Magnified 7x

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 Granular Structure
• Size – effects strength
• Size – effects toughness
• Orientation – affects directional strength
• Orientation at surface – corrosion
opportunities
• Can be seen through a small microscope
– Crystalline structure requires special
equipment
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 Strain
l
• Engineering Strain

l0

dl  l 
• True Strain
   ln 1  
l  l0 

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 Stress
F
• Engineering Stress 
A0

F
• True Stress

A
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 Stress and Strain
• These are point functions
• >0 for tension, <0 for compression
• Both are directional
• Both depend on plane considered
– Normal stress and strain
– Shear stress and strain
• Full stress or strain state is represented as
a 3x3 matrix
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Stress and Strain

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 Material Properties
• Tensile strength
• Yield strength
• Toughness
• Hardness
• Fracture toughness
• Modulus of Elasticity
• Poisson’s Ratio

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 Stress and Strain
• Elastic Range – linear
– σ=E·ε
– E is the modulus of elasticity or Young’s Modulus
– Full recovery, no permanent change
• Plastic Range – non-linear
– Varies with material
– Work hardening
– Necking
– Permanent change to size and strength

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Modulus of Elasticity

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Modulus of Elasticity

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Yield Point

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Necking

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 Stress Strain
• Power law relationship
• Typical for steel and aluminum
• Assumes slow strain
• Assumes uniform temperature

  K  n

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 Stress Strain
Material n K (MPa)

Low Carbon Steel 0.21 600

4340 Steel Alloy 0.12 2650

304 Stainless Steel 0.40 1400

Aluminum A2024-T3 0.17 780

Magnesium AZ-31B 0.16 450

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 Poisson’s Ratio
• Pull it and it gets
thinner
x y
• Squish and it gets   
thicker
• Consider a tensile
z z
specimen pulled in z
• Upper limit is 0.5 for
no material volume
change

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 Material Properties
Material Elasticity Yield Poisson’s
GPa MPa Ratio
Tungsten 407 0.28
Steel 207 180 0.30
Nickel 207 138 0.31
Titanium 107 450 0.34
Copper 110 69 0.34
Brass 97 75 0.34
Aluminum 69 35 0.33
Magnesium 45
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0.35
 Discussion - Surfaces
• Appearance
• Cover minor flaws
• Hide difference materials
• Protection from Corrosion
• Protection from scratches or impacts
• Increase / decrease friction
• Improve scratch resistance (hardness)

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 Manufacturing Considerations
• Cost
• Speed – timing for production
• Downstream effects
• Value to the consumer
• Weight
• Appearance
• Safety

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 Manufacturing Cost
• Materials
• Time
• Equipment
• Flexibility (changeover time and cost)
• Labor
• Waste disposal (toxic?)

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