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ENGINEERING
A.S.Khanna
Corrosion Science & Engineering
IIT Bombay
Surface Engineering- Scope
Surface
Characterization is
Failure of an External forces The economic perhaps the most
engineering can be benefits - powerful function
Sometimes
component occurs According to a which helps us the
thermal, technological
when its surface report the the UK modify existing
progress and
cannot adequately optical, coating market is surfaces, create
manufacturing
withstand the magnetic and approximately new coatings,
efficiency
external forces or electrical £21.3 b. formulations,
requires surface
environment to understand
wear, or modifications. (RSIC Report,
which it is mechanism of
subjected. corrosion. 2005) surface
degradation and
its improvement
Definition
To make changes to the surface of a material.
Purpose
To gain or improve upon the desired surface
properties of a material. To improve a
components; performance, service lifetime,
aesthetics or economics.
These processes involve diffusion of new elements into the surface of the
material. The original substrate material constituents play an active part in
the modified surface.
• Mechanical Processes
Cold working - surface by peening, shot blasting, explosive hardening or
other specialised machining processes induce compressive stresses,
increasing hardness and fatigue resistance.
• Changing surface texture using machining and blasting.
• Other Processes
Modification of surfaces by chemical/electro-etching, laser engraving,
various chemical, solvent and ultrasonic cleaning processes could also be
included here.
Surface Modification by Changing
Surface Chemistry
• Thermochemical Diffusion Processes
– Carburising (carburizing)
– carbonitriding
– nitriding nitrocarburising
– boronising
• In all these processes new element goes into interstitial position.
– aluminising (aluminizing, calorising, alonising)
– chromising (chromizing)
– siliconising (siliconizing)
– In this process new element goes into Substitutional SS
• Electrochemical Processes
– Anodising (anodizing) of aluminium, titanium
• Chemical Conversion Coatings
– Phosphating chemical blacking chromating
• Ion Implantation Processes
Surface Modification by Adding New
Material onto the Surface (Coating)
Welding Type Processes
Cladding
Material Properties
Bulk Surface
•Strength
•Density •Hardness
•Ductility •Friction
•Wear
•Corrosion
•Oxidation
Why Surface Treatment ?
To achieve desired
surface properties
which cannot be
achieved by
conventional
alloying process.
What are the surface Properties?
Corrosion
Oxidation
Wear
Erosion/abrasion
Hardness
Conductivity
What are the various modes by which
surface properties can be enhanced ?
• Coatings
Creating a • Cladding
Barrier • Surface Alloying
• Homogenization
Surface • Hardening
treatments • Reflectivity change
Different Techniques to achieve
Surface Modifications
• Case Hardening
• Slurry
Conventional • Hot Dip
• Quenching
Methods • Hardfacing
• Electrodeposition
• PVD
Advanced • CVD
• Thermal Spray
Methods • Laser Based
Selection of Surface Treatment
Method
Based upon Change in function property
Substrate characteristics
Thickness of the modified surface
Throughput of the process ( slow, fast)
Requirement of vacuum
Geometry of the component
Economics
Thickness as Selection Criteria for Coating
Technique
Surface Engineering
Mechanism
Mechanism ofof Coatings
Coatings
B
Interface
Coating Surface
Adhesion
•Roughness
Interdiffusion
•Erosion
Cleanliness
•Corrosion/oxidation
Roughness
•Friction
Expansion mismatch
•Porosity
•Electrical properties
Coating
Surface
modification
technique
Examples of Surface Modification in Industry
S.No Industry Part/machine Problem for which coating is
. required
1 Aircraft , Turbine Disc, Fretting wear
Gas Turbine Lybrinth seals Friction / Hot Corrosion
Turbine Blades Hot Corrosion and erosion
Rotor Shafts Fretting wear
2 Automobiles Exhaust Nozzles High Temperature Corrosion
Cylinder jackets and Rubbing wear
Liners
Piston Heads and Thermal Fatigue and
crowns Corrosive wear
Camshafts/Crank Fatigue/wear
shafts
3 Textile Yankey Dryers Abrasion and wear
Machinery Grooved rolls Abrasion and wear
Package drive rolls Abrasion and wear
Twisting rolls Abrasion and wear
Yarn guides Abrasion and wear
Tension gates & drives Abrasion and wear
4 Glass Work Scoops and Moulds Hot Corrosion/abrasion
Diamond Work Dies Hot Corrosion/abrasion
Bushing Plates Hot Corrosion/abrasion
Diamond Polishing Pads Abrasive Wear
5 Paper & Pulp Gripper Bars/pads Abrasive wear
Printing Industry Grip Rolls Abrasive wear
Transport Rolls Abrasion
Guide Plates Rubbing wear
Folder Rolls Surface wear
6 Chemical, Oil exploration Shafts Abrasive wear
Petrochemical Well Casing Corrosive wear
Tanks & Vessels Corrosive wear
Impellers Fatigue & Corr. Wear
Plug valves Chemical corrosion
7 Power Plants Gas Turbine Blades Corrosion and abrasion
Boilers Furnace Pipes Heat Corrosion
Superheater tubes Oxidation/sulfidation/erosion/Hot
Corrosion
Boiler Tubes Heat & sulfidation attack
Coat Chuts Abrasive wear
Plasma & Ion-based Surface Engineering (PISE)
techniques
Crankshafts
Industrial Scale Plasma Nitriding Facility UHV PN System for Space
For Large size Industrial Jobs Quality Plasma Nitriding
HVOF Plasma
Comparison of various Thermal Spray Processes
Attributes Flame SPRAY HVOF Detonation Wire Arc Air Plasma Vacuum Cold
Plasma spray
Jet Temp0C 3,200 5,200 5,000 >25,000 15,000 12,000 0-500
Coating after
Laser Glazing
Substrate Substrate
Performance of laser clad heat exchanger
tube with Ni-25Cr alloy exposed in coal
fired power plant for a year
Optical micrographs showing the fire cracks
on the heat exchanger tube exposed in a
coal-fired power plant
Without Cladding