Introduction to Surface Engineering

Presented by S.Sathiyaseelan

Surface engineering

Surface Engineering
PVD coatings Coatings Cr plate E-Ni Thermal spraying Anodising

Surface Modification Ion implantation Energy beam processing Thermochemical treatment

PVD Coatings
Coating temperatures below 250C

Coating thickness 1-4 m

Surface structure and edge radii are not altered

High adhesion of the coating

High hardness and low coefficient of friction Some coating of inner surfaces is possible

PVD Process

Advantages of PVD Coatings

Highly wear resistant materials (HV <4000) Increased abrasive wear resistance Anti-scuffing / anti-galling High fretting resistance High pitting resistance Tribological properties Reduced C.O.F. Corrosion resistant materials Combine in bulk - and surface properties Almost no change in tolerances; thin films Environmentally friendly

Benefits of PVD Within Applications

Smaller and lighter designs
Reduced energy consumption Increased power density Cheaper base materials Lifetime increase

Reduced Emissions

Properties of PVD Tribological Coatings

Example PVD Tribological Coating

Friction Considerations

Industrial Volume PVD Coatings Tribological Applications

PVD Coatings in Automotive Applications

Piston area: Piston (carbon based coatings under development) Top piston ring (thick CrN) Piston pin (W-DLC) Sliding bearing (AlSn) Connecting rod (CrN) Common rail: Fuel injection plungers (WDLC)

Transmission area: Gears (W-DLC & B4C) Camshaft area Rollers Bushings Tappets

Cams
High contact pressure (WDLC) Roller Bearings

Air Conditioner: General Purpose:

Opportunities for Weight Reduction

Typical application of PVD

Ion-plating-process

Fuel injection pump components

Sliding wear test

Dry running properties

Surface Engineering Solutions

Surface Engineering Solutions

Thermal oxidation

Thermal oxidation friction

Gear . Ti64, thermal oxidation

Deep case hardening

Nickel diffusion
Laser/EB surface alloying

Oxygen diffusion

Deep case hardening oxidation

Deep case hardening oxidation

Deep case hardening + coating

Load bearing capacity

Ti-alloys
All the examples shown above have used Ti6Al4V alloy substrates 550 alloy . specially developed O-diffusion treatments can produce cases up to 190m in depth Alloys with significant phase are suited to diffusion treatments, but attention must be paid to their bulk heat treatment condition