SURFACE ENGINEERING (A1MET327)

Lecture Notes
Lecture 1 and 2

Surface engineering

SE is a field related with science & technology of modifying surface characteristics as per needs,
so to enhance the life of the engineered product while operating.

The need for properties is primarily dictated by the service conditions and functionality of the
component.

Wear in different forms

Understanding SE
Surface engineering is an approach of developing the surfaces having features different from that
of bulk material for enhancing the life and functionality of the engineering component.

D.Santhosh Kumar MVGR College of Engineering (A)

Email: [email protected] Dept. of Mechanical Engineering
Vizianagaram, A.P
 SURFACE ENGINEERING (A1MET327)

Need
Old and worn out components.
New component at manufacturing stage

Care needed during SE

SE should minimize adverse effects of thermal and mechanical loading (if any) on the bulk
material of the engineering component to avoid any adverse affect on load carrying capability of
the engineering component.

The deterioration in properties of bulk material is known to take place if there is prolong
exposure to high temperature.

For example, long exposure of components at high temperature during carburizing leads to the
coarsening of grain structure of the steel components, which in turn deteriorates toughness.

Techniques and capabilities for SM

D.Santhosh Kumar MVGR College of Engineering (A)

Email: [email protected] Dept. of Mechanical Engineering
Vizianagaram, A.P
 SURFACE ENGINEERING (A1MET327)

A: Ion Implantation, B: PVD,

C: CVD, D:Electrolytic Plating,
E: Electro-less Plating,
F: Hot Dipping (Galvanizing/Aluminizing), G: Laser Surface Alloying,
H Transformation Hardening,
I : Mechanical Working, J: Nitriding, K: Carbonitriding, L: Carburizing,
M: Thermal Spraying,
N: Friction Surfacing,
O: Weld Overlays)

Purpose of SE

Enhancement of the performance of engineering component with respected to the following:

•Increase the resistance to corrosion, wear, oxidation, and sulfidation.
•Enhance the mechanical properties, electrical and electronic properties, thermal conductivity,
and insulation.
•Reduce the friction coefficient and improve lubrication characteristics.
•Improve aesthetics characteristics.

Surface and sub-surface zones

The surface of any component made of crystalline materials is characterized by a) the nature of
surface irregularity which is quantified in terms of surface roughness, and b) the sub-surface
region which is generally composed of the five distinct zones as shown schematically

Sub-surface regions

Zone I: Comprises a very thin layer of few nano meters called contamination layer which
retains absorbed gases, hydrocarbons, and moisture etc.

D.Santhosh Kumar MVGR College of Engineering (A)

Email: [email protected] Dept. of Mechanical Engineering
Vizianagaram, A.P
 SURFACE ENGINEERING (A1MET327)

•Zone II: Constitutes impurities such as oxides, nitrides, etc., which are formed as a result of
interactions between atmospheric or ambient gases and substrate surface.

Zone III: Involves a layer usually thinner than 1 micrometer with badly damaged crystalline
structure
•Zone IV: Consists of layer of thickness ranging from few microns to hundreds of micrometers
with grain structure deformed by the application of external stresses during manufacturing or
formation of residual stresses.

Zone V: Involves normal structure of bulk materials as per thermal and mechanical stresses
which is experienced by the material during manufacturing.

Properties for SE

Tribology performance governing the life of components subjected to wear is dictated by various
physical, mechanical, chemical, and dimensional properties of the surface materials composing
the engineering component in question.

•Physical properties: Thermal Conductivity, Thermal Insulation, Thermal Expansion

Coefficient, Refractoriness, Density, Optical Properties (absorption or reflection of radiations)
•Chemical properties: Chemical Affinity, Corrosion, Oxidation.

•Mechanical properties: Hardness, Strength, Ductility, Fracture Toughness, Bond Strength,

Residual Stress, Stress Corrosion Cracking, Hydrogen Embrittlement
•Dimensional properties: Straightness, Flatness, Roundness, Surface Roughness, Length etc.

Example
•The surface properties of any component are solely determined by its application and purpose
(service conditions), which is ascertained based on the combination necessary for building the
component.
•For example, a combination of toughness and hardness, corrosion resistance and smoothness
will be important for developing pump parts that have good cavitation resistance
•Enhancement of the thermal efficiency of heat exchanger using thermal barrier metal systems at
the surface.

D.Santhosh Kumar MVGR College of Engineering (A)

Email: [email protected] Dept. of Mechanical Engineering
Vizianagaram, A.P
 SURFACE ENGINEERING (A1MET327)

Surface modification

Primarily two approaches:

•Bringing change in one or more of the zones of sub-surface and

•Developing another layer of suitable material at the surface to achieve the properties desired for
the enhancement of tribological life of the component.

Changes at the surface

The changes at the surface and sub-surface zone are primarily made in two ways:
•Changing the structure of surface layers using thermal and mechanical methods without making
any compositional modification,
•Changing the chemical composition of surface and sub-surface layers.

Developing layer/film/coating
A layer of suitable material (similar or different from the substrate) is expounded on to the
surface of component for realizing the desired surface properties.

Changing the structure of surface and near-surface layers

Mechanical method: Based on localized plastic deformation and so work hardening of near
surface layers
–Burnishing
–Shot peening
–Contour rolling
D.Santhosh Kumar MVGR College of Engineering (A)
Email: [email protected] Dept. of Mechanical Engineering
Vizianagaram, A.P
 SURFACE ENGINEERING (A1MET327)

Thermal methods: Based on localized heating and controlled cooling to obtain desired
microstructure
–Flame and induction hardening
–Laser and electron beam hardening
–Plasma and TIG melting

Changing the chemical composition of surface and near-surface layers

Diffusion based processes

•Carburizing: Introducing carbon in low carbon steel

•Nitriding: Introducing nitrogen in ferritic steel
•Cyaniding: Increasing concentration of both carbon and nitrogen in steel
•Boronizing: Introducing boron in steel
•Vanadizing: Introducing vanadium in steel

Ion implantation: Introducing nitrogen and other elements and controlled lattice deformation
Laser alloying: Based on the inter-mixing of alloying elements in the substrate.

Developing a surface layer or overlays

•Diffusion based processes
–Chemical vapor deposition
–Physical vapor deposition
•Melting based methods
–Weld overlays
–Laser cladding
•Dipping in hot melt based methods
–Hot dip galvanizing
–Hot dip lead tin coating
–Hot dip aluminizing
–Hot dip chromizing

Electrolysis based methods

D.Santhosh Kumar MVGR College of Engineering (A)

Email: [email protected] Dept. of Mechanical Engineering
Vizianagaram, A.P
 SURFACE ENGINEERING (A1MET327)

•Electroplating of
–Cr & Ni for aesthetics
–Cd & Zn for controlling corrosion
–Cu & Ag for improving electrical properties
–Hard chromium for enhancing wear resistance

•Electro-less plating (Ni-P & Ni-B) for improved corrosion and wear resistance.

Comparison of SMTs

Surface modification techniques with respect to the technology level and complexity.

Capability

–To handle the material of low or high melting points

–To modify components up to certain size, area, thickness, and depth
–To apply surface modification under fabrication constraints at site or shop
–To reduce thermal or mechanical or tribological or chemical damage on the surface of work
piece
–To produce smooth surface, Ra
D.Santhosh Kumar MVGR College of Engineering (A)
Email: [email protected] Dept. of Mechanical Engineering
Vizianagaram, A.P
 SURFACE ENGINEERING (A1MET327)

–To provide control over the surface modification processes

•Initial investment, availability, and expertise needed

Scope of SE
•The scope of surface engineering basically involves four broad aspects:

–Designing the surface to be developed,

–Developing or modifying the substrate using suitable approach,
–Characterizing the engineered or modified surfaces,
–Putting them in application for the purpose

Design SM

Surface properties desired for the fulfillment of the service life required are determined by the
service conditions with respect to load, environment, and reliability.
Tribological components are subjected to different environments and stress conditions, hence,
there is the requirement for these components to possess varying set of properties for longer life.

•These properties are corrosion resistance for those working in moist environment, hardness for
low stress abrasion condition, fracture toughness and fatigue resistance for fluctuating load
condition such as gear tooth surfaces, etc.
•For the designing, the compatibility of materials and approach with substrate material,
configuration, and location must be kept in mind.

D.Santhosh Kumar MVGR College of Engineering (A)

Email: [email protected] Dept. of Mechanical Engineering
Vizianagaram, A.P
 SURFACE ENGINEERING (A1MET327)

D.Santhosh Kumar MVGR College of Engineering (A)

Email: [email protected] Dept. of Mechanical Engineering
Vizianagaram, A.P