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Vapor deposition; anodic coating; phosphate; chromate chemical conversion coating Source: After M. K. Gabel and D. M. Doorman in Wear Control Handbook, New York, ASME, 1980 p. 248.
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Contaminant to be Removed
Various contaminants build up on part surfaces, either due to previous processing or factory environment Principal surface contaminants found in the factory:
- Oil and grease, e.g., lubricants in metalworking - Solid particles such as metal chips, abrasive grits, shop dirt, dust, etc. - Polishing compounds. - Oxide films & rust
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Degree of Cleanliness
Refers to the amount of contaminant remaining after a given cleaning operation A simple test is a wiping method, in which the surface is wiped with a clean cloth
- Amount of soil absorbed by the cloth is observed Non-quantitative but easy to use
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Cleaning methods and associated chemicals should be selected to avoid pollution and health hazards.
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Alkaline Cleaning
Uses an alkali to remove oils, grease, wax, and various types of particles (metal chips, silica, light scale) from a metallic surface Most widely used industrial cleaning method. Alkaline solutions include sodium and potassium hydroxide (NaOH, KOH), sodium carbonate (Na2CO3), borax (Na2B4O7). Cleaning methods: immersion or spraying, usually at temperatures of 50-95C (120-200F), followed by water rinse to remove residue.
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Emulsion Cleaning
Uses organic solvents (oils) dispersed in an aqueous solution. The use of suitable emulsifiers (soaps) results in a two-phase cleaning fluid (oil-in-water), which functions by dissolving or emulsifying the soils on the part surface Can be used on either metal or nonmetallic parts Must be followed by alkaline cleaning to eliminate all residues of the organic solvent prior to plating.
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Solvent Cleaning
Organic soils such as oil and grease are removed from a metallic surface by means of chemicals (petroleum i.e. Chlorinated Hydrocarbons) that dissolve the soils. Common application techniques: hand-wiping, immersion, spraying, and vapor degreasing Vapor degreasing (a solvent cleaning method) uses hot vapors of chlorinated or fluorinated solvents Because the chemicals are hazardous, vapor degreasing has been largely discontinued as an industrial cleaning process, at least in the U.S.
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Acid Cleaning
Removes oils and light oxides from metal surfaces using acid solutions combined with water-miscible solvents, wetting and emulsifying agents Common application techniques: soaking, spraying, or manual brushing or wiping carried out at ambient or elevated temperatures Cleaning acids include hydrochloric (HCl), nitric (HNO3), phosphoric (H3PO4), and sulfuric (H2SO4)
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Ultrasonic Cleaning
Mechanical agitation of cleaning fluid by high-frequency vibrations (between 20 and 45 kHz) to cause cavitations - formation of low pressure vapor bubbles that scrub the surface. Combines chemical cleaning and mechanical agitation of the cleaning fluid. Cleaning fluid is generally an aqueous solution containing alkaline detergents. Highly effective for removing surface contaminants
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Blast Finishing
High velocity impact of particulate media to clean and finish a surface The media is propelled at the target surface by pressurized air or centrifugal force Most well-known method is sand blasting, which uses grits of sand as the blasting media Other blasting media:
Hard abrasives such as aluminum oxide (Al2O3) and silicon carbide (SiC) Soft media such as nylon beads
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Shot Peening
High velocity stream of small cast steel pellets (called shot) is directed at a metallic surface to cold work and induce compressive stresses into surface layers Used primarily to improve fatigue strength of metal parts Purpose is therefore different from blast finishing, although surface cleaning is accomplished as a byproduct of the operation
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Mass Finishing
Finishing parts in bulk by a mixing action in a container, usually in the presence of an abrasive media The mixing causes the parts to rub against the media and each other to achieve the desired finishing action Parts are usually small and therefore uneconomical to finish individually Processes include: 1) Tumbling 2) Vibratory finishing
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Tumbling
Use of a horizontally oriented barrel of hexagonal or octagonal cross-section in which parts are mixed by rotating the barrel at speeds = 10 to 50 rev/min Finishing by "landslide" action - media and parts rise in the barrel as it rotates, then top layer tumbles down due to gravity Drawbacks: slow, high noise levels, and large floor-space required
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Figure 28.1 - Diagram of tumbling (barrel finishing) operation showing "landslide" action of parts and abrasive media to finish the parts
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Tumbling Equipment
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Vibratory Finishing
An alternative to tumbling Vibrating vessel subjects all parts to agitation with the abrasive media, as opposed to only the top layer as in barrel finishing
Consequently, processing times for vibratory finishing are significantly reduced
The open tubs in this method permit inspection of the parts during processing, and noise is reduced
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Figure 28.2 - Typical preformed media shapes used in mass finishing operations: (a) abrasive media for finishing, and (b) steel media for burnishing
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Roller Burnishing
In roller burnishing the surface of the component is cold worked by a hard & highly polished rollers. Advantages:
1) It improves surface finish by removing scratches, tool marks & non uniformity. 2) Improvement in corrosion resistance.
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Roller Burnishing
Figure 33.1 Roller burnishing of the fillet of a stepped shaft to induce compressive surface residual stresses for improved fatigue life.
Figure 33.2 Examples of roller burnishing of (a) a conical surface and (b) a flat surface and the burnishing tools used. Source: Sandvik, Inc.
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Thermal Spraying
Spraying of molten coating materials onto a substrate, where they solidify and adhere to the surface Coating materials: It can be in the form of wire, rod or
powder. pure metals and metal alloys; ceramics (oxides, carbides, and certain glasses); other metallic compounds (sulfides, silicates); cermet composites; and certain plastics (epoxy, nylon, Teflon, and others). Substrates: metals, ceramics, glass, some plastics, wood, and paper Heating technologies: oxyfuel flame & plasma arc.
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Vapor Deposition
Vapor deposition is a process in which the substrate (Work piece surface) is subjected to chemical reactions by gases that contain chemical compounds of the metal to be deposited. The coating thickness is a few Micro meters. Typical applications for vapor depositions are the coating of cutting tools, drills, reamers, milling cutters, punches & dies.
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Applications of PVD
1. Decorative coatings on plastic and metal parts such as trophies, toys, pens and pencils, watchcases, and interior trim in automobiles 2. Coatings of magnesium fluoride (MgF2) onto optical lenses 3. Coating titanium nitride (TiN) onto cutting tools and plastic injection molds for wear resistance
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In Vacuum Evaporation, the metal to be Deposited is evaporated at high temperatures in vacuum and is deposited On the substrate. The coating material (cathode) is evaporated by several arc evaporators. The arc produces a highly reactive Plasma which consists of ionized vapor of the coating material. The vapor condenses on the substrate( anode) and coats it.
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Figure 33.5 Schematic illustration of the sputtering process. Source: ASM International
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Electroplating
Electrolytic process in which metal ions in an electrolyte solution are deposited onto a cathode workpart . Also called electrochemical plating The anode is generally made of the plating metal and thus serves as the source of the plate metal Direct current from an external power supply is passed between anode and cathode The electrolyte is an aqueous solution of acids, bases, or salts
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Electroplating
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Painting
Painting is widely used as a coating process because of the following properties: Decorative appearance Low cost Environmental protection Range of available colors Relative ease of application
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Painting
Common methods of applying paint are : 1) Dipping. 2) Brushing. 3) Spraying. In electrostatic spraying paint particles are charged and attracted to the surface being coated.
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Painting
Figure 33.11 Methods of paint application: (a) dip coating, (b) flow coating, and (c) electrostatic spraying. Source: Society of Manufacturing Engineers.
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