Surface Treatment, Coating, and Cleaning Processes

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CLEANING AND SURFACE TREATMENTS

Cleaning involves the removal of solid, semisolid or liquid contaminants from a surface.
Chemical Cleaning Mechanical Cleaning and Surface Preparation Diffusion and Ion Implantation

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Surface Treatments for Various Metals

TABLE 33.1 Metal Aluminum Beryllium Cadmium Die steels High-temperature steels Magnesium Mild steel Molybdenum Nickel- and cobalt-base alloys Refractory metals Stainless steel Steel Titanium Tool steel Zinc Treatment Chrome plate; anodic coating, phosphate; chromate conversion coating Anodic coating; chromate conversion coating Phosphate; chromate conversion coating Boronizing; ion nitriding; liquid nitriding Diffusion Anodic coating; chromate conversion coating Boronizing; phosphate; carburizing; liquid nitriding; carbonitriding; cyaniding Chrome plate Boronizing; diffusion Boronizing Vapor deposition; ion nitriding; diffusion; liquid nitriding; nitriding Vapor deposition; chrome plate; phosphate; ion nitriding; induction hardening; flame hardening; liquid nitriding Chrome plate; anodic coating; ion nitriding Boronizing; ion nitriding; diffusion; nitriding; liquid nitriding

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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Overview of Industrial Cleaning

Almost all workparts must be cleaned one or more times during their manufacturing sequence
Chemical and/or mechanical processes are used to accomplish this cleaning
- Chemical cleaning methods use chemicals to remove unwanted contaminants from the work surface - Mechanical cleaning involves removal of contaminants from a surface by various mechanical operations

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Reasons Why Manufactured Parts (and Products) Must be Cleaned

Prepare the surface for subsequent processing, such as a coating application or adhesive bonding Improve hygiene conditions for workers and customers Remove contaminants that might chemically react with the surface Enhance appearance and performance of the product

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Important Factors in Selecting a Cleaning Method

Contaminant to be removed Degree of cleanliness required Substrate material to be cleaned Purpose of the cleaning Environmental and safety factors Size and geometry of the part Production and cost requirements

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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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Other Factors in Selection of Cleaning Method

The substrate material must be considered, so that damaging reactions are not caused by the cleaning chemicals.
Example:
- Steels are resistant to alkalis but react with virtually all acids

Cleaning methods and associated chemicals should be selected to avoid pollution and health hazards.

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Chemical Cleaning Processes

Alkaline cleaning Emulsion cleaning Solvent cleaning Acid cleaning Ultrasonic cleaning In some cases, chemical action is augmented by other energy forms
Example: ultrasonic cleaning uses high-frequency mechanical vibrations combined with chemical cleaning

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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.

P7-11

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.

P7-12

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.

P7-13

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
P7-15

Mechanical Cleaning and Surface Preparation

Physical removal of soils, scales, or films from the work surface by means of abrasives or similar mechanical action ( Fibre Brushing) Often serves other functions such as improving surface finish and surface hardening. Processes:
1) Blast finishing 2) Shot peening 3) Mass finishing processes

P7-16

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

P7-17

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

P7-19

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
P7-23

Mass Finishing Media

Natural media (corundum, granite, limestone) - generally softer and nonuniform in size Synthetic media (Al2O3 and SiC) - greater consistency in size, shape, and and hardness Steel - used for burnishing, surface-hardening, and light deburring operations

P7-24

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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COATING AND DEPOSITION PROCESSES

Plating and Related Processes Conversion Coatings Vapor Deposition Physical Vapor Deposition Chemical Vapor Deposition Thermal Spray Coating Processes
P7-28

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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Application of Thermal Spraying

1. First applications were to rebuild worn areas on used machinery components had been machined undersize. 2. Also used in manufacturing as a coating process for corrosion resistance, high temperature protection, wear resistance, electrical conductivity, electrical resistance, electromagnetic interference shielding
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Thermal Spray Operations

Figure 33.3 Schematic illustrations of thermal spray operations. (a) Thermal wire spray. (b) Thermal metalpowder spray. (c) Plasma spray.
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Thermal Spray Operations

i. Thermal wire spray.: In this process oxy-fuel flame melts the wire and deposits it on the surface of substrate. ii. Thermal metal-powder spray: It is similar to the thermal wire spray process, but the coating metal is in state of powder instead of wire. iii. Plasma spray: It produces temperatures at the order of 8300 C. it results in very high Bond strength.

P7-32

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.

P7-33

Physical Vapor Deposition (PVD)

A family of coating processes in which a material is converted to its vapor phase in a vacuum chamber and condensed onto a substrate surface as a very thin film Can be used for a wide variety of coating materials: metals, alloys, ceramics and other inorganic compounds, and even certain polymers Possible substrates: metals, glass, and plastics PVD is a very versatile coating technology, applicable to an almost unlimited combination of coating substances and substrate materials

P7-34

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
P7-35

Physical Deposition: Vacuum Evaporation

Figure 33.4 Schematic illustration of the physical deposition process. Source: Cutting Tool Engineering.

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.

P7-36

Physical Vapor deposition: Sputtering

In Sputtering, an electric filed ionizes an inert gas (argon). The positive ions Bombard the coating material (cathode) and cause sputtering (ejecting) of its atoms. These atoms then condenses on the work piece

Figure 33.5 Schematic illustration of the sputtering process. Source: ASM International

P7-37

Chemical Vapor Deposition (CVD)

Involves the interaction between a mixture of gases and the surface of a heated substrate, causing chemical decomposition of some of the gas constituents and formation of a solid film on the substrate Reactions take place in enclosed reaction chamber Reaction product (metal or compound) reacts and grows on substrate surface to form the coating. Most CVD reactions require heat. Wide range of pressures and temperatures in CVD Variety of coating and substrate materials possible

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Chemical Vapor Deposition

Figure 33.7 Schematic illustration of the chemical vapor deposition process.

P7-39

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

Figure 33.8 Schematic illustration of the electroplating process.

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Common Coating Metals

Zinc - plated on steel products such as fasteners, wire goods, electric switch boxes, and sheetmetal parts as a sacrificial barrier to corrosion Nickel - for corrosion resistance and decorative purposes on steel, brass, zinc die castings, and other metals; also used as a base coat for chrome plate Tin - widely used for corrosion protection in "tin cans" and other food containers

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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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