FINISHING PROCESSES

SUBMITTED BY:
ROHI GOYAL(041821)
PRATIUSH TYAGI(041816)
SUMEET TREHAN(041823)
AMIT CHADHA(041806)
LALIT MOHAN (041813)
RAJESH KUMAR(041819)

ANODISING
Anodizing is a technique used to modify the
surface of a metal.
It may provide greater corrosion resistance,
create a different surface topography and
change the crystal structure close to the metal
surface.
This process derives its name from the fact that
the part to be treated forms the anode portion of
an electric circuit in this electrolytic process.

ANODISING OF Al
In the anodising process, the natural oxide
layer on Al is replaced by a thicker oxide
which is produced by an electrochemical
process.
The corrosion protection achieved from
anodising, depends on the thickness and
quality of the oxide film.

 In corrosive environments the thickness of

the oxide layer should be about 25
micrometer, while thinner layers may be
sufficient in milder conditions.
The anodic layer is quite porous and in
order to get good corrosion protection a
sealing of the layer is normally done in hot
water or steam.

 The parameters of this process needs to be

carefully controlled to get maximum corrosion
protection.
The oxide layer is an electrical insulator and as
long as it is free from faults it will be a very good
protection against galvanic corrosion.
Before sealing different dyes can be added to
the oxide layer for colouring.
The surface will become hard and fairly resistant
to wear, abrasion and scartching.

 However , anodising will not give a long

term protection against strong acids or
bases.
This is due to the decreased stability of
the oxide layer at high an low pH.

METHODS OF ANODISING
BATCH ANODISING: Involves racking parts and immersing
them in a series of treatment tanks.
Extrusions, sheets or bent metal parts,
castings, cookwares, cosmetic cases are
just a few items that are batch anodised.

CONTINOUS COIL ANODISING

Involves continuous unwinding of pre-rolled coils
through a series of anodising, etching and
cleaning tanks, and then rewinding for shipment
and fabrication.
This method is used for high volume sheet, foil
and less severely formed products such as
lighting fixtures, reflectors, louvers, spacer bars
for insulated glass, and continous roofing
systems.

ANODISINGS BENEFITS

Durability
Color stability
Ease of Maintenance
Aesthetics
Cost
Health and safety

MECHANICAL CONSIDERATIONS
Anodising will raise the surface, since the oxide created
occupies more space than the base metal converted.
This will generally not be of consequence except in case
ofn small holes threaded to accept screws.anodising
may cause screws to bind, thus the threaded holes may
need to be chased with a tap to restore the original
dimensions.
In case of unthreaded holes that accept screws or pins a
slightly oversized hole to allow the dimension change
may be appropriate.

USES
Anodised Al can be found in iPod nanos,
cookware, cameras, and sporting goods
due to its asthetic and corrosion
properties.
Most Al aircraft parts including major
components are anodised before
assembly and painting.
Anodised niobium find use in jewelry and
commemorative coins.

PVD PROCESS
It is a technique used to deposit thin films of
various materials onto various surfaces (e.g of
semiconductor wafers) by physical means.
It is fundamentally a vaporisation coating
technique, involving transfer of material on an
atomic level.
It is an alternative process to electroplating.

HOW DOES PVD WORK?

PVD processes are carried out under
vacuum conditions.
The process involves four steps: Evaporation
Transportation
Reaction
Deposition

EVAPORATION
During this stage, a target, consisting of
the material to be deposited is bombarded
by a high energy source such as a beam
of electrons or ions.
This dislodges atoms from the surface of
the target, vaporising them.

TRANSPORTATION
This process simply consists of the
movement of vaporised atoms from the
target to the substrate to be coated and
will generally be a straight line affair.

REACTION
In some cases coatings will consist of metal
oxides, nitrides, carbides and other such
materials.
In these cases, the target will consist of the
metal. The atoms of metal will then react with
the appropriate gas during the transport stage.
For the above examples, the reactive gases may
be oxygen, nitrogen, and methane.

DEPOSITION
This is the process of coating build up on
the substrate surface.
Depending on the actual process, some
reactions between target materials and the
reactive gases may also take place at the
deposition process.

Usages

Improved hardness and wear resistance.

Reduced friction.
Improved oxidation resistance.
Longer component life.

ADVANTAGES
Materials can be deposited with improved
properties compared to the substrate
materials.
Almost any type of inorganic material can
be used as well as some kinds of organic
materials.
The process is more environmentally
friendly than processes such as
electroplating.

DISADVANTAGES
It is extremely difficult to coat undercuts
and similar surface features.
High capital cost.
Some processes operate at vacuum and
temp. requiring skilled operators.
The rate of coating deposition is usually
quite slow.

APPLICATIONS

Aerospace
Automotive
Surgical/medical
Dies and moulds for all manner of material
processing
Cutting tools
Fire arms

CVD PROCESS
CVD is chemical reactions which
transform gaseous molecules, called
precursor, into a solid material, in the form
of thin film or powder, on the surface of a
substrate.
This process is widely used to fabricate
semiconductor devices.

TYPES OF CVD PROCESSES

CVD covers processes such as: Atmospheric Pressure Chemical Vapour
Deposition (APCVD).
Metal-Organic Chemical Vapour
Deposition (MOCVD).
Laser Chemical Vapour Deposition
(PCVD)
Photochemical Vapour Deposition (PCVD)

HOW DOES CVD WORKS?

Precursor gases (often diluted in carrier
gases) are delivered into reaction
chamber at approximately ambient temp.
As they pass over or come into contact
with a heated substrate, they react or
decompose forming a solid phase which
and are deposited onto the substrate.

COATING CHARACTERISTICS

Fine grained.
Impervious.
High purity.
Harder than similar materials produced
using conventional ceramic fabrication
processes.
These coatings are usually only a few
microns thick and generally deposited at
fairly slow rates.

CVD APPARATUS

Gas delivery system

Reactor chamber
Substrate loading mechanism
Energy source
Vacuum system
Exhaust system
Exhaust treatment systems
Process control equipment

ENERGY SOURCES
Resistive heating e.g tube furnaces.
Radiant heating e.g halogen lamps.
Radio frequency heating e.g induction
heating.
Lasers
Other sources may include UV-visible light
or lasers as a source of photo energy.

PRECURSORS
Materials are deposited from the gaseous state
during CVD.
Thus precursors for CVD processes must be
volatile, but at the same time stable enough to
be able to be delivered to the reactor.
Generally precursor compounds will only provide
a single element to the deposited material, with
others being volatilised during the CVD process.

TYPICAL PRECURSOR
MATERIALS

Halides-TiCl4, TaCl5 etc.

Hydrides-SiH4, GeH4,NH3 etc.
Metal Alkoxides Ti(oiPr)4 etc.
Metal Dialylamides Ti(NMe2)4 etc.
Metal Carbonyls Ni(CO)4 etc.

CVD Gas Products

An often neglected by-product of the CVD
process are volatile gases.
However these gases may be toxic,
flammable or corrosive so must be treated
appropriately.
Analysis of the off-gases can lead to a
better understanding of the CVD rection
mechanisms.

APPLICATIONS

Coatings.
Semiconductors and related devices.
Dense structural parts.
Optical fibres.
Composites.
Production of novel powders and fibres.
Catalysts.
Nanomachines.

Galvanization
Introduction:
Galvanization or galvanisation refers to any of several
electrochemical processes named after the Italian
scientist Luigi Galvani.

History

Originally, galvanization was the administration of electric shocks (in

the 19th century also termed Faradism, after Michael Faraday). It
stemmed from Galvani's induction of twitches in severed frogs' legs,
by his accidental generation of electricity. This archaic sense is the
origin of the meaning of galvanized when meaning 'stirred to sudden
action'. Its claims to health benefits have largely been disproven,
except for some limited uses in psychiatry.
Later the word was used for processes of electrodeposition. This
remains a useful and broadly applied technology, but the term
"galvanization" has largely come to be associated with zinc
coatings,to the exclusion of other metals.
In current use, it typically means hot-dip galvanizing, a chemical
process that is used to coat steel or iron with zinc. This is done to
reduce corrosion (specifically rusting) of the ferrous item; while it is
accomplished by non-electrochemical means, it serves an
electrochemical purpose.

Definition
Zinc coatings prevent oxidation of the protected
metal by forming a barrier, and by acting as a
sacrificial anode if this barrier is damaged. Zinc
oxide is a fine white dust that (in contrast to iron
oxide) does not cause a breakdown of the
substrate's surface integrity as it is formed.
Indeed the zinc oxide, if undisturbed, can act as
a barrier to further oxidation, in a way similar to
the protection afforded to aluminium and
stainless steels by their oxide layers.

HOT DIP GALVANIZING

Hot-dip galvanizing is the process of coating iron
or steel with a thin zinc layer by passing the
steel through a molten bath of zinc at a
temperature of around 450C. Zinc "rusts" to
form zinc oxide, a fairly strong material that
stops further rusting, protecting the steel below
from the elements. Galvanized steel is widely
used in applications where rust resistance is
needed, and can be identified by the
crystalization patterning on the surface (often
called a "spangle").

Galvanized coating
The above photomicrograph and accompanying figure
represent a typical cross section of a hot dip galvanized
coating. The outermost (Eta) layer of the coating is formed
as a covering of pure zinc that is carried out on the material
as it is withdrawn from the molten zinc bath. The
underlying series of zinc/iron alloys in the coating are the
result of a metallurgical reaction between molten zinc and
the steel or iron material being galvanized. As the zinc/iron
alloys form, they will grow perpendicularly to the steel
surface. The effect this has on corners and edges of
material is that the coating there is generally thicker than
the surrounding coating, as seen in the micrograph below.
This is in sharp contrast to other types of protective
coatings that tend to thin out at the edges and corners of
material.

 The galvanized coating itself is considered to be a self inspecting

system. This is because the reaction between the molten zinc and the
steel will not occur unless the steel surface is chemically clean. In
effect, a galvanized coating that appears sound and continuous is in
fact sound and continuous. If a coating should become damaged
however, the zinc will continue to provide cathodic protection to the
exposed steel. Even if areas as much as 1/4 inch in length and/or
width become exposed, the surrounding zinc will provide cathodic
protection to this area as long as the coating lasts.
As for mechanical protection, the galvanized zinc coating literally
becomes part of the steel substrate thus, an adhesion bond on the
order of several thousand psi exists between the two. Also, since the
zinc/iron alloys are harder than the underlying steel, they will provide
excellent abrasion resistance to the galvanized article. The Eta layer is
relatively ductile and also contributes to the protection of the
galvanized material by providing good impact resistance. The
combination of all these layers to produce the galvanized coating
provides toughness and resistance to mechanical damage in transport,
erection and service.

process:
The process of hot dip galvanizing results in a metallurgical bond
between zinc and steel with a series of distinct iron-zinc alloys. The
resulting coated steel can be used in much the same way as uncoated.
Galvanized steel can be welded, however one must exercise caution
around the resulting zinc fumes from welding. Galvanized steel is
suitable for high temperature applications of up to 200C. Use at
temperarures above this level will result in peeling of the zinc at the
intermetallic layer. Galvanized sheet steel is commonly used in
automotive manufacture to enhance corrosion performance of exterior
body panels of some models.
Steel strip can be hot-dip galvanized in a continuous line. Hot-dip
galvanized steel strip (also sometimes loosely referred to as
galvanized iron) is extensively used for applications requiring the
strength of steel and resistance to corrosion. Applications include:
roofing and walling, consumer appliances and automotive body parts.
One common use is in metal pails.

All galvanizing consists of four fundamental

steps:
Surface preparation
Prefluxing
Galvanizing
Finishing

PICKLING

FlUXING

GALVANIZING

FINISHING

 The preparation steps consist of cleaning and pickling

operations that free the surface of dirt, grease, rust and
scale. The preflux step serves to dissolve any oxide that
may have formed on the iron or steel surface after pickling
and prevents further rust from forming. Clean, oxide-free
work is galvanized by immersion into molten zinc. Finishing
operations include quenching, removing excess zinc and
inspection

Factors affecting the thickness and

appearance of galvanized coating are:
1. The chemical composition of steel
2. The surface condition of steel
3. Bath immersion time
4. Bath withdrawal rate
5. Steel cooling rate

The chemical composition of steel:

The chemical composition of the steel is very important to the quality of
the galvanized coating since a metallurgical reaction between the zinc
and the iron is occurring.
As an example, silicon contents in the steel between 0.05% - 0.11%
and above 0.25% will cause the zinc/iron alloy layers to grow
abnormally fast. In fact, the silicon causes the galvanizing reaction to
continue unabated and the outermost pure zinc layer is eventually
consumed in the process. This not only causes the coating to be
thicker than normal, it will also most likely consist entirely of alloy
layers. The increased presence of these alloy layers in the coating
causes it to become brittle and a dark gray, matte finish will also result.
Steel compositions that affect the coating formation and properties in
this manner are referred to as "reactive steels".

GENERAL CONSIDERATIONS
The generic composition of a steel to be galvanized that
will produce an acceptable coating will be carbon less
than 0.25%, phosphorous less than 0.05% and
manganese less than 1.3%. Also, as discussed above, in
order to avoid the adverse effects of silicon on the
galvanized coating, silicon content in the steel should be
in the range of 0-0.04% or 0.15-0.25%. Steel with these
recommended levels should develop a normal
galvanized coating. However, should the composition of
these elements fall outside any of the previously stated
ranges, the steel will most likely still able to be
galvanized provided that the Galvanizer is notified in
advance of any deviations.

Surface condition of steel:

In general, rough steel surfaces will cause
the galvanizing reaction to produce thicker
coatings due to the increased surface
area.
These thicker coatings, however, will be
rough and have a generally poor
appearance

Bath immersion time

Galvanizing is a diffusion process.
As with all diffusion processes, the reaction
between the molten zinc and the steel or iron will
proceed quickly at first but will slow down as the
alloy layers grow and become thicker.
Thus, continued immersion or dipping material
more than once will not produce a significantly
thicker coating except in the case of
reactive steels.

Bath withdrawal rate

The withdrawal rate of material from the
galvanizing bath has the greatest effect on the
outermost layer of pure zinc.
A rapid withdrawal will produce the thickest
coating because the largest amount of zinc will
be carried out on the material and will
subsequently solidify and become the pure zinc
layer.
Slower withdrawal allows the zinc to effectively
drain back into the kettle producing smoother,
thinner, and more uniform coatings

STEEL Cooling rate

Slower cooling rates, such as those experienced
with air cooling or even with thicker sections that
have been water quenched, allow the zinc/iron
alloying reaction to continue. The inner alloy
layers will use the outer Eta layer for their supply
of zinc causing the coating to become dull,
matte gray.
Quickly reducing the temperature to less than
300 degrees Fahrenheit will halt the galvanizing
reaction and minimize the formation of dull or
matte surfaces.

Benefits of Galvanizing
Lowest First Cost - Hot Dip Galvanizing is lower in first cost than
many other commonly specified protective coatings for steel.
Less Maintenance/Lowest Long Term Cost - Even in cases where
the initial cost of hot dip galvanizing is higher than alternative
coatings, hot dip galvanizing is almost invariably more cost effective
in the long term because it lasts longer and needs less maintenance.
Long Life - The life expectancy of hot dip galvanized coatings on
typical structural members is far in excess of 50 years in most rural
environments, and 20 to 25 years plus, even in severe urban and
coastal exposure.
Reliability - Galvanizing at Metalplate is carried out to the appropriate
ASTM standards for hot dip galvanizing. Coating life and
performance are reliable and predictable.
Toughest Coating - A hot dip galvanized coating has a unique
metallurgical structure which gives outstanding resistance to
mechanical damage in transport, erection, and service.

 Automatic Protection For Damaged Areas - Hot Dip Galvanized

coatings corrode preferentially to steel, providing cathodic or sacrificial
protection to small areas of steel exposed through damage. Unlike
organic coatings, small damaged areas need no touch up.
Complete Protection - Every part of a hot dip galvanized article is
protected, even recesses, sharp corners and inaccessible areas. No
coating applied to a structure or fabrication after completion can
provide the same protection as hot dip galvanizing.
Ease of Inspection - Hot Dip Galvanized coatings are assessed readily
by eye, and simple non-destructive thickness testing methods can be
used. The hot dip galvanizing process is such that if coatings appear
sound and continuous then they are sound and continuous.
Faster Erection Time - As hot dip galvanized steel members are
received they are ready for use. No time is lost on-site in surface
preparation, painting and inspection. When assembly of the structure is
complete, it is immediately ready for use, or for the next construction
stage.

Chrome plating is a finishing treatment utilizing

the electolytic depositon of chromium. The most
common form of chrome plating is the thin,
decorative bright chrome, which is typically a
10 m layer over a underlying nickel plate. It
imparts a mirror-like finish to items such as
metal furniture frames and automotive trim.
Thicker deposits, up to 1000 m, are called hard
chrome and are used in industrial equipment to
reduce friction and wear and to restore the
dimensions of equipment that has experienced
wear.

There are two types of chromium plating:

1. INDUSTRIAL CHROME PLATING
2. DECORATIVE CHROME PLATING
Industrial Chromium plating is also called as
Hard or engineered chrome

There are two types of industrial

chromium plating solutions:
1. Hexavalent chromium baths whose
main ingredient is chromic anhydride .
2. Trivalent chromium baths whose main
ingredient is chromium sulfate or
chromium chloride.
Trivalent chromium baths are not yet
common, due to restrictions
concerning color, brittleness, and plating
thickness.

Hard Chrome Plating

Most people would not be very familiar with hard chrome plating. Hard
chromium plating is chrome plating that has been applied as a fairly heavy
coating (usually measured in thousandths of an inch) for wear resistance,
lubricity, oil retention, and other 'wear' purposes. Some examples would be
hydraulic cylinder rods, rollers, piston rings, mold surfaces, thread guides,
gun bores, etc. 'Hard chrome' is not really harder than other chrome plating,
it is called hard chromium because it is thick enough that a hardness
measurement can be performed on it and the chrome hardness can be
measured, whereas thinner plating will break like an eggshell if a hardness
test is conducted, so its hardness can't really be measured directly.
Hard chrome plating is almost always applied to items that are made of
steel, usually hardened steel. It is metallic in appearance but is not
particularly reflective or decorative. Hard chrome plating is not a finish that
you would want on a wheel or bumper.
There are variations even within hard chrome plating, with some of the
coatings optimized to be especially porous for oil retention, etc.
Many shops who do hard chromium plating do no other kind of plating at all,
because their business is designed to serve only engineered, wear-type,
needs. If a shop says they do 'hard chrome only', they have no service that
most consumers would be interested in.

Decorative chrome plating

Decorative chrome plating is sometimes called nickel-chrome

plating because it always involves electroplating nickel onto the
object before plating the chrome (it sometimes involves
electroplating copper on the object before the nickel, too). The
nickel plating provides the smoothness, much of the corrosion
resistance, and most of the reflectivity. The chrome plating is
exceptionally thin, measured in millionths of an inch rather than in
thousandths
When you look at a decorative chromium plated surface, such as a
chrome plated wheel or truck bumper, most of what you are seeing
is actually the effects of the nickel plating. The chrome adds a bluish
cast (compared to the somewhat yellowish cast of nickel), protects
the nickel against tarnish, minimizes scratching, and symbiotically
contributes to corrosion resistance. But the point is, without the
brilliant leveled nickel undercoating, you would not have a reflective,
decorative surface.
By the way, there is no such thing as "decrotif chrome plating". That
is just a misspelling of 'decorative' that took on a life of its own.

INTRODUCTION TO THE
CHROME PLATING PROCESS

1.
2.
3.
4.
5.
6.

Chrome plating is not difficult providing the part has been

properly cleansed and the following requirements met:
Preparation of the chromic acid (CrO3) solution..(Do not
acquire the hydrogenated [ H2CrO4 ] chromic acid
crystals)
Temperature control of the bath (plating solution)
Preparation of lead anodes (peroxide)
Agitation method of the bath (bubbles)
Plating current density control and duration (controller)
Ventilation (for safety)

Hexavalent chromium
Hexavalent chromium or Cr(VI) compounds are those
which contain the element chromium in the +6 oxidation
state. chromates are often used as pigments for
photography, and in pyrotechnics, dyes, paints, inks, and
plastics. They can also be used for stainless steel
production, textile dyes, wood preservation, leather
tanning, and as anti-corrosion and conversion coating.
They are used as corrosion inhibitors, however due to their
toxicity they are being replaced by alternatives.
Hexavalent chromium is recognized as a human
carcinogen.

Sacrificial Anode
sacrificial anode, or sacrificial rod, is a metallic anode used in an
electrochemical process where it is intended to be dissolved to protect
other metallic components.
In laymen's terms, it's a piece of readily corrodible metal attached (by
either an electrically conductive solid or liquid) to the metal you wish to
protect. This piece of metal corrodes first, and generally must dissolve
nearly completely before the protected metal will corrode (hence the
term "sacrificial").
More scientifically, a sacrificial anode can be defined as a metal that is
more easily oxidized than the protected metal. Electrons are stripped
from the anode and conducted to the protected metal, which, for this
reason, is forced to become the cathode. As a result, the protected
metal is prevented from corroding.
For example when zinc and iron are put together in the presence of
oxygen, the zinc and oxygen will lose electrons at the same time.
However, as iron is less reactive than zinc, it tends to absorb the
electron zinc loss relatively. Therefore, iron is a neutral atom and zinc
is a cation and reacts with oxygen, and the iron is "safe" until all of the
zinc has corroded.