Surface Treatments:
Surface Hardening
Equipment & Coatings
Alfredo Valarezo
Surface Treatments
Thermochemical treatments (Carburizing,
nitriding, carbonitriding, chromizing)
Electrochemical treatments (hard chrome,
cadmium, nickel)
Thermomechanical treatments (thermal
Spray)
Mechanical treatments (shot peening,
blasting)
Clasificacin de los Procesos en
Ingeniera de Superficies
Ingeniera de Superficies: el termorociado
Clasificacin en consideracin de la naturaleza del depsito (por difusin atmica o de iones, o por
adicin de material en la superficie) y el espesor del recubrimiento.
Ingeniera de Superficies: el termorociado
Dureza de varios materiales y
tratamientos superficiales
Surface Hardening
Thermochemical treatments applied to steels in
which the composition of the part surface is
altered by adding various elements
Often called case hardening
Most common treatments are carburizing,
nitriding, and carbonitriding
Commonly applied to low carbon steel parts
to achieve a hard, wear-resistant outer shell
while retaining a tough inner core
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Carburizing
Heating a part of low carbon steel in a carbon-rich
environment so that C is diffused into surface
In effect the surface is converted to a high carbon
steel, capable of higher hardness than the low-C
core
Carburizing followed by quenching produces a case hardness of
around HRC = 60
Internal regions are low-C steel, with low hardenability, so it is
unaffected by quench and remains relatively tough and ductile
Most common surface hardening treatment
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Carburizing in Salt Bath
NaCN + O2 2NaCNO
2NaCNO + O2 Na2CO3 +CO + N2
2CO CO2 + C
Sodium Cyanide Salt
(Sal de Cianuro de sodio)
Salt Bath Furnace
Carburizing by Pack
Carburizing Steel 1020
Nitriding
Treatment in which nitrogen is diffused into surface
of special alloy steels to produce a thin hard
casing without quenching
Carried out at around 500C (950F)
To be most effective, steel must have alloying
ingredients such as aluminum (AlN) or chromium
(CrN) to form nitride compounds that precipitate
as very fine particles in the casing to harden the
steel
Hardness up to HRC 70
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Carburizing Steel 1015 (Temp. 550C)
Chromizing/Boronizing
Requires higher temperatures and longer
treatment times than the preceding hardening
treatments
Usually applied to low carbon steels
Casing is not only hard and wear resistant; it is
also heat and corrosion resistant
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Furnaces for Heat Treatment
Fuel-fired furnaces
Normally direct-fired - the work is exposed
directly to combustion products
Fuels: natural gas or propane and fuel oils
that can be atomized
Electric furnaces
Electric resistance for heating
Cleaner, quieter, and more uniform heating
More expensive to purchase and operate
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Batch vs. Continuous Furnaces
Batch furnaces
Heating system in an insulated chamber, with a door for
loading and unloading
Production in batches
Continuous furnaces
Generally for higher production rates
Mechanisms for transporting work through furnace
include rotating hearths and straight-through conveyors
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Other Furnace Types
Atmospheric control furnaces
Desirable in conventional heat treatment to avoid
excessive oxidation or decarburization
Include C and/or N rich environments for diffusion into
work surface
Vacuum furnaces
Radiant energy is used to heat the parts
Disadvantage: time needed each cycle to draw vacuum
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Selective Surface Hardening
Methods
These methods heat only the work
surface, or local areas of the work
surface
They differ from surface hardening
methods in that no chemical changes
occur
Methods include:
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Flame hardening
Induction hardening
High-frequency resistance heating
Electron beam heating
Laser beam heating
Flame Hardening
Heating of work surface by one or more torches
followed by rapid quenching
Applied to carbon and alloy steels, tool steels,
and cast irons
Fuels include acetylene (C2H2), propane (C3H8),
and other gases
Lends itself to high production as well as big
components such as large gears that exceed
the size capacity of furnaces
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Induction Heating
Application of electromagnetically induced
energy supplied by an induction coil to an
electrically conductive workpart
Widely used for brazing, soldering, adhesive
curing, and various heat treatments
When used for steel hardening treatments,
quenching follows heating
Cycle times are short, so process lends itself to
high production
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Induction Heating
Figure 27.7 Typical induction heating setup. High frequency alternating current
in a coil induces current in the workpart to effect heating.
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
High-frequency (HF) Resistance
Heating
Used to harden specific areas of steel work surfaces
by application of localized resistance heating at
high frequency (400 kHz typical)
Contacts are attached to workpart at outer edges
of the area
When HF current is applied, region under
conductor is heated quickly to high
temperature - heating to austenite range typically
takes less than a second
When power is turned off, area is quenched by
heat transfer to the surrounding metal
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
High-frequency Resistance Heating
Figure 27.8 Typical setup for high-frequency resistance heating.
2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
Surface Treatments
Thermochemical treatments (Carburizing,
nitriding, carbonitriding, chromizing)
Electrochemical treatments (hard chrome,
cadmium, nickel)
Thermomechanical treatments (thermal
Spray)
Mechanical treatments (shot peening,
blasting)
What is Thermal Spray?
Thermal Spray Processes
Intersplat bonding strength
Wetting/ adsorbatecondensates
Residual Stress (quenchingpeening)
LOW VELOCITY
Molten particle
Materials intrinsic
Properties
Particle Velocity
Kinetic Energy
Fluid dynamics
Particle Temperature
Oxidation/decomposition
Rapid cooling/phase
transformations
Local Deposition
Temperature
Particle State
The science behind thermal spray
HIGH VELOCITY
Semi -molten
particle
More
decomposition
Less
Decomposition
Z2
z
Z1
+
Residual Stresses
Tension
+
Plastically
worked zone
Compression
Substrate-splat adhesion
interface
Splat-splat-intersplat
interfaces
Interpass interfaces
Elastic plastic behavior
High strain strain rates
Heat transfer
Industries that demand Thermal Spray
Defense and Aerospace: Typical Applications
26
Landing Gear
Hydraulic Shafts
Gas and Aeroturbines
Part reclamation
Antiskid Plattforms
Worn out components,
in general
http://www.asetsdefense.org/
http://www.istockanalyst.com/article/viewarticle/articleid/1725016
http://alphamar-imw.com
Cyllinder Bore
Crankshaft Repair by HVOF
Propuesta de Partes a Reparar: Eje Trasero Camiones
Recubrimiento
Preparacion
Superficial
Propuesta de Partes a Reparar: Florero de la Transmisin
Recubrimiento
Propuesta de Partes a Reparar: Secciones de Manifold
Recubrimiento
Propuesta de Partes a Reparar: Asientos y Pines
Recubrimiento
Propuesta de Partes a Reparar a FUTURO: Carcazas
Recubrimiento
ELECTRODEPOSITION
Electroplating
ELECTROPLATING
Electroplating is a plating
process in which metal
ions in a solution are
moved by an electric field
to coat an electrode.
The process uses
electrical current to
reduce cations of a
desired material from a
solution and coat a
conductive object with a
thin layer of the material,
such as a metal.
ELECTROPLATING
The anode and cathode are both
connected to an external supply of
direct current
The anode is the positive terminal,
and the cathode is the negative.
The metal at the anode is oxidized
from the zero valence state to form
cations with a positive charge.
These cations associate with the
anions in the solution.
The cations are reduced at the
cathode to deposit in the metallic,
zero valence state.
The plating is most commonly a
single metallic element, not an alloy.
However, some alloys can be
electrodeposited, notably brass and
solder.
Ni - ELECTROPLATING
Nickel Electroplating is a process in
which a coat of nickel metal is
deposited over another metal for
inducing certain superior properties.
The process is carried out in an
electrolytic solution, and is widely
used in the electronics and chemical
industries.
Some of the features of nickel coating
that is deposited on the metal
surface are as follows:
Decorative appearance
Corrosion protection
Wear resistance
Low coefficient of friction.
Ferromagnetism
Controllable internal mechanical
stresses
Surface Engineering Techniques
The techniques covered may be
divided broadly into three
categories:
Techniques to prepare a surface
for subsequent treatment (e.g.,
cleaning and descaling)
Techniques to cover a surface
with a material of different
composition or structure (e.g.,
plating, painting, and coating)
Techniques to modify an existing
surface topographically,
chemically, or microstructurally to
enhance its properties (e.g.,
glazing, abrasive finishing, and
ion implantation)
Hydrogen Evolution and Cathode
Efficiency
The discharge of nickel ions is
not the only reaction that can
occur at the cathode; a small
percentage of the current is
consumed in the discharge of
hydrogen ions from water.
This reduces the cathode
efficiency for nickel deposition
from 100 per cent to 92 to 97
per cent depending on the
nature of the electrolyte.
The discharged hydrogen
atoms form bubbles of
hydrogen gas at the cathode
surface.
Deposition Rate
If the plating process is operated at 5 A/dm2, for example, it takes about 20
minutes to deposit a nickel coating with an average thickness of 20 um.
Faraday's Law for Nickel
W = (I*t*A)/(n*F)
where:
W = weight of plated metal in grams.
I = current in coulombs per second.
t = time in seconds.
A = atomic weight of the metal in
grams per mole.
n = valence of the dissolved metal in
solution in equivalents per mole.
F = Faraday's constant in coulombs
per equivalent. F = 96,485.309
coulombs/equivalent.
Nickel Plating Solutions
