ADVANCED SURFACE

ENGINEERING
ENMT801016

Outline
2

About

the class
Class introduction
Course content
Grading
General introduction to Advanced Surface
Engineering

Code: ENMT801016
Subject: Advanced Surface Engineering
SKS: 3
Class: Senior Undergraduate/Graduate
Term: Second Term 2012/2013
Class meet: Wed at 6:00 8:30 pm in K.209
3

 The

class is designed to give the students fundamental

concept in improving the performance, extending the
life, and enhancing the appearance of materials used
for engineering components
The class will review the latest technological
advancements and issues in surface engineering and its
practical application for both metallic and non metallic
materials.
4

After taking this course the students are expected to be able to:
Describe the phenomena of changes in materials properties
associated with surface treatment processes
Selecting and designing a variety of surface treatment process
according to the selected materials and their application in
industry
Obtain a right microstructure and desired mechanical
properties according to the selected surface treatment process
5

 For

the assignment, please note that a submission

date, time and venue will be specified at the time
of setting of each assignment.
Assignment that does not adhere to these submission
requirements will receive an automatic zero grade.

All

exam times and assignment deadlines are fixed

and the only excuses accepted for nonattendance
at an exam or non-submission of an assignment are
a serious certified illness or a family bereavement.
In such cases, a make-up exam (or make-up
assignment in the case of an assignment) of equal
or greater difficulty must be taken.

Examinations

and individual assignments are to be

the sole work of the student concerned group
efforts are not acceptable!
Students are also cautioned not to engage in any
plagiarism.
Anything that is not the students own work should
have a reference, following standard scientific
conventions.

In

such rare cases as it is necessary to include

verbatim text from an article or book, this should be
clearly placed in quotation marks.
The instructor will follow standard university
disciplinary procedures if students engage in any
form of cheating and/or plagiarism in
examinations/assignments.

 The

lecture notes/handouts in this class are edited

from different sources for the solely of teaching and
learning purposes.
It may contain copyrighted materials from their
respective owners; therefore, apart form teaching
and learning purposes, this lecture note may not be
reproduced, stored, or transmitted in any form or
by any means.
10

11

Students

are expected to make their own notes and

only relatively few handouts will be provided so
please stop me if you cant read my writing or if I
am going too fast.
Lecture notes/handouts are provided via the web
(www.nofrijon.org) as Adobe Acrobat (PDF) files.

 To
12

obtain handouts, please navigate my website

and then click on the subjects.
You need a password to open the file, see me if you
do not have one!
Questions and comments in class are strongly
encouraged! The instructor both welcomes and
values feedback from students regarding the
course.
Office hours: DTMM 2nd Fl. W 1:00 pm 6:00 pm

13

Students

needing special accommodation are

encouraged to see me after class or in my office within
office hours to discuss their situation confidentially.

Students

needing special accommodation should bring

their memorandum from the Program Office to me as
soon as possible; this can be discussed during an
appointment with me.

14

Exam

accommodation should be arranged at least

one week in advance.

If

at any time during the quarter, it is felt that the

accommodation that has been put in place is
inadequate then please consult me and/or the
professional staff in the Program Office.

This course is self contained and so a textbook is not

mandatory. However, students may also wish to consult the
following excellent texts:
ASM Handbook Vol. 4; Heat Treating, ASM
International, Ohio, USA, 1991.
ASM Handbook Vol. 5; Surface Engineering, ASM
International, Ohio, USA, 1994.
Karl-Erik Thelning, Steel and its heat treatment,
Butterworths, 1984.
15

The course will be graded on the following:

Mid-semester examination: 30% of final grade
Final examination: 30% of final grade
Teamwork problem based learning: 20% of final
grade
Case study: 20% of final grade
16

General introduction
17

Heat Treatment

Surface Engineering

Controlled heating and

cooling of metals to alter
their physical and
mechanical properties
without changing the
product shape

Sub-discipline of materials
science and engineering
dealing with the surface of
solid matters

Heat treatment
18

Heat treatment is often associated with increasing the

strength of material, but it can also be used to soften a
metal and thus alter certain manufacturability objectives
such as improve machining, improve formability, restore
ductility after a cold working operation.
Therefore, the most beneficial manufacturing processes are
the ones that not only help other manufacturing process, but
can also improve product performance by increasing
strength or other desirable characteristics.

Surface engineering
19

A branch of materials engineering aimed at the design,

manufacture, investigation and utilization of surface layers,
both technological and for end use, with the properties
better than those of the core, such as mainly anti-corrosion,
anti-fatigue, anti-wear and decorative.
Further, surface engineering techniques are also being used
in the automotive, aerospace, missile, power, electronic,
biomedical , textile, petroleum, petrochemical, chemical,
steel, power, cement, machine tools, construction industries.

Why?
20

To prepare as-produced metallic materials

(semi-finished products) for the next process
and/or treatments.
To lengthening the life time of the finishedproduct/materials during service.

Heat treating a metal

21

http://www.fandbfarm.com/blacksmith.html

By heating and cooling (or quenching) a metal we can change its properties.

The importance
22

For many castings the heat treatment

process is a decisive part to establish
the required casting performance.

http://www.magmasoft.de/ms/pics/HeatTreatment_320x240.gif

Steel casting
Most steel castings receive their
structure and mechanical properties
through a proper heat treatment.

 Cast
23

Iron
Residual stresses play a growing role for the
performance of cast iron components.
Aluminum Castings
Many non-ferrous high integrity components undergo a
comprehensive heat treatment to establish the required
strength or ductility. E.g. T6 treatment creates the
required properties, but also imposes substantial
residual stresses into the casting as a function of the
quenching and annealing conditions.

Metal manufacture processes

24

Raw Metals
(Ores extraction products)
Foundry
(casting)

Mechanical forming
(Plastic deformation)
Welding/
joining

Powder
metallurgy

Cutting
(machining)

Heat treatment
Finishing/Surface Engineering

Heat
treatment
Semi-Finished
Products
Finished Products

Metal Materials Quality

Chemical composition
Microstructure
Microstructure:
Metal microstructure is in microscopic resolution (1-100
m)
Consist of several constituents such as phase, crystallite
grain, crystal defects, segregation, inclusion

Schematic diagram of
microstructure

Grain boundary

Precipitation/particles
in matrix
Twins
Crystal unit
(Fe = 0.86 )

Dislocation
Inclusion
(High melting point)

Continuous grain boundary

precipitation

Crystal Defects
Crystal defects affect mechanical and
physical properties of metal materials
Edge dislocation

Screw dislocation

Twins

Burger vector
Dislocation line

Dislocation center
Burger vector)

Slip step

Remember!
Metals

with the same chemical composition may not

have identical mechanical/physical properties.
Heat treatment controls metals microstructures as so
to increase their mechanical properties.
Heat treatment optimize hardness and ductility of
metals/steels.

Factors affecting metal components malfunction

Surface deteroriation,
70%

Surface treatment
reduces the risk!

Obsolescence, 15%

Breakage, 15%

Cost of heat treatment compared with the total

cost of manufacture process
30

Trimming
20%

Etching
2%

Assembly
11%

Mould material,
components etc.
16%

EDM
16%
Grinding
5%
Heat treatment
3%

Milling
20%

Drilling
5%

With relative low cost of heat treatment

results in longer life of components

Surface characteristic
Metal Surfaces
Surface asprity

31

Micro roughness of the surface that is

composed of hills and bottoms.

Bielby layer
Adsorb film: water vapour, oxygen 3 x10-10 m.
Greasy film: finger print, or oil drops 3 x10-9 m.

Oxide layer
Rust products with their thickness
as little as 10-7 m.

Typical surface layers

Deformed layer
It is due to mechanical forming of metals.

Metalic sub-surface structure

32

Micrograph showing subsurface

deformation in leaded brass after
severe sliding wear against tool steel in
air.

Schematic diagram showing how the

severity of plastic deformation is
distributed beneath a worn metal surface
in the severe wear regime.

Surface Parameters
33

Arithmetic mean deviation :

Ra

1 L
y(x) dx
L 0

Root mean square deviation :

R 2q

1 L 2
Y (X) dx
L 0

Skewness :

1
S k 3 Y 4 p( y )dy
R q
Normal distribution Sk = 0

1
K 4
Rq

Kurtosis :

y4 p( y )dy

Normal distribution K = 3
Broad and flat distribution curve : K 3

Ra

R q2

Reference
plane

The importance
34

Surface

engineering is aimed at the design,

manufacture, investigation and utilization of surface
layers, both technological and for end use, with
properties better than those of the core, such as
mainly anti-corrosion, anti-fatigue, anti-wear and
decorative.

 Other
35

applications include properties such as

optical, thermophysical, electrical, magnetic,
adhesive, ablation, passivation, inhibition,
biocompatibility, diffusion and others
Modification of near-surface structure, chemistry or
property of a substrate in order to achieve superior
performance and/or durability.
It is an enabling technology and can impact a wide
range of industrial sectors.

 Combining
36

chemistry, physics, and mechanical

engineering with metallurgy and materials science,
it contributes to virtually all engineering disciplines.
It can be done on a given surface by metallurgical,
mechanical, physical, and chemical means, or by
producing a thick layer or a thin coating.
Both metallic and non-metallic surfaces can be
engineered to provide improved property or
performance.

Why surface engineering?

37

Specific

properties rely on surfaces; wear, friction,

corrosion, fatigue, reflectivity, emissivity, color,
thermal/electrical conductivity, bio-compatibility
By improving durability, it reduces waste of natural
resources and energy

38

Surface

engineered automotive parts and

components can extend warranties and reduce
emissions.
For example: A hardened engine valve will last a
minimum of five years without replacement.
Surfaces have different properties than bulk
material / need to optimize both

39

Surfaces

can be completely reengineered

Surfaces can be functionalized to achieve a
specific molecular configuration
Surface engineering techniques are both varied
and complex providing a change to the outermost
material interface

Benefits
40

Extend

product life (durability)

Improve resistance to wear, oxidation and corrosion
(performance)
Satisfy the consumer's need for better and lower
cost components
Reduce maintenance (reliability and cost)
Reduce emissions and environmental waste

41

Improve

the appearance; visually attractivity

Improve electrical conductivity
Improve solderability
Metallize plastic component surfaces
Provide shielding for electromagnetic and radio
frequency radiation.

Scales of surface engineering

42

Five

orders of magnitude in thickness; it can vary

from several mm for weld overlays to a few atomic
layers or nanometers for physical vapor deposition
(PVD) and chemical vapor deposition (CVD)
coatings or ion implantation.
Atomic-layer deposition is also possible.

43

Superlattice Coatings

Duplex Coatings

Superhard CVD-Diamond Films

Multilayer Coatings

 Three
44

orders of magnitude in hardness: Example of

coating hardness range from 250-300 HV for soft
metal or spray coatings, 3500 HV for Titanium
Nitride PVD coatings and up to 10,000 HV for
diamond coatings
Almost infinite possibilities in the range of
compositions and/or microstructure
Nano-composite, nano-layered, amorphous,
crystalline, quasicrystalline

Significance of surface engineering

45

It

is an enabling technology
It can combine various surface treatments with thin
film and coating deposition.
It can substantially improve wear and corrosion
resistance of structural components.

46

It

increases component lifetime and resistance to

aggressive environments.
It can produce functional coatings that modify
biocompatibility and optical and electrical
properties of critical components

Techniques in surface engineering

47

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)

48

Techniques

to modify an existing surface

topographically, chemically, or microstructurally to
enhance its properties e.g., conventional carburizing
and nitriding, and more enhanced techniques in
glazing, abrasive finishing, and ion implantation
Techniques for the testing and characterization of
the modified surfaces extrapolated to surfacespecific applications