FINISH

PROCESSES
 FINISH PROCESSE

Surface Preparation

MECHANICAL CHEMICAL
 MECHANICAL SURFACE PREPARATION

Methods: wire brushing, polishing, buffing wheels, surface

conditioning abrasives, belt polishing, mass finishing, blast
finishing, and impact blasting with glass beads.
Blast Finishing:
Abrasives (sand) are propelled by a high velocity jet of air or
water.
Purpose: To remove surface contamination, take off old paints,
roughen surfaces before painting, remove surface irregularities,
and for surface modification (removing distortion, decreasing
corrosion & increasing fatigue life)
·(-) The blasting machine should be isolated for operators’ safety.
·Blast finishing depends on
(1) The pressure (should be optimum).
(2) the blast angle
(3) the distance from the nozzle to the surface.
Impact Blasting with Glass Beads:
This finish process uses glass beads instead of abrasives.
·(+) 1. Glass beads are chemically inert (no chemical reactions
with the surface).
2. Low consumption.
3. Safe process.
4.Environmentally acceptable.
· Purpose:

1) To remove burrs and contamination from the surface.

2) To perform peening on the surface (plastic deformation).

This increases fatigue life, corrosion resistance, and surface

strength.
PLATING PROCEDURES
Plating is the process of application of coatings for the base
material to impart it properties not inherent in the base.

Purpose: To provide properties

for the surfaces (Corrosion
resistance, wear resistance,
conductivity, colour, and
reflectability).
Methods of Plating
1-Brush Plating:
Brush plating is used to impart surfaces a masking by a liquid
organic coating. Nickel and copper solutions are used with
these coatings. Before plating the surface must be precleaned
and free from oil, grease, dirt, and dust. The process is
performed by hand.
2-Metalising Non-conductors:
It is the process of imparting non-conductors a metal-layer in
order to increase electrical conductivity, strength, and
appearance. There are TWO methods of metalising:
 2-Metalising Non-conductors:

1- Using conductive paints: 2 Catalytic Deposition:

In this process a metal film

The non-conductor is
is applied on a non-
coated with a conductive
conductors by catalytic
paint that consists of
deposition. (Example:
varnish or lacquer and a
Electroless nickeling of
conductive component
plastics).
(graphite, copper, or
silver).
{Catalyst = a substance that
makes another substance
change chemically without
changing itself}.
Electroplating:
Purpose: provides surfaces with decorative and protective coatings.
Deposited metals: (anode) Al, Ni, Cr, Cu, Ag, Zn, and Au.

Principle: The workpiece (cathode) is plated with a different metal

(anode), while both are suspended in a bath containing an electrolyte. A
d-c of density of 6 to 24 V is required.

1)current density.

Electroplating 2) temperature of
depends on electrolyte

3) condition of surface.
Chrome Plating:
Chrome plating is used to impart wear and abrasive resistance to
surfaces (dies and punches). The process consists of passing a d-c
from an anode to a cathode (workpiece) through a suitable electrolyte
chromium-carrying electrolyte in the presence of a catalyst.

{Catalyst = a substance that makes another substance change

chemically without changing itself}.
Tin Coating (Electrotinning)
It is the process of electroplating steel sheets by tin. These sheets are
used in manufacture of food cans.
Copper and Nickel Plating
Nickel plating provides a good corrosion resistance and bright
appearance for steel. But it is recommended to apply copper plating
before nickel because copper provides adhesive properties for nickel.
Galvanising
It is a zinc coating (by spraying or electroplating) of low-carbon steels
to protect them from atmospheric deterioration. A spangle effect can
be obtained if tin and aluminium are added.

(+) Low cost , (-) Zinc is harmful for environment.

Example: Highway guard rails.
Parkerizing
Most enamels and paints require a base or primer before being used.
For this aim, Parkerizing is applied. Parkerizing is the process of
placing a thin phosphate coating by dipping steel in a solution of
manganese dihydrogen phosphate at 90C and for 45 min.

Calorizing
Calorizing is the process of protection steel from oxidation at high
temperatures by forming a protecting film of aluminium oxide Al2O3
on the steel surface. Al2O3 layer is produced by defusing Al into the
steel surface at a high temperature.
Anodising

Anodising is the
process of forming a
coating on an
aluminium (anode)
surface by oxidation
(not by plating). The
process is the reverse
of electroplating.
Sulphuric or chromic
acid is used as an
electrolyte.
(+) Provides porous
surface for better
painting by organic
coatings.
Hard Surfacing
Hard Surfacing is the process of increasing the surface resistance to
wear and abrasion.
Methods: 1) Fusion welding,
2) Heat treatment.
3) by contact with other materials (compression).
 Design Considerations of Metal Deposition

Determination of Mass Deposited

Faraday’s law is used to describe electrolytic processes (electroplating): “ The mass of
the metal deposited (m) is equal to the electrochemical equivalent of that metal
multiplied by the current flowing and the time for which it flows”. An efficiency
factor is also considered in Faraday’s law. m=Exixtx
Where:
E = Electrochemical efficiency, g per A
i = Current flowing, A
t = Time of current flowing, s
 = Deposition efficiency, decimal

Note: E and  are constant for a certain metal, so m depends on i and t, that is why
ampere – hour meter is applied (to determine i and t ).
Plating Time:
The time required for plating, min:

F x T x 60
t=
CD
F = Conversion factor to deposit one mil of electroplate thickness, A-h/ft3.
T = Plate thickness, mils
CD = current density, A/ft2.
Note: mil = 1/1000 in

Tank capacity:
If the tank is circular, so, knowing D, the graph in fig 22.7 is used to determine v/h
(volume per unit height).
If the tank is rectangular, graph in 22.8 is applied.