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MAE 493N/593T
Dr. Konstantinos A. Sierros
West Virginia University
Mechanical & Aerospace Engineering
ESB Annex 263
kostas.sierros@mail.wvu.edu
Course material
You can read and download course material from the following blog;
http://wvumechanicsonline.blogspot.com
e‐handouts will be also uploaded in the blog
Please print responsibly!
In‐class activity
A rough surface has the profile illustrated in the above figure. Sketch the
form of the probability density function and evaluate the Rq in terms of the
dimension α. What are the values of the skewness and kurtosis of this
surface?
Physical nature of metallic surfaces
• Metal surfaces exposed to air absorb O2 and H2O vapour and form metal oxide (MO)
layers
• Noble metals (not very reactive!) : 1‐2 atoms thick MO layer
• More reactive metals: Thicker layers
• Rate of growth of MO films depend on:
‐ Crystallographic orientation of underlying material
‐ Temperature (very important!); High temperature increases growth rate
• High temperature: Nuclei is formed; Then crystals are formed; Rougher surfaces
Examples
• Iron surfaces can form oxide layer which is a mixture of various oxides of Fe
Cupric oxide
CuO
Cu2O
Cuprous oxide
Copper surface
• 2 or more different Cu
layers
• Alloy surfaces when exposed to air form a mixture of different oxides in a
single layer
• For stainless steel alloy, a mixture of Fe and Cr oxide form on the surface
and the Cr oxide provides the corrosion protection
MO beneficial?
• In some cases they are. The surface becomes passivated (no further chemical
activity).
• Examples include Al and Ti
• But in some other cases the MO layer has an open microstructure so O2
diffusion continues
• Oxides of iron are a prime example
http://www.chem1.com/acad/webtext/elchem/ec7.html
Role of tribology in surface engineering
• Machined or mechanically abraded and polished surfaces
• Beilby layer: Layer of parent metal that is heavily deformed as a result of
surface engineering
• Beilby layer may consist of smeared layer of metal, metal oxide, polishing
powder etc.
• Beneath the Beilby layer lies a heavily sheared region with different
mechanical properties from the bulk (modified grain structure)
In‐service behaviour of surfaces
• Depends on many different parameters
• Surface preparation methods (eg. mechanical or chemical surface
modification)
• Surface operation conditions (eg. contact between surfaces, lubrication)
Surface‐related phenomena
Surface Engineering
Surface engineering
Surface Engineering
Surface modification of
existing surface Deposition of additional
• chemical material on surface
• mechanical (thin layer)
• thermal
Surface engineering
• Surface engineering on existing surface
Cold‐working processes
Prevents fatigue failure
Shot‐peening
and improves wear resistance
• Hammering the surface of a material with small
spheres of steel, ceramic or glass media at relatively
high velocities.
• These shot particles create a series of overlapping
dimples on the material's surface which put the upper
layers into compression, and help to prevent fatigue
failure in the material.
http://www.progressivesurface.com/shotpeening.php
Thermal treatment (Hardening)
• Thermo‐chemical process
• Diffusion of C atoms into
surface
• Formation of hard outer layer
• Increased C content
Surface engineering
• Deposition of additional material (thin layer)
Ion implantation
• N, C, Ti, Al ions with high energies hit the surface and penetrate up to 0.5 μm
• Energies lie in the range of 50‐200 keV
• Dosage rates around 1015 ions/mm2
• Can be applied to ceramic and metal surfaces
• Cause minimal changes to surface topography
Sputtering
http://www.matec.org/animations/matec/M061FL02.swf
Summary
• Metallic surfaces and MO layer formation
• Role of tribology in surface engineering
• Surface engineering
• Processing of existing surfaces
• Adding new layer materials