Surface Engineering &

Characterization
Dr. Ahmed Umar Munawar
Office 321
Ahmed.munawar@scme.nust.edu.pk
Course Outline
1- Fundamentals
 Surface dependent properties and failure
 Importance and scope of Surface Engineering
 An overview on the applications
 Chemisorption
 Physisorption
 Adsorption
 Surface tension
Course Outline
1- Fundamentals
 Particle surface interaction
 Kinetic and nucleation of thin films
 Grain structure of coatings
 Vacuum Science and Technology
Course content
2- Conventional Surface engineering
 Surface engineering by material removal
 Surface engineering by material addition
 Electrodeposition/ plating
 Electro-less plating
 Pack carburizing, aluminizing, diffusion coatings
 Surface modifications by liquid
 Surface modifications by gaseous medium
Course content
3- Advanced Surface engineering techniques
 Surface Engineering by laser beams
 Electron beam assisted modification and joining
 HVOF
 Cold spray
 Thermal/ Electron beam evaporation
 Physical vapor deposition PVD
 Chemical vapor deposition CVD
 Plasma enhanced CVD
 Ion Implantation
Course content
4- Surface Coatings
 Coatings for corrosion resistance
 Coatings for optical applications
 Magnetic coatings
 Hard coatings
 Coatings for electronic applications
 Thermal Barrier Coating systems
Course content
5- Characterization of surface and coatings
 Film thickness
 Structural characterization
 Chemical characterization
 Functional Properties
 Surface Engineering
Surface Engineering can be defined as: Treatment of a
surface and near-surface regions of a material to allow
the surface to perform functions that are distinct from
those functions demanded from the bulk of the material.

Surface Treatment industry is essentially market led !

New techniques for surface modification are constantly

evolved, depending on the application requirements.
 Surface Engineering
The desired properties or characteristics of surface
engineered components include:

Improved corrosion resistance through barrier or

sacrificial protection
Improved oxidation and/ or sulfidation resistance
Improved wear resistance
Reduced frictional energy losses
Improved magnetic properties
Improved thermal insulation
Improved aesthetic appearance
 Surface Dependent Properties/ failures
Corrosion
Corrosion of Metals is a
chemical or electrochemical
process in which the surface
atoms of a solid metal react
with a substance in contact with
the exposed surface.

Metallic corrosion causes

material damage of large
amounts every year !
 Surface Engineering
Methods to control Corrosion

Altering the metal by alloying, that is, using a more highly alloyed
and expensive stainless steel than plain carbon or low- alloy steel

Changing the environment by desiccation or use the inhibitors.

Applying organic, metallic, or inorganic (glasses & ceramics)

coatings.
Improved thermal insulation
Improved aesthetic appearance
 Surface Dependent Properties/ failures
Friction and Wear
Friction is the resistance to motion when two bodies in contact are forced
to move relative to each other.

It is closely associated with any wear mechanisms that may be operating

and with any lubricant and/ or surface films that may be present.

In moving machinery, friction is responsible for dissipation and loss of

much energy.

The need to control friction is the driving force behind its study. In many
cases, low friction is desired (bearings, gears etc.), and sometimes high
friction is required (brakes, screw, threads)
 Surface Dependent Properties/ failures
Friction and Wear
Friction force is the tangential force that must be overcome in order for
one solid contacting body to slide over another.

It acts in the plane of the surfaces and is usually proportional to the

surfaces, N or:

F = µN

µ, the friction constant, refers to the ration between the friction force F
and the load N.
µ = F/ N
 Surface Dependent Properties/ failures
Friction and Wear
For well-lubricated bearings, µ ~ 0.03

µ value of 0.2-0.3 allows for normal walking

However, walking on ice is difficult as µ is lower ~ <0.05

Static coefficient of friction µs is usually greater than dynamic or kinetic

coefficient of friction µk.

Friction is not a unique property of materials but depends on the

measuring conditions as well.
 Surface Engineering
Surface Treatment Primary property benefits
Flame/ Laser/ EB hardening Improved wear resistance through the development of hard martensite surface.

Laser melting Improved wear resistance through grain refinement and formation of fine dispersion
of precipitates.
Shot peening Improved fatigue strength due to compressive stresses induced on the surface.
Carburizing Used primarily for steels to increase wear resistance.
Nitriding Used mainly for steels to improve wear and corrosion resistance.
Carbunitriding Used for steels to improve wear resistance.
Chromizing
Electroplating Improved corrosion resistance (Ni-Cr multi layer coatings), electrical properties (Cu
and Ag coatings) and Aesthetic appearance (Bright Ni or decorative Cr coatings)

Thermal Spraying Many ceramic and metallic for wear and corrosion resistance, and thermal insulation.
Physical Vapor Deposition Coatings for improved thermal, electronics, decorative and magnetic properties
Chemical Vapor deposition Epitaxial growth of semi-conductors.
Comparison of the coating processes
Surface dependent properties
Surface Engineering Application
Thermal Barrier Coatings