EXPERIMENTAL AND INVESTIGATION OF

FLANGE COUPLING USING SILICON FOUL

RELEASE COATING
ABSTRACT
 ABSTRACT

Silicone coatings are largely used in marine to release foul and corrosion presents
processes; This work on quantitative way represents improvement, in terms of
wear and corrosion resistance, which is obtained by depositing silicone coating on
foundation material. Chemical vapour deposition systems are very versatile,
allowing to use a variety of substrates (like steel, zinc, copper, aluminium and
plastic), and they provide bright and long-lasting appearance to the silicone
components, so that they have great use in auto-industry. silicone coating has been
a valuable surface treatment for parts in high wear environments due to its high
hardness, reactivity of silicone and low coefficient of friction. Its use has grown
considerably in the aerospace and automotive industry for several decades.
Corrosion testing is done on coupling with contact geometry at sliding contact of
silicone hard coated sample with coupling.
 Chapter-1

INTRODUCTION
 Chapter-1

INTRODUCTION

The very common meaning of corrosion to the great majority of the people is rust.
The word “Rust” is more specifically reserved for iron, whereas corrosion is
commonly defined as the deterioration of a substance (usually a metal) or its
properties because of a reaction with its environment. The terms corrosion and rust
are almost synonymous since iron and its alloys are the most commonly used
material by mankind and corrosion of iron must have been the one of the first
serious corrosion problems affected humans . Corrosion is a naturally occurring
phenomenon and just like all natural processes, corrosion of materials is
spontaneous and it drives the materials to its lowest possible energy states. Most of
the metals and alloys have a natural tendency to combine with water and oxygen
present in its environment and return to its most stable state. Iron and steel quite
often interact with their environment return to their native and stable oxide states.
Similar to any natural disasters such as earthquakes or severe 2 weather changes,
corrosion results in dangerous and expensive damage to everything from
automobiles, home appliances, drinking water systems, gas and petroleum
pipelines, bridges and buildings

Coupling:
In piping industries coupling is one of the most important component and it is
available in different materials . A couplings (used in piping or plumbing) is a
very short length of pipe or tube, with a socket at one or both ends that allows two
pipes or tubes to be joined, welded (steel, brazed or soldered (copper, brass etc.)
together
Types of couplings:
Sleeve coupling:
A sleeve coupling consists of a pipe whose bore is finished to the required
tolerance based on the shaft size. Based on the usage of the coupling a keyway is
made in the bore in order to transmit the torque by means of the key. Two threaded
holes are provided in order to lock the coupling in position.

Bush pin Type flange coupling:

This is used for slightly imperfect alignment of the two shafts. This is modified
form of the protected type flange coupling. This type of coupling has pins and it
works with coupling bolts. The rubber or leather bushes are used over the pins. The
coupling has two halves dissimilar in construction. The pins are rigidly fastened by
nuts to one of the flange and kept loose on the other flange. This coupling is used
to connect of shafts which having a small parallel misalignment, angular
misalignment or axial misalignment. In this coupling the rubber bushing absorbs
shocks and vibration during its operations. This type of coupling is mostly used to
couple electric motors and machines.

Flange coupling:
Coupling is a device used to connect the shafts together for the purpose of
transmitting power and torque. Generally, couplings are used for connection of
shafts unit that are manufactured separately. Such as motor and generator; electric
motor and centrifugal pump etc. Due to the inconvenience in transportation of shaft
of greater length, it becomes necessary to join two or more shafts by means of
coupling. The shafts that are connected by coupling should be easy enough to
assemble and dismantle for the purpose of repair and alterations. The severe failure
due to shearing of bolts head, key head, nuts and other projecting parts may cause
accidents. So, it should be covered by giving suitable shape to the flanges or by
providing guards. The shaft to be connected by the coupling may have collinear
axes, intercepting axes or a parallel axes with a small distance in between them.
The flange coupling is further classified into two types; Rigid and Flexible
Coupling. Rigid flange coupling consists of two separate grey cast iron flanges.
One keyed to the driving shaft and the other to the driven shaft by means of nuts
and bolts arranged on a circle concentric with the axes of the shafts. There are two
types of rigid flange couplings; Protected and Unprotected rigid flange coupling. In
a protected rigid flange coupling, a protective circumferential rim covers the nut
and bolt head. So in any case of failure of bolts during operation, broken piece of
bolt will dash against this rim and eventually fall down, protecting the operator
from any possible injuries. In unprotected rigid flange coupling such protective
circumferential rim is absent. So, in any case of failure of bolts, it may hit and
harm the operator.

Material And Its Properties:

Rigid flange is usually manufactured by casting as it consists of projection and
recess. The commonly used material for flange coupling is grey cast iron which is
characterized by graphitic microstructure causing fracture of the material to have a
grey appearance. It is one of the most commonly used form of cast iron and the
widely used cast material based on casting properties. Most alloys of
Ironcontain2.5-4% carbon, 1-3% silicon and the rest is iron by weight proportion.
It has less tensile strength and shock resistance as compared to its compressive
strength. Its mechanical properties are controlled by the size and morphology of
the graphite flakes which deflect a passing crack and initiate counter less new
cracks as the material breaks due to which it has good wear resistance and damping
capacity. It also experiences less solidification shrinkage than other cast iron that
does not form a graphitic microstructure during casting process.
 Chapter-2
LITERATURE SURVEY
 Chapter-2
LITERATURE SURVEY

Siraj MohammadAli Sheikh {1} In this paper titled analysis of universal coupling
under different torque condition Drive shafts are one of the most important
components in vehicles. It generally subjected to torsional Stress and bending
stress due to weights of components. Thus, these rotating components are
susceptible to fatigue by the nature of their operation. Common sign of driveshaft
failure is vibration or shudder during operation. Driveshaft mainly involves in
steering operation of vehicle. Drivers will lose control of their vehicle if the drive
shafts broke during high speed cornering. Because of this human life can be in
great danger if we don’t know when, where and how the drive shaft will failed. It
is very important to know the accurate prediction for the drive shaft to fail.

N. Cristello and I.Y. Kim (Canada) {2} In this paper titled Design
Optimization of an Automotive Universal Joint Considering Manufacturing Cost In
this research, universal joint designs are analyzed and compared using a weighted
sum of three objective functions: minimization of machining cost, maximization of
adjoining shaft joint angle, and minimization of total part volume.

Initially, both silicones and fluoropolymers were identified as FR surfaces

because both polymers exhibit low critical surface tension and this character is
considered crucial for foul releasing ability (Baier and Meyer 1992; Callow and
Fletcher 1994). Baier and Depalma (1971) studied the relationship between the
critical surface tension of the polymer surface and the relative amount of
bioadhesion. The results were shown as the ‘‘Baier curve.’’ An important feature
of this curve is that the minimum in bioadhesion does not occur at the lowest
critical surface energy

Commercially available FR coatings are based on silicone elastomers

formed from polymerized dimethylsiloxanes (PDMS) (Yebra et al. 2004). Poly
(dimethylsiloxane) elastomers are inherently weak materials and exhibit very poor
mechanical properties (Dewimillea et al. 2005). Therefore, they may not be
durable enough to survive on a ship’s hull. Because of their poor mechanical
strength, there is a great need to improve the mechanical properties of PDMS-
based FR coatings.

Matsushita tested a foul release system on both boat hulls and a propeller
from the training ship ‘Yuge-Maru’. These tests showed that a foul release system
can protect propellers from fouling and electrochemical corrosion, with only a
small amount of fouling near the hub of the propeller and a 30% reduction in the
consumption rate of the ships sacrificial anodes. Matsushita also found problems
with the robustness of the coatings used past a surface time of one year. Since 1993
more development of these coatings generally has taken place, and in particular
research into improving the adhesive qualities of these coatings to marine
propellers12.

various electrodeposition techniques have been discussed to understand the

behaviour of the properties of respective coatings. Generally, black coatings used
for both decorative and solar absorbing functions are prepared by liquid phase
deposition or vapour phase deposition. Black chromium and black nickel are the
most important electrodeposited materials whereas the films elaborated by vapour
phase deposition include mainly titanium alloys and carbon based materials.
Phosphating is an essential chemical conversion process for automotive
components and domestic appliances to improve the corrosion resistance.

The performance of coatings is to be evaluated by weight gain studies,

micro hardness evaluation, abrasion resistant test, corrosion resistant measurement
by electrochemical methods. The surface morphology of the coatings is the
predominant properties of the coating which will be assessed by XRD, SEM and
XPS. The absorption coefficient of the coatings to be evaluated by UV-Visible
spectrometer. Salt spray analysis to be carried out to follow up the corrosion and
get an idea about the performance of black coatings in automobile parts.
 CHAPTER-3

COATINGS AND METHODS

 CHAPTER-3

COATINGS AND METHODS

TYPE OF COATING MATERIALS

1. Chromium
2. zinc
3. Yttrium oxide
4. black oxide
5. Silicone

1. Chromium

Chromium is a chemical element with symbol Cr and atomic number 24. It is the
first element in Group 6. It is a steely-grey, lustrous, hard and brittle metal which
takes a high polish, resists tarnishing, and has a high melting point. The name of
the element is derived from the color because many of its compounds are intensely
colored. Chromium oxide was used by the Chinese in the Qin dynasty over 2,000
years ago to coat metal weapons found with the Terracotta Army.

2. Zinc

Zinc, like all metals, corrodes when exposed to the atmosphere. However, because
of its ability to form dense, adherent corrosion byproducts, the rate of corrosion is
considerably lower than ferrous materials (10 to 100 times slower depending on
the environment). Zinc corrosion products develop naturally on the surface as the
coating is exposed to natural wet and dry cycles in the atmosphere and are often
referred to as the zinc patina. The zinc patina acts as an additional barrier between
the steel and the environment. There are a number of zinc coatings which are often
generically termed “galvanizing,” but each has unique characteristics. These
characteristics not only affect applicability, but also economics and performance in
the environment. The method of application, adhesion to the base metal, hardness,
corrosion resistance, and thickness of each zinc coating varies

3. Yttrium oxide

Yttrium oxide is one of the most important compounds of yttrium and accounts for
the largest use. It is widely used in making YVO4 europium, and Y2O3 europium
phosphors to give the red color in color television tubes. Many hundreds of
thousands of pounds are now used in this application. Yttrium oxide also is used to
produce yttrium-iron-garnets, which are very effective microwave filters. It also
has potential use in ceramic and glass formulas, as the oxide has a high melting
point and imparts shock resistance and low expansion characteristics to glass.
Hard, dense layers are deposited by electron-beam evaporation or sputtering.
Typical applications are protection of aluminum and silver mirror coatings,
intermediate layer in wide band visible AR coatings and for XeCl (308 nm) laser
AR and dielectric mirror designs. Yttrium oxide is the thermodynamically most
stable oxide and is suitable for extreme operation conditions. It is used as a coating
in metal production. Yttria is often used with zirconia to form Yttrium Stabilized
Zirconia (YSZ). Yttria has the common characteristics of ceramics that are not
found in metallic or organic materials, including high hardness (Next to Diamond),
high mechanical strength, high temperature stability, chemical resistance, erosion
resistance, low electrical conductivity As with all ceramic materials, performance
of the final product directly depends on the particle size of the ceramic material.
Mechanical strength of the final part depends on the ability of the particles to pack
to the appropriate density. An excess of large particles can form discontinuities in
the body, which are a weak point. In products where gas or liquid flow through the
material is important, the packing density of the individual particles defines the
porosity of the final product. Yttria is a fairly easy material to analyze using
Horiba’s LA-series particle size analyzers. Samples are usually dispersed in water,
with 0.1% sodium pyrophosphate added as a surfactant. A short period of
ultrasonics is usually required to disperse agglomerates, particularly in the finer
grades.

4. Black oxide

Black oxide is the conversion coating formed by a chemical reaction with the iron
in metal to form an integral protective surface. contrasted to an applied coating
which bonds to the metal but does not react chemically. A black oxide conversion
coating is applied to ferrous alloys when a blend of caustic, oxidizers and additives
react with the iron to form magnetite (Fe3O4), the black oxide of iron. Black oxide
coatings are offered under a variety of trade names including. Black oxide will not
affect the part dimension, hardness, temper or surface properties a polished surface
retains its gloss and a dull surface finish will retain its matte finish. Black oxide
will not chip, peel, flake or rub off. Hot black oxide is a conventional hot (285 F˚)
process which produces a true black oxide iron magnetite. All the benefits of black
oxide are available from the “hot” oxidizing process. A black oxide coating can be
formed in either a hot or cold solution the “cold” black oxide process, applied at
room temperature or slightly elevated temperatures, are not true oxides, but soft
deposits that offer less corrosion and abrasion resistance than the “hot” oxide
process. The cold black oxides oftentimes display color variations on the same part
or part-to-part. The “cold” process does not meet automotive or military
specifications for black oxide coatings. Premier Finishing only employs the “hot”
black oxide process

SELECTION OF COMPONENT

 Flange coupling

PROBLEMS IDENTIFICATION

Fig: corroded flange coupling

A coating serves many purposes. Some of these are presented as Protection of

steel structures from the environment by acting as a barrier between the substrate
and the aggressive environment, such as the marine and industrial environments.
Control of solvent losses. Control of marine fouling; certain constituents in
coating control the growth of marine fouling in seawater.
 Pleasant appearance; certain types of coatings provide a pleasant appearance
and produce attractive surroundings. Change in light intensity; by selection of
appropriate coatings the light intensity in rooms and buildings can be varied as
desired. Visibility; many combinations of colors because of their visibility from
large distances are used on television and radio towers to warn aircraft.
Modification of chemical, mechanical, thermal, electronic and optical properties
of materials. Application of thin coatings on low-cost substrates results in
increased efficiency and cost savings.

METHODOLOGY
Coating is a covering that can be applied to the surface of an object, normally
called as substrate. The purpose of application of coating is the value enhancement
of the substrate by improving its appearance, corrosion resistant property, wear
resistance, etc.
When compared the non-coated coupling with the silicone coated coupling, the
difference in component life will changes the rate of services. The improved
component life and component wear and corrosion services are last longer and
hence reduce the rate of service of the coupling.

BASIC INTRODUCTION OF COATINGS

A coating is a covering that is applied to the surface of an object, usually referred

to as the substrate. The purpose of applying the coating may be decorative,
functional, or both. The coating itself may be an all-over coating, completely
covering the substrate, or it may only cover parts of the substrate.
 An example of all of these types of coating is a product label on many drinks
bottles- one side has an all-over functional coating (the adhesive) and the other side
has one or more decorative coatings in an appropriate pattern (the printing) to form
the words and images. Paints and lacquers are coatings that mostly have dual uses
of protecting the substrate and being decorative, although some artists paints are
only for decoration, and the paint on large industrial pipes is presumably only for
the function of preventing corrosion.

Functional coatings may be applied to change the surface properties of the

substrate, such as adhesion, wetability, corrosion resistance, or wear resistance. In
other cases, e.g. semiconductor device fabrication (where the substrate is a wafer),
the coating adds a completely new property such as a magnetic response or
electrical conductivity and forms an essential part of the finished product.

A major consideration for most coating processes is that the coating is to be

applied at a controlled thickness, and a number of different processes are in use to
achieve this control, ranging from a simple brush for painting a wall, to some very
expensive machinery applying coatings in the electronics industry. A further
consideration for 'non all over' coatings is that control is needed as to where the
coating is to be applied. A number of these non-all-over coating processes are
printing processes. Many industrial coating processes involve the application of a
thin film of functional material to a substrate, such as paper, fabric, film, foil, or
sheet stock. If the substrate starts and ends the process wound up in a roll, the
process may be termed “roll-to-roll” or “web-based” coating. A roll of substrate,
when wound through the coating machine, is typically called a web. Coatings may
be applied as liquids, gases or solids.
PURPOSES OF A COATING

A coating serves many purposes. Some of these are presented as below:-

Protection of steel structures from the environment by acting as a barrier between
the substrate and the aggressive environment, such as the marine and industrial
environments. Control of solvent losses. Control of marine fouling certain
constituents in coating control the growth of mildew and marine fouling in
seawater. Reduction in friction (coating reduces friction between two contacting
surfaces). Pleasant appearance; certain types of coatings provide a pleasant
appearance and produce attractive surroundings.

Change in light intensity; by selection of appropriate coatings the light

intensity in rooms and buildings can be varied as desired. Visibility; many
combinations of colors because of their visibility from large distances are used on
television and radio towers to warn aircraft. Modification of chemical, mechanical,
thermal, electronic and optical properties of materials. Application of thin coatings
on low cost substrates results in increased efficiency and cost savings.

FOUL RELEASE COATING

COPPER-BASED COATINGS
Copper antifouling coatings have been used in the marine industry for two hundred
years. The current generation of copper paints relies on three factors for its
effectiveness: the toxicity of copper; secondary biocides which are effective against
organisms not harmed by copper; and an ablative resin
system which slowly but constantly dissolves, talon& with it early stages of fouling.
Copper has been used since antiquity as an antifouling agent. Copper
sheathing was first used on ships of the Bri6sh Navy in 1779.

It is widely distributed in animal and plant tissues; for humans copper is an essential
trace element and is comparatively non-toxic compared to other trace elements.
Copper is an effective control agent for many but not all forms of marine life.

SECONDARY BIOCIDES

DCOI has broad-spectrum activity against bacterial slime, barnacles, against algae,
tube worms, hydroids bryozoans, tunicates and diatoms. DCOI and its metabolites
remain in the environment for only short periods of time; in seawater they bind
strongly and essentially irreversibly to sediment and subsequently are rapidly
degraded

The `zinc complex of 2-pyridinethiol-1-oxide possesses broad spectrum antimicrobial

activity against algae, bacterial slime, fungi and diatoms. It is frequently used in
combination with cuprous oxide to provide protection against hard as well as soft
marine fouling organisms.

ABLATIVE RESINS

Ablative ("self-polishing") resins are made from polymers with labile functional
groups such as esters. Hydrolysis of these groups releases a small molecule and
creates a hydrophilic site on the polymer backbone. The small molecule released is
sometimes toxic and may contribute to antifouling performance through its
poisonous properties. When the polymer backbone accumulates a sufficient number
of hydrophilic sites it becomes water-soluble and washes from the surface of the
coating taking with it algae, diatoms, and other marine organisms and their juvenile
forms. A fresh surface is thus created, and the process is repeated. Ablative coatings
require a constant water Bow past the surface and are most effective at consistently
high water velocities. The lifetime of these coatings is determined by the initial
thickness of the coating and by the temperature of the seawater. In temperate waters
ablation is on the order of 75 mm pa year; thus a new coating applied at a thickness
of 375 mm (15 mils) would be expected to give five years of service.

NON TOXIC FOULING RELEASE COATING

Prospective nontoxic hull paints include fluoro polymer- and siloxane-based

coatings. These coatings, which have been a subject of intense laboratory and field
studies for the past 25 years, are called "fouling-release" to differentiate them from
their poisonous precursors. Ideally these "nonstick" coatings should completely
prevent the attachment of fouling but actually they do foul, but only weakly. They
significantly limit the strength of the joint between fouling and hull, making the bond
so weak that it can be broken by the weight of the fouling or by the motion of the
ship through the water. The performance of fouling-release coatings is determined by
three properties. Surface energy is the first of these; a low surface energy will
discourage the initial attachment of fouling. The modulus of the coating is important
because it influences the mechanism by which the joint between a coating and a
foulant will fail. Lastly, the thickness of the coating can be important factor in
favoring peel fracture rather than shear fracture.

The fracture mechanics at an interface - in this case, the joint between fouling
and a coating - differs from that of a solid because the interface determines the
direction of crack propagation. A joint is tough if a large amount of energy is
expended in order to propagate a crack along it. Toughness of the joint is strongly
influenced by the deformation of the adherents near the crack tip. Elastomeric
coatings, such as the silicones, deform readily and failure of the joint occurs by peel, a
mechanism which requires lower energy than failure by shear. As a crack moves along
an inner face a polymer in the crack tip is placed in tensile stress. An adhesive slips on
a silicone surface toward the crack tip, reducing the extension of the polymer, thus
reducing its tensile stress, and reducing the energy needed to propagate the crack.
Studies have shown_ that, in joints with one mobile side, the shear stress at the
interface can be as low as 5-100 kPa Thus the Bruited amount of bio adhesion on
silicone polymers is a consequence of the ability of the fouling to slip on the polymer
surface. This behavior does not occur on fluoro polymers

FLUORINATED COATINGS

Fluorinated polymers were first considered attractive fouling-release candidates

because of their low surface energy. Subsequent research has demonstrated that many
other factors are of equal or greater importance than surface energy. The most
productive route to fouling-free performance is to discourage the initial bonding of
marine organisms. This is accomplished by constructing a well- organized surface of
closely-packed fluorinated groups, driving its surface energy as low as possible, and
cross linking or otherwise stabilizing the surface in so that it resists rearrangement and
penetration of marine adhesives. Fouling is minimized when:

 The surface is very smooth. Teflon @ (polytetrafluoroethelene)

accumulates marine fouling rapidly because it is a porous material. Marine
adhesives
invade cavities in the surface and cure inside them creating a secure
mechanical
interlock even where chemical compatibility does not exist.
 The surface is composed exclusively of fluorinated groups. CF3 groups are
 more effective than CF2 groups, which in turn are more effective than
CF3groups, in reducing the energy of the surface.
 There is sufficient fluorine in the bulk of the coating to effectively control
the organization of fluorine at the surface.
 Dipoles such as -CF2-CH2- M e located well beneath the surface
 The surface is cross linked in order to hold fluorine in place, resist
rearrangement and infiltration of marine adhesives, and maintain stability in the
marine environment.

SILICONE COATINGS

Coatings based on silicones have also been extensively tested for resistance to marine
fouling. The critical discovery that fouling release does not correlate with surface energy
alone, but with the square root of the product of surface energy g and elastic modulus E
.The minimum in adhesion coincides with the lowest value of elastic modulus tested,
although this does not correspond to the lowest surface energy tested, demonstrating
that elastic modulus is at least as important as surface energy in determining the
performance of silicone fouling-release coatings. Therefore the most effective route to
fouling-free performance is to encourage the release of fouling organisms from the
surface by predisposing the adhesive joint between the foulant and the coating to quick
and easy failure by peeling This is accomplished by judicious control of the thickness
and elastic modulus of the silicone coating Fouling release from silicone coatings is
best enabled when:

 The silicone resin has a linear, highly flexible backbone that is substituted
with a sufficient number of groups to diminish surface energy while
 preserving
backbone mobility.
 The silicone resin has the lowest elastic modulus consistent with physical
toughness.
 The silicone resin is stable in the marine environment, and resistant to
hydrolysis which causes loss of mass and development of surface
roughness.
 The coating is applied at a thickness that favors failure by peel rather than
failure by shear at the coating-foulant joint.
 The coating is very smooth.

Some commercial nontoxic silicone coatings contain a silicone oil which

migrates from the bulk of the coating to the surface and into the water. Fouling settles
on the oil rather than on the surface of the coating. The joint between oil and coating is
weak and fails readily; the oil migrates into the water taking early stages of fouling with
it. The oil also plasticizes the coating Despite the encouraging performance of
commercial coatings based on this technology, we see two drawbacks to this approach
First the silicone oils are lost, usually. Within two years in temperate waters, with
several consequences. The mechanical properties of the coating deteriorate significantly
and sharply, and the coating becomes brittle and cracks. The weak boundary layer is no
longer formed, fouling settles and adheres with tenacity, and the coating must be
replaced. Second, silicone oils are released into the environment. Although there is no
toxicity associated with these compounds in seawater, we believe that a policy of
absolutely no release to the environment will prove best in the long run.
 SELECTION COATING MATERIALS
SILICON

Silicon is formed in two ways, reaction bonding and sintering. Each forming
method greatly affects the end microstructure. Reaction bonded Si is made by
infiltrating compacts made of mixtures of Si and carbon with liquid silicon. The
silicon reacts with the carbon forming more Si which bonds the initial Si particles.
Sintered Si is produced from pure Si powder with non oxide sintering aids.
Conventional ceramic forming processes are used and the material is sintered in an
inert atmosphere at temperatures up to 2000ºC or higher. Both forms of silicon
carbide (Si) are highly wear resistant with good mechanical properties, including
high temperature strength and thermal shock resistance. Our engineers are always
available to best advise you on the strengths and weaknesses of each ceramic for
your particular needs.

General silicon carbide information

Silicon is composed of tetrahedral of carbon and silicon atoms with strong bonds
in the crystal lattice. This produces a very hard and strong material. Silicon carbide
is not attacked by any acids or alkalis or molten salts up to 800°C. In air, SiC forms
a protective silicon oxide coating at 1200°C and is able to be used up to 1600°C.
The high thermal conductivity coupled with low thermal expansion and high
strength give this material exceptional thermal shock resistant qualities. Silicon
carbide ceramics with little or no grain boundary impurities maintain their strength
to very high temperatures, approaching 1600°C with no strength loss. Chemical
purity, resistance to chemical attack at temperature, and strength retention at high
temperatures has made this material very popular as wafer tray supports and
paddles in semiconductor furnaces.
The electrical conduction of the material has lead to its use in resistance heating
elements for electric furnaces, and as a key component in thermostats (temperature
variable resistors) and in varistors (voltage variable resistors).

Typical silicon characteristics include:

 Low density
 High strength
 Good high temperature strength (Reaction bonded)
 Oxidation resistance (Reaction bonded)
 Excellent thermal shock resistance
 High hardness and wear resistance
 Excellent chemical resistance
 Low thermal expansion and high thermal conductivity

Typical silicon applications include:

 Fixed and moving turbine components

 Seals, bearings, pump vanes
 Ball valve parts
 Wear plates
 Kiln furniture
 Heat exchangers
 Semiconductor wafer processing equipment

Silicon Carbide is the only chemical compound of carbon and silicon. It was
originally produced by a high temperature electro-chemical reaction of sand and
carbon. Silicon carbide is an excellent abrasive and has been produced and made
into grinding wheels and other abrasive products for over one hundred years.
Today the material has been developed into a high quality technical grade ceramic
with very good mechanical properties. It is used in abrasives, refractories,
ceramics, and numerous high-performance applications. The material can also be
made an electrical conductor and has applications in resistance heating, flame
igniters and electronic components. Structural and wear applications are constantly
developing.

SILICON PROPERTIES
Properties value

Poisson’s Ratio 0.14

Coefficient of Thermal 4.0

Expansion
Thermal Conductivity 120 W/m•°K

Specific Heat 750 J/Kg•°K

TYPES OF COATING

1. Pvd coating

2. Cvd coating

PHYSICAL VAPOUR DEPOSITION (PVD)

The basic PVD processes fall into two general categories: sputtering and
evaporation. The application of PVD techniques ranges over a wide variety of
applications from decorative, to high temperature superconducting films. The
thickness of the deposits can vary from angstroms to millimeters. Very high
deposition rates (25µm/sec) have been achieved with the advent of electron beam
heated sources. A very large number of inorganic materials metals, alloys In
physical vapor deposition (PVD) processes, the coating is deposited in vacuum by
condensation from a flux of neutral or ionized atoms of metals. Several PVD
techniques are available for deposition of hard coatings. Among them, cathodic arc
vapor (plasma or arc ion plating) deposition, magnetron sputtering (or sputter ion
plating), and combined magnetron and arc processes are the most widely used
techniques to deposit various hard coatings.

These PVD processes differ with respect to the type of evaporation of the
metallic components and the plasma conditions employed during the deposition
process. The transition of the metallic component (to be deposited) from a solid to
a vapor phase (in which metal atoms are ionized in different ways) may be
performed by heating of an evaporation source (as in cathodic arc) or by sputtering
of a target (as in magnetron sputtering). Cathodic arc and magnetron sputtering
techniques allow evaporation of metals with different melting points such as Ti and
Al from a Ti–Al alloy cathode/target.

The PVD arc evaporation process employs higher energy input than the
PVD sputtering process. In the case of arc evaporation, a small limited cathodic
area is evaporated with a very high energy arc that quickly moves over a spot on
the metal surface to be evaporated. The plasma generated consists of highly
ionized metal vapor. In the case of sputtering, atoms are ejected mechanically from
a target by the impact of ions or energetic neutral atoms.
 The high micro-hardness provides excellent abrasion resistance, and allows
the cutting edge to stay sharper for longer
 The lowered Coefficient of Friction means there is less resistance during the
cut; therefore, less heat is generated heat build-up being another major factor
in cutting edge break down
  The lowered Coefficient of Friction also means the chips generated during
the cutting process are evacuated more efficiently; therefore, the heat that is
generated does not have as much time to transfer from the chip to the tool –
more heat stays in the chip
 The lowered Coefficient of Friction will reduce machining noise and the
load placed on spindle motors
 The lack of chemical affinity between various coatings and work pieces will
reduce material “pick-up,” another leading cause of cutting edge
breakdown. For example, when cutting titanium with a ZrN coated end mill,
the titanium has no chemical affinity towards ZrN; therefore, you will
experience almost no “pick-up.”
 The lowered Coefficient of Friction creates a free-cutting tool – this may
reduce or eliminate burrs and help to improve the surface finish or machined
parts.

Chemical vapour deposition or CVD is a generic name for a group of processes

that involve depositing a solid material from a gaseous phase and is similar in
some respects to physical vapour deposition (PVD).PVD differs in that the
precursors are solid, with the material to be deposited being vaporised from a solid
target and deposited onto the substrate.

SELECTION OF COATING PROCESS

TYPES OF CVD PROCESSES

CVD covers processes such as:

 Atmospheric Pressure Chemical Vapour Deposition (APCVD)

  Low Pressure Chemical Vapour Deposition (LPCVD)
 Metal-Organic Chemical Vapour Deposition (MOCVD)
 Plasma Assisted Chemical Vapour Deposition (PACVD) or Plasma
Enhanced Chemical Vapour Deposition (PECVD)
 Laser Chemical Vapour Deposition (LCVD)
 Photochemical Vapour Deposition (PCVD)
 Chemical Vapour Infiltration (CVI)
 Chemical Beam Epitaxy (CBE)

CVD WORK

Precursor gases (often diluted in carrier gases) are delivered into the reaction
chamber at approximately ambient temperatures. As they pass over or come into
contact with a heated substrate, they react or decompose forming a solid phase
which and are deposited onto the substrate. The substrate temperature is critical
and can influence what reactions will take place.

Coating Characteristics

CVD coatings are typically:

 Fine grained
 Impervious
 High purity
 Harder than similar materials produced using conventional ceramic
fabrication processes
CVD coatings are usually only a few microns thick and are generally deposited at
fairly slow rates, usually of the order of a few hundred microns per hour.

CVD APPARATUS

A CVD apparatus will consist of several basic components:

 Gas delivery system – For the supply of precursors to the reactor chamber
 Reactor chamber – Chamber within which deposition takes place Substrate
loading mechanism A system for introducing and removing substrates,
mandrels etc
 Energy source – Provide the energy/heat that is required to get the
precursors to react/decompose.
 Vacuum system – A system for removal of all other gaseous species other
than those required for the reaction/deposition.
 Exhaust system – System for removal of volatile by-products from the
reaction chamber.
 Exhaust treatment systems – In some instances, exhaust gases may not be
suitable for release into the atmosphere and may require treatment or
conversion to safe/harmless compounds.

Process control equipment Gauges, controls etc to monitor process parameters such
as pressure, temperature and time. Alarms and safety devices would also be
included in this category.

Energy Sources

There are several suitable sources of heat for CVD processes. These include:
  Resistive Heating e.g. tube furnaces
 Radiant Heating e.g. halogen lamps
 Radio Frequency Heating e.g. induction heating
 Lasers other energy sources may include UV-visible light or lasers as a
source of photo energy.

Materials That Can be Produced by CVD Processes

CVD is an extremely versatile process that can be used to process almost any
metallic or ceramic compound. Some of these include:

 Elements
 Metals and alloys
 Carbides
 Nitrides
 Borides
 Oxides
 Inter metallic compounds
CHAPTER 4
TESTING
 TESTING

CORROSION TEST

Cyclic corrosion testing (CCT) has evolved in recent years, largely within the
automotive industry, as a way of accelerating real world corrosion failures, under
laboratory controlled condition. As the name implies, the test comprises different
climates which are cycled automatically. So the samples under test undergo the
same sort of changing environment that would be encountered in the natural world.
The intention being to bring about the type of failure that might occur naturally,
but more quickly, i.e. accelerated. By doing this manufacturers and suppliers can
predict more accurately, the service life expectancy of their products.
KNOOP HARDNESS TEST

The Knoop hardness test is a micro hardness test - a test for mechanical hardness
used particularly for very brittle materials or thin sheets, where only a small
indentation may be made for testing purpose.
A pyramid diamond point is pressed into the polished surface of the test material
with a known (often 100g) Load, for a specified dwell time, and the resulting
indentation is measured using a microscope.
 CHAPTER 5
ADVANTAGE
ADVANTAGE OF COATING

 Reduce the wear

 High strength
 Long life
 Corrosion resistance
 Increases tensile strength, toughness and stability,
 Decreases residual stresses,
 Decreases brittleness
 Chapter-6

APPLICATION
 APPLICATION OF COATING

 Automobile components like:

 Cutting tools
 Machine parts (bearings, shafts, springs, etc.)
Chapter-7

RESULT
 RESULT

• To improve the wear strength

• To improve the hardness
• To improve the life of component
 Chapter-8

REFERENCE
 REFERENCE

 Rujuta M. Nakhale and G. K. Gattani “Design and Analysis of Coupling

using ANSYS”. (IJPRET), 2015; Volume 3 (9): 202-206, ISSN: 2319-507X
(IJPRET)

 Kondru Nagendra Babu and Dr. D Sunnel “Failure analysis of flange

coupling with two different materials”. (IJERT), Vol. 4 Issue 04, April2015,
ISSN: 2278-0181
 J. Stein et al. Structure-Property Relationships of Silicone Biofouling-
Release Coatings: Effect of Silicone Network Architecture on
Pseudobarnacle Attachment Strengths. Biofouling, 2003, 19 (2), 87–94 4.
 C. J. Kavanagh et al. The Effects of Silicone Fluid Additives and Silicone
Elastomer Matrices on Barnacle Adhesion Strength. Biofouling, Dec. 2003,
19 (6), 381–390 5. A.
 Beigbeder et al. Preparation and characterisation of silicone-based coatings
filled with carbon nanotubes and natural sepiolite and their application as
marine fouling-release coatings. Biofouling, Jul. 2008, 24 (4), 291–30
 J. Stein et al. Silicone Foul Release Coatings: Effect of the Interaction of Oil
and Coating Functionalities on the Magnitude of Macrofouling Attachment
Strengths. Biofouling, 2003, 19 (Supplement), 71–82
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approaches to marine antifouling coatings. Surface & Coatings Technology
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 Watanabe K (2010) Drag reduction of non-Newtonian fluids in a circular
pipe with a highly water-repellent wall. AIChE Journal 47: 256-262.
 Mutton RJ, Atlar M, Downie M (2006) The effect of a foul release coating
on propeller noise and cavitation. Advance materials and coatings
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