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Surface Treatment
For Material Properties
Conversion Coatings
• Oxidation
• Phosphate Coatings
• Chrome Coatings
Thermal Treatments
• Surface Heat Treatment
• Diffusion Coating
• Hot-Dip Coatings
• Weld Overlay Coatings
Thermal Treatments –
Hot-Dip Coatings
• These coatings are used for corrosion protection
• Galvanizing
– Parts are dipped into a molten zinc bath
• Galv-annealing
– Galvanized parts are then heat treated to ~500 ºC to form Fe-Zn inter-
metallic
• Used for metals that need spot welded to protect copper electrode from alloying
with zinc and reducing its life
• Zn-Al Coatings
– Gives a different corrosion protect and a more lustrous appearance (can
greatly reduce spangles easily observed on galvanized parts)
• Aluminum Coatings
– Alloyed with Si
– Coatings used on steel for high temperature applications that need a
lustrous appearance
• Example – Automobile exhaust
Department of Automobile Engineering 09AE05 – AUTOMOTIVE COMPONENT MANUFACTURING 11/13/2018
PSG College of Technology 10
Benjamin Shiloh Davidson
Thermal Treatments –
Weld Overlay coatings
• Typically used to improve wear resistance by creating a hard
surface over a tough bulk body
• Hard Facing
– Weld buildup of parts – alloy composition controls final properties
– Examples – cutting tools, rock drills, cutting blades
– Cladding of material for corrosion resistance
• Thermal spraying
– Molten particle deposition – a stream of molten metal particles are
deposited on the substrate surface
– Major difference from hard facing is that the surface of the substrate is
not subjected to welding. Instead it just undergoes a bonding process
with the molten particles.
Metal Coatings
• Electroplating
• Electroless Coatings
• Metallizing of Plastics and Ceramics
Metal Coatings –
Metallizing of Plastics and Ceramics
• Poor adhesion is the major challenge (As in all
coating processes, however it is more
challenging in this case.)
• Applications
– Decorative (plumbing fixtures, automotive parts),
reflectivity (headlights), electrical conduction
(electronic touchpads), and EMF shielding
Vapor Deposition
• Physical Vapor Deposition (PVD)
– Thermal PVD
– Sputter Deposition
– Ion plating
• Chemical Vapor Deposition (CVD)
Powder
Coating
• Fully formulated paint
ground into a fine
powder
• Powder is sprayed onto
part, retained by static
electricity
• Heat cured onto part
• Can virtually eliminate
VOCs
• Sprayed, dipped or
tumbled to coat,
followed by heating to
bond
• Key characteristics:
– Low friction coefficient
(0.02 – 0.08)
– Can sustain load of 250
ksi
Summary
• Don’t overlook coatings importance to overall
product performance
• Coating technology is very specialized – get a
couple of expert opinions before committing