introduction to surface engineering

Introduction to Introduction to Surface EngineeringSurface Engineering

Introduction to Introduction to Surface EngineeringSurface Engineering

Presented by Presented by S.SathiyaseelanS.Sathiyaseelan

Surface engineering

Surface Engineering• PVD coatings• Coatings• Cr plate• E-Ni• Thermal spraying• Anodising

Surface Modification•Ion implantation•Energy beam processing•Thermochemical treatment

PVD Coatings

• Coating temperatures below 250°C

• Coating thickness 1-4 µm

• Surface structure and edge radii are not altered

• High adhesion of the coating

• High hardness and low coefficient of friction

• Some coating of inner surfaces is possible

PVD Process

Advantages of PVD Coatings

• Highly wear resistant materials (HV <4000)• Increased abrasive wear resistance• Anti-scuffing / anti-galling• High fretting resistance• High pitting resistance• Tribological properties• Reduced C.O.F.• Corrosion resistant materials• Combine ‘in bulk’ - and surface properties• Almost no change in tolerances; thin films• Environmentally friendly

Benefits of PVD Within

Applications• Smaller and lighter designs

• Reduced energy consumption

• Increased power density

• Cheaper base materials

• Lifetime increase

• Reduced Emissions

Properties of PVD Tribological

Coatings

Example PVD Tribological

Coating

Friction Considerations

Industrial Volume PVD Coatings

“Tribological Applications”

PVD Coatings in AutomotiveApplications

Piston area:•Piston (carbon based•coatings under•development)•Top piston ring (thick CrN)•Piston pin (W-DLC)•Sliding bearing (AlSn)•Connecting rod (CrN)Common rail:•Fuel injection plungers (WDLC)

Transmission area:

• Gears (W-DLC & B4C)

• Camshaft area

• Rollers

• Bushings

• Tappets

• Cams

Air Conditioner:

• High contact pressure (WDLC)

General Purpose:

• Roller Bearings

Opportunities for Weight Reduction

Typical application of PVD

Ion-plating-process

Fuel injection pump components

Sliding wear test

Dry running properties

Surface Engineering Solutions

Surface Engineering Solutions

Thermal oxidation

Thermal oxidation - friction

Gear . Ti64, thermal oxidation

Deep case hardening

• Nickel diffusion

• Laser/EB surface alloying

• Oxygen diffusion

Deep case hardening - oxidation

Deep case hardening - oxidation

Deep case hardening + coating

Load bearing capacity

Ti-alloys

• All the examples shown above have used Ti6Al4V alloy substrates

• 550 alloy . specially developed O-diffusion treatments can produce

• cases up to 190µm in depth• Alloys with significant β phase are

suited to diffusion treatments, but attention must be paid to their bulk heat treatment condition