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Surface Treatments: Surface Hardening
Equipment & Coatings
Alfredo Valarezo
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Surface Treatments
• Thermochemical treatments (Carburizing, nitriding, carbonitriding, chromizing)
• Electrochemical treatments (hard chrome, cadmium, nickel)
• Thermomechanical treatments (thermal Spray)
• Mechanical treatments (shot peening, blasting)
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Clasificación en consideración de la naturaleza del depósito (por difusión atómica o de iones, o por
adición de material en la superficie) y el espesor del recubrimiento.
Ingeniería de Superficies: el termorociado Clasificación de los Procesos en Ingeniería de Superficies
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Ingeniería de Superficies: el termorociado
Dureza de varios materiales y tratamientos superficiales
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Surface Hardening
Thermochemical treatments applied to steels in which the composition of the part surface is altered by adding various elements
• Often called case hardening
• Most common treatments are carburizing, nitriding, and carbonitriding
• Commonly applied to low carbon steel parts to achieve a hard, wear-resistant outer shell while retaining a tough inner core
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Carburizing
Heating a part of low carbon steel in a carbon-rich environment so that C is diffused into surface
• In effect the surface is converted to a high carbon steel, capable of higher hardness than the low-C core – Carburizing followed by quenching produces a case hardness of
around HRC = 60
– Internal regions are low-C steel, with low hardenability, so it is unaffected by quench and remains relatively tough and ductile
• Most common surface hardening treatment
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Carburizing in Salt Bath
Salt Bath Furnace
NaCN + O2 → 2NaCNO
2NaCNO + O2 → Na2CO3 +CO + N2
2CO → CO2 + C
Sodium Cyanide Salt
(Sal de Cianuro de sodio)
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Carburizing by Pack
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Carburizing Steel 1020
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Nitriding
Treatment in which nitrogen is diffused into surface of special alloy steels to produce a thin hard casing without quenching
• Carried out at around 500C (950F)
• To be most effective, steel must have alloying ingredients such as aluminum (AlN) or chromium (CrN) to form nitride compounds that precipitate as very fine particles in the casing to harden the steel
• Hardness up to HRC 70
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Carburizing Steel 1015 (Temp. 550C)
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Chromizing/Boronizing
• Requires higher temperatures and longer treatment times than the preceding hardening treatments
• Usually applied to low carbon steels
• Casing is not only hard and wear resistant; it is also heat and corrosion resistant
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Furnaces for Heat Treatment
• Fuel-fired furnaces – Normally direct-fired - the work is exposed
directly to combustion products
– Fuels: natural gas or propane and fuel oils that can be atomized
• Electric furnaces – Electric resistance for heating
– Cleaner, quieter, and more uniform heating
– More expensive to purchase and operate
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Batch vs. Continuous Furnaces
• Batch furnaces – Heating system in an insulated chamber, with a door for
loading and unloading
– Production in batches
• Continuous furnaces – Generally for higher production rates
– Mechanisms for transporting work through furnace include rotating hearths and straight-through conveyors
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Other Furnace Types
• Atmospheric control furnaces – Desirable in conventional heat treatment to avoid
excessive oxidation or decarburization
– Include C and/or N rich environments for diffusion into work surface
• Vacuum furnaces – Radiant energy is used to heat the parts
– Disadvantage: time needed each cycle to draw vacuum
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Selective Surface Hardening Methods
• These methods heat only the work surface, or local areas of the work surface
• They differ from surface hardening methods in that no chemical changes occur
• Methods include: – Flame hardening – Induction hardening – High-frequency resistance heating – Electron beam heating – Laser beam heating
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Flame Hardening
Heating of work surface by one or more torches followed by rapid quenching
• Applied to carbon and alloy steels, tool steels, and cast irons
• Fuels include acetylene (C2H2), propane (C3H8), and other gases
• Lends itself to high production as well as big components such as large gears that exceed the size capacity of furnaces
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Induction Heating
Application of electromagnetically induced energy supplied by an induction coil to an electrically conductive workpart
• Widely used for brazing, soldering, adhesive curing, and various heat treatments
• When used for steel hardening treatments, quenching follows heating
• Cycle times are short, so process lends itself to high production
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Figure 27.7 Typical induction heating setup. High frequency alternating current in a coil induces current in the workpart to effect heating.
Induction Heating
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
High-frequency (HF) Resistance Heating
Used to harden specific areas of steel work surfaces by application of localized resistance heating at high frequency (400 kHz typical)
• Contacts are attached to workpart at outer edges of the area
• When HF current is applied, region under conductor is heated quickly to high temperature - heating to austenite range typically takes less than a second
• When power is turned off, area is quenched by heat transfer to the surrounding metal
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Figure 27.8 Typical setup for high-frequency resistance heating.
High-frequency Resistance Heating
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Surface Treatments
• Thermochemical treatments (Carburizing, nitriding, carbonitriding, chromizing)
• Electrochemical treatments (hard chrome, cadmium, nickel)
• Thermomechanical treatments (thermal Spray)
• Mechanical treatments (shot peening, blasting)
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What is Thermal Spray?
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Thermal Spray Processes
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σ
z
σ
+
z
+
Plastically
worked zone
-
Z2
Z1
LOW VELOCITY Molten particle
More decomposition
HIGH VELOCITY Semi - molten
particle
Less Decomposition
The science behind thermal spray P
arti
cle
Sta
te
•Particle Velocity
•Kinetic Energy
•Fluid dynamics
•Particle Temperature
•Oxidation/decomposition
•Rapid cooling/phase transformations
Loca
l De
po
siti
on
Te
mp
era
ture
•Intersplat bonding strength
•Wetting/ adsorbate-condensates
•Residual Stress (quenching-peening)
Mat
eri
als
intr
insi
c P
rop
ert
ies •Substrate-splat – adhesion
interface
•Splat-splat-intersplat interfaces
•Interpass interfaces
•Elastic –plastic behavior
•High strain – strain rates
•Heat transfer
Tension Compression
Residual Stresses
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Industries that demand Thermal Spray…
• Defense and Aerospace: Typical Applications – Landing Gear
– Hydraulic Shafts
– Gas and Aeroturbines
– Part reclamation
– Antiskid Plattforms
– Worn out components, in general
26
http://www.asetsdefense.org/ http://www.istockanalyst.com/article/viewarticle/articleid/1725016 http://alphamar-imw.com
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Cyllinder Bore
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Crankshaft Repair by HVOF
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Propuesta de Partes a Reparar: Eje Trasero Camiones
Recubrimiento
Preparacion Superficial
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Propuesta de Partes a Reparar: Florero de la Transmisión
Recubrimiento
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Propuesta de Partes a Reparar: Secciones de Manifold
Recubrimiento
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Propuesta de Partes a Reparar: Asientos y Pines
Recubrimiento
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Propuesta de Partes a Reparar a FUTURO: Carcazas
Recubrimiento
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ELECTRODEPOSITION Electroplating
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ELECTROPLATING
• Electroplating is a plating process in which metal ions in a solution are moved by an electric field to coat an electrode.
• The process uses electrical current to reduce cations of a desired material from a solution and coat a conductive object with a thin layer of the material, such as a metal.
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ELECTROPLATING
• The anode and cathode are both connected to an external supply of direct current
• The anode is the positive terminal, and the cathode is the negative.
• The metal at the anode is oxidized from the zero valence state to form cations with a positive charge.
• These cations associate with the anions in the solution.
• The cations are reduced at the cathode to deposit in the metallic, zero valence state.
• The plating is most commonly a single metallic element, not an alloy. However, some alloys can be electrodeposited, notably brass and solder.
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Ni - ELECTROPLATING
• Nickel Electroplating is a process in which a coat of nickel metal is deposited over another metal for inducing certain superior properties.
• The process is carried out in an electrolytic solution, and is widely used in the electronics and chemical industries.
• Some of the features of nickel coating that is deposited on the metal surface are as follows:
– Decorative appearance – Corrosion protection – Wear resistance – Low coefficient of friction. – Ferromagnetism – Controllable internal mechanical
stresses
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Surface Engineering Techniques
• The techniques covered may be divided broadly into three categories:
• Techniques to prepare a surface for subsequent treatment (e.g., cleaning and descaling)
• Techniques to cover a surface with a material of different composition or structure (e.g., plating, painting, and coating)
• Techniques to modify an existing surface topographically, chemically, or microstructurally to enhance its properties (e.g., glazing, abrasive finishing, and ion implantation)
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Hydrogen Evolution and Cathode Efficiency
• The discharge of nickel ions is not the only reaction that can occur at the cathode; a small percentage of the current is consumed in the discharge of hydrogen ions from water.
• This reduces the cathode efficiency for nickel deposition from 100 per cent to 92 to 97 per cent depending on the nature of the electrolyte.
• The discharged hydrogen atoms form bubbles of hydrogen gas at the cathode surface.
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Deposition Rate
If the plating process is operated at 5 A/dm2, for example, it takes about 20 minutes to deposit a nickel coating with an average thickness of 20 um.
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Faraday's Law for Nickel
• W = (I*t*A)/(n*F)
• where: • W = weight of plated metal in grams. • I = current in coulombs per second. • t = time in seconds. • A = atomic weight of the metal in
grams per mole. • n = valence of the dissolved metal in
solution in equivalents per mole. • F = Faraday's constant in coulombs
per equivalent. F = 96,485.309 coulombs/equivalent.
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Nickel Plating Solutions