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