UNIT-VIII-MECHANICAL SURFACE TREATMENT AND COATING

DIFFERENTSURFACETREATMENTPROCESSES

After Manufacturing a product , some of its surfaces have to be processes further to ensure certain required properties and characteristic. The following are the different surface engineeringprocesses. 1.Mechanicalsurfacetreatmentandcoating 2.Casehardeningandhardfacing 3.Thermalspraying 4.Vapourdeposition 5.Diffusioncoating 6.Electroplating 7.Anodizng 8.Conversioncoating 9.Hotdipping 10.Porcelainenamelling,ceramiccoatingandorganiccoating 11.Painting 12.Ionimplantation

Characteristicswhichimprovethroughsurfaceengineering

Surface engineering is an important aspect of all manufacturing processes/It is used to impartspecificphysicalandmechanicalpropertiessuchasappearance,corrosion,friction,wear and fatigue resistance. Many techniques are applied for modifying surfaces .It may be necessarytoperformsurfaceengineeringinorderto,

1. Improve resistance to corrosion and oxidation in gas turbine components, sheet metals for automobilesetc., 2.Improvefatigueresistancesuchasbearings,shaftsetc. 3.Improvelubrication(suchasretainlubricationproperly) 4.Reduceadhesion. 5.Modifysurfacetexture. 6.Impartdecorativefeaturesetc. Surfacepreparationtechniquesforcoatings Surfacepreparation Surface preparation of the substrate is very essential in order to ensure good electrodeposits.Thefollowingstepsareusuallyfollowedforefficientelectrodepositing 1.Removaloforganicimpuritiesandgreasefromthesurface This is done by employing organic solvents like trichloroethylene ,methylene chloride and hot aqueous alkali,pH increase and catalysis the hydrolysis of fatty impurities.Alkai treatmentcanalsobecarriedoutbymakingthesurfaceofarticlecathodicbyusingacurrentof 30to80oC.Theliberatedhydrogenontheelectrodehelpsintheremovaloforganicimpurities. Acidpickling The excess alkali from above process is now removed by dipping the articles in a10 % h2so4 solution. This treatment also removes scales or rust from the surface. Pickling in dilute h2so4 and simultaneously making the surface anodic by using about 100 mA cm^2 current density.Itismoreeffectivemethodofremovingoxidesscalesfromthesurface. Polishing This is done in order to obtain a lustrous surface. The articles are polished by using siliconcarbidewheels,followedbysandblastingandmechanicalbuffing.

 Thermalormechanicalmodificationofsurfacesofsurfaceengineering. Several techniques are used to mechanically improve the surfaces properties of finished components.Thecommonmethodsare, 1.shotpleening 2.Waterjetpleening 3Laserpeening 4.Rollerburnishing 5.Explosivehardening 6.Cladding 7.Mechanicalplating

In thermal modification surface treatment, coatings are applied to metal surfaces by spray gun with a stream of oxyfuel flame, electric arc or plasma arc. The coatings are various metals and alloys, carbides and ceramics. The coating materials are in form of wire rod or powder or in droplets or particles impact the surface at high speeds. Several thermal spraying processes are used.Theseareasfollows,

1.thermalwirespraying 2.Thermalmetalpowderspraying 3.Plasma 4.Detonation 5.Highvelocityoxyfuelgasspraying 6.Wirearc The surface to be sprayed are first cleaned and roughened to improve bond strength .The coating has a a layered structure deposited material and may have porosity due to entrapped airandoxideparticlesbecauseofthehightemperaturesinvolved.

 Thevariousmechanicalcleaningprocesses. Thedifferentmechanicalcleaningprocessesareasfollows 1.tumbling 2.powerbrushing 3.wirebrushing 4.precleaning 1.Tumbling

Tumbling is a process of cleaning or eliminating the slurry of abrasive agent such as sand,granite chips or aluminium oxide pallet that are present along with the workpieces.In the process,workpiecesareplacedinalargebarrelordrum.Theendsofabarrelareclosedbycast iron lids. Horizontal trunnious are employed for the support of barrel .The barrel is charged with work pieces and slurry of abrasive agents. It is then rotated at a speed ranges from 2550 rpm .Due to repeated rubbing against each other resulting in the elimination of sand and fins fromtheworkpieces. The process of tumbling is performed only for the parts which withstand the action of tumbling. The rotation of the barrel also cause elimination of sharp edges and fins due to continuouspeeningactiontherebyrelievingtheinternalstressesintheworkpieces. 2.PowerBrushing

For eliminating light sand, rust or loosely adhering scale from casting ,manual wire brushingisused.Butforbetterproductivemethodspowerbrushingmachinesareemployed.In power brushes. Large range of fills materials are available which not only eliminates the scale .rust ,sand ,sand but also develop a finished surface. It is also used to remove excessive plastic residue.Inindustries,powerbrushesareemployedforedgeblending,polishingandeliminating contaminantsfromthesurfacewhichareoperatedbyhorsepower. The power brushes are made of wire, fibre cord etc.The brushes used on these machinesaregenerallyofrotarytypeandaremadeindifferentshapessuchaswheel,cup,roller typeetc. VariouschemicalcleaningprocessesindetailandWhysurfacecleaningisrequired? Thevariouschemicalcleaningprocessesarefollows a)Solventcleaning

 It is used to remove oils,greases,buffing compounds chlorinated or fluorinated hydrocarbons ,toulenes,xylene,acetone etc.This is followed by cleaning with stream and hot watercontainingwettingagentsandalkalis/ b)Alkalicleaning Trisodium phosphate along with soaps and caustic soda is used for the removal of old paint Coating from metal surface .This method can be made more effective by the application of an electrodecurrentandmakingthemetalcathodicinalkalimedium.Analkalitreatmentisalways followed by thorough rinsing with water and then immersion in slightly acidic to remove alkali traces. c)Picklingandetching

Itisgenerallyusedtoremovethescalesonmetalsurfacesbyimmersingthemetalsand in an acid pickling solution ,aluminium is pickled in alkaline solution .Acid pickling of steel is accompaniedbydippinginwarmdiluteH2SO4towhishsomeinhaitorhasbeenadded. Surface cleaning is required for smooth bright and strong deposit surface and to secure long life services of protective coatings on a metal surface. Maximum coating adhesion can be obtained only if the base metal is free from any dirt extraneous matter such as grease and combustionproducts. EXAMPLES:Oxides,sulphidesetc. Differentdegreasingmethodsindetailswiththehelpofneatsketches. Vapourdegreasing It is a simple process. The equipment consists of condensing coils and cooling jackets heater boiling solvent .Generally the solvent used is a halocarbon solvent such as trichloroethylene. Heaterraisethetemperatureoftheliquidsolventstoitsboilingpoint.Whenthesolvent starts boiling it produces hot, heavy vapours that rise to an established vapour line .As the solvent vapours line. Parts ambient temperature are now introduced into the solvent vapour andthecondensesonthepartsurface.Theliquidsolventcondensate,anddissolvesthegreases cleaned,morevapoursareproducedintheboilingsumptoreplacethosethatwerecondensed.

2.Immersiondegreasing Thepartsaresuccessivelyimmersedintwotanksofthesamesolventinliquidform,the firsttankactingasawashandthesecondasrinse. 3.SteamCleaning The application of detergent and alkaline cleaners using steam cleaners is an effective degreasing method. Heavy greases and waxes are dissolved and flushed away by the impingement of steam and the action of chemicals. Hot water spray cleaning using chemicalsisalmostaseffectiveassteamcleaning.

4.Wiping The surface are degreased using a clean brush for cloth soaked in halo carbon or other degreasingsolvent.

5.DetergentDegreasing The surfaces are scrubbed in a solution of liquid detergent and then washed with clean hotwater,followedbydryinginair.

PART-2
Surfaces Coating and Casehardening, Thermal Spraying, Vapour Deposition, Ion Implantation, Diffusion Coating, Electroplating, Electroless Plating and Electro Forming,CeramicOrganicandDiamondCoating Whatissurfacecoating?Whyitisprovidedonvariousproducts: SurfaceCoating Surface coating or surface treatment is defined as a process in which surface layer of materials are applied to the original metal surface of the part with the help of different methodslikemechanical,electrochemicalthermalordiffusion. Surfacecoatingisprovidedonvariousproductsduetothefollowingreasons

1.Tochangethesurfacepropertieswithrespecttotherequirements.

2.Toapplytheexpectedcolourstothesurfacesoftheproduct. 3.Forsmooth,attractiveandpleasantappearanceoftheworkpieceorproduct. 4.Forprovidingtheworkpiecewithsomeexpectedfunctionalpropertieslike, (i)Corrosionresistance (ii)Abrasivewearresistance (iii)Transmithardness (iv)Forprovidinghighdurability (v)Improvementofelectricalandtemperatureresistances. Thus, with the help of surfaces coating technology, a manufacturer can select a low gradematerialandmadeitcorrespondingtotheneed. Diffusioncoating&varioustypesofdiffusioncoating: Diffusioncoating Aprotectivecoatingobtainedbydiffusingthecoatingmetalintoabasemetaliscalled asdiffusioncoating.Itisalsotermedascementation. Diffusioncoatingareobtainedbyheatingthebasemetalinarevolvingdrumcontaining apowderofthecoatingmetal.Thecoatingmetalgetsdiffusedintothebasemetalandresults intheformationoflayersofalloyofvaryingcomposition.Theouterlayersarericherinthe coatingmetalandthelayeradjacenttothebasemetalmaybeanintermediatecompounda solidsolution.Thethicknessofthecoatingiscontrolledbyvaryingthetimeoftreatmentand temperature.Itissuitableforcoatingmetalscanbeusedasanalloyofiron. EXAMPLE:Zn,chromiumandaluminium Typesofdiffusioncoatingare 1.Sheradizing 2.Colourizing 3.Chromizing

1.Sheradizing

 Sheradizingisatypeofcementationordiffusioncoatinginwhichthebasemetalis heatedinarevolving,containingzincpowderascoatingmetal.Asaresult,diffusionofcoating metaltakesplaceforminglayersofalloyofvaryingcomposition.Itisusedforcoatingiron articles;thesearticlesarefirstcleanedandthenplacedwithzincdustinadrum.Toavoid oxidationofzinc,thedrumistightlypackedorsealed.Nowthedrumisrotatedslowlyfor2to3 hoursandthetemperatureismaintainedbetween350oCand370oCbyusinggasheatingor electricity.ThezincetsdiffusedintotheironsurfaceformingalayerofFeZnallot.Athinfilmof FeZnalloyisobtainedoverthesurfaceofironattheendoftheprocess.Sheradizingisusedfor smallsteelarticleslikebolts,nuts,washersetc. 2.Colorizing Colorizingisacementationordiffusioncoatingsdoneusuallyonmetalobjectssuchas steelparts.Themetalsobjectssurfaceiscleanedbysandblastingandthentheobjectissealed tightlyinadrumwithamixtureofaluminiumpowderandaluminiumoxidetogetherwitha traceofNH3actingasflux.Theprocessismadetooccurintheabsenceofairinareducing atmosphereofhydrogenbymaintainingthetemperaturetoabout8001000degrees.Atthe endoftheprocessalayerofAl3Fe3isobtainedwhichcorrespondstoabout25%ofAlby weight.Thecoatingisemployedforprotectionoffurnaceparts. CHROMIZING Chromozingisatypeofcementationordiffusioncoatingsobtainedbyheatingabase metalwithamixtureof55%chromiumpowderand45%aluminainasealeddrumat temperaturemaintainedbetween1300to1400degreecentigradeforabout3to4 hours.Aluminahelpsinpreventingthecoalescenceofchromiumparticles.Thisprocessis carriedoutinthreestages 1. Fe+ 2.CrCl2+H2Cr+2HCl(REDUCTION) 3.CrCl2Cr+Cl2(DECOMPOSITON) CrCl2FeCl2+Cr(DISPLACEMENTREACTION)

ACorrosionresistantchromizedcoatedsurfaceisobtainedwithchromiumcontentindiffusion layervaryingfrom10%to20%. Q10.Briefoutvariousinorganiccoatings.Discusstheirimportanceandapplications. Ans:

Inorganiccoatings Theseareproducedbychemicalactionwithorwithoutelectricalassistance.The treatmentschangetheimmediatesurfacelayerofmetalintoafilmofmetallicoxideor compoundwhichhasbettercorrosionresistancethanthenaturaloxidefilmandprovidesan effectivebaseforsupplementaryprotectionsuchaspaints. ANODIZING Itinvolvestheelectrolyticoxidationofasurfacetoproduceatightlyadherentoxide scalewhichisthickerthanthenaturallyoccurringfilm.Itisanelectrochemicalprocess,during whichaluminiumistheanode.Theelectriccurrentpassingthroughanelectrolyteconvertsthe metalsurfacetoadurablealuminiumoxide.Theoxidizedsurfaceishardandabrasionresistant whichprovidessomedegreeofcorrosionresistance.Anodiccoatingprovidesanexcellent surfaceforbothpaintingandadhesivebonding.Anodizingiswidelyusedwith7000series alloys,magnesiumandtitaniumalloys. CHROMATEFLIMING Thetreatmentinvolvesshorttimeimmersioninstronglyacidicchromatesolutions. However,sprayingorapplicationbybrushingorswabbingcanalsobeusedfortouchupof Variousinorganiccoatingsare 1.Anodizing 2.Chromatefilming 3.Phosphatising 4.Nitriding 5.Passivefilms 6.Cladding 7.Electroplating 8.Packcementation 9.Electrolessplating 10.Physicalvapourdeposition

parts.Theirmainpurposeistoprovideasuitablesurfaceforsealingresinsorpaints.These treatmentsareavailableforaluminium,magnesium,cadmiumandzincalloyssolution. Austeniticstainlesssteelsandhardenablestainlesssteelssuchasmartensitic,precipitation hardeningandmaragingstainlesssteelsareoftencoatedwiththisprocess. CLADDING Thecorrosionresistanceofasubstratecanbeimprovedbymetallurgicallybindingto thesusceptiblecorealloyandasurfacelayerofametaloranalloywithgoodcorrosion resistance.Claddingisselectedsuchthatifitgetsdamaged,itprovidescathodicprotectionby corrodingsacrificially.Claddingisdominantlyappliedinthemanufacturingofsheet,plateor tubing.Theapplicationoftheprocessislimitedtosimpleshapedarticlesthatdonotrequire muchsubsequentmechanicaldeformation. ELECTROPLATING Itisobtainedbypassinganelectricalcurrentthroughasolutioncontainingdissolved metalionsandthemetalobjecttobeplated.Themetalobjectservesasthecathodeinan electrochemicalcell,attractingmetalionsfromthesolution.Ferrousandnonferrousobjects areplatedwithavarietyofmetalsincludingAl,brass,bronze,cd,cu,cr,fe,pb,ni,tinandznaswell aspreciousmetalsuchasAg,Auandpt.Theprocessisregulatedbycontrollingvarietyof parameters,includingthevoltageandamperage,temperatureandpurityofbothsolutions. PACKCEMENTATION Diffusioncoatingsareformedbydepositingalayerofaluminiumonthe,metalsurface andthenheatingthecomponentinafurnaceforaperiodoftime.Duringthisheattreatment, theAlandmetalatomsmitigateordiffuseintoeachotherasaresultthesecoatingsarecalled diffusioncoatings.Thisprocessisusuallyperformedbyapackcementationprocess,inwhichAl depositionandtheheattreatmentoccursimultaneously.Itiswidelyusedtoconferoxidation resistanceonferrousalloys. ELECTROLESSPLATING Electrolessnickelplatingisachemicalreductionprocesswhichdependsuponthe catalyticreductionprocessofnickelionsinanaqueoussolutionandthesubsequentdeposition ofnickelmetalwithouttheuseofelectricalcorrosionresistanceandhighhardness.Applicable inmakingvalves,pumppartsetc PHYSICALVAPOURDEPOSITON

 Itreferstoaprocessinwhichmaterialsinavapourstatearecondensedthrough condensation.Chemicalreactionorconversationtoformasolidmaterial.Theseprocessesare usedtoformcoatingstoalterthemechanical,electrical,thermal,potical,corrosionresistance andwearpropertiesofthesubstrates.Itisusedtoformfreestandingbodiesfilmsandfibres andtoinfiltratetoformcompositematerials. PART3 Listvariousoforganicandinorganiccoatingsandbetweenorganicandorganic coatingswiththeirapplications. Organiccoatings Organiccoatingsareinertorganicbarriersappliedonmetallicsurfacesandother constructionalmaterialsforcorrosionprotectionaswellasdecoration Variousorganiccoatingsare 1.Paints 2.Varnishes 3.Enamels 4.Lacquers 5.Emulsionpaints Inorganiccoatings Theseareproducedbychemicalactionwithorwithoutelectricalassistance.The treatmentchangetheimmediatesurfacelayerofmetalintoafilmofmetallicoxideor compoundwhichhasbettercorrosionresistancethanthenaturaloxidefillandprovidesan effectivebaseofsupplementaryprotectionsuchaspaints 1. 2. 3. 4. 5. Anodizing Chromatefilming Phosphating Nitriding Passivefilms

6. Cladding 7. Electroplating 8. Packcementation 9. Electrolessplating 10. Vapourdeposition 11. Hotdipgalvanizing 12. Thermalspraying ORGANICCOATINGS 1.Thesearetheorganicbarriersovera metalsurface 2.coatingdoesnotreactwiththebase metal 3.Surfacecharacteristicsofthebasemetal arenotchanged 4.Noelectricalassistancerequired. 5.Theyprovidecorrosionresistanceand aestheticappearance. ApplicationsofOrganicCoatings 1. 2. 3. 4. 5. 6. Automobileindustry. Polishingwoodenfurniture. Lustrous,glossyandhardsurfacecanbeachieved. Interiordecoration. Coatingcottonfabricswhichareusedinpreparingartificialleathers. Externalsurfacesofbricksworks,concreteetc.,afteraddingaweatherresisting compound. 7. Corrosionresistantpaintingofelectricandtelegraphpolesandtowers. 8. Forpaintinghotwaterpipes,tanks,oiltanksandgasstoragetanksetc. ApplicationsofInorganicCoatings (a) Protectionofironfromatmosphericcorrosionintheformofroofingsheets,wires, pipes,nails,bolts,screwsetc. (b) Coatingsteel,copperandbrasssheets. (c) Coatingintricateshapes. INORGANICCOATINGS 1.Ametalsurfaceiscoatedbyanother metal. 2.Coatedmetalreactswiththebasemetal andformsalayer 3.Surfacecharacteristicsofthebasemetal change 4.Electricalassistanceisrequiredforsome processes. 5.Theyprovidecorrosionresistanceand sometimesformabaseforpaints.

Protectionoffurnaceparts. Protectionofgasturbineblades. Digitalandelectronicinstruments. CoatingPrintedCircuitBoards(PCB) Decorativeandfunctionalpurposes. Jewellarycoatings. Dipcoatingandspraycoating.Distinguishbetweenthesetwoprocess.Comparethe meritsanddemerits. SprayCoating Inthisprocess,thecoatingmetalinthemoltenstatefromasprayinggunissprayedon theroughsurfaceofthebasemetal.Themetalsthussprayandadherestothebasemetal surface.Asealeroilisappliedtothespraycoating,becausetheyarecontinuousbutsome porous.Thisprovidesthemetalasmoothsurface. DipCoating Thisprocessingeneralconsistsofimmersingthebasemetalinabathofmoltencoating metal,coveredbyamoltenfluxlayer.Thefluxcleansthebaseofmetalsurfaceandprevents theoxidationofmoltencoatingmetal. ComparisionofSprayandDipCoating Theprocessofspraycoatingofferscertainadvantagesoverdipcoatingmethodssuchas (i) (ii) (iii) Greaterspeedofworking. Applicabletothelargersurfaces Easyapplicationofeventhickcoatingtorestrictedareas.

(d) (e) (f) (g) (h) (i)

Theadvantagesofdipcoatingoverspraycoatingare Thecoatingproducedhavegoodadhesivestrength Providesgoodprotectionfromatmosphericcorrosion. Diffusioncoatingapplicationofsurfaceengineering. (i) (ii)

DiffusioncoatingIsaprocessinwhichanalloyingelementisdiffusedintothesurfaceofthe metal.Italtersthesurfaceproperties.Thealloyingmetalscanbesuppliedinsolid,liquid, gaseousstate. Diffusioncoatingprocesshasdifferentnamesdependingonthediffusedmetal, diffusionprocessarecarburizing,Nitridingandboroninzingetc. Carburizing Inthisdiffusionprocess,carbonistheelementaddedtothesurfaceforthelowcarbon steelandalloysteels.Heatthesteelsat870oto950oinanatmosphereofcarbonaceousgases andthenquench.Ahardhighcarbonsurfacesproducedtypicalapplicationsaregears,cams, shafts,pistonpins,pistons,sprockets,clutchplatesandbearings. Nitriding Inthisdiffusionprocess,nitrogenistheelementaddedtothesurfaceofsteels,alloy steels,stainlesssteelsandhighspeedtoolsteels.Heatthesteelat500oto600oCinan atmosphereofammoniagas.Coredepth0.10.66mmcanbeobtained.Typicalapplicationsare gears,cuttersandvalves. Boronizing Intheprocess,boronistheelementaddedtosteelsurfaces.Thepartisheatedusing boroncontaininggas(or)solidincontactwithpart,anextremelyhardandwearresistant surfacecharacteristicareobtained.Coredepth0.025to0.075mmcanbeobtained.Typical applicationsarediesteelsandtoolsetc. Mechanicalcoatingprocesses. (i) Galvanizing Galvanizationisaprocessinwhichtheironarticleisprotectedfromcorrosion bycoatingitwithathinlayerofzinc.Nthisprocess,firstironorsteeliscleaned bypicklingwithdilutesulphuricacidsolution(H2SO4)atatemperaturerangeof 60to90oCfor15to20minutes.Therefore,itremovesscale,rustandother impuritiespresentifanyandthenwashedwellanddried.Thenafter,dippedin thebathmoltenzincwhichisat425to450oC.Topreventitfromoxide formation,thesurfaceofbathiscoveredwithaflux(ammoniumchloride). Whentheironpieceistakenoutitiscoatedwithathinlayerofzinc.Andto removeexcesszinc,itispassedthroughapairofhotrollers.Lastly,itis annealedatatemperatureof450oCandthencooledslowly.

(ii)

Itismostwidelyusedfortheprotectionofironandsteelproductssuch aswires,pipes,nails,bolts,screws,buckets,tubes,roofing,sheets,etc. ElectrostaticPainting

Electrostaticpaintingisthemechanicalcoatingprocessinwhichthepaintparticlesare chargedelectrostaticallybyapplyingD.Cvoltagebetweenthepaintbooth(cathode)and workpiece(anode).TheparticlesarecontrolledinthepathofelectrostaticfieldwhichIs formedbetweentheworkpieceandpaintboothasshowninfigure. Thepaintparticlesstickstotheworkpieceandgetsaccumulatedonit.Thenthework pieceisremovedfromthepaintboothandtreatedthermallybybakinginanoversoasto completetheprocessofcoating. Applications. (a) Electroplating Electroplatingistheprocessormethodofcoatingmetals,tochangetheir surfacepropertiessastoimproveappearance,increasethehardnessandtoimprove resistancetocorrosionandwearorchemicalattack. Electroplatingistheelectrodepositionofmetal,bymeansofelectrolysisover thesurfaceofmetals,alloysornonmetals. Thewearresistanceofametalpartcanbeimprovedbyelectroplatingaharder metalonitssurface.Themetalsmostoftenplatedonbasemetalsormaterialsare chromium,nickelandrhodium.Forexamplemetalslikeironwhichareeasilycorroded byatmosphericair,moistureandCO2arecoatedelectrolyticallywithbasemetalssuch asnickelorchromiumwhicharemoreresistanttowearorchemicalattack. Someoftheapplicationsofelectroplatingare. Platingforprotectionfromcorrosionandchemicalattack. Platingfordecoration. Platingforspecialsurfaceandengineeringeffects. Electroforming. Platingonnonmetallicmaterials. Therefore,thisprocessiswidelyusedinautomobiles,aircraft,refrigerators, radios,cameras,typewriters,umbrellas,watches,etc. (b) Parkerizing

 Variouschemicalcoatingprocessesandphosphatecoating. ChemicalCoatingProcess Theprocessofcoatingathinlayerofmaterialovertheoriginalmetalsurfacesofcomponent bymeansofcomponentbymeansofchemicalprocessisknownaschemicalcoatingprocess. Thisprocessisappliedoncomponentstoimprovethesurfacepropertiessuchascorrosion resistance,strengthstability,durability,appearanceetc. Thedifferenttypesofchemicalprocessareasfollows, Anodizing Chromecoating Electroplating Parkerizing Phosphatecoating.

PhosphateCoating Phosphatecoatingisobtainedbythechemicalreactionofaqueoussolutionof phosphateofiron,manganeseandzincwithbasemetalssuchasiron,steelandzinc.The chemicalreactionproducesasurfacefilmconsistingofmanganeseironphosphatesorzinciron phosphates.Forincreasingthereactionrate,acceleratorssuchasnitrites,chloratesornitrates arealsoadded.Applicationofphosphatecoatingonthebasemetalsurfacecanbedoneby brushingorspraying.Thiscoatingdoesnotoffercorrosionresistancebutoffersexcellentbases forpainting,impregnationwithoilsetc.Ironandmanganesecoatingsaregenerallyusedto reducewearcausedbyfriction.Phosphatecoatingcanbedoneonothermetalssuchas aluminum,cadmiumandtin.Thecolorofphosphatecoatingisusuallygrey. Theobjectivesofphosphatecoatingsareasfollows, 1. 2. 3. 4. Togivebetterresistancetocorrosion. Toprovidesurfaceaswearresistance. Togivedecorativeappearancebydifferentshadesofcoloredcoatings. Togiveadhesionsurfaceforpaints,oil(or)wax. Tofulfilltheaboveobjectivesdifferentphosphatecoatingareappliedonmetal surfacesofcomponents.Theyareasfollows, IronPhosphateCoating Thiscoatingactsasacleaner,andisbasicallyappliedonsteelcomponentsasbase coatfortheprocessofpainting. LeadPhosphateCoating

(a)

(b)

(c)

(d)

Thiscoatingisappliedonironandsteelcomponentsforbettercorrosionresistance. ManganesePhosphateCoating ThiscoatingisappliedonInternalCombustion(IC)enginepartsandgearstoavoid gallingeffect.Thecoatofthismaterialincreasesfrictionandalsoactsaslubricant. Zinc(or)ZincironPhosphateCoating Thiscoatingisappliedoniron,steel,cadmium(or)zincplatedcomponentsto Increasetheadhesionpropertyofmetalsurfacesforconsequentfinishes, specificallywhensurfacesareexposedtoenvironment.

Porcelainenameling&Ceramiccoatings.&itstheirapplications: (a) PorcelainEnameling Porcelainenamelingisalsocalledasvariousenameling.Porcelainenamelisan inorganiccoatingwithvitreousorglossywhichisappliestothesurfaceofthemetal atextremelyhightemperature.Therearetwoprocessesthroughwhichporcelain enamelcoatingcanbeapplied.Theyare, (i) WetProcess (ii) DryProcess. (i) WetProcess Inwetprocessofporcelainenameling,slurryisappliedonthesurfaceofthe metal.Theinitialstepinwetprocessisthatslurryoftheporcelainenamel mixtureistobeprepared.Thensiliconoxideandborax,titaniumoxideand zirconiumoxideasopaquematerials,astabilizer,coloredmetaloxidesand potassiumorsodiumoxideasfluxarecompletelymixedtogether.Thecomplete mixtureissmeltedtogether,groundandthencooled.Theadditionofsodium silicatewaterandclaytothemixtureformsamasswhichismilledtogetherto formaslurry.Themetalsurfaceisthencoatedwithaslurrybyaprocessofclip coating,flowcoatingorspraying.Finally,thecoatingisdriedandheatedata temperaturebetween500oCto800oC. (ii) DryProcess Indryprocessofporcelainenameling,theinitialstepistoheatthecomponent toanappropriatetemperature.Thesurfaceofthearticleisappliedwithdry powderofporcelainenamel.Duetothestickynature,thesurfaceofthe componentgetsfusedwithpowder.Forcompletelyfusedpowderonthesurface ofthecomponentitisreheatedtoasuitabletemperature.Finally,thepowderis fusedinthesurfaceofthecomponent.

Applications 1. Porcelainenamelingiswidelyusedinvarioususedinvariouscoatingapplicationswhich includewaterheaters,heatexchangers,outdoorarchitecturalpanelsandsigns. 2. Itactsasaprotectivesurfaceforcookingutensils,kitchenandbathroomfixturesand applicationssuchasdishwashers,refrigeratorsanddryers. 3. Porcelainenamelsarealsousedinchemicalprocessingvessels,agriculturalpanels, storagetanks,pipingandpumpcomponents.Italsoactsasaacidresistant. (b) CeramicCoatings Aceramiccoatingisdefinedasaninorganic,nonmetallicandprotectivecoating onthesurfaceofametalwhichisappropriateforuseatredheatoraboveredheat. Ceramiccoatingsaremorepreferableduetotheirstabilityatboththeroom temperatureaswellasatimmenselyhightemperatureandalsoinbetweenthese twolimits.Thewidelyusedmaterialsforceramiccoatingsaresilicidesand aluminides. Sandblastingisusedforthepreparationofbasemetalsurfacesforceramic coating.Onthepreferredsurfaces,thematerialrequiredforcoatingissprayedand thendriedthroughairandfinallybakedatatemperatureofabout540oC.Thetime thatistakenforbakingusuallydependsuponthesizeofthecoatingcomponent. Silicidecoatingsoffermoreprotectionwhencomparedtoaluminitecoatings. Theprotectionofferedbysilicidecoatingsareupto1928oCwhileitisrestrictedto below165oCinaluminitecoatings.Ceramiccoatingsarecorrosionresistantand increasethestrengthandrigidityofthemetalparts.Itprovidesgreaterresistanceto chemicalattackandincreasedresistancetomechanicalabrasion.Duetoincreased thermalstability,largevarietiesofthermalandelectricalinsulatorspossessceramic coatings. Applications Ceramiccoatingshaveawiderangeofapplicationsinaircrafts,rockets, satellites,gasturbines,steelindustries,textileindustries,chemicalindustries,dataprocessing industries,kitchenwares,sanitarywares,jewelleryetc. Metalizing&itsapplications: (a) Wiremetalizing (b) Powdermetalizing Metalizing Itistechniqueofcoatingmetalonthesurfaceofnonmetallicobjects.Itisalso knownasmetalspraying.

(a)

WireMetalizing Inwiremetalizing,themetallicgunusesametalintheformofwire.Initially,the surfaces,tobecoatedarecleanedandroughenedtoimprovebondstrength.The coatingmaterialissprayedonthemetalsurfacebyusingaspraygun(metallicgun), whichcomprisesof, (i) Agastorchwithaholeatthecentreofthetipforthewire. (ii) Agearandasmallairturbineinordertofeedinthewirethroughthetop intotheflameasfastasitmelts. (iii) Anaircaparoundthetorchtipand (iv) Anozzletosupplyablastofairtoatomizethemoltenmetalanddeposit itonthepreparedsurface. Inthisprocessthewireisfedintothemetallicgunataspecificrate,meltedbyan oxyacetyleneflameandthenitisblownontothesurface,beingcoatedby compressedair.However,wiremetalizingismostcommonlyusedbecauseofthe followingreasons, (a) (b) (c) Themetalusedislessexpensive Itcanbehandledveryeasilyand Easyavailability. PowderMetalizing Inthismethod,coatingmaterialisintheformofpowder.Thepowderedmetalis fedthroughrubberhosetospraygunfromacontainerandoutthroughthecenter oftheflame. Inthiscase,asmallamountofairissufficienttodepositthemoltenmetalonthe surfacebeingcoated,sincethemetalisalreadyintheatomizedform.Thepowder gunhasnogearsorturbine,costslessandislightertohandle. Applications Themetalizingisused, 1. Incorrosionprotection. 2. Toobtainhardandnoblesurfaces. 3. Insolderingthesurfaces. 4. Toincreasetheelectricalconductivityofpoorconductors. 5. Toincreasethermalconductivityoftheconductors. 6. Themetalizingisalsoemployedinreflectingsurfaces,decorativefilms andspecialmetalforms.

(b)