Surface Engineering - Manufacturing Processes
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Transcript of Surface Engineering - Manufacturing Processes
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Surface EngineeringSurface Engineering
Rasikh Tariq (ME-113006) [Group Leader]Khawar Shahzad (ME-113009)Mohammad Adam (ME-113125)
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Presentation Flow
Career Counseling
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Surface Engineering – An Surface Engineering – An IntroductionIntroduction
Mohammad Adam (ME-113125)
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IntroductionIntroduction
Sub-branch of materials science
Deals with the surface of solid material.
To improve the Serviceability
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AdvantagesAdvantages
conservation of scarce materials
improved functionality
solution to previously engineering problems
possibility to create new products
reduction of power consumption and effluent output
demand for greater strength
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AdvantagesAdvantages
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Surface IntegritySurface Integrity
Surface integrity reference to the nature of the surface condition that is
produced by the manufacturing process.
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Surface textureSurface texture
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8(a) Terminology used in specifying and measuring surface quality; (B) Symbols used on drawing by part designers, with
definition of symbol
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Cleaning ProcessesCleaning Processes
The removal of soils, grease , or films removing oil, dirt, scale other foreign material that may adhere to the surface of the product by applying different
techniques to make it a useful part. Classification1.Mechanical Cleaning2.Chemical Cleaning
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Mechanical CleaningMechanical Cleaning
Involves the physical removal of
soils,
scales,
or films from the work surface.
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Vibratory FinishingVibratory Finishing
• Bowls are loaded with work pieces and
• media are vibrated at frequencies between
900 and 3600 cycles per minute.
The process is less noisy and easily
controlled and automated.
It is used to debur, clean, and brighten a
large number of relatively small work pieces
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Barrel FinishingBarrel Finishing
• Parts are mixed with media
• Rotating the barrel at speeds of 10 to 50 rev/min.
• Finishing is performed by rotation.
This cycle of rising and tumbling
occurs continuously and,
over time, subjects all of the parts to
the same desired finishing action a
‘‘landslide’’ action of the media.
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Blast FinishingBlast Finishing
High-velocity impact of particulate media to clean and finish a surface.
The most well-known of these methods is sand blasting,
which uses sand (SiO2) as the blasting media.
Other media are also used in blast finishing, including hard abrasives such as aluminum oxide
(Al2O3) and silicon carbide (SiC)
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Chemical CleaningChemical Cleaning
• Chemical cleaning operations are effective mean of removing
• oil,
• dirt,
• other foreign material that may
adhere to the surface of the product.
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Coating ProcessesCoating Processes
Rasikh Tariq (ME-113006) [Group Leader]
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Surface Finishing & Coating Processes
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Painting, Wet or LiquidPainting, Wet or Liquid
Synthetic organic compounds that contain
Pigments
Dry by polymerization
or both
And adsorption of oxygen
Role of Heat and older oil-based materials.
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PaintsPaints
Provide protection
Decoration
Fill or hide surface irregularities
Surface Friction
Modify the light
Heat absorption
Radiation Characteristics
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Painting MethodsPainting Methods
Dipping
Spray Painting
Automation Painting
Electrostatics spray finishing
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Painting MethodsPainting Methods
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Click on the above picture Click on the above picture
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Painting MethodsPainting Methods
21Click on the above picture
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Electrostatic Spray FinishingElectrostatic Spray Finishing
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AdvantagesPrime Coat
DisadvantagesEdges & Holes
Automobile Bodies (Good Corrosion Resistance)
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24Basic steps in the electro-coating process
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Electrostatic Spray FinishingElectrostatic Spray Finishing
25Click on the above picture
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DryingDrying
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Powder Coating
27A schematic of a powder coating system.
AdvantagesHigh-quality finish
Lower cost than liquid
painting.
More efficient
Disadvanta
gesNot good for large
objects (massive tanks)
Heat-sensitive objects.
thickness >0.03mm.
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Power CoatingPower Coating
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Click on the above picture
Click on the above picture
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Hot Dip CoatingHot Dip Coating
Direct immersion into a bath of molten metal
Disadvantages
Metal exposed to the temperatures of molten.
Advantages
Imparting corrosion resistance to steel.
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Chemical Conversion CoatingChemical Conversion Coating
Good corrosion resistance.
Intermediate bonding layer
Blackening or coloring metals
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Surface Enhancement
Khawar Shahzad ME-113009
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Surface Enhancement – Presentation Flow
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Vaporized Deposition ProcessesVaporized Deposition Processes
Form a thin coating on a substrate BY EITHER:
condensation or
chemical reaction of a gas
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Types of Vaporized Deposition Types of Vaporized Deposition ProcessesProcesses
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Physical Vapor DepositionPhysical Vapor Deposition
Physical vapor deposition (PVD) is a
group of thin film processes
material is converted into its vapor phase in a vacuum chamber and
condensed onto a substrate surface as a very thin layer.
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Process LayoutProcess Layout
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ApplicationsApplications
Solar Energy
Semi-conductors
Trophies
Watchcases,
Interior trim in automobiles.
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Chemical Vapor DepositionChemical Vapor Deposition
Chemical vapor deposition (CVD) involves
Interaction between a mixture of gases and the surface of a heated substrate
Causing chemical decomposition of some of the gas constituents
Formation of a solid film on the substrate.
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Advantages
Control of grain size is possible;
Good bonding of coating to substrate surface.
Disadvantages
Certain reaction ingredients are relatively expensive;
Material utilization is low.
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Chemical Vapor DepositionChemical Vapor Deposition
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Surface HardeningSurface Hardening
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Clad MaterialsClad Materials
Composites
Components are joined as solids
Using techniques such as:
Roll bonding
Explosive welding and
Extrusion
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Clad MaterialsClad Materials
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Thank youThank you
Question/Answers?
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