Surface Engineering (eBook)

Dheerendra Kumar Dwivedi, PhD, is Professor in the Department of Mechanical and Industrial Engineering, Indian Institute of Technology Roorkee. He has been involved in teaching, research and development, industrial consultancy for the last 20 years broadly in the area of manufacturing technologies in general and casting, welding and surfacing modification for improved mechanical properties in particular. He has developed more than 100 hours video lectures in area of manufacturing technologies under NPTEL program of MHRD Govt. of India. He supervised 10 PhD thesis and more than 50 M. Tech. dissertation. He has published in more than 100 research papers in peer reviewed SCI and SCIE indexed International Journal with h factor 21 and i-10 index 43. He has published a book on production and properties of cast Al-Si alloys with New Age International, New Delhi. He has executed more than 16 R & D project and 50 industrial consultancy project of worth Rs. 50 Millions. He has undertaken five bilateral international collaborative research projects with reputed university namely Chemnitz University, Germany, University of Coimbra, Portugal, University of Uberlandia, Brazil, University of Zacatecas, Mexico and Physical Technical Institute, Minsk, Belarus. Author has undertaken research projects in the area of oxy-fuel flame and high velocity oxy-fuel spraying for improved abrasive and erosive wear resistance, laser cladding of none-cobalt base alloys for improved cavitation resistance, laser assisted nitriding and ion implantation cast martensitic stainless steel for improved erosion resistance, friction stir processing of cast Al-Si alloys, Ni-Al-Bronzes from funding agencies namely DST, BRNS, MHRD, CSIR etc. 

Preface 6
Contents 8
About the Author 13
1 Surface Engineering 14
1.1 Introduction 14
1.2 Purpose and Need of Surface Engineering in Industries 14
1.3 Surface and Subsurface Regions 15
1.4 Properties for the Enhanced Life and Performance of Mechanical Components 16
1.5 Classification of Surface Modification Techniques 17
1.5.1 Changing the Structure of Surface and Near-Surface Layers 17
1.5.2 Changing the Chemical Composition of Surface and Near-Surface Layers 18
1.5.3 Developing a Surface Layer or Overlays 18
1.6 Scope of Surface Engineering 20
1.6.1 Designing Surface Modification 20
1.6.2 Developing the Modified Surface 20
1.6.3 Investigating and Characterizing the Modified Surfaces 21
1.6.4 Application of Modified Surfaces 22
1.7 Role of Surface Properties Affecting Wear and Friction Behavior 22
1.7.1 Surface Energy 23
1.7.2 Surface Composition 24
1.7.3 Surface Microstructure 25
1.7.4 Surface Roughness 27
1.8 Advantages, Limitations, and Applications 28
2 Surface Damage: Causes and Mechanisms 30
2.1 Material Properties and Its Effect on Performance of Components 30
2.2 Common Factors Leading to the Deterioration of Surfaces 30
2.3 Types of Wear and Mechanisms and Classical Governing Laws 32
2.3.1 Adhesive Wear 33
2.3.2 Abrasive Wear 40
2.3.3 Erosive Wear 44
2.3.4 Corrosion Wear 49
2.3.5 Diffusive Wear 50
2.4 Techniques to Evaluate Damage of Wear Surfaces 52
2.4.1 Material Loss 52
2.4.2 Weighing 53
2.4.3 Dimensional Measurement 53
2.4.4 Optical Method 53
2.4.5 Hardness of Surface and Subsurface Layers 53
2.4.6 Chemical Composition and Phase Analysis 53
2.4.7 Surface Roughness 54
3 Materials for Controlling the Wear 57
3.1 Materials Properties and Wear 57
3.1.1 Hardness 57
3.1.2 Ductility 58
3.1.3 Toughness 58
3.1.4 Stacking Fault Energy 58
3.1.5 Fatigue Resistance 59
3.1.6 Fracture Toughness 59
3.1.7 Affinity to Atmospheric Gases 59
3.1.8 Thermal Stability of Surface Layers 59
3.2 Materials Properties Required for Better Wear Resistance 60
3.2.1 Adhesive Wear 60
3.2.2 Abrasion 61
3.2.3 Erosion 61
3.2.4 Surface Fatigue Wear 62
3.2.5 Cavitation 62
3.2.6 Fretting Wear 63
3.3 Selection of Materials for Surface Engineering 63
3.3.1 Iron Base Alloy 63
3.3.2 Cobalt Base Alloys 63
3.3.3 Nickel Base Alloys 64
3.3.4 Copper Base Alloys 64
3.4 Structure and Wear of Material 64
3.4.1 Ferrous Metals 65
3.4.2 Carbon Steel 65
3.4.3 Alloy Steel 66
3.4.4 Stainless Steel 67
3.4.5 Hadfield Steel 68
3.4.6 Gray Cast Iron 68
3.4.7 White Iron 68
3.4.8 Chromium Irons 69
3.4.9 Non-ferrous Metals 75
3.4.10 Cobalt Base Alloys and Composites 76
3.4.11 Nickel Base Alloys 77
3.4.12 Thermal Barrier Coating 79
3.4.13 Functionally Graded Materials (FGM) 81
3.5 Common Materials for Surface Modifications for Specific Applications 82
3.6 Common Materials and Their Typical Applications 83
4 Surface Engineering by Changing the Surface Metallurgy 85
4.1 Approach 85
4.2 Transformation Hardening Methods 86
4.2.1 Flame Hardening 87
4.2.2 Induction Hardening 87
4.2.3 Laser Beam Hardening 90
4.3 Re-melting of Base Metal or Modified Surfaces Using Laser and TIG 93
4.4 Plastic Deformation-Based Approaches 94
4.4.1 Shot Peening 96
4.4.2 Burnishing and Contour Rolling 97
4.4.3 Friction Stir Processing 98
5 Surface Engineering by Changing the Composition 103
5.1 Approach 103
5.2 Carburizing 105
5.2.1 Solid Carburizing 108
5.2.2 Liquid Carburizing 108
5.2.3 Gas Carburizing 109
5.2.4 Cyaniding 109
5.3 Nitriding 110
5.4 Plasma Carburizing and ?Plasma? Nitriding 112
5.5 Surface Modification by Changing Chemical Composition 113
5.5.1 Laser Alloying 114
5.5.1.1 Laser-Assisted Nitriding 114
5.6 Surface Modification Using Diffusion-Based Processes (PVD, CVD) 117
5.6.1 Vacuum Deposition 118
5.6.2 Ion Implantation 118
5.6.3 Sputtering 121
5.6.4 Ion Plating 121
5.7 Ion Beam-Assisted Deposition 123
5.7.1 Chemical Vapor Deposition 123
5.8 Boronizing 126
6 Surface Modification by Developing Coating and Cladding 129
6.1 Approach 129
6.2 Technical Factor Affecting Performance 131
6.2.1 Protection and Dilution of Coating and Cladding 131
6.2.2 Energy Density 132
6.2.3 Cooling Rate 133
6.3 Metals for Developing, Coating, and Cladding 133
6.4 Weld Surfacing 134
6.4.1 Gas Welding 134
6.4.2 Shielded Metal Arc Welding 135
6.4.3 Submerged Arc Welding 137
6.4.4 Gas Metal Arc Welding 141
6.4.4.1 Pulse Gas Metal Arc Welding 142
6.4.5 Flux-Cored Arc Welding 143
6.4.6 Gas Tungsten Arc Welding 145
6.4.7 Plasma Arc Welding 148
6.5 Laser Cladding 149
6.6 Thermal Spraying 153
6.6.1 Flame Spraying Process 157
6.6.2 High-Velocity Oxy-Fuel Thermal Spraying 168
6.6.3 Detonation Spray 172
6.6.4 Cold Spraying 176
6.6.5 Electric Arc Wire Spray Process 177
6.6.6 Plasma Arc Spray 177
6.7 Electroplating 178
6.8 Electroless Process 179
7 Characterization of Engineered Surfaces 182
7.1 Introduction 182
7.2 Characterization of Surface Properties 182
7.2.1 Surface Roughness 183
7.2.1.1 Stylus-Based Approach 183
7.2.1.2 Laser-Based Approach 184
7.2.2 Confocal Scanning Microscope 184
7.3 Thickness of Coatings and Films 185
7.3.1 Weight Measurement of Coating Deposited 185
7.3.2 Indentation Method 185
7.3.3 Ultrasonic Testing 186
7.4 Bond Strength of Coating–Substrate 187
7.4.1 Bend Test 188
7.4.2 Scratch Test 188
7.4.3 Tensile Test 189
7.5 Soundness of Modified Surfaces Using Non-destructive Testing (NDT) 190
7.5.1 Dye Penetrant Test 190
7.5.2 Magnetic Particle Testing 191
7.5.3 Ultrasonic Testing 192
7.5.3.1 Transmission Approach 192
7.5.3.2 Reflection Approach 193
7.5.3.3 Pitch-Catch Method 193
7.5.4 Radiographic Testing 194
7.6 Destructive Testing of Modified Surfaces 196
7.6.1 Hardness Testing 196
7.6.2 Microhardness 199
7.6.3 Tensile Test 200
7.6.4 Toughness Testing 201
7.6.5 Fatigue Behavior 204
7.6.6 Fracture Toughness 206
7.7 Adhesive Wear 207
7.7.1 Procedure of Pin-on-Disk Unidirectional Sliding Adhesive Wear Test 208
7.7.2 Reciprocating Pin-on-Flat Wear Test 209
7.7.3 Abrasive Wear Test 210
7.7.4 Solid Particle Erosive Wear Test 212
7.7.5 Slurry Erosive Wear Test 214
7.7.6 Cavitation Testing Rigs 215
7.7.7 Corrosion Testing 216
7.8 X-Ray Diffraction (XRD) Analysis 217
7.9 Scanning Electron Microscopy (SEM) 219
7.10 Compositional Analysis 221
7.11 Energy Dispersive X-Ray (EDAX) Analysis 221
7.12 Macroscopic Observation 222
7.13 Metallographic Examination 223
References 227
Index 231