Surface Engineering - Manufacturing Processes

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

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

8(a) Terminology used in specifying and measuring surface quality; (B) Symbols used on drawing by part designers, with

definition of symbol

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

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)

24Basic steps in the electro-coating process

Electrostatic Spray FinishingElectrostatic Spray Finishing

25Click on the above picture

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.

Power CoatingPower Coating

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Click on the above picture

Click on the above picture

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

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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