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CHAPTER 33

Surface Treatment, Coating, andCleaning

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Surface Treatments for Various MetalsTABLE 33.1Metal TreatmentAluminum Chrome plate; anodic coating, phosphate; chromate

conversion coating

Beryllium Anodic coating; chromate conversion coating

Cadmium Phosphate; chromate conversion coating

Die steels Boronizing; ion nitriding; liquid nitriding

High-temperature steels Diffusion

Magnesium Anodic coating; chromate conversion coating

Mild steel Boronizing; phosphate; carburizing; liquid nitriding;carbonitriding; cyaniding

Molybdenum Chrome plate

Nickel- and cobalt-base alloys Boronizing; diffusion

Refractory metals Boronizing

Stainless steel Vapor deposition; ion nitriding; diffusion; liquid nitriding;nitriding

Steel Vapor deposition; chrome plate; phosphate; ion nitriding;induction hardening; flame hardening; liquid nitriding

Titanium Chrome plate; anodic coating; ion nitriding

Tool steel Boronizing; ion nitriding; diffusion; nitriding; liquid nitriding

Zinc Vapor deposition; anodic coating; phosphate; chromatechemical conversion coating

Source: After M. K. Gabel and D. M. Doorman in Wear Control Handbook, New York, ASME, 1980 p. 248.

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Roller Burnishing

Figure 33.1 Roller burnishing of the fillet of a stepped shaft to inducecompressive surface residual stresses for improved fatigue life.

Figure 33.2 Examples of roller burnishing of(a) a conical surface and (b) a flat surfaceand the burnishing tools used. Source:Sandvik, Inc.

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ThermalSpray

Operations

Figure 33.3Schematicillustrations ofthermal sprayoperations. (a)Thermal wirespray. (b)Thermal metal-powder spray. (c)Plasma spray.

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Physical Deposition

Figure 33.4 Schematic illustrationof the physical deposition process.Source: Cutting Tool Engineering.

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Sputtering

Figure 33.5 Schematic illustration ofthe sputtering process. Source: ASMInternational

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Ion-Plating Apparatus

Figure 33.6 Schematicillustration of an ion-platingapparatus. Source: ASMInternational.

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Chemical Vapor Deposition

Figure 33.7 Schematic illustration of the chemical vapor depositionprocess.

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Electroplating

Figure 33.8 Schematic illustration ofthe electroplating process.

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Electroplating Guidelines

Figure 33.9 (a) Schematic illustration of nonuniform coatings (exaggerated) in electroplated parts. (b)Design guidelines for electroplating. Note that sharp external and internal corners should be avoided foruniform plating thickness. Source: ASM International.

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Hot Dipping

Figure 33.10 Flowline forcontinuous hot-dip galvanizing ofsheet steel. The welder (upperleft) is used to weld the ends ofcoils to maintain continuousmaterial flow. Source: AmericanIron and Steel Institute.

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Types of Ceramics and Their Properties andApplications

TABLE 33.2Property Type of ceramic ApplicationWear resistance Chromium oxide

Aluminum oxideAluminum titania

Pumps, turbine shafts, seals, compressor rodsfor the petroleum industry; plastics extruderbarrels; extrusion dies

Thermal insulation Zirconium oxide(yttria stabilized)Zirconium oxide(calcia stabilized)Magnesium zirconate

Fan blades, compressor blades, and seals forgas turbines; valves, pistons, and combustionheads for automotive engines

Electrical insulation Magnesium aluminateAluminum oxide

Induction coils, brazing fixtures, generalelectrical applications

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Painting

Figure 33.11 Methods of paint application: (a) dip coating, (b) flow coating, and (c) electrostatic spraying.Source: Society of Manufacturing Engineers.