Surface Treatments & Engineering

Metrology & Instrumentation

Group 8
ME 260
Fall 2005
11/30/05

Kurt Sorenson
Derek Benavidez
Colin Evans
Steven Best

Introduction

Surface Treatments
Why?
Types

Cleaning
Mechanical Measurements
Standards
Types
Dimensioning

Why use a surface treatment?

Improves
durability

Controls Friction

Reduces Adhesion

Why use surface treatment? (cont)

Improves
Lubrication

Rebuild Surfaces

Aesthetics

Types of Treatments

Mechanical Surface Treatments

Mechanical Plating & Cladding
Case Hardening
Thermal Spraying
Vapor Deposition
Laser Treatments

Mechanical Surface Treatments

Peening

Shot Peening
Laser Shot Peening
Water-jet Peening
Ultrasonic Peening

Roller Burnishing

Explosive
Hardening

Mechanical Plating & Cladding

Mechanical Plating

Cladding

Laser Cladding

Case Hardening and Hard Facing

Case Hardening

Hard Facing

Spark Hardening

Thermal Spraying

Combustion
Spraying

Thermal Wire
Spray

Thermal MetalPowder Spray

Plasma Spray

Vapor Deposition

Physical Vapor Deposition

Vacuum Deposition

Sputtering

Chemical Deposition

Ion Platting

Physical Vapor Deposition

Sputtering

Chemical Vapor Deposition

Thermochemical
Process

Cutting Tools

Thicker

Tedious

Ion Implantation & Diffusion Coating

Particulates penetrate substrate

Modifies surface properties

Increases

hardness
Improves durability

Masking capability

Laser Treatments

Heating
Melting
Vaporization
Peening

Electroplating, Electroless Plating,

and Electroforming

Electroplating

Workpiece (cathode) is
plated with other metal
(anode) through a
water-based
electrolytic solution
A SLOW Process!!!
75 micrometers/hour
Solution must be
replenished
Sacrificial anode
Additional salts of
metal

Electroplating, Electroless Plating,

and Electroforming

Operation Sequence

Chemical Cleaning
Acid Bath
Application of a Base Coat
(Optional)
Final Electroplating
Rinse Tanks

Common Plating Metals

Nickel
Cadmium, Copper
Tin, Zinc

Electroplating, Electroless Plating,

and Electroforming

Electroless Plating

Chemical Reaction
More Expensive $$
Uniform Thickness

Electroforming

Metal-fabrication
Metal electrodeposited
on a mandrel

Conversion Coatings

Anodizing

The workpiece is
the anode in an
electrolytic cell

Coloring

Alters color of
metals, alloys, and
ceramics
Conversion of
surfaces into
chemical
compounds:
oxides, chromates,
and phosphates

Hot Dipping

Workpiece is dipped
into molten metal

Zinc- galvanized-steel
sheet
Tin- food containers

Hot-dipped Galvanizing
line

Porcelain Enameling; Ceramic and

Organic Coatings

Enamels- fuse a coating

material by heating to 425 to
1000.

Ceramic coatings- Intense

temp applied

Organic coatings- Wide

range of properties:
flexability, durability, color,
texture

Diamond Coating and Diamond-Like

Carbon

Techniques

Chemical vapor
deposition
Plasma-assisted
vapor deposition
Ion-beamenhanced
deposition

Diamond
Properties

Hardness, wear
resistance, thermal
conductivity

Surface Texturing & Painting

Texturing Techniques

Etching
Electric Arcs
Lasers
Atomic oxygen

Paint Classification

Enamels
Lacquers
Water-based paints

Cleaning of Surfaces

3 types

Mechanical Cleaning

Electrolytic Cleaning

Physically disturb
contaminants
Abrasive bubbles aid
in contaminant
removal

Chemical Cleaning

Solution
Saponification
Emulsification
Dispersion
Aggregation

Engineering Metrology and

Instrumentation
Metrology refers to the measurement
of any type of dimensions
(length, thickness, diameter, angle, etc.)

Focus on Dimensional Tolerance

(functionality, interchangeability, cost)

Describing Quality of Instruments

Resolution- the smallest difference in

dimensions that an instrument can detect.

Precision- the instruments ability to give

repeated measurements (thermal
expansion affects precision, standard
measuring temperature is 200 C).

Accuracy- The ability of a measurement

to match the actual value of the quantity
being measured.

Types of Measurement and

Instruments Used

Types of Measurement and

Instruments Used

Common Analog Instruments

A caliper gage with a vernier

A vernier

The Micrometer
(c)

(a)

Analog Micrometer

Digital Micrometer

Angle-Measuring Instruments
Bevel Protractor

Vernier for angular

measurement

Angle-Measuring Instruments
Sine Bar

Gage blocks are added until the top surface is parallel to the
surface plate. The angle is calculated using trig.
relationships.

Comparative Length Measurement

Multiple-Dimension
Gaging

Electronic Gages

Measuring Bore
Diameters

Vertical Length
Mesauring Instrument

Laser Scan Micrometer

Straightness Measurement

Interferometry for Measuring

Flatness
Optical Flat is a glass disk or fused-quartz disk with
parallel flat surfaces. A light beam with one wavelength is
aimed at the surface at an angle and splits into two beams.
The number of fringes relates the distance between part
and flat.

Interferometry for Measuring

Shaped or Textured Surfaces
Fringes on a surface
with two inclinations,
the greater the incline,
the closer the fringes.

Curved fringe
patterns indicate
curvatures on the
workpiece surface

Fringe
pattern
indicating a
scratch on
the surface.

Measuring Roundness

Measuring roundness using

V-block and dial indicator

Measuring Roundness

Part supported
on centers and
rotated
Circular tracing, with part being
rotated on a vertical axis

Measuring Profiles

Radius Gages

Dial Indicators

Measuring Profiles

Gear-Tooth Caliper

Gear-Tooth Micrometer

Horizontal-Beam Contour Projector

Image is
projected on
screen at
magnification of
100X or higher.
Measurements
made directly
on screen.

Gages
Plug gages
for holes

Ring gages for

round rods

GO means smaller than desired size and should fit perfectly,

if NOT GO gage also fits then tolerance is not met.

Gages

Snap Gage with

adjustable anvils

Gages

Pneumatic Gage

Modern Measuring Instruments

and Machines
Electronic

gauges
Laser Micrometers
Laser Interferometry
Photoelectric digital length measurement
Coordinate-measuring machines (CMM)

Electronic Gauges

Determine travel length by

changes in electrical
resistance, inductance, or
capacitance.
A commonly used E-Gauge is
the linear-variable differential
transformer (LVDT)
Generally use a very accurate
specified probe tip.

Laser Micrometers

A laser beam scans a workpiece, generally at a rate of

350 times per second.
Generally capable of resolutionsas high as 0.125 m
(5 in).

Laser Interferometry

Used primarily to check and calibrate machine

tools.
Also are used to compensate for positioning
errors in CMM and CNC machines

Photoelectric Digital Length

Measurement

Measures basic dimensions of general 3D

parts.
Resolution ranges from 5 - 0.01 m.

Coordinate-Measuring Machines
(CMM)

Very versatile and capable

of measuring complex
profiles with resolution of
0.25 m; 10in at high
speeds.
Larger machines can be
expensive although most
of the touch probe
machines for small shops
cost around $20k

More CMMs

References

www.brownandsharpe.com
www.faro.com
www.lk-cmm.com
www.renishaw.com
http://www.nd.edu/~manufact/index3.htm
http://www.nd.edu/~manufact/figures.html