ADVANCED SURFACE

ENGINEERING

Nofrijon Sofyan, Ph.D.

Dr. Ir. Myrna Ariati Mochtar, M.S.
Wahyuaji Narottama Putra, S.T., M.T.

ENMT801016
 HANDOUT #03
FUNDAMENTAL OF SURFACE ENGINEERING

http://www.millmaxusa.co
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 INTRODUCTION

Modern production processes require inherent

state-of-the-art surface technologies
Rising standards of technical products are
creating the perception that surface
technologies are often the central impetus
needed for meeting product specifications

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Design engineers thus face two essential tasks:
On the one hand, part specifications need to be transformed into properties
of materials and surfaces.
On the other hand, selected materials technologies have to be integrated in
corresponding process chains.

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 ASPECT OF SURFACE ENGINEERING

Apart from the required part specifications, production costs

and ecological aspects are important issues
In addition to production standards, economic conditions lead to
increasing significance of surface technologies
Thus, surface technologies therefore have to be considered as
one of the key technology fields in production engineering

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REQUIREMENTS ON PART SURFACES
Systematic selection of suitable surface treatments is always
based on acquiring a complete set of requirements on the part
surface with respect to intended operating conditions
The surface is responsible for all mechanical, thermal,
chemical, and electrochemical interactions with the
environment
This leads to the main functions that
need to be fulfilled by technical
surfaces:
corrosion resistance
wear resistance
defined tribological behavior
optical behavior
decorative behavior
matched interface behavior (e.g. for 6
joining purposes).
 In addition, especially highly specialized products
may demand specific functions.
Parts used in micro-technology for example can
require special electromagnetic properties of
surfaces.
Ultimately, requirements on part surfaces are
determined by the particular load conditions under
which the final product operates.

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 Wear and corrosion are the main stresses that have to be
controlled by surface technology in the realm of mechanical
engineering.
Incorrect materials selection as well as unsuitable or
missing protective layers lead to manifold damages

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 In many cases, appropriate surface treatment can either prevent or at least
delay such damages.
However, adjusting part surface characteristics carefully is essential in order to
handle overall operating conditions.

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 Wear mechanisms

fatigue abrasion tribochemical adhesion

stress cycles micro-cutting reactions
physisorption adhesive
micro-structural changes
micro-ploughing chemisorption bonds
cracking micro-cracking formation of material
delamination reaction layer transfer

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 Surface technology focuses on reacting adequately to the
specific kinds of load and stress.
For this, the materials properties of part surfaces are
systematically modified or produced, particularly by means
of:
applying a protective coating to the workpiece
modifying the surface zone of the workpiece

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 Typical coating processes are chemical vapor deposition
(CVD), physical vapor deposition (PVD), thermal spraying,
build-up brazing and welding, as well as cladding and dip
coating.
Surface-modification processes, on the other hand, include
thermo-chemical diffusion processes, thermal surface
hardening, implantation methods, and mechanical surface-
hardening processes.

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SELECTING SURFACE
TECHNOLOGIES
Designing a suitable surface treatment from a
given combination of loads is challenging.
Not only is it often difficult to precisely and
thoroughly understand the operating
conditions of a part, but very large variety of
possible materials and materials technological
processes have to be considered.

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 The process of selecting an appropriate coating or surface
treatment requires a systematic approach.
The selection process needs to be implemented at an early
stage of product development.
It is necessary that the designers or developers already
consider surface requirements during concept phases,
directly after taking down customer and market demands.

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The following facets and questions need to be considered carefully:
Function:
What are the functional characteristics of the part surface?
What kind of requirements exist?
Purpose:
What needs to be maximized?
What needs to be minimized?

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 Limitations: Which constraints and boundary conditions have to be met? e.g.
from a technical point of view
from an economic point of view
considering design-to-cost concepts
considering design for environment concepts
considering life-cycle costs
Options:
What options exist?

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PROCESSES FOR SURFACE
TREATMENT
There are many available different surface
modification and coating processes
Each process has its own assets and
drawbacks
Thus, it is our responsibility to select which
one best suit for our purpose based on costs
per piece and customer benefit

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COST DETERMINATION
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EXAMPLE ON FATIGUE

Stage II
Crack initiation at the sites of stress
concentration (microcracks, scratches,
indents, interior corners, dislocation slip
steps, etc.).
Quality of surface is important.
Stage I

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Crack propagation
Stage I:

Initial slow propagation along crystal planes with high

resolved shear stress.
Involves just a few grains, and has flat fracture surface

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 Stage II:
Faster propagation perpendicular to the applied stress.
Crack grows by repetitive blunting and sharpening process
at crack tip.
Rough fracture surface.
Crack eventually reaches critical dimension and propagates
very rapidly

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Factors that affect fatigue life
Magnitude of stress (mean, amplitude)
Quality of the surface (scratches, sharp transitions and edges).

Solutions to Crack:
Polishing (removes machining flaws etc.)
Introducing compressive stresses (compensate for applied tensile stresses) into
thin surface layer by Shot Peening- firing small shot into surface to be treated.
High-tech solution - ion implantation, laser peening.

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 Case Hardening - create C- or N- rich outer layer in steels by
atomic diffusion from the surface. Makes harder outer layer
and also introduces compressive stresses
Optimizing geometry - avoid internal corners, notches etc.

Thermal Fatigue: Thermal cycling causes expansion and

contraction, hence thermal stress, if component is restrained.
Solutions:
eliminate restraint by design
use materials with low thermal expansion coefficients

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 Corrosion fatigue: Chemical reactions induce pits which act
as stress raisers. Corrosion also enhances crack
propagation.
Solutions:
decrease corrosiveness of medium, if possible
add protective surface coating
add residual compressive stresses

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 CLASSIFICATION OF SURFACE
ENGINEERING

The traditional, well established processes:

Painting
Electroplating
Anodizing
Thermal and plasma spraying
Nitriding, Carburizing, Boriding

Plasma
Spray 27
The more technologically advanced coating
technologies:
Physical and chemical vapor deposition
Ion implantation
Ion-assisted deposition
Ion-beam mixing
Laser treatment

Ion-beam
deposition 28
REFERENCES
ASM Handbook Vol 4: Heat Treating, ASM
International, Ohio, USA, 1991.
ASM Handbook Vol 5: Surface Engineering, ASM
International, Ohio, USA, 1994.

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