Surface Coating

• Any mixture of film-forming materials plus pigments,

solvents, and other additives, which, when applied to a
surface and cured or dried, yields a thin film that is functional
and often decorative.

• Surface coatings include paints, drying oils and

varnishes, synthetic clear coatings, and other products whose
primary function is to protect the surface of an object from
the environment.

• These products can also enhance the aesthetic appeal of an

object by accentuating its surface features or even by
concealing them from view.
 SURFACE PROCESSING OPERATIONS
1. Industrial Cleaning Processes
2. Heat Treatment
3. Coating Processes
– Diffusion
– Ion Implantation
– Plating and Related Processes
– Conversion Coating
– Vapor Deposition Processes (CVD and PVD)
– Organic Coatings
– Ceramic Coatings
– Thermal and Mechanical Coating Processes
 Overview of Industrial Cleaning
• Almost all workparts must be cleaned one or
more times during their manufacturing sequence
• Processes used to clean the work surfaces
– Chemical cleaning methods - use chemicals to
remove unwanted contaminants from the work
surface
– Mechanical cleaning - involves removal of
contaminants by various mechanical operations
 Why Parts Must be Cleaned Prior to
Surface Treatments

• Prepare surface for subsequent processing, such

as a coating application or adhesive bonding
• Improve hygiene conditions for workers and
customers
• Remove contaminants that might chemically
react with the surface
• Enhance appearance and performance of the
product
Factors in Selecting a Cleaning Method

• Contaminant to be removed
• Degree of cleanliness required
• Substrate material to be cleaned
• Purpose of cleaning
• Environmental and safety factors
• Size and geometry of the part
• Production and cost requirements
Schematic representation of a metal surface, adapted
from Bhushan and Gupta (1991)
 Chemical Cleaning Processes

• Alkaline cleaning
• Emulsion cleaning
• Solvent cleaning
• Acid cleaning
• Ultrasonic cleaning
 Ultrasonic Cleaning
Mechanical agitation of cleaning fluid by
high-frequency vibrations (between 20 and 45
kHz) to cause cavitation (formation of low
pressure vapor bubbles that scrub the surface)
• Combines chemical cleaning and mechanical
agitation of the cleaning fluid
• Cleaning fluid is generally an aqueous solution
containing alkaline detergents
• Highly effective for removing surface
contaminants
 Mechanical Cleaning
Physical removal of soils, scales, or films from the
work surface by abrasives or similar mechanical
action
• Often serves other functions also, such as
deburring, improving surface finish, and surface
hardening
• Processes:
– Blast finishing
– Shot peening
– Mass finishing processes
 Surface Coatings Types
Examples of Surface Coatings are:
• Architectural paints developed to protect the internal and
external walls of buildings and houses
• Industrial coatings developed to protect mechanical
components from chemical corrosion and weather
conditions.
• Tribological coatings developed to promote low friction and
improved wear resistance to surfaces that will be in
contact.
• For polymer coatings to be built on a substrate, they start
out in the form of a paint that is applied conformally to the
part’s geometry. The paint is then dried and cured to form
the final functional coating.
 Types of Coating

1. Diffusion and ion implantation

2. Plating and related processes
3. Conversion coating
4. Vapor deposition processes
5. Organic Coatings
 Processes to Alter Surface Chemistry

• Two processes that impregnate the surface of

a substrate with foreign atoms
– Diffusion
– Ion implantation
 Diffusion
Alteration of surface layers of material by diffusing
atoms of a different material (usually an element)
into surface, usually at high temperatures
• Surface still contains a high proportion of
substrate material
• Diffused element has maximum percentage at
the surface and rapidly declines with distance
below surface
• Applications: metallurgy and semiconductor
manufacture
 Profile of Diffused Element

• Characteristic profile
of diffused element
as a function of
distance below
surface in diffusion
• Plot given here is for
carbon diffused into
iron
 Diffusion three processes

Diffusion coating can be done using three

processes:
• Solid state diffusion
• Liquid state diffusion
• Chemical vapor diffusion
 Ion Implantation
Embedding atoms of one (or more) foreign
element(s) into a substrate surface using a
high-energy beam of ionized particles
• Results in alteration of the chemistry and physical
properties of layers near the substrate surface
• Produces a much thinner altered layer and
different concentration profile than diffusion
• Alternative to diffusion when the latter is not
feasible due to high temperatures required
 Some General Comments on Coating
of Engineering Materials
• Metal products are almost always coated - by
painting, plating, or other process
– Exceptions: stainless steel, brass
• Nonmetallic materials are sometimes coated
– Plastic parts to give metallic appearance
– Antireflection coatings on glass lenses
– Coating and deposition processes used in the fabrication
of semiconductor chips and printed circuit boards
 Reasons for Coating Metal Parts and
Products
• Corrosion protection
• Enhance product appearance
– Add color and/or texture
• Wear resistance and/or friction reduction
• Increase electrical conductivity or resistance
• Prepare metallic surface for subsequent
processing
• Rebuild surfaces worn or eroded during service
 2.Plating and Related Processes
Coating thin metallic layer onto the surface of a
substrate material
• Substrate is usually metallic, although
methods are available to plate plastic and
ceramic parts
• Processes:
– Electroplating (most common plating process)
– Electroforming
– Electroless plating
– Hot dipping
 Electroplating
Electrolytic process in which metal ions in an
electrolyte solution are deposited onto a cathode
workpart
• Also called electrochemical plating
• Anode is generally made of the plating metal and
serves as source of the plate metal
• Direct current from an external power supply is
passed between anode and cathode
• Electrolyte is an aqueous solution of acids, bases,
or salts
 Electroplating

• Setup for electroplating

 Common Coating Metals
• Zinc - plated on steel products such as fasteners,
wire goods, electric switch boxes, and sheetmetal
parts as a sacrificial barrier to corrosion
• Nickel - for corrosion resistance and decorative
purposes on steel, brass, zinc die castings, etc.
– Also used as base coat for chrome plate
• Tin - widely used for corrosion protection in "tin
cans" and other food containers
 More Coating Metals
• Copper - decorative coating on steel and zinc,
either alone or alloyed as brass
– Also important in printed circuit boards
• Chromium - decorative coating widely used in
automotive, office furniture, and kitchen
appliances
– Also one of the hardest electroplated coatings for wear
resistance
• Precious metals (gold, silver) - plated on jewelry
– Gold is also used for electrical contacts
 Electroforming
Electrolytic deposition of metal onto a pattern
until the required thickness is achieved, after
which the pattern is removed to leave the
formed part
• Process is virtually the same as electroplating
but its purpose is different
– Whereas typical plating thickness is only about
0.05 mm (0.002 in) or less, electroformed parts
are often substantially thicker, so the production
cycle is proportionally longer
 Electroformed Products
• Metals used for electroforming: copper, nickel,
and nickel cobalt alloys most common
• Typical applications: fine molds and dies (e.g.,
for lenses) and plates for embossing and
printing
• Notable application: molds for CDs and DVDs
– Surface details imprinted onto CDs and DVDs are
measured in m
 Electroless Plating
Metallic plating process driven entirely by chemical
reactions - no electric current is supplied
• Deposition onto a part surface occurs in an
aqueous solution containing ions of the desired
plating metal
– Workpart surface acts as a catalyst for the reaction in
the presence of reducing agent
• Metals that can be plated: nickel, copper, and
gold
• Notable application: copper for plating
through-holes of printed circuit boards
 Hot Dipping
Metal substrate (part) is immersed in a molten
bath of a second metal; when removed, the
second metal is coated onto the first
• Common substrate metals: steel and iron
• Coating metals: zinc, aluminum, tin, and lead
• Primary purpose is corrosion protection
 3.Conversion Coatings
Family of coating processes in which a thin film
of oxide, phosphate, or chromate is formed on
a metallic surface by chemical or
electrochemical reaction
• Immersion and spraying are the two common
methods of exposing metal surface to the
reacting chemicals
• Common metals treated: steel (including
galvanized steel), zinc, and aluminum
Reasons for Using Conversion Coatings
• Corrosion protection
• Preparation for painting
• Wear resistance
• Permits surface to better hold lubricants for
metal forming processes
• Increase electrical resistance of surface
• Decorative finish
 Conversion Coating Processes
• Chemical conversion coatings - chemical
reaction only
– Phosphate and chromate conversion coatings are the
common treatments
• Anodizing - oxide coating produced by
electrochemical reaction
– Anodize is a contraction of anodic oxidize
– Most common on aluminum and its alloys
 4.Physical Vapor Deposition (PVD)
Family of processes in which a material is converted
to its vapor phase in a vacuum chamber and
condensed onto substrate surface as a very thin
film
• Coating materials: metals, alloys, ceramics and
other inorganic compounds, even some polymers
• Substrates: metals, glass, and plastics
• Very versatile coating technology
– Applicable to an almost unlimited combination of
coatings and substrate materials
 Applications of PVD
• Decorative coatings on plastic and metal parts
such as trophies, toys, pens and pencils,
watchcases, and interior trim in automobiles
• Antireflection coatings of magnesium fluoride
(MgF2) onto optical lenses
• Depositing metal to form electrical connections in
integrated circuits
• Coating titanium nitride (TiN) onto cutting tools
and plastic injection molds for wear resistance
 Processing Steps in PVD
• All physical vapor deposition processes
consist of the following steps:
1. Synthesis of coating vapor
2. Vapor transport to substrate
3. Condensation of vapors onto substrate surface
• These steps are generally carried out in a
vacuum chamber, so evacuation of the
chamber must precede PVD process
 Physical Vapor Deposition

• Setup for
vacuum
evaporation,
one form of
PVD, showing
vacuum
chamber and
other process
components
 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 and formation of a solid film on the
substrate
• Reactions occur in enclosed reaction chamber
• Reaction product nucleates and grows on
substrate surface to form the coating
• Most CVD reactions require heat
• Variety of coating and substrate materials
 Chemical Vapor Deposition

• Typical
reactor
used in
CVD
 Applications of CVD
• Industrial metallurgical processes
– Mond process to reduce nickel from its ore
• Coated carbide tools
• Solar cells
• Refractory metals on jet engine turbine blades
• Integrated circuit fabrication
• Other applications for resistance to wear,
corrosion, erosion, and thermal shock
 Organic Coatings
Polymers and resins (natural or synthetic)
usually formulated to be applied as liquids
that dry or harden as thin surface films on
substrate materials
• Advantages:
– Wide variety of colors and textures available
– Capacity to protect the substrate surface
– Low cost
– Ease with which they can be applied
 Ingredients in Organic Coatings
1. Binders - give the coating its properties
2. Dyes or pigments - provide color to the
coating
3. Solvents - dissolve the polymers and resins
and add proper fluidity to the liquid
4. Additives
 Binders
Polymers and resins that determine the solid state
properties of the coating, such as strength,
physical properties, and adhesion to the
substrate surface
• Binder holds the ingredients in the coating during
and after application to the surface
• Common binders in organic coatings:
– Natural oils (to produce oil-based paints)
– Resins of polyesters, polyurethanes, epoxies, acrylics, and
cellulosics
 Dyes and Pigments
Provide color to the coating
• Dyes - soluble chemicals that color the
coating liquid but do not conceal surface
beneath
– Coatings generally transparent or translucent
• Pigments - solid particles of microscopic size
dispersed in coating liquid but insoluble in it
– Not only color the coating, but also hide the surface
below
– Since pigments are particulate, they also tend to
strengthen the coating
 Solvents
Liquid substances used to dissolve the binder
and certain other ingredients in the liquid
coating composition
• Common solvents used in organic coatings:
– Aliphatic and aromatic hydrocarbons
– Alcohols
– Esters
– Ketones
– Chlorinated solvents
 Additives
• Surfactants (to facilitate spreading on the surface)
• Biocides and fungicides
• Thickeners
• Heat and light stabilizers
• Coalescing agents
• Plasticizers
• Defoamers
• Catalysts to promote cross-linking
 Application Methods
• Brushing
• Rolling
• Spraying
• Dip coating (immersion)
• Flow coating (showering)
 Classification and nomenclature for
coatings
• classified into three groups:

• Drying glycerol, Natural resins and Synthetic

resins.
• Drying glycerol esters of fatty acids, mainly
unsaturated. Obtained from seeds and fruits
(sunflower, cotton, flax, etc.). They have the
ability of drying in the air (chemical curing).
Currently used as modifiers in synthetic resigns
(alkyd, phenolic). g oils
 Classification and nomenclature for
coatings
• Modified natural resins are chemically
modified celluloses, rosins and natural
rubbers, such as nitrocellulose and ester rosin.
• Synthetic resin : Acrylic, Alkyd, Epoxy,
Fluorocarbon, Amino resins, Vinyl,
 Classification and nomenclature for
coatings
• Market category
The paint and coatings industry is normally divided
into three broad market categories:
(a)architectural (decorative) coatings;
(b)OEM/product (industrial) coatings; and
(c) specialty (maintenance) coatings
 Ceramic coating technology
• Modern technology calls for systems performing
satisfactorily under extreme and often adverse
operating conditions; hence it has become a
technical and economic necessity to protect
structural materials from the hostile environment.
• Thus ceramic coating technology (CCT) has found
widespread applications in many diverse industries
for the protection of structural materials. Ceramic
coatings are used to minimize effects such as high
temperature degradation, corrosion, erosion and
wear.
 Ceramic coating technology
• Ceramic coating technology, the process of
preparing or depositing a ceramic layer on a
surface, offers the best solution in such
situations.
• Ceramics, with their excellent properties such as
high temperature stability, resistance to
corrosion, erosion and wear, chemical inertness
etc., have found increasing use in high technology
systems.
 Applications of ceramic coatings
• Ceramic coating technology is used to prepare
coatings for various applications. They can be
broadly classified as follows:
• a) Protective coatings
• b) Process improvement and control
• c) Free standing structures
• d) Reclamation coatings