SURFACE MODIFICATION

METHODS

Dr. M. KAMARAJ

DEPT OF METALLURGICAL AND MATERIALS ENGINEERING

INDIAN INSTITUTE OF TECHNOLOGY MADRAS

CHENNAI 600 036
29-Dec-09 11111 1
 OUTLINE

Coating Techniques:
Hardfacing by welding methods
Thermally spray processes
Applications

29-Dec-09 11111 2
LOSS OF USEFULNESS OF MATERIAL OBJECTS

The cause of loss of usefulness of material objects

29-Dec-09 11111 3
INTRODUCTION

Surface Engineering :

- is a discipline that combines chemistry, physics,

Mechanical engg with Metallurgy and Materials
science

- provides the weapon for deterioration processes

Raw materials Thermal Energy Product

product SE Enhanced Product

29-Dec-09 11111 4
PERFORMANCE OF COMPONENTS

Chemical : acids, alkalis, salts, solvents, etc

Thermal : High temperatures, direct flames,

oxidising gases, etc
Atmospheric: humidity, rain, snow, sunlight, sea water,
erosion, etc
Mechanical : Abrasion, vibration, adhesion, galling, etc

29-Dec-09 11111 5
SIGNIFICANCE OF SURFACE ENGINEERING

Main purpose may be :

i. To minimize corrosion
ii. Reduce frictional energy losses
iii. Reduce wear
iv. Act as a diffusion barrier
v. Provide thermal insulation
vi. Exclude certain wave length of radiation
vii. Promote radiation electronic interactions
viii. Electrically insulate
ix. Improve asthetic appearance for the surface
29-Dec-09 11111 6
SURFACE TREATMENT METHODS

29-Dec-09 11111 7
HARDFACING BY WELDING PROCESSES

What is hardfacing

AWS : “ hard surfaceing” or hardfacing is defined as

- the deposition of filler metal on a metal surface to

obtain the desired properties and /or dimensions,

the desired properties being those that will resist

abrasion, impact, erosion, galling, cavitation, and

corrosion (RT &HT)

29-Dec-09 11111 8
 SURFAC MODIFICATION BY
WELDING PROCESSES

29-Dec-09 11111 9
Gas welding
Oxyacetylene
welding process

29-Dec-09 11111 10
Oxyacetylene :welding process
In this process flame adjustment is important and is described by the length
of the outer cone — the feather containing excess acetylene — as a ratio to
the inner cone.
The acetylene feather contains particles of carbon which tend to carburise
the surface of the base metal and also reduce oxides on it.

Flame adjustment with length of outer11111

29-Dec-09 cone (feather) as a ratio of the inner
11 cone
Flame adjustments for the different types of surfacing alloys
are as follows:

1. Neutral: nickel base self-fluxing alloys.

2. Slightly reducing: carbon or alloy steels containing a high
percentage of iron.
3. 1X—2X feather: deposition of Co-based alloys onto
austenitic stainless steels, to prevent carburismg the base
material.
4. 3 X feather: Co base alloys on other substrates.
5. 4X feather: surfacing rods comprising tungsten carbides in a
ferrous tube.
29-Dec-09 11111 12
Manual Metal Arc
Welding (MMAW)
Process

- an electric arc is maintained

between the electrode and the
work piece

29-Dec-09 11111 13
Advantages

1. It is adaptable to small arid large complex parts.

2. Positional welding is possible, i.e. vertical.
3. It can be used in places with limited access.
4. A wide range of consumables is available.
5. Deposition rates up to 4kg/h are possible.
6. It is ideal for one-off and small series work.
7. It is useful where only small quantities of hardfacing alloys are
required.

Disadvantages
1. A skilled operator is required for high quality deposits.
2. Removal of slag is necessary, reducing the duty cycle.
3. Dilution tends to be high.
4. Granular carbides in tubular electrodes are usually melted.
29-Dec-09 11111 14
 Tungsten inert gas (TIG)
In TIG welding an electric arc is maintained between the non-
consumable tungsten electrode and the workpiece. The filler material in
rod or wire form.
The arc melts the parent material to form the molten pool
protected from the atmosphere by the inert gas shielding. Filler
into the pool manually to produce the surface coating.

TIG welding,
29-Dec-09 also known as inert gas tungsten
11111 arc, tungsten arc gas shielded and
15 gas
tungsten arc welding
Advantages
1. Low penetration is achieved, with dilution 5—10% depending on
technique.
2. The process can be closely controlled by the welder, and small areas
can be surfaced, e.g. small pores in hardfacing deposits.
3. The process can be used manually with a hand-held torch and hand-
fed filler rod, or mechanised for special applications.
4. A deposit thickness of 2 mm upwards is achievable.
5. It provides a deposition rate of up to 2kgh-1
6. It is capable of high quality deposits.

Disadvantages
1. The process is not suitable for site welding, as draughts tend to disrupt
the gas shield.
2. It is generally restricted to a workshop.
29-Dec-09 11111 16
Metal inert gas/metal active gas (MIG/MAG)
In the MIG/MAG process an electric arc is maintained between the
electrode wire and the workpiece. The parent metal and the consumable
wire are melted by the arc to form a molten pool, which is protected from
the atmosphere by gas fed coaxially with the wire through the welding gun
nozzle.

MIG/MAG, also known as C02, gas shielded metal arc

29-Dec-09 11111 17
or inert gas metal arc welding
Advantages
1. It is a continuous process that is used semi-automatically with a
hand- held gun, or is wholly mechanised by traversing the gun
and/or the workpiece.

2. Deposition rate is 3-6 kgh-1.

3. No slag removal is required.

4. It provides a positional surfacing capability.

Disadvantages
1. Use of gas shielding makes the process marginally less transportable
than MMA and gas must be selected to suit the surfacing alloy.

2. Dilution may be high unless appropriate procedures are used.

29-Dec-09 11111 18
Submerged-arc (SAW)

In submerged-arc welding an electric arc is maintained between the

electrode and workpiece. The electrode dips into the covering of flux
dispensed from a hopper and an arc is struck to the workpiece.

29-Dec-09 11111 19
Submerged-arc welding
Submerged-arc (SAW)

The arc remains submerged under the flux coating, some of which melts
and protects the molten pool from oxidation. The electrode is fed at a
controlled rate to maintain a stable arc of constant length, and flux which
has not melted can be recovered and reused.

29-Dec-09 11111 20
Submerged-arc welding
Advantages
1. It is a mechanised process.
2. Deposit thickness of 3mm upwards is achieved.
3. Deposit rate is 10 kgh-1 upwards on suitable workpieces.
4. A wide range of consumables is available.

Disadvantages
1. It is suited to large workpieces which can tolerate the high current and
high deposit rates without overheating.
2. It is intended primarily for workshop use in a fixed installation.
3. Dilution may be high unless appropriate Procedures are used.
4. Applications are generally limited to cylindrical or flat components;
there is limited access to internal surfaces of larger bores.
5. Flux costs must be taken into account.
29-Dec-09 11111 21
SUMMARY:
The key
characteristics
of the arc weld
surfacing
processess

29-Dec-09 11111 22
 WELD DILUTION

Dilution

Schematic of dilution definition

29-Dec-09 11111 23
SURFAC MODIFICATION BY PLASMA
PROCESSES
Two different arc Modes:
Non-transferred arc :
Plasma spraying
- An arc is established
between the electrode and
the constricting orifice :
working piece is essentially
kept out of the electrical
circuit

The heat imparted to the

job is obtained from the
29-Dec-09 11111 24
plasma jet only
SURFAC MODIFICATION BY PLASMA
PROCESSES

Transferred arc :PTA

The arc is struck between

the cathode and the work
piece (anode)

This results in greater

energy transfer to the
workpiece

29-Dec-09 11111 25
PLASMA TRANSFERRED ARC (PTA)

PTA
- basically a fusion welding process where the
substrate materials are fused along with the
deposited metals in the weld pool

- deposits very precise coatings of perfectly

controlled alloys on mechanical parts that are subject
to intense wear, significantly extending their service
life.

-it is particularly effective in protection against

corrosion,
29-Dec-09
thermal shock11111
and abrasion. 26
 PLASMA TRANSFERRED ARC (PTA)

Oscillation unit Electrode

Plasma nozzle
Power source Focusing nozzle

Ballast resistance
Shielding nozzle
PTA method
schematic
29-Dec-09 11111 27
illustration Work piece
PLASMA TRANSFERRED ARC (PTA)

A PTA hardfacing systems incorporates three gas flow

systems:
1. Inner gas flow called plasma gas, usually argon
plasma gas helps to generate the plasma and protect
the thoriated W electrode
2. An outer gas or shielding gas provides an inert
blanket over the weld pool to protect from oxidation
and contamination
3. A third gas flow system is used to deliver the
hardfacing consumable, which is generally powder
form : Ar. He or Ar-H2 mixture
29-Dec-09 11111 28
MATERIALS FOR PTA HARDFACING

Carbide-strengthened alloys
Boride-strengthenedd alloys
Silicide-strengthenedd alloys
Intermetallic laves-phase alloys
Solid solution alloys
Cermet composites

29-Dec-09 11111 29
APPLICATIONS

Transportation Applications:

The valve train accounts - 25 % of the total frictions loss

and consequent wear

Valve seats experience – erosion, galling, corrosion and

fatigue

Diesel engines pose a very severe wear environment

-sulfidation, V2O5 corrosion

Co- base alloys, Intermetallic alloys

29-Dec-09 11111 30
 APPLICATIONS

quid roll fittings, accessories for

ships, petroleum chemistry and
power generation, hydro-transport,
pump plungers etc

Extruding machine
screws

valves of internal combustion engines

(motorcar,
29-Dec-09 marine, locomotive etc.)
11111 31
LIMITATIONS

Equipment is relatively expensive

- Significant advantages can not be derived from a

PTA system unless auxiliary equipment such
as special tooling, positioners and manipulators
are incorporated
-a medium to high volume production rate is required
- easily portable
- high-energy process – adequate understanding of the
weld configuration to prevent problems like
distortion and cracking
29-Dec-09 11111 32
LASER CLADDING PROCESS

29-Dec-09 11111 33
 COATING AND WELD PATTERNS

Cross-sections and bead appearances by diode laser and TIG

cladding.
29-Dec-09 11111 34
FRICTION SURFACING

- It is one of the coating techniques on the surface of the

substrate where Welding and surfacing are used when a
piece is broken or badly worn
Characteristic of this process from other methods:

1) Provides higher bond strength between deposit and

substrate
2) Coating thickness by this process is greater than most
other techniques range 3-10mm also there are some
process that will produce very thin coating.

3) Less porosity compared to thermal spray process.

29-Dec-09 11111 35
4) Provide a high hardness
PROCESS: FRICTION SURFACING

- It is a solid phase deposition technique where by a

rotating consumable bar ,usually in the range of 10-40mm
in diameter is pressed on to a laterally moving substrate

29-Dec-09
Coating thickness : 11111
0.5-3mm depending on Consumable
36
diameter and substrate
FRICTION SURFACING

• Friction Surfacing is a process

derived from friction welding
whereby a coating material,
in rod form (termed the
MechtrodeTM) is rotated
under pressure, generating
a plasticized layer in the rod
at the interface with the substrate.

29-Dec-09 11111 37
 HARDNESS
Hardness variance profile along 250-mm length of high speed
steel deposit in the tempered condition of :

(a) fusion welding based surfacing process ±4 Rc and

(a) friction surfaced ±1 Rc.

29-Dec-09 11111 38
APPLICATIONS

• Mainly knives & guillotine blades

• Used for reconditioning of worn shafts and
good quality of deposits obtained.
• Used in cutting tools
• Anti corrosion overlay of slide valve plates
• Disc brakes
• Wear tiles for sinter plants, wire rubbing pads
29-Dec-09 11111 39
The following examples show some of the geometries
that have been successfully Friction Surfaced.

29-Dec-09 11111 40
 THERMAL SPRAYING
Definition of Thermal Spraying: ASM
- A group of processes in which a finely divided material (metallic
or nonmetallic) is heated rapidly in a hot gaseous medium &
simultaneously projected at high velocity on to a prepared
substrate surface where it builds up the desired coating”

- powder, rod, cord or wire

29-Dec-09 11111 41
 PRICIPLE OF TS

1 - Spraying particles transport

2 - Impact on the surface
3 - Thermal transfer from particles to substrate
4 - Particles Solidification and
5 - Mechanical bond
29-Dec-09
6 - Local Fusion 11111 42
THERMAL SPRAY METHODS

Process Energy source Other names for the process

Low energy process

a)Flame spraying Oxyfuel Oxyfuel gas-powder spraying
Oxyfuel gas-wire spraying
Metallising

b)Arc spraying Electrical Electrical arc spraying

Twin arc spraying
Metallising

High energy process

a)Plasma spraying Electrical Air/Vacuum/Low pressure plasma

b)Detonation flame spraying Oxyfuel D - Gun

c)High velocity oxyfuel Oxyfuel High velocity oxygen fuel

spraying High velocity flame
29-Dec-09 11111 43
High velocity air fuel
CLASSIFICATION

29-Dec-09 Thermal spray classification

11111 44
FLAME SPRAYING

Flame spraying is the oldest of the thermal spraying

processes
Flame spray uses the chemical energy :
- combustion of gases to generate heat
Oxyacetylene torches are the most common :
- acetylene as the main fuel in combination of
oxygen to generate the highest combustion
temperature
29-Dec-09 11111 45
FS process : Powder, wires or rods are
introduced axially through the
rear of the nozzle into the flame
at the nozzle exit
- the feedstock materials are melted and the
particles/droplets accelerated toward the substrate
29-Dec-09 11111 46
surface by the expanding gas flow and air jets
OXY FUEL GAS WIRE SPRAYING

Schematic diagram of Oxy-fuel

29-Dec-09 11111 gas wire spraying 47
MATERIALS USED

• Zn & Al  anti-corrosion cathodic coatings on

steel.
• Ni/Al composite wire  bond coats, heat
& oxidation resistance.
• Mo  bond coats, excellent resistance to
adhesive wear.
• High Chromium steel hard and wear resistant
coating.
SS, Ni and monel  anti-corrosion
• 29-Dec-09 11111 and wear. 48
WIRE ARC SPRAYING

29-Dec-09 Schematic diagram of11111

Wire Arc Spraying 49
29-Dec-09 11111 50
Detonation Thermal Spraying Process

Barrel 1-1.5m long and 20-30 mm Internal dia into which the
gas mixture is injected and ignited by a spark plug

Schematic diagram of D-Gun

29-Dec-09 11111 wire spraying 51
 ADVANTAGES

• Dense microstructure with 0.1-2 % porosity.

• Smooth surfaces finish (1-4  Ra).
• Better impact wear /fretting wear /erosion
/corrosion/resistance.
• Controlled residual compressive stress
• Negligible thermal degradation of powder but
also to preserve bulk microstructure
29-Dec-09 11111 52
Materials and Applications

• WC/Co coatings :
- D-Gun coatings have higher degree of retained
carbides
(Due to the reducing atmosphere of the confined
combustion zone in the barrel and the shorter dwell
time)

- D-Gun coatings : densest and hardest

29-Dec-09 11111 53
HIGH VELOCITY OXYFUEL SPRAYING

29-Dec-09 11111 54
29-Dec-09 11111 55
HVOF spraying Tungsten Carbide / Cobalt Chromium Coating
29-Dec-09 11111 56
(WC/10Co4Cr) onto Roll for the Paper Manufacturing Industry
Materials Used

(i) Cr3C2- NiCr

(ii) NiCrMo (wire process)

29-Dec-09 11111 57
 SURFAC MODIFICATION BY
PLASMA PROCESSES
Non-transferred arc :
Plasma spraying
- An arc is established between the
electrode and the constricting
orifice
: working piece is essentially kept
out of the electrical circuit

The heat imparted to the job is

obtained from the plasma jet only

29-Dec-09 11111 58
PLASMA SPRAYING (APS)

Schematic diagram of Plasma Spraying

29-Dec-09 11111 59
PLASMA SPRAYING (APS)

29-Dec-09 11111 60
Schematic diagram of Plasma Spraying
AIR PLASMA SPRAYING

29-Dec-09 11111 61
 SPRAYING MATERIALS

 Pure metal Mo,Ni,Ta,Al ,Zn.

 Alloys NiCr, NiCrAlY, FeCrBSiC ,

steels ,Bronzes.
 Pseudo alloys CuW, AlMo.

 Ceramics/Carbides Al203 ,Cr203 ,Ti02 ,Zr02 ,

WC.
 Cermets Cr3C2/NiCr ,WC/Co ,
29-Dec-09 11111 62
Zr02/NiAl
COLD SPRAY PROCESS

A coating technology: in which spray particles ranging in size from

1 to 50m in dia, in the solid state are accelerated to high velocity
(above 700-1200m/s, supersonic velocity) and subsequently develop a
deposit or coating on a substrate by an impaction process

Various terms: Kinetic energy metallization,

Kinetic spraying,
29-Dec-09 11111 High velocity powder deposition
63 &
Cold gas-dynamic spray method
COLD SPRAY PROCESS

Schematic diagram of Cold spraying

29-Dec-09 11111 64
ADVANTAGES

 TS may be used to deposit non-weldable coating materials

such as plastics or ceramics
 No distortion
 No post treatment
 Reduced cost
 Low Heat Input -No HAZ.
 Versatility: Almost any M, C or P.
 Thickness Range: 0.001 inch to more than 1 inch thick,
depending on the material and spray system.
29-Dec-09 11111 65
 SUPERALLOYS: APPLICATIONS
- aircraft gas turbine engines

- Industrial land-based turbines

Two general types of environmental

effects:

i. Oxidation ii. Hot corrosion

iii. Combination of these effects

The result of 2500 h low altitude sea flight

service on an uncoated and NiAl coated blade
turbine blade
29-Dec-09 11111 66
COATING PROCESSES
Air-plasma sprayed coating
contain porosity & micro-cracks :
- help to redistribute thermal stresses but provide
corrosion paths through the coating

Low-pressure plasma spray coating :

-Provide high coating purity and essentially eliminates

oxides and porosity

HVOF, EBPVD

Or combinations methods oxides and porosity

29-Dec-09 11111 67
COATING THICKNESS/DEPTH OF PENETRATION

Typical coating thickness/depth of penetration for various coating

and surface hardening processes
29-Dec-09 11111 68