Modern Surface Technology

, by Bach, Friedrich-Wilhelm; Mö; hwald, Kai; Laarmann, Andreas; Wenz, Thomas

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ISBN: 9783527315321 | 3527315322
Cover: Hardcover
Copyright: 8/23/2006

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This translation of a successful German title provides a broad and fundamental overview of current coating technology. Edited by experts from one of the largest research centers for this field in Germany, this valuable reference combines research and industrial perspectives, treated by authors from academia and industry alike. They discuss the potential of the many innovations introduced into industrial application in recent years, allowing materials scientists and engineers to find the appropriate solution for their own specific coating problems. Thus, with the aid of this book, it is possible to make coating technology an integral part of R&D, construction and production.

Preface

List of Contributors

XVII

1 Selecting Surface-treatment Technologies

(10)

W. Tillmann, E. Vogli

1.1 Introduction

(1)

1.2 Requirements on Part Surfaces

(3)

1.3 Selecting Coating and Surface Technologies

(1)

1.4 Processes for Surface Modification and Coating

(4)

1.5 Economic Assessment of Surface-treatment Technologies

(1)

1.6 Summary and Conclusions

(1)

References

(1)

2 Stainless Austenitic Steel Surface Hardening for Increased Wear Resistance

(20)

M. Wägner

2.1 Introduction

(1)

2.2 Fundamentals

(8)

2.2.1 Heat Treatment

(1)

2.2.1.1 Surface-hardening Processes

(1)

2.2.2 Stainless Steels

(1)

2.2.2.1 Classification of Stainless Steels

(1)

2.2.2.2 Stainless Austenitic Steels

(4)

2.3 Technologies for Surface Hardening of Austenitic Stainless Steels

(9)

2.3.1 Kolsterising

(1)

2.3.1.1 Influence on Microstructure

(1)

2.3.1.2 Influence on Chemical Composition

(1)

2.3.1.3 Influence on Mechanical Properties

(1)

2.3.1.4 Wear Resistance

(1)

2.3.1.5 Influence on Corrosion Resistance

(1)

2.3.2 Kolsterising plus PVD Coating

(1)

2.3.2.1 Coating Adhesion

(1)

2.3.2.2 Wear Resistance

(1)

2.3.2.3 Fatigue Strength

(2)

2.4 Applications

(1)

2.4.1 Application Limitations

(1)

2.5 Outlook

(1)

References

(2)

3 Fundamentals of Thin-film Technology

(20)

M. Nicolaus, M. Schäpers

3.1 Introduction

(1)

3.2 Classification of Thin-film Coating Processes

(1)

3.3 General Aspects of Gas-phase Coating Processes

(4)

3.3.1 PVD – Physical Vapour Deposition

(1)

3.3.1.1 Evaporation

(1)

3.3.1.2 Sputtering

(1)

3.3.1.3 Ion Plating

(1)

3.3.2 CVD – Chemical Vapour Deposition

(1)

3.4 Plasma Properties

(2)

3.4.1 Low-pressure Plasma

(1)

3.5 Coating Configuration

(1)

3.5.1 Coating Structure

(1)

3.6 Electrodeposition and Electroless Plating Processes

(11)

3.6.1 Introduction

(1)

3.6.2 Fundamental Terms

(1)

3.6.2.1 Electrolyte

(1)

3.6.2.2 Electrodes, Electrode Reactions, Electrode Potential

(1)

3.6.2.3 Electrolysis and Faraday's Laws

(1)

3.6.2.4 Overpotential

(1)

3.6.3 Electroless Plating

(1)

3.6.4 Electrodeposition of Metal

(2)

3.6.5 Electrodeposition of Metal from Non-aqueous Solvents

(2)

3.6.6 Summary and Outlook

(1)

References

(1)

4 Innovations in PVD Technology for High-performance Applications

(14)

K. Bobzin, E. Lugscheider, M. Maes, P. Immich

4.1 Introduction

(1)

4.2 Market Situation

(1)

4.3 Application Examples

(8)

4.3.1 Tool Coatings for Cutting

(1)

4.3.2 Tool Coatings for Forming

(2)

4.3.3 Coatings for Plastic Parts

(1)

4.3.4 Coatings for Machine Elements

(2)

4.3.5 Part Coating for High-temperature Applications

(1)

4.4 Summary

(1)

References

(3)

5 Development and Status Quo of Thermal CVD Hard-material Coating

(22)

A. Szabo

5.1 Introduction

(1)

5.2 Early CVD Hard-material Coating

(1)

5.3 Fundamentals of Deposition Processes

(4)

5.3.1 Chemical Mechanism

(1)

5.3.2 Interdisciplinary Fundamentals

(1)

5.3.3 CVD System and Reaction-chamber Techniques

(3)

5.4 Combination Coatings

(3)

5.5 Material and Coating Properties

(4)

5.5.1 Physical Properties of Coating Materials

(1)

5.5.2 Comparison of Coating Combinations

(1)

5.5.2.1 Classic TiC-TiN

(1)

5.5.2.2 Balanced TiN-TiC

(1)

5.5.3 Effects of Thermal Expansion

(2)

5.5.4 Effects of Hardness

(1)

5.6 Performance of Hard-material Coatings – Applications

(3)

5.6.1 Wear Resistance

(1)

5.6.2 Heat Treatment and Dimensional Accuracy

(1)

5.7 CVD Coating at Lower Temperatures

(2)

5.7.1 Moderate-temperature CVD, MTCVD

(2)

5.7.2 Plasma-activated CVD, PACVD

(1)

5.8 Summary and Conclusions

(1)

References

(4)

6 Hot-filament CVD Diamond Thin Films

(14)

O. Lemmer, R. Cremer, D. Breidt, M. Frank, J. Müller

6.1 Introduction

(1)

6.2 Differences of Diamond Tools

(1)

6.3 Substrate Pre-treatment

(1)

6.4 Production of CVD Diamond

(1)

6.5 Hot-filament Process

(2)

6.6 Controlling CVD Diamond Properties

(1)

6.7 Industrial Deposition of CVD Diamond

(1)

6.8 Post-treatment of CVD Diamond

(1)

6.9 Applications for Diamond-coated Tools

(5)

6.10 Summary and Conclusions

(1)

References

100

(1)

7 An Introduction to Electrodeposition and Electroless Plating Processes

101

(18)

W. Olberding

7.1 Introduction

101

(1)

7.2 Fundamentals of Electrodeposition (Considering Nickel Deposition as Example)

101

(8)

7.2.1 Structure of Electroplated Nickel Coatings

104

(1)

7.2.2 Deposition Mechanism

105

(1)

7.2.3 Current-density Distribution

106

(1)

7.2.4 Electroless Plating of Nickel

107

(2)

7.3 Overview of System Technologies

109

(5)

7.3.1 Barrel Plating

109

(2)

7.3.2 Rack Plating

111

(1)

7.3.3 Continuous Plating

112

(2)

7.3.4 Brush Plating

114

(1)

7.3.5 Tank Plating

114

(1)

7.4 Overview of Individual Process Steps in Electroplating

114

(2)

7.4.1 Degreasing

114

(1)

7.4.2 Activating or Pickling

115

(1)

7.4.3 Carryover

115

(1)

7.4.4 Coating Passivating Materials such as Stainless Steel and Aluminium

116

(1)

7.4.5 Summary of Pre-treatment

116

(1)

7.5 Microstructuring and Electroforming

116

(1)

7.6 Summary

117

(1)

References

118

(1)

8 Fundamentals of Thermal Spraying, Flame and Arc Spraying

119

(18)

Z. Babiak, T Wenz, L. Engl

8.1 Introduction

119

(1)

8.2 Fundamentals of Thermal Spraying

119

(4)

8.2.1 Structure of Thermal Spray Coatings

121

(1)

8.2.2 Adhesion of Thermal Spray Coatings

122

(1)

8.3 Flame Spraying

123

(4)

8.3.1 Flame Spraying Process

123

(2)

8.3.2 Materials and Applications

125

(2)

8.4 Arc Spraying

127

(7)

8.4.1 Arc Spraying Process

127

(4)

8.4.2 Special Arc Spraying Processes

131

(1)

8.4.3 Materials and Applications

131

(3)

8.5 Summary and Conclusions

134

(1)

References

134

(3)

9 Spray Materials

137

(8)

J. Beczkowiak

9.1 Introduction

137

(1)

9.2 Spray Material Properties Determined by Production Issues

137

(5)

9.2.1 Powder-production Processes

138

(4)

9.3 Material Selection for Coating Applications

142

(3)

9.3.1 Materials for Wear Protection

143

(1)

9.3.2 Materials for Corrosion Protection

143

(1)

9.3.3 Materials for Biotechnology

144

(1)

9.3.4 Materials for Special Applications

144

(1)

10 High-velocity Oxygen Fuel Flame Spraying

145

(14)

O. Brandt

10.1 Introduction

145

(1)

10.2 Characteristics

146

(4)

10.2.1 HVOF Gun

146

(1)

10.2.2 Fuel Gases and Process Parameters

147

(1)

10.2.3 Spray Materials

148

(2)

10.3 Technical Considerations

150

(1)

10.4 Applications

151

(2)

10.5 Process Monitoring and Control

153

(2)

10.6 Development Trends

155

(1)

10.6.1 Application Technology

155

(1)

10.6.2 Coating Materials

155

(1)

10.6.3 Process Technology

156

(1)

10.6.4 Techniques and Methods

156

(1)

10.7 Summary

156

(1)

References

157

(2)

11 Triplex II – Development of an Economical High-performance Plasma Spray System for Highest-quality Demands even under Challenging Production Conditions

159

(20)

H. Zimmermann, H.-M. Höhle

11.1 Introduction

159

(2)

11.2 Fundamentals of Plasma Spraying

161

(3)

11.3 Standard Plasma Gun Design

164

(4)

11.4 Development of the High-performance Three-cathode Plasma Gun Triplex

168

(3)

11.5 Triplex II – A New Era in Plasma Spraying Technology

171

(3)

11.6 Positive Feedback from Industry

174

(4)

11.6.1 Chromium Oxide Coating of Anilox Rollers for Printing Industry

174

(1)

11.6.2 Abradable Coatings

175

(2)

11.6.3 Thermal-barrier Coatings

177

(1)

11.6.4 Further Applications

178

(1)

11.7 Summary

178

(1)

References

178

(1)

12 System Technology, Gas Supply, and Potential Applications for Cold Gas Spraying

179

(12)

W. Krömmer, P. Heinrich

12.1 Introduction

179

(1)

12.2 System Design

179

(7)

12.2.1 Pressure Tank and Nozzle

179

(1)

12.2.2 Control Unit

180

(1)

12.2.3 Touch Screen

181

(1)

12.2.3.1 Main Mask Parameters

182

(1)

12.2.4 Gas Heater LINSPRAY®

183

(1)

12.2.5 Gas Supply for Cold Gas Spraying

184

(1)

12.2.6 Helium Recovery

185

(1)

12.3 Applications

186

(2)

12.4 Summary

188

(1)

References

189

(2)

13 Diagnostics in Thermal Spraying Processes

191

(14)

J. Prehm, K. Hartz

13.1 Introduction

191

(1)

13.2 Classification of Diagnostic Methods

191

(1)

13.3 Methods for Particle Diagnostics

191

(7)

13.3.1 Laser Doppler Anemometry (LDA)

191

(3)

13.3.2 Phase Doppler Anemometry (PDA)

194

(1)

13.3.3 Laser Two-focus Method (L2F)

195

(1)

13.3.4 Particle Image Velocimetry (PIV)

195

(2)

13.3.5 In-flight Particle Diagnostics

197

(1)

13.4 Methods for Plasma and Hot Gas Diagnostics

198

(1)

13.4.1 Enthalpy Probe Diagnostics

198

(1)

13.5 Methods for Online Process Control

199

(3)

13.5.1 Particle-flux Imaging (PF I)

200

(2)

13.6 Summary and Conclusions

202

(1)

References

202

(3)

14 Sol-gel Coating Processes

205

(16)

M. Kursawe, V Hilarius, G. Pfaff, R. Anselmann

14.1 Introduction

205

(2)

14.1.1 Background and Origin of Sol-gel Chemistry

205

(1)

14.1.2 Material Fabrication by Means of Sol-gel Techniques

206

(1)

14.2 Sol-gel Coating Formation for SiO2

207

(3)

14.2.1 Coatings with SiO2 Sol from Salts of Silicic Acid

207

(1)

14.2.2 Coatings with SiO2 Sol from Si Alkoxides

208

(2)

14.3 Application Examples

210

(9)

14.3.1 Translating an Idea into a Product: Development of an Anti-reflection Coating for Glass

210

(4)

14.3.2 Application of Wet Chemical Coating Techniques for a Common Product Type: Pearlescent Pigments

214

(1)

14.3.2.1 Gloss and Colour

214

(1)

14.3.2.2 Production of Pearlescent Pigments with Interference Colours

215

(2)

14.3.3 Effect Pigments on SiO2 Flakes

217

(2)

14.3.4 Coating of SiO2 Spheres for Cosmetic Formulations

219

(1)

14.4 Conclusions

219

(1)

References

220

(1)

15 Hot-dip Coating

221

(18)

W. Bleck, D. Beste

15.1 Mechanisms of Corrosion Protection

221

(3)

15.2 Phase Diagrams Fe-Zn, Al-Zn, and Fe-Al-Zn

224

(3)

15.3 Metal Coatings

227

(2)

15.4 Systems Technology

229

(5)

15.4.1 Design of Hot-dip-coating Systems

229

(2)

15.4.2 Reacting Agents in Molten Zinc

231

(2)

15.4.3 Surface Post-treatment

233

(1)

15.5 Quality Control

234

(2)

15.5.1 Testing Mechanical Properties

234

(1)

15.5.2 Testing Corrosion Properties

234

(2)

15.6 Summary and Conclusions

236

(1)

References

237

(2)

16 Build-up Brazed Wear-protection Coatings

239

(14)

H. Krappitz

16.1 Introduction

239

(1)

16.2 Brazing and Soldering

239

(9)

16.2.1 Fundamentals

239

(2)

16.2.2 Repair Brazing

241

(1)

16.2.3 Coating by Build-up Brazing of Sintered Hard Metals

242

(2)

16.2.4 Brazing of Ceramics

244

(2)

16.2.5 Brazing of Hard-material Particles

246

(2)

16.3 BrazeCoat Technology

248

(4)

16.3.1 Coating with Mats of Filler Metal and Hard Material (BrazeCoat M)

248

(2)

16.3.2 Coating with Suspensions of Filler Metal and Hard Material (BrazeCoat S)

250

(2)

16.4 Summary

252

(1)

References

252

(1)

17 Applications of Coating Processes in Brazing Technology

253

(10)

K. Möhwald, U. Holländer, A. Laarmann

17.1 Introduction

253

(1)

17.2 Brazing Filler-metal Application by Thermal Spraying

254

(3)

17.3 Electroplating and Electroless Plating Methods for Brazing Filler-metal Application

257

(2)

17.4 Brazing Filler-metal Application by PVD

259

(2)

17.5 Summary and Conclusions

261

(1)

References

262

(1)

18 Surface Protection by Means of Build-up Welding

263

(34)

A. Gebert, B. Bouaifi

18.1 Introduction

263

(1)

18.2 Process Variants

264

(1)

18.3 Characterisation of Build-up Welded Coatings

265

(3)

18.4 Build-up Welding Techniques

268

(15)

18.4.1 Distinguishing Features

268

(2)

18.4.2 Shop Welding (Manual Arc Welding, Gas Flame)

270

(1)

18.4.3 Processes with Protective Slag

271

(1)

18.4.3.1 Electroslag Build-up Welding (RES – Resistance Electroslag)

271

(1)

18.4.3.2 Submerged Arc Build-up Welding

271

(2)

18.4.4 Inert-gas-shielded Arc Welding

273

(1)

18.4.4.1 Tungsten Inert Gas Build-up Welding (TIG Process)

273

(1)

18.4.4.2 Gas-shielded Metal Arc Welding

274

(1)

18.4.4.3 Plasma-transferred Arc Process (PTA)

276

(1)

18.4.4.4 Plasma MIG Process

279

(1)

18.4.5 Resistance Roll Seam Technique

280

(1)

18.4.6 Laser Cladding

281

(2)

18.5 Coating Materials for Build-up Welding

283

(12)

18.5.1 Materials for Corrosion Protection

283

(1)

18.5.1.1 Corrosion-resistant Iron-based Materials

284

(1)

18.5.1.2 Nickel Alloys

285

(1)

18.5.2 Materials for Wear Protection

285

(1)

18.5.2.1 Nickel Hard Alloys

287

(1)

18.5.2.2 Iron Hard Alloys

288

(1)

18.5.2.3 Cobalt Hard Alloys

292

(1)

18.5.2.4 Aluminium Pseudo-alloys

294

(1)

18.6 Summary and Conclusions

295

(1)

References

296

(1)

19 Non-destructive Testing and Assessment of Coatings

297

(26)

W. Reimche, R. Duhm

19.1 Introduction

297

(1)

19.2 Coatings

297

(2)

19.2.1 Processes

297

(1)

19.2.2 Coating Properties

298

(1)

19.2.3 Test Planning

299

(1)

19.3 Thickness-measurement Techniques

299

(12)

19.3.1 Geometric Measurement of Parts

302

(1)

19.3.2 Differential Weight Analysis Before and After Coating

302

(1)

19.3.3 Coating-thickness Measurements Based on Magnetic Pull-off

302

(1)

19.3.4 Coating-thickness Measurements Based on Acoustic Principles

303

(2)

19.3.5 Coating-thickness Measurements with Magnetic-induction Techniques

305

(1)

19.3.6 Coating-thickness Measurements with Eddy-current Techniques

306

(3)

19.3.7 Coating-thickness Measurement by Means of X-ray Fluorescent Analysis

309

(1)

19.3.8 Coating-thickness Analysis by Means of Beta-backscatter Technique

310

(1)

19.4 Internal Stresses in Coatings

311

(1)

19.4.1 Roentgenographic Assessment of Internal Stresses –X-ray Diffractometry

311

(1)

19.5 Detecting Coating Defects

312

(7)

19.5.1 Detection of Open Defects in Coatings – Dye-penetration Test

313

(1)

19.5.2 Detection of Laminar Separation/Coating Delamination –Ultrasonic Testing

313

(2)

19.5.3 Detection of Laminar Separation/Coating Delamination –Lock-in Thermography

315

(2)

19.5.4 Detection of Internal Coating Defects – Eddy-current Testing

317

(1)

19.5.5 Assessment of Coating Adhesion by Means of Electromagnetic Testing

318

(1)

19.6 Summary and Conclusions

319

(1)

References

320

(3)

Subject Index

323

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Modern Surface Technology

Summary

Author Biography

Table of Contents

Supplemental Materials