Modern Surface Technology

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

• ISBN13: 9783527315321
• ISBN10: 3527315322
• Edition: 1st
• Format: Hardcover
• Copyright: 2006-08-23
• Publisher: Wiley-VCH

Summary

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.

Author Biography

Professor Bach is Head of the Materials Institute of the UniversitSt of Hannover and Director of the Research Center for Surface Technologies and Innovation Services (FORTIS) in Witten, Germany. He is one of the highest renowned experts on surface technologies in Germany. Dr. M÷hwald is also member of FORTIS. <br> Dr. Laarmann works as a Technical Consultant for Benteler Steel/Tube in Paderborn, T. Wenz is a Project-Engineer at Durum Verschleiss-Schutz in Willich.<br> Professor Bach is Head of the Materials Institute of the UniversitSt of Hannover and Director of the Research Center for Surface Technologies and Innovation Services (FORTIS) in Witten, Germany. He is one of the highest renowned experts on surface technologies in Germany.<br> Dr. M÷hwald is also member of FORTIS Board of Directors, A. Laarmann and T. Wenz also belong to FORTIS.

Table of Contents

Preface	V
List of Contributors	XVII
1 Selecting Surface-treatment Technologies	1	(10)
W. Tillmann, E. Vogli
1.1 Introduction	1	(1)
1.2 Requirements on Part Surfaces	1	(3)
1.3 Selecting Coating and Surface Technologies	4	(1)
1.4 Processes for Surface Modification and Coating	5	(4)
1.5 Economic Assessment of Surface-treatment Technologies	9	(1)
1.6 Summary and Conclusions	9	(1)
References	10	(1)
2 Stainless Austenitic Steel Surface Hardening for Increased Wear Resistance	11	(20)
M. Wägner
2.1 Introduction	11	(1)
2.2 Fundamentals	11	(8)
2.2.1 Heat Treatment	11	(1)
2.2.1.1 Surface-hardening Processes	12	(1)
2.2.2 Stainless Steels	13	(1)
2.2.2.1 Classification of Stainless Steels	14	(1)
2.2.2.2 Stainless Austenitic Steels	15	(4)
2.3 Technologies for Surface Hardening of Austenitic Stainless Steels	19	(9)
2.3.1 Kolsterising	19	(1)
2.3.1.1 Influence on Microstructure	20	(1)
2.3.1.2 Influence on Chemical Composition	21	(1)
2.3.1.3 Influence on Mechanical Properties	21	(1)
2.3.1.4 Wear Resistance	21	(1)
2.3.1.5 Influence on Corrosion Resistance	23	(1)
2.3.2 Kolsterising plus PVD Coating	24	(1)
2.3.2.1 Coating Adhesion	25	(1)
2.3.2.2 Wear Resistance	26	(1)
2.3.2.3 Fatigue Strength	26	(2)
2.4 Applications	28	(1)
2.4.1 Application Limitations	28	(1)
2.5 Outlook	29	(1)
References	29	(2)
3 Fundamentals of Thin-film Technology	31	(20)
M. Nicolaus, M. Schäpers
3.1 Introduction	31	(1)
3.2 Classification of Thin-film Coating Processes	31	(1)
3.3 General Aspects of Gas-phase Coating Processes	32	(4)
3.3.1 PVD – Physical Vapour Deposition	32	(1)
3.3.1.1 Evaporation	32	(1)
3.3.1.2 Sputtering	33	(1)
3.3.1.3 Ion Plating	35	(1)
3.3.2 CVD – Chemical Vapour Deposition	35	(1)
3.4 Plasma Properties	36	(2)
3.4.1 Low-pressure Plasma	37	(1)
3.5 Coating Configuration	38	(1)
3.5.1 Coating Structure	38	(1)
3.6 Electrodeposition and Electroless Plating Processes	39	(11)
3.6.1 Introduction	39	(1)
3.6.2 Fundamental Terms	40	(1)
3.6.2.1 Electrolyte	40	(1)
3.6.2.2 Electrodes, Electrode Reactions, Electrode Potential	40	(1)
3.6.2.3 Electrolysis and Faraday's Laws	42	(1)
3.6.2.4 Overpotential	44	(1)
3.6.3 Electroless Plating	44	(1)
3.6.4 Electrodeposition of Metal	45	(2)
3.6.5 Electrodeposition of Metal from Non-aqueous Solvents	47	(2)
3.6.6 Summary and Outlook	49	(1)
References	50	(1)
4 Innovations in PVD Technology for High-performance Applications	51	(14)
K. Bobzin, E. Lugscheider, M. Maes, P. Immich
4.1 Introduction	51	(1)
4.2 Market Situation	52	(1)
4.3 Application Examples	53	(8)
4.3.1 Tool Coatings for Cutting	54	(1)
4.3.2 Tool Coatings for Forming	55	(2)
4.3.3 Coatings for Plastic Parts	57	(1)
4.3.4 Coatings for Machine Elements	58	(2)
4.3.5 Part Coating for High-temperature Applications	60	(1)
4.4 Summary	61	(1)
References	62	(3)
5 Development and Status Quo of Thermal CVD Hard-material Coating	65	(22)
A. Szabo
5.1 Introduction	65	(1)
5.2 Early CVD Hard-material Coating	66	(1)
5.3 Fundamentals of Deposition Processes	66	(4)
5.3.1 Chemical Mechanism	66	(1)
5.3.2 Interdisciplinary Fundamentals	67	(1)
5.3.3 CVD System and Reaction-chamber Techniques	67	(3)
5.4 Combination Coatings	70	(3)
5.5 Material and Coating Properties	73	(4)
5.5.1 Physical Properties of Coating Materials	74	(1)
5.5.2 Comparison of Coating Combinations	74	(1)
5.5.2.1 Classic TiC-TiN	74	(1)
5.5.2.2 Balanced TiN-TiC	74	(1)
5.5.3 Effects of Thermal Expansion	75	(2)
5.5.4 Effects of Hardness	77	(1)
5.6 Performance of Hard-material Coatings – Applications	77	(3)
5.6.1 Wear Resistance	79	(1)
5.6.2 Heat Treatment and Dimensional Accuracy	79	(1)
5.7 CVD Coating at Lower Temperatures	80	(2)
5.7.1 Moderate-temperature CVD, MTCVD	80	(2)
5.7.2 Plasma-activated CVD, PACVD	82	(1)
5.8 Summary and Conclusions	82	(1)
References	83	(4)
6 Hot-filament CVD Diamond Thin Films	87	(14)
O. Lemmer, R. Cremer, D. Breidt, M. Frank, J. Müller
6.1 Introduction	87	(1)
6.2 Differences of Diamond Tools	88	(1)
6.3 Substrate Pre-treatment	88	(1)
6.4 Production of CVD Diamond	89	(1)
6.5 Hot-filament Process	90	(2)
6.6 Controlling CVD Diamond Properties	92	(1)
6.7 Industrial Deposition of CVD Diamond	93	(1)
6.8 Post-treatment of CVD Diamond	93	(1)
6.9 Applications for Diamond-coated Tools	94	(5)
6.10 Summary and Conclusions	99	(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