SURFACE TREATMENT

OF
METALS
 SURFACE TREATMENT OF METALS
 End Products of Any of the Metal Working Process do
not have Desired/Smooth Surface Finish
 The Surface Should Be Uniform And Without Peelings,
Pits & Burs.
 A process Imdtly followed by any Metal Working
Process to get Desired surface is called Surface Treatment
process
 Metal finishing Alters the surface of metal products
 Without Metal finishing , Products made from metals
would last only a fraction of their present life-span.
 It further involves two sub processes
 Surface Cleaning (Surface Cleaning Is A Preparatory Operation prior to
Surface Treatment to Provide Good Adhesion To Coating)
 Surface Coating (PROTECTIVE /DECORATIVE COATING)
SURFACE CLEANING
OF
METALS
 TYPES OF CONTAMINATIONS
 THERE ARE SIX TYPES OF UNWANTED
SURFACE CONTAMINANTS AS UNDER :-
 PIGMENTED COMPOUNDS

 OILS AND GREASES

 CHIPS AND CUTTING FLUIDS

 RUST AND SCALE

 POLISHING/BUFFING COMPOUNDS

 MISC CONTAMINANTS
 CLASSIFICATION OF CLEANING PROCESSES
 CLEANING PROCESSES ARE CLASSIFIED INTO :-
 CHEMICAL CLEANING
 ALKALINE PICKLING
 ACID PICKLING
 EMULSIFIED SOLVENT CLEARING
 ELECTROLYTIC CLEANING
 VAPOUR DEGREASING
 ULTRASONIC CLEANING
 MECHANICAL CLEANING
 ABRASIVE/BLAST CLEANING
 TUMBLING
 BARREL ROLLING
 POWER BRUSHING
 MECHANICAL POLISIHING AND BUFFING
 ALKALINE PICKLING
 EFFICIENT & ECONOMICAL PROCESS FOR REMOVING OILS ,
GREASES, MINERALS , LARDS AND UN-PIGMENTED COMPOUNDS
 CAUSTIC SODA OR SODIUM META SILICATE ARE THE COMMON
ALKALINE CLEANING AGENTS
 SOME SOAP IS ADDED TO THE SOLUTION TO AID IN
EMULSIFICATION

 CARE SHOULD BE TAKEN WHILE CLEANING ASSEMBLIES

COMPRISING OF DISSIMILAR METALS SO THAT TO AVOID GALVANIC
CORROSION

 THROUGH CLEANING & RINSING WITH PLAIN WATER IS MUST

AFTER ALKALINE CLEANING TREATMENT
 ALKALINE CLEANING IS NOT SUITABLE FOR ZINC, ALUMINIUM,
BRASS, LEAD AND TIN METALS
ALKALINE PICKLING
 ACID PICKLING
 EMPLOYED TO CLEAN/REMOVE
 UNWANTED PIGMENTED COMPOUNDS
 METAL OXIDES/RUST
 OILS AND GREASES (TO SOME EXTENT)

 DILUTED SULPHURIC ACID , MURIATIC ACID OR PHOSPHORIC

ACIDS ARE NORMALLY USED IN THE PROCESS.

 ACID IS EITHER SPRAYED OR PARTS DIPPED INTO ACID BATH

 SOMETIMES PICKLING INHIBITORS e.g. DETERGENTS, GLYCOLS,

ETHER ETC. ARE ALSO ADDED TO DECREASE THE HARMFUL
EFFECTS OF ACID SPECIALLY FOR NON FERROUS METALS
 Contd/-
 SOAPS AND OTHER HYDROLYZABLE COMPOUNDS ARE
NOT ADDED TO THE CLEANING SOLUTION AS THEY
FORM INSOLUBLE MATERIALS AFTER REACTION WITH
ACIDS.

 ACID CLEANING OF STEEL CREATES HYDROGEN WHICH

WHEN GET ABSORBED CAUSES “HYDROGEN
EMBRITLEMENT”

 HENCE STEEL SHOULD BE HEATED AFTER ACID

PICKLING TO REMOVE HYDROGEN
PICKLING CONTAINER
 EMULSIFIED SOLVENT CLEANING
 DESIGNED TO CLEAN METALS LIKE ZINC, LEAD & ALUMINIUM
WHICH MAY GET CORRODED BY ALKALINE OR ACID
CLEANERS

 ORGANIC SOLVENTS (Tetra-Chloroethylene, Toluene, Turpentine oil ,

Acetone , Thinner etc) IS MIXED WITH SOAP OR KEROSENE OIL
(EMULSIFYING AGENT) WITH SMALL AMOUNT OF WATER
 SOMETIME CASTOR OIL IS ALSO ADDED

 AFTER CLEANING, HOT WATER PRESSURE SPRAY IS GIVEN

 VERY DILUTED ALKALINE CLEANING IS RESORTED TO FOR A

SHORT DURATION IF SURFACE COATING THROUGH
ELECTROPLATING IS TO BE FOLLOWED THERE AFTER.
 ELECTROLYTIC CLEANING
 USED WHERE EXTREME CLEANLINESS IS REQD e.g. PRIOR TO
ELECTRO PLATING PROCESS
 AN ALKALINE CLEANING SOLUTION (e.g. Sodium Carbonate or
Na2CO3 @10%) IS USED & ELECTRIC CURRENT IS PASSED
THROUGH IT
 PART TO BE CLEANED IS MADE ONE OF THE ELECTRODES,
NORMALLY CATHODE
 SOFT METALS (ZINC, TIN LEAD ETC) ARE ANODICALLY
CLEANED TO AVOID ETCHING OR CORRODING
 O₂ IS EMITTED AT +ve POLE OR ANODE AND H₂ IS EMITTED
AT -ve POLE OR CATHODE
 STEEL IS NORMALLY ANODICALLY CLEANED TO AVOID
“HYDROGEN EMBRITTLEMENT”
 ELECTROLYTIC CLEANING

H₂ Electro-Plating
O₂
 VAPOUR DEGREASING
 EFFECTIVE AND WIDELY USED METHOD TO REMOVE
IMPREGNATED GREASE & OILS e.g. IN BEARINGS
 EFFECTIVE IN REMOVING SOLUBLE MTRLS FROM CREVICES
WHERE OTHER CLEANERS MIGHT GET ENTRAPPED
PERMANENTLY
 TRI-CHLORO-ETHYLENE SOLUTION IS HEATED TO A BOILING
POINTS & COMPONENTS ARE SUSPENDED ABOVE THE HEATING
POT.
 THE CONDENSED VAPOURS REMOVE ALL OIL AND GREASE FROM
THE METAL PARTS
 METHOD IS USED PRIOR TO LACQUERING, JAPANNING,
ENAMELING AND OTHER ORGANIC COATING PROCESSES.
 MUST BE FOLLOWED BY LIGHT ALKALINE PICKLING IF
COMPONENT IS TO BE ELECTROPLATED.
VAPOUR DEGREASER
 ULTRASONIC CLEANING
 ULTRASONIC VIBRATIONS OF SUFFICIENTLY HIGH POWER ARE
INDUCED IN FLUIDS WHERE COMPONENTS REQD TO BE CLEANED
ARE DIPPED
 DUE TO INDUCED CAVITATIONAL EFFECT DIRT, GREASE AND
MANY OTHER IMPURITIES INCLUDING LIGHTLY IMPREGNATED
ONES GET RIPPED APART AND EMULSIFIED.
 FLUIDS NORMALLY USED ARE CYCLOHEXANE OR
TRICHLOROETHYLENE. A LITTLE BIT OF DETERGENT IS ALSO
ADDED.
 FREQUENCY OF ULTRASONIC WAVES MAY BE UPTO 3000 Hzs
 IT IS AN EXPENSIVE METHOD . NORMALLY UTILISED FOR :-
 CLEANING OF PRECISION COMPONENTS e.g. CAMERAS, WATCHES etc
 CLEANING OF PRECIOUS METALS
 COMPLEX CONFIGURED COMPONENTS
 TIGHTLY ADHERING AND EMBEDDED IMPURITIES
 POWDERED COATED COMPONENTS
ULTRASONIC CLEANING
FACTORS INFLUENCING CLEANING PROCESS
 CLEANING PROCESS IS INFLUENCED BY THE
FOLLOWING FACTORS :-
 TYPE OF CONTAMINANTS
 DEGREE OF CLEANLINESS REQD
 COMPOSITION OF METAL
 CONDITION OF METAL
 THICKNESS OF RUST OR SCALE
 ALLOWABLE METAL LOSS
 SURFACE FINISH TOLERANCE
 SHAPE AND SIZE OF WORK PIECE
 COST INVOLVED
 AVAILABLE EQPTS
 PRODUCTION REQMT
SURFACE COATING
OF
METALS
 METAL SURFACE COATING METHODS
 DIFFERENT PROTECTIVE/DECORATIVE COATINGS ARE
CARRIED ON THE FINISHED PRODUCTS OF METALS
DEPENDING UPON THEIR USAGE , COST EFFECTIVENESS
AND DURABILITY DESIRED :-
 METALLIC COATINGS
 ELECTROPLATING
 HOT DIPPING
 GALVANIZING AND TIN COATING
 CALORIZING (ALUMINIUM COATING)
 PARKERIZING OR PHOSPHATE COATING
 ANODIZING
CADMIUM COATING
 METAL SPRAYING
 Contd/-
 PLASTIC COATINGS
 DIPPING
 SPRAYING
 DEPOSITING

 ORGANIC COATINGS
 PRIMERS
 OIL PAINTS
 ENAMELS
 VARNISHES
 LACQUERS
 SHELLAC
 RUBBER

 INORGANIC COATINGS
 PORCELAIN ENAMEL
 CERAMICS
METALLIC
COATINGS
 ELECTRO-PLATING
 IT IS ANALOGOUS TO A GALVANIC CELL ACTING IN
REVERSE & ITS ESSENTIAL ELEMENT ARE
 CATHODE
 ANODE
 ELECTROLYTE (Salt Of Metal To Be Deposited Plus Conductivity
Booster Chemicals e.g. Diluted H2SO4
 DC CURRENT WITH LOW VOLTAGE
 COATING CAN BE OF SAME METAL OR OF ANY OTHER
DESIRED METAL
 METAL TO BE DEPOSITED IS MADE ANODE
 METAL TO BE COATED IS MADE CATHODE
 METAL DEPOSITATION RATE IS DIRECTLY PROPORTIONAL
TO THE DENSITY OF CURRENT INDUSED
 HOT DIPPING
 IT IS CORROSION RESISTANT LAYER OF A LOW
MELTING POINT METAL e.g. TIN, LEAD & ZINC ETC
OVER HARD METAL LIKE STEEL, COPPER, BRASS etc.
 CARRIED OUT EITHER BY CONTINOUS FLOW METHOD
OR BY GIVING AN IMMERSEN BATH IN A MOLTEN
METAL
 FIRST COATING IS GIVEN OF AN ALLOY LAYER WHICH
GET DIFFUSED WITH THE BASE METAL AND IMPART
ADHERENCE & UNIFORMITY TO THE ACTUAL COATING
LAYER OF THE METAL
 GALVANIZING & TIN COATING
 GALVANIZING IS A COMMERCIAL NAME OF ZINC COATING
OVER IRON FORMING METALLURGICAL BOND OF Zn-Fe
ALLOY
 IT CAN BE DONE BY FOUR METHODS
 SHERARDIZING (Vapour Galvanizing where Zn diffuses into the
metal forming Zn-Fe-phase)
 ELECTROPLATING
 SCOOPING OR SPRAYING
 HOT DIPPING
 BASE METAL IS NORMALLY FLUXED BY DIPPING INTO THE
SOLUTION OF ZnCl2 & Hcl
 WORKING TEMP IS Approx 450°C
 IF TIN REPLACES ZINC THEN COATING LAYER IS THEN IS
CALLED TIN COATING. ITS WORKING TEMP IS Approx 350°C
GALVANIZING
 CALORIZING
 TO PROTECT IRON COMPONENTS FROM OXIDATION AT
HIGHER OPERATING TEMP OR SIMPLY TO IMPROVE
CORROSION RESISTANCE, IT IS COATED WITH
ALUMINIUM/CHROMIUM+ALUMINIUM LAYER. THIS
PROCESS IS CALLED CALORIZING
 NORMALLY CARRIED OUT BY DIPPING IRON
COMPONENT IN MOLTEN ALUMINIUM FOR 20 Minutes
& THEN SUBJECTED TO DIFFUSION HEAT TREATMENT AT
900°C FOR 24 Hrs
 Employed In Making Furnace Boxes , Refinery Flue Gases
Tubes ,Tubes used in Chemical industry etc.
 ANODIZING
 ANODIZING IS A PROCESS TO ENHANCE THE EXISTING
Al₂O₃ LAYER ON ALUMINIUM
 PROCESS PROVIDES RELIABLE PROTECTIVE COATING TO
Aluminum Components AS OTHER METALLIC COATINGS
e.g. Paintings, Varnishing etc do not Adhere Well With
Aluminum Surface
 IT IS AN OPPOSITE PROCESS TO ELECTROPLATING
 HERE ALUMINIUM IS MADE ANODE AND CATHODE
CAN BE either LEAD OR GRAPHITE
 AQUEOUS SOLUTION IS OF H2SO4, Chromic ACID OR
Oxalic ACID
 Contd/-
 WHEN CURRENT FLOWS, O2 Gas IS LIBRATED AT
ANODE & Hence Thick Al2O3 LAYER IS FORMED OVER
ALUMINIUM COMPONENT
 THE LAYER FORMED IS PORUS. HENCE SEALING
PROCESS IS CARRIED OUT BY DIPPING IT IN BOILING
WATER Mixed With POLLUSSIUM CHROMATE) FOR ½
an Hour.
 CADMIUM COATING

 Cadmium is a common plating material that

has properties superior to other metal coatings in
some applications.
 It displays excellent corrosion resistance and is
valued for its natural lubricity or smoothness.
 It exhibits good corrosion resistance, and
meets the salt-spray test requirements of the
automotive industry.
 It can be soldered readily and is toxic to fungus
and mold growth. In the past, numerous military
specifications have specified the use of cadmium.
 The major cadmium complex used in
electroplating baths is cadmium cyanide, or
Cd(CN-24).
 PHOSPHATE COATING OR PARKERIZING
 It is basically for steel or iron to provide corrosion resistance
 Metal is dipped in in a solution of Manganese Di-Hydrogen
Phosphate Mn(H2PO4)2.2(H2O) pre heated at 90°C &held
there for 45 min
 Phosphate gets decomposed and forms a thick Layer over
Steel/Iron
 Phosphate Coatings On its Own Do Not Provide desired
result Because The Coating Is Porous. Therefore, Oil Or Other
Sealers Are Used To Achieve Corrosion Resistance
 Parkerizing is normally used as a primary coating prior to
Paint/Enamel Coating
 Widely used in Auto Industry ,Washing Machines, Weapon
Industry etc
 METALALLIZING
 Impregnating Atomized & Protective Metal Particles Over
Base Metal By Spraying And Forming Thick Layer Is Called
Metallization
 Normally done by two methods
 SPRAY GUN/TORCH method which has an Arrangement Of
Oxyacetylene Flame at The Tip of Orifice & Compressed Air
is blown through pipe. Feeder metal is in the form of a wire

 Wire is feed through a Gear System . As soon as it melts

,molten metal get blown away & get atomized. These
Atomized particles are sprayed over the base metal where
they form layer of desired thickness. It is then cured in a
furnace to give smooth finish
Contd/-

 POWDERED COATING method where metal is already

in a form of Powdered fine particles . Gun sprays it
over a heated Base Metal

METAL SPRAYING IS WIDELY USED TO

RECLAMATION INDUSTRY
METALALLIZING
 PLASTIC
COATINGS
 PLASTIC COATING METHODS
 Plastic coating is resorted to achieve a composite
character mtrl with Mechanical Properties of metals &
Protective & Corrosive Resistance Properties of
Plastics
 Wide Usage In Chemical Industry, Food Industry,
Decorative Furniture Industry & Household Utility
Items industry.
 Protective Coating Is Of One Of the Thermoplastic
Compounds e.g. P.V.C (Plasticized Poly Vinyl Chloride)
P.T.F.E. (Poly-Tetrafloro Ethylene) , Nylon & Polythene
etc
 Contd/-
 There Are Basically Four Plastic Coating Methods:-
 DIPPING
 LIQUID PLASTICAL METHOD :- METAL ARTICLE IS HEATED &
DIPPED IN LIQUID PLASTIC SOLUTION. HEAT CAUSES CROSS LINK
BETWEEN THE TWO.
 FINE POWDER DIPPING :- PRE HEATED METAL ARTICLE IS
PLACED IN GAS AGITATED POWDERED PLASTIC CONTAINER
 SPRAYING
 ELECTROSTATIC SPRAYING :- METAL ARTICLE CONNECTED TO –ve
TERMINAL & SPRAY GUN IS CONNECTED TO +VE END OF A HIGH
VOLTAGE SOURCE . PLASTIC POWDER WHEN SPRAYED AT HIGH
SPEED GETS CHARGED WHILE COMING OUT & GET DEPOSITED
ON THE METAL
 HEAT TREATMENT IS THEN EMPLOYED TO GET SMOOTH COATING
 Contd/-
 FLAME SPRAYING Fine Plastic Powder
Agitated By an Inert Gas Is Forced Through A Nozzle
Of Spray Gun With Flame Arrangement at The
Orifice. The Molten Granules Get Coated On Metal.
 Heat Treatment Later Is Done To Form Smooth
Layer

 VACUUM DEPOSITION Vacuum is employed

to attract plastic powdered particles towards the
Preheated Metal Article.
 Due to absence of air, bubble free coating is
Achieved.
ORGANIC COATINGS
 ORGANIC COATINGS
 They form a corrosive resistance/decorative layer or
combination of both over metal articles
 But their resistance to abrasion is average as compared to other
Metal Coatings
 And Close Dimensional Tolerance also may not be possible
(non uniformed thick layer )
 Resistance to high temp is also poor
 They can be classified as :-
 Primers
 Oil paints
 Enamels
 Varnishes
 Lacquers
 Shellac
 Rubber coating
 PRIMERS
 They form a Preparatory Coating prior to any other
organic coating over metals

 They have better adhesive qualities & Provide a

firm base

 They also have better filling & binding Properties

 They are also designed to react with rust etc &

convert it into a metal salt

 They can be easily pigmented to any colour

 OIL PAINTS
 Basic Ingredients of Oil Paints are Oil (Normally linseed oil)
called Vehicle, Pigmented Particles (For colouring) and a
Solvent (Turpentine or Spirit)
 Varnish is also added to enhance glossiness
 Solvent is used to control viscosity
 Oils (basically poly-un-saturated) are used based on a
property called iodine number ie number of grams of
iodine which can be dissolved in One Hundred gram of
oil
 Iodine number greater than 130 are Fast drying & less
than 115 are slow drying Paints
 ENAMELS
 Enamels have Varnish as a Vehicle instead of oil.
Pigment is dissolved in varnish. Small amount of oil
can also be added.

 Enamels give glossy finish because of varnish

 Drying is either due to oxidation or polymerization

 Sometimes Metals are Baked at some particular

temperature after Enamel Coating to provide stability

 They Provide better Finish & Corrosion resistance as

compared to the Oil Paints
 VARNISHES, LACQUERS AND SHELLAC
 When Pigment is replaced by Resin in a Paint, It is
called Varnish coating. Solvent is used as on reqd
basis

 Lacquers are made of Lac (An extract from a Lac insect

living on kurusum tree) dissolved in a Varnish

 Shellac Coating is when Lac is dissolved in Alcohol

instead of Varnish.

 Shellac sometimes provide a primer layer to

lacquering or varnishing
 RUBBER COATING
 Rubber Coating Are Basically Of Three Types :-
 CHLORINATED RUBBER :- They are natural rubbers treated with
chlorine. They Provides Resistance to water . Used to coat metal
components either exposed to moisture or are submerged in water.
They are not resistant to oil, grease or acids. Example is rubber paint
under Car Floor
 NEOPRENE RUBBER :- It is an Artificial Rubber (Polychloroprene) with
good Chemical stability. It when dissolved in a solvent coated over
Metals , forms a strong layer & is Resistant to Acids, Alkalis & Oils
 HYPALON RUBBER :- It is also a Synthetic Rubber (Chloro-Sulphonated
Polyethylene). It is Resistance to Oxidation ,Temprature & UV Light .
Hence It used for External Coatings e.g Roof , Outside Furnace etc.
Any colour can be added to this & hence also used for Decorative
Coatings
INORGANIC
COATINGS
 INORGANIC COATINGS
 These coatings provide excellent Resistance to
Corrosion & High Temperatures, Abrasions & Chemical
Reactions

 They also Add on to the appearance

 Close tolerance is possible

 They are basically of two types

 Pigmented glass coating (Vitreous Enamel)
 Ceramic coating
 VITREOUS ENAMEL COATING
 Basically a Glass Coating Opacified (Porcelain) by an
inorganic pigment.
 Composition is as under
 Glass former (SiO2 + Boron)
 Flux (Na₂O or K₂O )
 Stabilizers (CeO & Al2O3)
 Pigments (Oxides of Cadmium, Chromium & Iron etc)

 Above composition is powdered & slurry is formed by

Mixing it with Clay, Water & Sodium Silicate
 Contd/-
 Slurry is then either Sprayed ,Coated or Applied over
metal by Dipping
 It is then dried by heating at 125°C and than further
to 500 to 800°C for Curing
 On cooling it makes a strong Bond with the metal
 CERAMIC COATING
 Basically They are Chemical , Acid & Heat resistance
Coating Mtrls . Also known as Refractory Mtrls
 They are Oxides, Silicides, Aluminous Carbides, Nitrides or
any other refractory type mtrls
 They find usage in Thermal Insulators, Furnaces, Kitchen
wares , Gas Turbines and Aircraft/Rocket Industry.
 Heat resistance Coating Mtrls can withstand temperatures
as high as upto 1600ᴼC & Increase the Durability and
provide thermal insulation to the exhaust system
components & Kitchen Wares
ANY QUESTIONS
?