Surface treatment of automotive components
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M.S.Ramaiah School of Advanced Studies 1
Surface Treatment for Automotive Components
Santosh S BBB0912001 Pruthvi VJ BBB0912004 Bharath IG BBB0912005 Raj Bharath M BYB0912007
Materials and Manufacturing Processes for Automobiles (AME 2513)
Module Leader Dr. Srikari S Department Dept. of AAE
Submitted by : Rajbharath.M(BYB0912007)
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Introduction
Need for surface treatment
Benefits of surface treatment
Manufacturing
Surface Treatment
Finished Product
Figure 1: Different stages of product development [Author]
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Surface Treatment
Surface Hardening
Surface Coating
Case hardening, Mechanical surface treatment.
Chemical vapour deposition, Plating.
Types of Surface Treatment
Figure 2: Types of Surface Treatment [Author]
Surface hardening - Top surface layer infused with dopants. Surface coating - New layer is coated on the surface.
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Case Hardening Chemical structure manipulation by diffusing the atoms of alternate elements.
Different types includes:
Figure 3: Different case hardening techniques [1]
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Nitriding Nitrogen is diffused into the surface of the component being treated.
Nitriding Temperature: 500-600°C [2]
2NH3 ▲ 2N + 3H2 [2]
Figure 4: Schematic diagram of nitriding apparatus [2] Figure 5: Microstructure of nitrided component [3]
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Process Capabilities [5] Nitriding was adopted to increase the
strength of the crank shaft.
Figure 8: Nitrided crank shaft [5]
Figure 7: Effect of nitriding time on case depth [2] Figure 6: Effect of case depth on hardness [4]
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Carburizing
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Carburization produces a hard, wear resistant layer on the surface.
Typically, case hardens low carbon steel.
Figure 9: Carburizing process [6]
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Quenched microstructure [6]
Carbon Ferrite
Etching: Carburized gear Figure 10: carbon diffusion [6]
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Fig 11: Carburized Steering Pinion [7]
Fig 12: Carburized spur gear [13]
Applications
Hydraulic power steering
Transmission
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Induction hardening
Fig 14: Process overview [8]
Eddy current Fig 15: Quenching[12]
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Fig 17: Sprocket – under induction hardening [10]
Applications
Fig16:Simultaneous dual frequency (SDF) – Green Hardening (for gears). [9] Induction hardening is characterized by precise energy metering. Ultra low power consumption. Short process times. Targets surface layer alone. Save energy and reduce rework effort. SDF
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Mechanical Surface Treatment
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Shot Peening
Overlapping indentations are produced on the surface.
The surface of the component is plastically deformed, which induces the compressive stress on the surface.
Fatigue strength increases by 25% - 50%.
Figure 18 Shot peening Process [14]
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Gear tooth Bending fatigue on a AXOD of Ford Taurus (1981)
Case Study
Figure 19 Weibull analysis of Life v/s Failure [15]
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Laser Peening
The surface of the work piece is subjected to laser shocks.
As a result of which compressive stress is induced in the component, thus improving the fatigue life.
Specifications: Laser intensity - 100-300 J/cm2
Pulse duration - 30 seconds
Figure 20 Laser Peening Working [16]
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Laser Peening emerging applications for Engine Components Reduce material cross-section and improve fuel efficiency.
Retard erosion inside fuel injector tip and reduce emissions.
Case Study
Fuel injector tip Figure 21 Comparison of Laser peening [17]
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Surface Coating
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Electroplating
Electroplating is carried out to impart properties such as wear resistance, corrosion resistance and other similar properties.
Chromium, nickel, cadmium, copper, zinc and tin are commonly plated materials.
Anodizing, galvanizing, chrome plating.
Figure 22 : Chrome plating [18]
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Galvanization process
Cathodic protection
Figure 23: Galvanization process [19]
Figure 24: Cathodic protection [20]
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Anti-corrosion treatment for BIW
Figure 25: Anti-corrosion treatment for BIW [21]
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Benefits / Enhancement
Improved fatigue endurance limit. Better wear resistance. Higher strength. Ability to withstand bending loads for a longer time. Better corrosion resistance. Better surface finish delays crack propagation.
Possible enhancements in the components manufactured:
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Queries
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References [1] Anon., Surface Treatment, Coating and Cleaning,
http://www.ielm.ust.hk/dfaculty/ajay/courses/ieem215/lecs/9_surfacetreatment.pdf, retrieved on 29.12.2012.
[2] Kenneth G. Budinski and Michael K. Budinski., (2009) Engineering Materials: Properties and Selection, 9th edition, Prentice Hall Publishers.
[3] Mumin Sahin, Ceyhun Sevil., (2011) "Investigation of properties of ion-nitrided AISI 304 austenitic-stainless steel", Industrial Lubrication and Tribology, Vol. 63 Iss: 5, pp.359 – 366.
[4] Anon., Heat Treatment Properties, http://www.tohokusteel.com/en/pages/kirin1.htm, retrieved on 29.12.2012.
[5] Anon., Double the Strength, http://www.nitriding.co.uk/double-strength-please!, retrieved on 29.12.2012.
[6] Hiroshi Yamagatta – “Science and technology of materials” [pg 180 onwards]. [7] “Hardness and case depth analysis through optimization techniques”
http://shodhganga.inflibnet.ac.in/bitstream/10603/1259/12/12_chapter%203.pdf [8] Induction hardening - http://www.ustudy.in/node/4157 [9] Mark davis – “Gear hardening goes green”
http://www.eldec.de/fileadmin/00_Dateien/PDF/Veroeffentlichungen/0909_GearSolutions.pdf
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[10] Daewei hating machine co., ltd - http://www.dw-inductionheating.com/hardening-
induction-heating-applications.html/hardening-induction-heating, retrieved on 29.12.2012
[12] Industrial heating - http://directories.industrialheating.com/Articles/Cover_Story/d08079c356cb7010VgnVCM100000f932a8c0, retrieved on 29.12.2012
[13] Thermex metal treating ltd - http://www.thermexmetal.com/carburizing- carbonitriding, retrieved on 29.12.2012 [14] Mordern Mechanical Surface treatment.,(2006) Volker Schulze, Wiley-VCH [15] Adam J. Vahratian, Robert P. Garibay., Application of Statistically capable Shot Peening Automotive Components Design, http://www.shotpeener.com/library/pdf/1993146.pdf, retrieved on 29.12.2012. [16] Laser-assisted materials processing lab https://engineering.purdue.edu/LAMPL/research_peening.html, retrived on 29.12.2012 [17] H.L.Chen, Lawrence Livermore National Laboratory , “Laser Peening - A Means to Strengthen Metals” [18] Anon., Chrome plating alternatives, http://www.rowantechnology.com/Tech- Info.htm, retrieved on 30.12.2012
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[19] Anon., Zinc coatings and thin organic coatings, Coating process, http://www.arcelormittal.com/automotive/saturnus/sheets/catalogue.pl?id_ sheet=N&language=EN, retrieved on 30.12.2012 [20] Anon., Zinc coatings protecting steels, Cathodic protection [pg. 7], http://www.galvanizingasia.com/pdfs/ZincCoatingProtectingSteel.pdf, retrieved on 30.12.2012 [21] Anon., “The inside story of how BMW's are made...” , http://www.usautoparts.net/bmw/bmw/assembly/painting.htm, retrieved on 30.12.2012
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Thank You