1. Kurt Sorenson Derek Benavidez Colin Evans Steven Best
Surface Treatments & Engineering Metrology & Instrumentation Group 8 ME 260 Fall /30/05
Kurt Sorenson
Derek Benavidez
Colin Evans
Steven Best

2. Introduction Surface Treatments Cleaning Mechanical Measurements Why?
Types
Cleaning
Mechanical Measurements
Standards
Dimensioning

3. Why use a surface treatment?
Improves durability
Controls Friction
Reduces Adhesion

4. Why use surface treatment? (cont)
Improves Lubrication
Rebuild Surfaces
Aesthetics

5. Types of Treatments Mechanical Surface Treatments
Mechanical Plating & Cladding
Case Hardening
Thermal Spraying
Vapor Deposition
Laser Treatments

6. Mechanical Surface Treatments
Peening
Shot Peening
Laser Shot Peening
Water-jet Peening
Ultrasonic Peening
Roller Burnishing
Explosive Hardening

7. Mechanical Plating & Cladding
Laser Cladding

8. Case Hardening and Hard Facing
Spark Hardening

9. Thermal Spraying Combustion Spraying Thermal Wire Spray
Thermal Metal-Powder Spray
Plasma Spray

10. Vapor Deposition Physical Vapor Deposition Vacuum Deposition
Sputtering
Chemical Deposition
Ion Platting

11. Physical Vapor Deposition

12. Sputtering

13. Chemical Vapor Deposition
Thermochemical Process
Cutting Tools
Thicker
Tedious

14. Ion Implantation & Diffusion Coating
Particulates penetrate substrate
Modifies surface properties
Increases hardness
Improves durability
Masking capability

15. Laser Treatments
Heating
Melting
Vaporization
Peening

16. Electroplating, Electroless Plating, and Electroforming
Workpiece (cathode) is plated with other metal (anode) through a water-based electrolytic solution
A SLOW Process!!!
75 micrometers/hour
Solution must be replenished
Sacrificial anode
Additional salts of metal

17. Electroplating, Electroless Plating, and Electroforming
Operation Sequence
Chemical Cleaning
Acid Bath
Application of a Base Coat (Optional)
Final Electroplating
Rinse Tanks
Common Plating Metals
Nickel
Cadmium, Copper
Tin, Zinc

18. Electroplating, Electroless Plating, and Electroforming
Chemical Reaction
More Expensive $$
Uniform Thickness
Electroforming
Metal-fabrication
Metal electrodeposited on a mandrel

19. Conversion Coatings Anodizing- Coloring-
The workpiece is the anode in an electrolytic cell
Coloring-
Alters color of metals, alloys, and ceramics
Conversion of surfaces into chemical compounds: oxides, chromates, and phosphates

20. Hot Dipping Workpiece is dipped into molten metal
Zinc- galvanized-steel sheet
Tin- food containers
Hot-dipped Galvanizing line

21. Porcelain Enameling; Ceramic and Organic Coatings
Enamels- fuse a coating material by heating to 425 to 1000.
Ceramic coatings- Intense temp applied
Organic coatings- Wide range of properties: flexability, durability, color, texture…

22. Diamond Coating and Diamond-Like Carbon
Techniques
Chemical vapor deposition
Plasma-assisted vapor deposition
Ion-beam-enhanced deposition
Diamond Properties
Hardness, wear resistance, thermal conductivity

23. Surface Texturing & Painting
Texturing Techniques
Etching
Electric Arcs
Lasers
Atomic oxygen
Paint Classification
Enamels
Lacquers
Water-based paints

24. Cleaning of Surfaces 3 types Mechanical Cleaning Electrolytic Cleaning
Physically disturb contaminants
Electrolytic Cleaning
Abrasive bubbles aid in contaminant removal
Chemical Cleaning
Solution
Saponification
Emulsification
Dispersion
Aggregation

25. Engineering Metrology and Instrumentation
Metrology refers to the measurement of any type of dimensions
(length, thickness, diameter, angle, etc.)
Focus on Dimensional Tolerance (functionality, interchangeability, cost)

26. Describing Quality of Instruments
Resolution- the smallest difference in dimensions that an instrument can detect.
Precision- the instruments ability to give repeated measurements (thermal expansion affects precision, standard measuring temperature is 200 C).
Accuracy- The ability of a measurement to match the actual value of the quantity being measured.

27. Types of Measurement and Instruments Used

28. Types of Measurement and Instruments Used

29. Common Analog Instruments
A caliper gage with a vernier
A vernier

30. The Micrometer
(a)
(c)
Analog Micrometer
Digital Micrometer

31. Angle-Measuring Instruments
Bevel Protractor
Vernier for angular measurement

32. Angle-Measuring Instruments
Sine Bar
Gage blocks are added until the top surface is parallel to the surface plate. The angle is calculated using trig. relationships.

33. Comparative Length Measurement
Multiple-Dimension Gaging

34. Electronic Gages Vertical Length Mesauring Instrument
Measuring Bore Diameters
Vertical Length Mesauring Instrument

35. Laser Scan Micrometer

36. Straightness Measurement

37. Interferometry for Measuring Flatness
Optical Flat is a glass disk or fused-quartz disk with parallel flat surfaces. A light beam with one wavelength is aimed at the surface at an angle and splits into two beams. The number of fringes relates the distance between part and flat.

38. Interferometry for Measuring Shaped or Textured Surfaces
Fringe pattern indicating a scratch on the surface.
Fringes on a surface with two inclinations, the greater the incline, the closer the fringes.
Curved fringe patterns indicate curvatures on the workpiece surface

39. Measuring roundness using V-block and dial indicator

40. Measuring Roundness Part supported on centers and rotated
Circular tracing, with part being rotated on a vertical axis

41. Measuring Profiles
Dial Indicators
Radius Gages

42. Measuring Profiles
Gear-Tooth Caliper
Gear-Tooth Micrometer

43. Horizontal-Beam Contour Projector
Image is projected on screen at magnification of 100X or higher. Measurements made directly on screen.

44. Ring gages for round rods
Plug gages for holes
Ring gages for round rods
GO means smaller than desired size and should fit perfectly, if NOT GO gage also fits then tolerance is not met.

45. Gages
Snap Gage with adjustable anvils

46. Gages
Pneumatic Gage

47. Modern Measuring Instruments and Machines
Electronic gauges
Laser Micrometers
Laser Interferometry
Photoelectric digital length measurement
Coordinate-measuring machines (CMM)

48. Electronic Gauges
Determine travel length by changes in electrical resistance, inductance, or capacitance.
A commonly used E-Gauge is the linear-variable differential transformer (LVDT)
Generally use a very accurate specified probe tip.

49. Laser Micrometers
A laser beam scans a workpiece, generally at a rate of 350 times per second.
Generally capable of resolutionsas high as µm (5 µin).

50. Laser Interferometry
Used primarily to check and calibrate machine tools.
Also are used to compensate for positioning errors in CMM and CNC machines

51. Photoelectric Digital Length Measurement
Measures basic dimensions of general 3D parts.
Resolution ranges from µm.

52. Coordinate-Measuring Machines (CMM)
Very versatile and capable of measuring complex profiles with resolution of 0.25 µm; 10µin at high speeds.
Larger machines can be expensive although most of the touch probe machines for small shops cost around $20k

53. More CMM’s

54. References www.brownandsharpe.com www.faro.com www.lk-cmm.com