Kurt Sorenson Derek Benavidez Colin Evans Steven Best Surface Treatments & Engineering Metrology & Instrumentation Group 8 ME 260 Fall 2005 11/30/05 Kurt Sorenson Derek Benavidez Colin Evans Steven Best

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

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

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

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

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

Mechanical Plating & Cladding Laser Cladding

Case Hardening and Hard Facing Spark Hardening

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

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

Physical Vapor Deposition

Sputtering

Chemical Vapor Deposition Thermochemical Process Cutting Tools Thicker Tedious

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

Laser Treatments Heating Melting Vaporization Peening

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

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

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

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

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

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…

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

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

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

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)

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.

Types of Measurement and Instruments Used

Types of Measurement and Instruments Used

Common Analog Instruments A caliper gage with a vernier A vernier

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

Angle-Measuring Instruments Bevel Protractor Vernier for angular measurement

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.

Comparative Length Measurement Multiple-Dimension Gaging

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

Laser Scan Micrometer

Straightness Measurement

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.

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

Measuring roundness using V-block and dial indicator

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

Measuring Profiles Dial Indicators Radius Gages

Measuring Profiles Gear-Tooth Caliper Gear-Tooth Micrometer

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

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.

Gages Snap Gage with adjustable anvils

Gages Pneumatic Gage

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

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.

Laser Micrometers A laser beam scans a workpiece, generally at a rate of 350 times per second. Generally capable of resolutionsas high as 0.125 µm (5 µin).

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

Photoelectric Digital Length Measurement Measures basic dimensions of general 3D parts. Resolution ranges from 5 - 0.01 µm.

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

More CMM’s

References www.brownandsharpe.com www.faro.com www.lk-cmm.com www.renishaw.com http://www.nd.edu/~manufact/index3.htm http://www.nd.edu/~manufact/figures.html