ELECTROPLATING PROCESS Introduction.pptx

ELECTROPLATING PROCESS
Electroplating is basically the process of plating a metal onto the other by
hydrolysis mostly to prevent corrosion of metal or for decorative purposes.
Electroplating is majorly applied to modify the surface features of an object
(e.g corrosion protection, lubricity, abrasion), but the process can also be used
to build thickness or make objects by electro forming.
The Anode and Cathode
In electroplating practice, the current is usually introduced from an external source
and the anode is the positive electrode and cathode is a negative electrode. The
cathode is the electrode where the electrochemical reduction reaction occurs. The
anode is that where the electrochemical oxidation reaction occurs.
The electroplating process uses an anode and a cathode. In electroplating, the
metal dissolved from the anode can be plated onto the cathode. The anode is
provided with direct current, oxidizing and dissolving its metal atoms in the
electrolyte solution. At the cathode, the dissolved metal ions are decreased and the
metal is placed on the product.

USES OF ELECTROPLATING
Improving wear resistance.
Improving the thickness of the
metal surface.
Enhancing the electrical
conductivity like plating a copper
layer on an electrical component.
Minimizing Friction.
Improving surface uniformity.

GASEOUS STATE PROCESSES
• Gaseous state processes cover surface engineering techniques in which the coating
or surface treatment material passes through a gaseous or vapor phase prior to
depositing on to or modifying the surface. The main generic coating sub-groups
are Chemical Vapour Deposition (CVD) and Physical Vapour Deposition (PVD).
The former utilises gaseous reagents as the source of coating species, whereas in
PVD at least one of the coating species is evaporated or otherwise atomised from
solid within the coating chamber
 Improved coating adhesion, due to the ablity to clean and pre-heat substrates
by energetic ion and neutral bombardment of the substrate surface. This
mechanism is sometimes called sputter cleaning.
 Uniform coating thicknesses, through gas-scattering effects and the ability to
rotate or displace samples relative to the vapor source during deposition.
 Avoidance of a final machining or polishing stage after coating, as in most
cases the coating replicates the original surface finish.

 Controlled coating structures, due to the effect of bombardment in obviating
columnar growth and encouraging atom mobility.
 Deposition of a wide range of coating and substrate materials, including
insulators, usually by the use of radio frequency biasing.
 Controllable deposition rates, using a wide variety of vapour sourcesincluding
resistance heated, electron beam, induction and sputter magnetron.
 Usually no effluents or pollutants are produced, as in most cases there are no
harmful by-products or toxic chemical solutions used.
 High purity deposits through the use of a controlled vacuum environment and
pure source materials.
 Lower deposition temperatures, as direct energisation of the coating species
provides many of the benefits previously only achievable on hot substrates.
Thus lower bulk substrate temperatures can be used for ceramic deposition
compared to non plasma-assisted vapour deposition.
 Avoidance of the hydrogen embrittlement problems sometimes experienced in
electroplating.

CHEMICAL VAPOUR DEPOSITION
• In the basic CVD process gases containing volatile compounds of the element
or elements to be deposited are introduced into a reaction chamber, and
condense on to the substrate to form a coating. Figure shows a hot-wall CVD
layout typicalIy used for tool coating with TiN or TIC.
• The deposition pressure in CVD can range from atmospheric to 1 Pa or less.
Also there are various means of assisting the process, such as through the use of
laser or electron beams, or by ion bombardment of the growing films. The latter
method promises the benefit mentioned earlier for PVD, that is the reduction in
coating temperatures

PHYSICAL VAPOUR DEPOSITION
 PVD involves the atomisation or vaporisation of material from a solid source
and the deposition of that material on to the substrate to form a coating
 The advantages of the PAPVD processes in fact extend well beyond those
listed. They include the possibility to deposit alloy compounds, multi-layer
compositions and structures, and the ability to vary coating characteristics
continuously throughout the film, giving the concept of a functionally graded
coating.

HIGH VELOCITY OXYGEN FUEL (HVOF)
COATING
 High-Velocity Oxygen Fuel (HVOF) coating is a thermal spray coating process
used to improve or restore a component’s surface properties or dimensions, thus
extending equipment life by significantly increasing erosion and wear resistance,
and corrosion protection.
 Molten or semi-molten materials are sprayed onto the surface by means of the
high temperature, high-velocity gas stream, producing a dense spray coating
which can be ground to a very high surface finish.
 The utilization of the HVOF coating technique allows the application of coating
materials such as metals, alloys, and ceramics to produce a coating of
exceptional hardness, outstanding adhesion to the substrate material and
providing substantial wear resistance and corrosion protection.
 As the technology specialists in HVOF coating, Bodycote provides an array of
spray coating materials to suit your specific needs. Backed by a customer-driven
service, our facilities process a wide variety of component sizes to exacting
standards with reliable, repeatable results.

Powder metallurgy
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Introduction to Powder metallurgy
• Powder metallurgy is a branch of metallurgy
which deals with the production of metal and
nonmetal powders and subsequently
manufacture of components by using these
powders.
• It is process in which powdered materials are
BLENDED,PRESSED into desired shape and
then HEATED to bond surface.

Steps involved in production of
component (processes)
1) Powder production
2) Blending or mixing
3) Compacting(i.e. pressing)
4) Sintering
5) Sizing or impregnation
6) Testing and inspection.

Steps involved in manufacturing powder
metallurgical component
Powder Metallurgy

• Powders are manufactured by various methods and the
powder from each method has typical properties.
1) Mechanical process
a) Machining
This method is used to produce filings, turning ,chips etc.
which are subsequently pulverized by crushing and milling.
Since relatively coarse powders are obtained by this
method, it is suitable only for few special cases such as Mg
powder in pyrotechnic applications, silver solders and dental
alloys.
The powder particles are of irregular shape.

B) Crushing
The solid materials are crushed by hammers, jaw crushers,
gyratory crushers, etc .the powder particles of brittle material
are angular in shape and ductile material are flaky in shape.
Any material can be crushed to powder form; however, the
method is very much suitable for brittle materials.
C) Milling:
Milling is the most important and widely used method for the
production of powders of required grade and fineness.
Milling is done by using equipments such as ball mills, rod
mills, eddy mills etc.

Powder Production
 Mechanical:
(a) Roll crusher (b) Ball mill

In ball milling methods, the material to be powdered is tumbled
or rotated in a container with large number of hard balls.
The speed of container is properly controlled so that the balls hit
the material making particles finer and finer.
Milling may be done by dry or wet method. In wet method, a
liquid medium such as distilled water ,alcohol, acetone, or
stearic acid is used in the drum.
Any type of material can be powdered by milling method.
However it is widely used for carbide –metal mixtures.
D) shotting:
In this method molten metal is poured on a vibrating screen and
liquid droplets are solidified either in air or a neutral gas.

The size and characters of the powder depends on the
temperature of molten metal, size of openings in the screen
and frequency of vibrations of the screen.
Shape of particle is nearly spherical.
E)Graining :
Graining involves the same procedure as shotting, the only
difference being the solidification of molten metal droplet is
done in water.
The powder obtained by shotting and graining method are
coarse and subsequently pulverization methods are used for
further reduction of size.

Powder Production
 Mechanical:
Automization
 Produce a liquid-metal stream by injecting
molten metal through a small orifice
 Stream is broken by jets of inert gas, air, or water
 The size of the particle formed depends on:
Temperature of the metal
Metal flowrate through the orifice
Pressure of jet
Nozzle size and jet characteristics

The process consists of main three stages
• Melting
• Atomization
• Solidification and cooling
 Melting is done by induction, arc, plasma
or electron-beam technique to maintain purity
of melt.
 Atomization is done by high velocity water,
compressed air or inert gas.
 The disintegrated particles are solidified in
controlled atmosphere, vacuum , air or water.
• Main two types of techniques:
• Water Atomization
• Gas Atomization
Powder Production

Main two types of Automization Techniques:
Water Atomization
Gas Atomization
Powder Production

Gas Atomisation
Compressed air, nitrogen, argon or helium are used for
disintegration.

Water atomization technique for production of
powders
Water Automization

Physical processes
condensation:
In this method ,metal vapours are condensed to obtain metal
powders.
This method is highly suitable for volatile metals because they
get easily transformed to their vapours.
Large quantities of Zn ,Mg and Cd powders are manufactured by
this method.
The powder shape is nearly spherical.

Characteristic of Metal powder
• Chemical composition
• Particle shape, size and its distribution
• Particle porosity
• Specific surface
• Compacting properties
• Sintering properties

2)Mixing or blending
The metal obtained from above methods may not be suitable for
their further processing . To make them suitable, powder
conditioning is done which involves mechanical, chemical or
thermal treatments or alloying and are described below:
1)Annealing :
Before mixing or blending of powders, annealing is usually done
in reducing atmosphere or in vacuums.
This eliminates work hardening effect, reduces the oxide content
and impurity level and alters the apparent density.
High temp. annealing increases the apparent density of powder
and reduces the pressure requirements: whereas,

Mixing or blending
low temp annealing decreases apparent density of powder and
increases the pressure requirements during compaction.
These powder form a spongy mass during annealing and hence it
is pulverized to obtain powder.
Mixing or blending.
In this process ,through mixing of powders of same material or of
different material is done for obtaining the desired properties
during compaction ,sintering and in the final sintered
component.

Mixing or blending
This gives uniform distribution of particles in the compact and
consistent performance of the powder during pressing or
sintering.
For obtaining this at improved levels, small amount of lauryl
alcohol or camphor is usually added to the powder during
mixing.
This also improves bonding of particles which improves green
strength of compacts.
Various types of machines are used for mixing or blending;
however a double cone or y cone mixer is more common.

Some common equipment geometries used for blending powders
(a) Cylindrical, (b) rotating cube, (c) double cone, (d) twin shell
Blending and Mixing

Mixing or blending
Certain material like graphite, Mos2, stearic acid, stearates of Zn
and Li, etc are added to these powders during mixing which
may have one or more of the following functions:
1)It may acts as a lubricant, reducing the friction between the
punch and the die walls.
2)It may easily transform to a gas or vapour which creates
porosity during sintering. This can be used to control porosity
of the component.
3)It may acts as binder , increasing green strength which
facilitates handling of cold compacts.

3)Compacting
Compacting in metal dies is one of the most important methods
for shaping of metal powders.
Powder mix is fed in to the die cavity through a hopper and feed
shoe. And feed shoe is oscillated to assist the powder flow.
The volume of the powder is controlled by adjusting the position
of the bottom punch in the die cavity.
When the die has been evenly filled with powder, these upper
surface is leveled by a sweep of feed shoe and top punch is
pushed in to the die cavity.
The pressure is then applied on any one punch or simultaneously
on both the punches to compact the powder.

Compacting
After maximum compression the upper punch is removed and
the compact is ejected by raising the lower punch, leaving it
free for next similar operation.

Compacting
Most important effect of compacting are as follows
1)It reduces voids between powder particles and increases the
density of compact.
2)It produces adhesion and cold welding of the powders and
gives sufficient green strength.
3)It is plastically deforms the powder and allows recrystallization
during subsequent sintering.

4) sintering
Sintering is carried out to increase strength and hardness of a
green compact and consists of heating the compact to some
temperature under controlled conditions with or without
pressure for a definite time.
Sintering process is concerned with:
A) Diffusion: this takes place especially on the surface of the
particles as the temperature rises.
B) Densification: this decreases porosity present in the green
compact and increases the particle contact area. Due to this,
the compact size decreases. This decrease may not occur

The possible diffusion mechanisms are
Surface diffusion
Volume diffusion
Grain boundary diffusion
Evaporation and condensation
Sintering

4) sintering
uniformly because of variation in the density of compact and
hence this leads to the distortion of component.
c) Recrystallization and grain growth: This occurs between the
particle at the contact area, leading to a structure similar to
original one.

4) Sintering
• Parts are heated to ~80% of melting
temperature
• Transforms compacted mechanical bonds to
much stronger metal bonds
• Many parts are done at this stage. Some will
require additional processing

4) sintering
Depending upon temperature of sintering, sintering process is
classified as solid phase sintering or liquid phase sintering.
The most common method is solid phase sintering in which the
green compacts are heated usually above the recrystallization
temperature of low melting metal.
The liquid phase sintering is carried out above the melting point
of one of the alloy constituents or above the melting point of
an alloy formed during sintering.

5)sizing(coining) or impregnation:
The sintered compact may have slightly different size from the
desired one due to distortion occurring during the sintering
process.
The size restriction is done by placing the component in a master
die and applying pressure. This is called sizing

sizing(coining) or impregnation:
Due to this the interconnected porosity is likely to closed and
fillings of these pores with oil or some other metal (i.e.
impregnation)will not possible.
Therefore, if the component is to be impregnated, sizing should
be avoided.

Testing and inspection
The component should be tested for various properties before it
is put to the service.
The various test which are conducted are compressive strength,
tensile strength, porosity, density, hardness, composition,
microstructure, etc.
It is also inspected for size, shape and amount of defects. once
component satisfies the properties, it is ready for use.
Final properties of a sintered component depend upon:
1) Size , shape, distribution, porosity, density, chemical
composition, surface characteristics, etc of particles.
2) Compacting pressure, type and amount of lubricant used,

6)Testing and inspection
etc.
3) Sintering temp.and time, type of sintering etc.
4) Type of atmosphere.

Advantage of powder metallurgy
1)Metal plus metal components can be manufactured by P/M.
2)Metal plus non metal component can be manufactured by
P/M.
3)Controlled porosity can be obtained bin the component.
4)It is possible to produce components with properties similar to
the parent metals.
W or Mo (high hardness) + Cu or Ag (good electrical
conductivity) product(high hardness, good electrical
conductivity)
5)Manufacture of cemented carbide cutting tools is only possible
by P/M.

Advantage of powder metallurgy
6)P/M parts may be welded, brazed, machined, heat treated,
plated or impregnated with lubricants or other materials.
7)Some of the metal powders find application in other field such
as painting, welding, explosives, plastics and R.c.c.
8)Close control over the dimension of the finished part can be
easily obtained.
9)No machining or minimum machining is required and hence
the scrap is minimum.
10)Fast production of simple shaped component is possible due
to lesser number of steps involved.
11)Highly skilled or qualified personnel is not required for plant
operation and maintainace.

limitation of powder metallurgy
1)Most of the powder used in P/M are fine and fine powders of
some of the metals like Mg,Al,Zr,Ti etc. are likely to explode
and cause fire hazards when they come in contact with air
and hence, they should be preserved carefully.
2)It is not suitable to manufacture small number of component
because of high initial investment on tooling and equipment.
3)Large sized component can not be manufacture because of the
limited capacity of presses available for compaction.
4)Complex shaped part can not be manufactured with ease by
P/M.
5)P/M part have poor corrosion resistance because they are
porous.

limitation of powder metallurgy
6)Components with theoretical density can not be
manufactured.
7)Due to the presence of porosity, mechanical properties such as
ductility,u.t.s. and toughness are poor as compared to
components manufactured by conventional methods. The
surface finish is also poor.

PROPERTIES OF POWDER PARTICLES
1)Specific surface:
It is defined as the total surface area of a powder per unit
weight(cm2/gm).
It depends on size, shape, density, and surface conditions of the
particles.
2)Density:
a) Apparent density:
Apparent density of a powder is defined as the mass per unit
volume of loose or unpacked powder.
The lower apparent density of the powder, the longer will be
compression stroke and deeper dies will be required to
produce a compact of given thickness and density.

PROPERTIES OF POWDER PARTICLES
b) Tap density:
The tap density is the apparent density of the powder after it
has been mechanically shaked or tapped until the level of
powder remains constant.
This has same effect as apparent density on pressing
characteristics.
3)Flow rate:
It is defined as the rate at which a metal powder will flow under
gravity from container through orifice having specific shape
and size.
Flow rate depends on particle size, shape, distribution , amount
of absorbed gases, amount of moisture and coeff. Of friction.

properties of powder particles
5)compressibility:
It is defined as the powder ability to under go deformation under
the applied pressure.
6) compactibility:
It is defined as the minimum pressure required to produce a
compact of given green strength.
7) Green density:
It is density of a cold compact.
Weight of the compact/ volume of compact.
Green density increases with increase
a)Compaction pressure b) particle size c)apparent density

properties of powder particles
d)Decrease of particle irregularity e)decrease of particle
hardness f) decrease of compacting speed.
8)Green strength:
It is mechanical strength of green compact of green compact
The strength of green compact is depend upon the shape ,size,
distribution, surface condition, hardness, yield strength, etc.
9)Mechanical properties:
Compressive strength, hardness.
10)Microstructure

Oil impregnated porous bearing(self
lubricating bearing)
Bronze bearings are widely used and made up of cu and Sn
(90:10) with addition of graphite.
Graphite acts as solid lubricant.
Processes:
1)Mixing
2)Cold compaction
3)Sintering
4)Repressing or sizing
5)impregnation

The working of the bearing
Oil Impregnated Porous Bearings
(Self Lubricating Bearings)

Metal powder of cu and Sn with small amount of fine natural
graphite are blended or mixed to obtain the desired alloy
composition(90 cu: 10 sn)
This powder is cold compacted at pressures between 20 to 50
kg/mm2 to form green compact of desired shape and size.
These compacts are sintered in a reducing atmosphere at a
temp. of about 800c.
A typical sintering consists of holding compact at 400-450c for
removal of part of graphite and diffusion of molten Sn in to
the copper, followed by further heating to 800c for 5
minutes.

At this temp. a tin rich liquid phase is formed which is absorbed
by copper.
Distortion occurring during sintering can be eliminated by
repressing(i.e. repressing) or machining.
The repressed or machined components are impregnated with
cold or hot oil using pressure, vaccum or a combination of
these.
Such a oil impregnated bearing is called self lubricating bearing.

Application of P/M
1) Automotive application
In motor car industry, porous bearings are used for starters, wipers,
sliding doors, dynamos, clutches and brakes of cars, buses, trucks
and tractors.
Electrical contacts, crank shaft drive, piston rings, connecting rod and
brake linings are other powder metallurgy parts.
Sintered friction materials are used for brakes in cars, trucks, aircraft
and similar application.
2) Defence application
Metal powder plays an important role in military and national defense
systems. These poedr find use in rockets, missiles, cartridge cases,

Application of P/M
Bullets and military pyrotechnics such as tracers etc.
3)High temp. application:
Components made of w,Mo, and Ta by P/M are widely
used in the electric light bulbs, fluorescent tubes,
radio valves , mercury arc rectifiers and x-ray tubes
in the form of filament, cathode, anode, screen and
control grids.
Refractory metal carbides are used for dies, rolls,
cutting tools, etc. at high temperature.

Application of P/M
4) Aerospace application:
Metal powder play an important role in rockets, missile,
satellites and space vehicles.
Metal powder of Be, Al, Mg and Zr are used as solid fuels in
rockets and missiles.
Tungsten parts with uniform distribution of porosity are
used in plasma jet engine and ion engine which are
operated at about 1800c
Bronze bearing, filters, ferrite cores for transformers and
inductor coils and alnico magnetic materials in
communication systems are used in various space
satellites and vehicles.

ELECTROPLATING PROCESS Introduction.pptx

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