SURFACE ENGINEERING PRACTIC

SURFACE ENGINEERING PRACTIC

Acknowledgements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Foreword .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Introduction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Surface engineering – a conspectus 21
PART 1: ADVANCES IN SURFACE ENGINEERING AND PROCESSING

TECHNOLOGY
Section 1.1 PVD processes
1.1.1 Keynote
Advances in surface processing technology 33
A. Matthews
Dept. of Engineering Design and Manufacture, The University of Hull, UK
1.1.2
Hard coatings on aluminium alloys by PVD . . . . . . . . . . . . . . . . . . . . . . . 45
F. Ashrafizadeh and T. Bell*
Dept. of Materials, Isfahan University of Technology, Iran
*Dept. of Metallurgy and Materials, University of Birmingham, UK
1.1.3
The wear behaviour of CVD- and PVD-coated tools in metal stamping and
plastics injection moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
S.E. Franklin
Philips Plastics and Metalware Factories, Eindhoven, The Netherlands
6 Table of contents
Section 1.2 Ion implantation
1.2.1
The application of ion implantation to problems of corrosion and wear 73
D.C. Ingram
Whickham Ion Beam Systems Ltd, Darlington, UK
1.2.2
Effects of boron ion implantation on mechanical properties of engineering
ceramics and cermets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
M.T. Laugier
Materials Research Centre, NIHE, Limerick, Ireland
1.2.3
The effects of deposition parameters on the microstructures of ion-plated
niobium coatings 89
P.K. Datta, R. HiIl,* K.N. Strafford** and L. Ward
Surface Engineering Research Group, Newcastle Upon Tyne Polytechnic, UK
*Dept. of Physics, Newcastle Upon Tyne Polytechnic, UK
**Gartrell School of Mining, Metallurgy and Applied Geology, South
Australian Institute of Technology
1.2.4
A new pr~cess for boronizing metals 102
D.N. Tsipas and J. Russ*
MIRTEC S.A., Volos, Greece
* Instituto de Ingenieria, Caracas, Venezuela
Section 1.3 Spray coating processes
1.3.1 Keynote
Plasma spray processing – advanced production features and quality
considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
A.R. Nicoll
Plasma-Technik A.G., Wohlen, Switzerland
1.3.2
Effect of discontinuous spray deposition on the wear of VPS alumina
coatings on steel and tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
R. Kingswell, D.T. Gawne* and K.T. Scott
Materials Engineering Centre, Harwell Laboratory, UK
* Dept. of Materials Technology, Brunei, The University of West London, UK
1.3.3
Developments in arc cladding techniques. . . . . . . . . . . . . . . . . . . . . . . . . 151
J .H. Nixon
The Welding Technology Centre, Cranfield Institute of Technology, UK
Table of contents 7
Section 1.4 Laser processing
1.4.1
The influence of convection on the homogeneity of laser applied coatings. . . 159
H.T. Hegge and J.Th.M. de Hosson
Dept. of Applied Physics, University ofGroningen, The Netherlands
1.4.2
A new structure of laser melted Cr12 tool steel
J. Zhu, J. Liu, C. Chou and N. Chen
Tsinghua University, Beijing, China
168
1.4.3
Laser treatment of plasma-sprayed coating 177
Y.M. Zhu, M.W.Xiang, M.C. Liang and L.Z. Ding
Dept. of Mechanical Engineering, Tsinghua University, Beijing, China
1.4.4
Corrosion resistant fused oxide coatings by laser processing 183
S.RJ. Saunders, A.A. Ansari, MJ. Bennett,* A.T. Tuson,*, F. Fellowes**
and W.M.Steen**
Division of Materials Applications, NPL, Teddington, UK
* Materials Development Division, Harwell Laboratory, Didcot, UK
** Dept. of Mechanical Engineering, University of Liverpool, UK
1.4.5
The structure and sliding-contact wear resistance of a laser-hardened
austempered ductile iron .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
G.-X. Lu and H. Zhang
Dept. of Materials Engineering, Jilin Institute of Engineering, Changchun,
China
PART 2: FUNDAMENTAL ASPECTS OF SURFACE COATINGS – SCIENCE
AND TECHNOLOGY
Section 2.1 Ceramic coatings
2.1.1 Keynote
Surfaces in ceramics technology’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
P. Vincenzini
Research Institute for Ceramics Technology, Faenza, Italy
2.1.2
Ti and TiN coatings on 316Lsurgicalsteel. 233
J. Gluszek, J. Jadrkowiak, J. Masalski and W. Popytak
Technical University of Wroc/aw,Poland
2.1.3
Influence of titanium dioxide on the durability of industrial coatings . . . . . . 242
N. Reeves
Tioxide Group pic, Stockton-on-Tees, UK
8 Table of contents
2.1.4
Thermal barrier coatings for aero gas turbines
T.N. Rhys-J ones
Rolls-Royce pic, Filton, UK
258
Section 2.2 Inorganic and conversion coatings
2.2.1 Keynote
Surface coatings for gas turbines
T.N. Rhys-Jones
Rr)lls-Royce pic, Filton, UK
273
_.2.2
On the design of coatings materials to resist high temperature chloridation 282
K.N. Strafford, P.K. Datta* and G. Forster*
Gartrell School of Mining, Metallurgy and Applied Geology, South Australian
Institute of Technology
*Surface Engineering Research Group, Newcastle Upon Tyne Polytechnic, UK
2.2.3
On the creation of a coatings and high temperature corrosion data bank 301
R. Streiff
Universite de Provence, Marseille, France
2.2.4 Keynote
Zinc coatings in surface engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
F.e. Porter
Consultant to Zinc Development Association, London, UK
2.2.5
Reflectivity changes as a means of monitoring the performance of coated
steels at elevated temperatures 315
R.D. Jones and R.W. Richards
Coating Technology Group, University College of Wales, Cardiff. UK
2.2.6
Molybdate-orthophosphoric acid conversion coating solutions for tinplate
surfaces 328
G.D. Wilcox, D.R. Gabe* and M.E. Warwick**
Dept. of Chemistry, Loughborough University of Technology, UK
* Institute of Polymer Technology and Materials Engineering, Loughborough
University of Technology, UK
** International Tin Research Institute, Uxbridge, UK
Section 2.3 Organic coatings
2.3.1 Keynote
Adhesion measurement with organic coatings in the wet state after exposure
to water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
H. Hemmelrath, E. Fischer* and W. Funke
Forschungsinstitut fiir Pigmente and Lacke, Stuttgart, FRG
* Institut fiir Technische Chemie, FRG
Table of contents 9
2.3.2 Keynote
Weathering of coatings – fonuulation and evaluation 349
S.P. Pappas
Polymers and Coatings Dept., North Dakota State University, Fargo, USA
2.3.3
Recent developments in accelerated weathering of coatings using plasma
erosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
N.A.R. Falla
Paint Research Association, Teddington, UK
2.3.4
The characterization of polymer/metal interfacial layers 366
A.N. MacInnes, J .E. Castle and J.F. Watts
Dept. of Materials Science and Engineering, University of Su”ey, UK
2.3.5
Some electrically conducting organic coatings and their applications 377
P. Kathirgamanathan, D. Shah, A.S. Bhuiyan,* R. Hill* and R.W. Miles*
Cookson Central Research, Perivale, UK
* Dept. of Physics, Newcastle Upon Tyne Polytechnic, UK
2.3.6
Thin films of CdTe produced using the coevaporation of CdTe with Te . . . . . 387
R.W. Miles, T. Owens, S. Arshed and R. Hill
Dept. of Physics, Newcastle Upon Tyne Polytechnic, UK
PART 3: ENGINEERING APPLICATIONS OF COATINGS
Section 3.1 Overview
3.1.1 Keynote
Applications and perfonuance of coatings: some perspectives and
prospects 397
K.N. Strafford, P.K. Datta* and J.S. Gray*
Gartrell School of Mining, Metallurgy and Applied Geology, South Australian
Institute of Technology
*Surface Engineering Research Group, Newcastle Upon Tyne Polytechnic, UK
Section 3.2 The inhibition of high temperature corrosion
3.2.1
Study of the effect of nitride coatings on the corrosion resistance of some
conventional stainless steel and NiCrMo-type alloys. . . . . . . . . . . . . . . . . . 423
W.Y. Chan and I.c. Elliott
Inco Alloys Ltd, Hereford, UK
10 Table of contents
3.2.2
Composition optimization of coatings materials to inhibit breakaway corrosion
in complex gas atmospheres at elevated temperatures 439
K.N. Strafford, P.K. Datta*, A.R. Cooper* and G. Forster*
Gartrell School of Mining, Metallurgy and Applied Geology, South Australian
Institute of Technology
*Surface Engineering Research Group, Newcastle Upon Tyne Polytechnic, UK
3.2.3
The resistance of aluminized iron-nickel-chromium-base alloys to gaseous
environments of high sulphur and low oxygen potentials at high temperature. .. 454
F.H. Stott, S.W.Green and F. Starr*
Corrosion and Protection Centre, UMIST, UK
* British Gas Corporation, London Research Station, UK
3.2.4
Environmental embrittlement of superalloys during coating processes. . . . . . 466
S. Osgerby and B.F. Dyson
Division of Materials Applications, NPL, Teddington, UK
3.2.5
The oxidation of a case borided 9CrlMo steel in high temperature steam 475
P. Rowley and l.A. Little
Dept. of Materials Science and Metallurgy, University of Cambridge, UK
3.2.6
Observations on the use of the spark discharge melting process to improve
the high temperature oxidation resistance of a 3Cr 8WO.5Vtool steel 488
Q.F. Peng
Dept. of Metallurgy and Materials, University of Birmingham, UK
3.2.7
The problems of internal oxidation and its elimination in gaseous
carbonitriding 492
W. Biao, Z. Zhang* and X. Yuan*
Dept. of Metallurgy and Materials, University of Birmingham, UK
* Yunnan Engineering Institute, China
Section 3.3 Corrosion performance
3.3.1
Effect of alloying elements on the anodic polarization behaViour of zinc in
NaCI solutions containing NO;, CrO~- and HPO~- ions .. . . . . . . . . . . . . . 499
M.S. Abdel-Aal, Z.A. Abdul-Aziz and M.S. Hassan
Chemistry Dept., Assiut University, Egypt
Table of contents 11
3.3.2
The passivation of forging brass in an acidic solution based on Cr+6
compounds and selective dissolution of H’ phase. . . . . . . . . . . . . . . . . . . . 512
E. Zacny
University of Mining and Metallurgy, Institute of Foundry Engineering,
Cracow, Poland
3.3.3
Passivation and corrosion behaviour of some electrodeposited tin-cobalt
alloycoatings.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
A. Reed and K.N. Strafford*
Harvey Plating Ltd, Darlington, UK
*Gartrell School of Mining, Metallurgy and Applied Geology, South
Australian Institute of Technology
3.3 .4
Comparative corrosion resistance of galvanized and galvannealed steel 543
M.T. Akerdida and S.B. Lyon
Corrosion and Protection Centre, UMIST, UK
3.3 .5
Fretting corrosion behaviour of Galfan (Zn-5% AI) coated steel wire in
synthetic seawater 553
S. Price and D.E. Taylor
Dept. of Physical Sciences, Sunderland Polytechnic, UK
3.3.6
Development of aluminium-alloy coatings for the protection of steel
P.L. Lane and C.J.E. Smith
Materials and Structures Dept., Royal Aerospace Establishment,
Farnborough, UK
566
3.3.7
Effect of nitriding conditions on corrosion resistance of Cr17Ni2 steel in
sulphate and chloride solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
J. Mankowski, E. Rolinski* and J. Flis
Institute of Physical Chemistry, Polish Academy of Sciences, Warsaw,Poland
* Institute of Materials Science and Engineering, WarsawTechnical
University, Poland
3.3.8
Electrochemical behaviour of TiN and TiC CVD coatings on steels. . . . . . . . 587
A. Rota, B. Elsener and H. Bohni
Institute for Materials Chemistry and Corrosion, Swiss Federal Institute of
Technology, Zurich, Switzerland
12 Table of contents
3.3.9
Propertiesof chromiumcoatingsplated from flowingsulphate’- potassium
silicon fluoride electr?lyte with the addition of Na2Mo04 610
B. Szczygiel, I. Drela and J. Kubicki
Institute of Inorganic Technology and Mineral Fertilizers, Technical University
of Wroclaw,Poland
Section 3.4 Wear and mechanical behaviour
3.4.1
A sustained deposition process for nickel-chromium and nickel-chromiumiron
coatings for corrosion and wear resistance. . . . . . . . . . . . . . . . . . . . . 619
C.U. Chisholm, M. El-Sharif and A. Watson*
School of Engineering, Glasgow College, UK
* Dept. of Chemistry, Paisley College of Teclmology, UK
3.4.2
Improving wear resistance by spark discharge cladding . . . . . . . . . . . . . . . . 634
Q.F. Peng, Q. Ao and Q.X. Ao
Wolfson Institute for Surface Engineering, University of Birmingham, UK
3.4.3
Corrosion and mechanical properties of electroless nickel-high boron
coatings 642
P.K. Datta, K.N. Strafford* and S. Allaway**
Surface Engineering Research Group, Newcastle Upon Tyne Polytechnic, UK
*GartrellSchool of Mining, Metallurgy and Applied Geology, South Australian
Institute of Technology
**Ever Ready, Tanfield Lea, Co. Durham, UK
3.4.4
Stress corrosion, fretting and fatigue control by surface pre-stressing
P. O’Hara
Metal Improvement Co., Newbury, UK
663
3.4.5
Hard chromium plating to improve the cavitation erosion and abrasion
resistance of stainless steels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676
W. Biao, B. Wu and T. Bell
Dept. of Metallurgy and Materials, University of Birmingham, UK
3.4.6
Antifriction self-lubricating coatings on the base of fIXedmetals complexes 686
I.E. Uflyand, l.V. Kokoreva, A.S. Kuzharov* and V.N. Sheinker
State PedagogicalInstitute, Rostov-on-Don, USSR
* Institute of Agricultural Engineering Industry, Rostov-on-Don, USSR