Surface coatings for protection against wear

448 Pages·2006·5.11 MB·English

240 x 159 /Pantone 2935C & 2735C 27.8mm
Wear is a major factor in reducing the safety, reliability and service life of any S
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machine with moving parts. This important book reviews the use of coatings to
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protect machine components against wear. f
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The first group of chapters introduces the subject by looking at mechanisms of
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surface wear, the mechanical testing of coatings and the range of surface coatings o
methods. The bulk of the book reviews the principles, applications, strengths and a
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weaknesses of particular coating techniques. There are chapters on chemical and i
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physical vapour deposition methods, electroless plating, electroplating, thermal g
spraying, welding and laser surface treatments. The book concludes with an s

assessment of future trends. f
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With its distinguished editor and international team of contributors, Surface p
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coatings for protection against wear will be a standard text for materials and o Surface coatings
mechanical engineers with an interest in wear prevention. t
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Dr Brian Mellor works within the Engineering School of the University of i
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Southampton. He is also Technical Manager of the University’s Engineering n
Materials Consultancy Service. a
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Woodhead Publishing and Maney Publishing
on behalf of
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The Institute of Materials, Minerals & Mining
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Woodhead Publishing Ltd CRC Press LLC B. G. Mellor
Abington Hall 6000 Broken Sound Parkway, NW
Abington Suite 300
Cambridge CB1 6AH Boca Raton
England FL 33487
www.woodheadpublishing.com USA
ISBN-13: 978-1-85573-767-9 CRC order number WP2579
ISBN-10: 1-85573-767-1 ISBN-10: 0-8493-2579-X
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The Institute of Materials, Minerals & Mining
Surface coatings for protection against wear
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Surface coatings
for protection
against wear
Edited by
B.G. Mellor
Woodhead Publishing and Maney Publishing
on behalf of
The Institute of Materials, Minerals & Mining
CRC Press
Boca Raton Boston New York Washington, DC
Woodhead publishing limited
Cambridge England
Woodhead Publishing Limited and Maney Publishing Limited on behalf of The
Institute of Materials, Minerals & Mining
Woodhead Publishing Limited, Abington Hall, Abington, Cambridge CB1 6AH,
England www.woodheadpublishing.com
Published in North America by CRC Press LLC, 6000 Broken Sound Parkway,
NW, Suite 300, Boca Raton, FL 33487, USA
First published 2006, Woodhead Publishing Limited and CRC Press LLC
© 2006, Woodhead Publishing Limited, except Chapter 2 which is © Crown
Copyright
The authors have asserted their moral rights.
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Reasonable efforts have been made to publish reliable data and information, but
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British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
Library of Congress Cataloging in Publication Data
A catalog record for this book is available from the Library of Congress.
Woodhead Publishing ISBN-13: 978-1-85573-767-9 (book)
Woodhead Publishing ISBN-10: 1-85573-767-1 (book)
Woodhead Publishing ISBN-13: 978-1-84569-156-1 (e-book)
Woodhead Publishing ISBN-10: 1-84569-156-3 (e-book)
CRC Press ISBN-10: 0-8493-2579-X
CRC Press order number: WP2579
The publishers’ policy is to use permanent paper from mills that operate a
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Printed by TJ International Limited, Padstow, Cornwall, England
Contents
Contributor contact details ix
Preface xi

1 Understanding surface wear in engineering materials 1
R.J.K. Wood, University of Southampton, UK
1.1 Introduction 1
1.2 Role of stress distributions in wear 2
1.3 Wear in tribocontacts 6
1.4 Stress fi elds for coated systems 40
1.5 Conclusions 48
1.6 References 48
1.7 Appendix: Nomenclature 55

2 Mechanical testing of coatings 58
N.M. Jennett and M.G. Gee, National Physical
Laboratory, UK
2.1 Introduction 58
2.2 Thickness 59
2.3 Fracture and adhesion testing 62
2.4 Scratch testing 66
2.5 Instrumented indentation testing 68
2.6 Impact excitation 73
2.7 Surface acoustic wave spectroscopy 73
2.8 Residual stress measurement 76
2.9 Conclusions 77
2.10 References 77

3 The range of surface coating methods 79
P.H. Shipway, University of Nottingham, UK
3.1 Introduction 79
v
vi Contents
3.2 Basic classifi cation of processes employed for coating 80
3.3 Processes: coatings deposited on to the substrate 81
3.4 Processes: coatings formed by reactions involving
the substrate 91
3.5 Comparison of the methods 94
3.6 Future trends 97
3.7 References 98
3.8 Further reading 98

4 Chemical vapour deposition methods for protection
against wear 101
D.W. Wheeler, Atomic Weapons Establishment, UK
4.1 Introduction 101
4.2 The chemical vapour deposition process 102
4.3 Factors affecting the coating characteristics 108
4.4 Advantages and disadvantages of chemical
vapour deposition 110
4.5 Plasma-assisted chemical vapour deposition 111
4.6 Hard coatings produced by chemical vapour deposition 112
4.7 Conclusions 132
4.8 Future trends 135
4.9 Sources of further information 136
4.10 Acknowledgements 137
4.11 References 137

5 Physical vapour deposition methods for protection
against wear 146
S.J. Bull, University of Newcastle, UK
5.1 Introduction 146
5.2 Fundamentals of physical vapour deposition 147
5.3 Commercial physical vapour deposition processes 156
5.4 Coatings for wear resistance 164
5.5 Applications 171
5.6 Future trends 178
5.7 References 179

6 Electroless plating for protection against wear 184
C. Ponce de León, University of Southampton, UK,
C. Kerr, Tin Technology Ltd, UK, and F.C. Walsh,
University of Southampton, UK
6.1 Introduction 184
6.2 Electrolyte composition and operating conditions 192
Contents vii
6.3 Characteristics of electroless deposits 195
6.4 Conclusions 217
6.5 References 219
6.6 Appendix: Professional associations 224

7 Electroplating for protection against wear 226
R.G.A. Wills and F.C. Walsh, University of
Southampton, UK
7.1 Introduction 226
7.2 Electrodeposited metallic coatings 232
7.3 Electrodeposited composite coatings 240
7.4 Anodised coatings on light metals 241
7.5 Conclusions and further reading 241
7.6 References 245
7.7 Appendix: Professional associations 247

8 Thermal spraying methods for protection against
wear 249
J.M. Guilemany and J. Nin, Universitat de Barcelona,
Spain
8.1 Introduction 249
8.2 Thermal spray process fundamentals 256
8.3 Coating structures 266
8.4 Post-spray treatments 272
8.5 Structure–property relationships 272
8.6 Industrial applications 283
8.7 Unsuccessful coatings and applications 288
8.8 Future trends 290
8.9 References 293

9 Welding surface treatment methods for protection
against wear 302
B.G. Mellor, University of Southampton, UK
9.1 Introduction 302
9.2 Welding processes suitable for hardfacing 303
9.3 Nature of the deposit 310
9.4 Hardfacing materials 315
9.5 Hardfacing alloy selection 360
9.6 Hardfacing process selection 361
9.7 Distortion and residual stresses 366
9.8 Successful and unsuccessful applications 369
9.9 Conclusions 370
9.10 References 370
viii Contents
10 Laser surface treatment methods for protection
against wear 377
H.C. Man, Hong Kong Polytechnic University,
Hong Kong, PR China
10.1 Introduction 377
10.2 Operation principles 377
10.3 Lasers for laser surface engineering 380
10.4 Advantages and limitations of laser surface engineering 381
10.5 Applications on ferrous alloys 382
10.6 Applications on aluminium alloys 383
10.7 Applications on titanium alloys 386
10.8 Conclusions 388
10.9 References 390

11 Future trends in surface coatings for protection
against wear 392
A.O. Kunrath, D. Zhong, B. Mishra and
J.J. Moore, Colorado School of Mines, USA
11.1 Introduction 392
11.2 Coating materials 392
11.3 Coating architectures 394
11.4 Smart systems 399
11.5 New processes 401
11.6 Conclusions 408
11.7 References 408
Index 415
Contributor contact details
Chapter 1 NG7 2RD
UK
Professor R.J.K. Wood
School of Engineering Sciences Email: philip.shipway@nottingham.
University of Southampton ac.uk
Highfi eld
Southampton Chapter 4
SO17 1BJ
UK Dr D.W. Wheeler
Atomic Weapons Establishment
Email: [email protected] Aldermaston
Reading
Chapter 2 Berkshire
RG7 4PR
Dr N.M. Jennett and Dr M.G. Gee
UK
National Physical Laboratory
Hampton Road Email: [email protected]
Teddington
Middlesex Chapter 5
TW11 0LW
UK Professor S.J. Bull
Chemical Engineering and
Email: [email protected]
Advanced Materials
Email: [email protected]
University of Newcastle
NE1 7RU
Chapter 3
UK
Professor P.H. Shipway Email: [email protected]
School of Mechanical, Materials
and Manufacturing Engineering
Chapter 6
University of Nottingham
University Park Dr C. Ponce de León and
Nottingham Professor F.C. Walsh
ix