Surface modification by solid state processing

209 Pages·2014·21.39 MB·English

by  Rosa M Miranda

Surface modifi cation by solid state processing
Related titles:
Handbook of friction-vibration interactions
(ISBN 978–0–85709–458–2)
Anti-abrasive nanocoatings: Current and future applications
(ISBN 978–0–85709–211–3)
Defect structure in nanomaterials
(ISBN 978–0–85709–206–9)
Sur face modifi cation
by solid state
processing
E dited by
R osa M iranda
amsterdam (cid:129) boston (cid:129) cambridge (cid:129) heidelberg
london (cid:129) new york (cid:129) oxford (cid:129) paris (cid:129) san diego
san francisco (cid:129) singapore (cid:129) sydney (cid:129) tokyo
Woodhead Publishing is an imprint of Elsevier
Woodhead Publishing is an imprint of Elsevier
80 High Street, Sawston, Cambridge, CB22 3HJ, UK
225 Wyman Street, Waltham, MA 02451, USA
Langford Lane, Kidlington, OX5 1GB, UK
Copyright © 2014 Woodhead Publishing Limited. All rights reserved
No part of this publication may be reproduced, stored in a retrieval system or transmitted
in any form or by any means electronic, mechanical, photocopying, recording or
otherwise without the prior written permission of the publisher.
Permissions may be sought directly from Elsevier’s Science & Technology Rights
Department in Oxford, UK: phone (+44) (0) 1865 843830; fax (+44) (0) 1865 853333;
email: [email protected]. Alternatively, you can submit your request online by
visiting the Elsevier website at http://elsevier.com/locate/permissions, and selecting
Obtaining permission to use Elsevier material.
Notice
No responsibility is assumed by the publisher for any injury and/or damage to persons or
property as a matter of products liability, negligence or otherwise, or from any use or
operation of any methods, products, instructions or ideas contained in the material
herein.
Because of rapid advances in the medical sciences, in particular, independent verifi cation
of diagnoses and drug dosages should be made.
British Library Cataloguing-in-Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Control Number: 2013955438
ISBN 978-0-85709-468-1 (print)
ISBN 978-0-85709-469-8 (online)
For information on all Woodhead Publishing publications
visit our website at http://store.elsevier.com/
Typeset by Refi neCatch Limited, Bungay, Suffolk
Printed and bound in the United Kingdom
Contents
List of fi gures and tables ix
List of abbreviations xviii
About the contributors xx
Introduction xxiii
1 Overview of coating technologies 1
Luisa Quintino, Instituto de Engenharia Mecânica
and Instituto Superior Técnico, Lisbon, Portugal
1.1 Introduction 2
1.2 Surface coating technologies 5
1.3 Chemical and electrodeposition 7
1.4 Vacuum deposition 10
1.5 Arc welding 12
1.6 Thermal spraying 14
1.7 Cladding 16
1.8 Comparison between cladding processes 21
1.9 Conclusion 22
1.10 References 22
2 Friction surfacing 25
Pedro Vilaça, School of Engineering, Aalto University,
Finland
2.1 Introduction 26
2.2 Fundamentals 28
2.3 Main features for visual analysis
characterization 31
v
Surface modifi cation by solid state processing
2.4 Parameters 34
2.5 Metallurgical features of FS involving steels
and aluminium alloy 41
2.6 Mechanical features 47
2.7 Friction surfacing in the scope of surfacing
engineering 51
2.8 Advantages and limitations 54
2.9 Analytical establishment of performance
analysis 55
2.10 Conventional and innovative applications 60
2.11 Challenges in modelling FSW 65
2.12 Conclusions 66
2.13 References 68
3 Friction stir processing 73
João Gandra, Instituto Superior Técnico,
Lisbon, Portugal
3.1 Introduction 74
3.2 Processed zone 75
3.3 Material fl ow 78
3.4 Typical defects in friction stir welding and
processing 80
3.5 Property enhancement 83
3.6 Process parameters 93
3.7 Tool geometry 96
3.8 Multiple-pass friction stir processing 98
3.9 Conclusions 103
3.10 References 104
vi
Contents
4 Surface reinforcements of light alloys 113
Rosa Miranda, Universidade Nova de Lisboa,
Portugal
4.1 Introduction 114
4.2 Basics of the process 117
4.3 Methods of reinforcement 119
4.4 Reinforcement materials 125
4.5 Multiple-pass FSP 134
4.6 Surface hybrid composites 137
4.7 Magnesium alloys 138
4.8 Functionally graded materials 140
4.9 Conclusions 146
4.10 References 146
5 Characterization of FSP by electrical conductivity 153
Telmo G. Santos, Universidade Nova de Lisboa,
Portugal
5.1 Introduction 154
5.2 Fundamentals 157
5.3 Measurement approaches 162
5.4 Performance and applications 167
5.5 Conclusions 173
5.6 References 174
Index 177
vii

List of fi gures and tables
Figures
1.1 C lassifi cation of surface engineering
technologies 4
1.2 E xamples of typical industrial applications of
surface coatings. (a) Buildup of worn industrial
gas turbine compressor blade platform. (b) Profi le
of hardfaced railways. (c) Buttering welds of
materials with poor weldability. (d) Surface
cladding for wear and corrosion resistance 6
1.3 A nodized aluminium 8
1.4 E lectroplated screws 10
1.5 E xample of physical vapour deposition
application 11
1.6 B uildup application via submerged arc
welding (SAW) 13
1.7 E xample of thermal spraying application 15
1.8 L aser cladding process delivering powder
via a coaxial nozzle that surrounds the
laser beam 17
1.9 ( a) Typical cladding arrangement before the
detonation of the explosive. (b) Schematic
drawing of the collision process. (c) Geometry
of the steady-state collision 19
ix
Surface modifi cation by solid state processing
1.10 Typical wavy bond generated by explosion
cladding 20
1.11 Illustration of FS process 20
2.1 F lash formation due to unconstrained ‘third-
body region’ during FS of similar rod and
plate materials. (a) Steel, (b) aluminium alloy,
(c) NiAl–bronze 28
2.2 F undamentals and main nomenclature of the
FS process 29
2.3 T hermo-mechanics of FS. (a) Sectioned
consumable, (b) process parameters, (c) thermo-
mechanical transformations and speed profi le 30
2.4 S chematic representation of true coating area
after mechanical fi nishing and main dimensions
nomenclature 33
2.5 P resentation for visual analysis of FS of
coatings of AISI H13 consumable rod over
substrate AISI 1020 produced under different
FS parameters 33
2.6 E ffect of axial forging force on coating cross
section morphology and joining interface. FS
of AISI 1020 rod deposited over an AISI 1020
plate 35
2.7 E ffect of rotation speed on coating cross section
morphology and joining interface. FS of AISI
1020 rod deposited over an AISI 1020 plate 36
2.8 S ubstrate presenting the thermo-mechanically
affected zone 36
2.9 E ffect of travel speed on coating cross section
morphology and joining interface. FS of AISI
1020 rod deposited over an AISI 1020 plate 37
x