Dheerendra Kumar Dwivedi Surface Engineering Enhancing Life of Tribological Components Surface Engineering Dheerendra Kumar Dwivedi Surface Engineering Enhancing Life of Tribological Components 123 DheerendraKumar Dwivedi Department ofMechanical andIndustrial Engineering Indian Institute of Technology Roorkee Roorkee,Uttarakhand India ISBN978-81-322-3777-8 ISBN978-81-322-3779-2 (eBook) https://doi.org/10.1007/978-81-322-3779-2 LibraryofCongressControlNumber:2017960917 ©Springer(India)Pvt.Ltd.,partofSpringerNature2018 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. 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Theregisteredcompanyaddressis:7thFloor,VijayaBuilding,17BarakhambaRoad,NewDelhi110001,India Preface The wear and corrosion predominantly cause premature failure and reduce the performance of engineering components during service. A new field “surface engineering” is being developed through extensive research across the globe to tackle the wear and corrosion problems. This book provides engineers with enhanced capability to analyze service condition and potential mechanisms of surface degradation so as to select the suitable material for longer service life and improved performance of component and modify surfaces using an appropriate methodofsurfaceengineering.Thetextbookprovidesmatterinlucidandstructured manner in seven chapters. This book is well illustrated with schematics, pho- tographs,microstructure,XRDpatterns,EDAXmapping,andtechnicaldatatables. Thisbookfocusesontheinfluenceofmaterialsandmethodsofsurfaceengineering onstructure,properties,andwearperformanceduringtheservice.Thisbookbegins with the need to study the subject of surface engineering, scope of surface engi- neering, classification of techniques of surface engineering of commercial and academic importance. This book includes conventional material system (steel, cast iron, stellite, WC–Co, PCDs, etc.) and newer materials like multilayer structures, functionally gradient materials (FGMs), intermetallic barrier coatings, and thermal barrier coating. Most ofthe conventional as well asadvancedsurface modification techniques such as burnishing, shot peening, flame and induction hardening, laser and electron beam hardening, plasma and TIG melting, carburizing, nitriding, cyaniding, boronizing, ion implantation, laser alloying, chemical vapor deposition, PE chemical vapor deposition, physical vapor deposition, weld overlays, laser cladding, electroplating, electroless plating are included. This book also includes introduction of friction stir processing of aluminum alloys. Further, finding of studiesonstructure,mechanicalandwearpropertiesofweldsurfacing,flamespray coating, HVOF-spray coating, laser cladding offerrous metals, nickel- and cobalt base alloys and their composites in as-spray conditions is included. This book providesanoverviewofvariousdestructiveandnondestructivetechniquesusedfor v vi Preface (thickness, soundness, and chemical composition; metallurgical, mechanical, and tribological properties) the characterization of engineered surfaces. This book is expected to be a useful text matter for undergraduate and postgraduate students besidespracticingengineeringandthoseinterestedtopursuetheresearchinthearea of surface engineering. Roorkee, India Dheerendra Kumar Dwivedi Contents 1 Surface Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Purpose and Need of Surface Engineering in Industries . . . . . . . 1 1.3 Surface and Subsurface Regions . . . . . . . . . . . . . . . . . . . . . . . . 2 1.4 Properties for the Enhanced Life and Performance of Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.5 Classification of Surface Modification Techniques . . . . . . . . . . . 4 1.5.1 Changing the Structure of Surface and Near-Surface Layers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.5.2 Changing the Chemical Composition of Surface and Near-Surface Layers. . . . . . . . . . . . . . . . . . . . . . . . 5 1.5.3 Developing a Surface Layer or Overlays . . . . . . . . . . . . 5 1.6 Scope of Surface Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.6.1 Designing Surface Modification . . . . . . . . . . . . . . . . . . 7 1.6.2 Developing the Modified Surface . . . . . . . . . . . . . . . . . 7 1.6.3 Investigating and Characterizing the Modified Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.6.4 Application of Modified Surfaces . . . . . . . . . . . . . . . . . 9 1.7 Role of Surface Properties Affecting Wear and Friction Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.7.1 Surface Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.7.2 Surface Composition . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.7.3 Surface Microstructure . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.7.4 Surface Roughness. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.8 Advantages, Limitations, and Applications. . . . . . . . . . . . . . . . . 15 2 Surface Damage: Causes and Mechanisms . . . . . . . . . . . . . . . . . . . . 17 2.1 Material Properties and Its Effect on Performance of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.2 Common Factors Leading to the Deterioration of Surfaces . . . . . 17 vii viii Contents 2.3 Types of Wear and Mechanisms and Classical Governing Laws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.3.1 Adhesive Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.3.2 Abrasive Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.3.3 Erosive Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2.3.4 Corrosion Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 2.3.5 Diffusive Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2.4 Techniques to Evaluate Damage of Wear Surfaces . . . . . . . . . . . 39 2.4.1 Material Loss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.4.2 Weighing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2.4.3 Dimensional Measurement . . . . . . . . . . . . . . . . . . . . . . 40 2.4.4 Optical Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2.4.5 Hardness of Surface and Subsurface Layers. . . . . . . . . . 40 2.4.6 Chemical Composition and Phase Analysis . . . . . . . . . . 40 2.4.7 Surface Roughness. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 3 Materials for Controlling the Wear . . . . . . . . . . . . . . . . . . . . . . . . . 45 3.1 Materials Properties and Wear. . . . . . . . . . . . . . . . . . . . . . . . . . 45 3.1.1 Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 3.1.2 Ductility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 3.1.3 Toughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 3.1.4 Stacking Fault Energy . . . . . . . . . . . . . . . . . . . . . . . . . 46 3.1.5 Fatigue Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3.1.6 Fracture Toughness . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3.1.7 Affinity to Atmospheric Gases . . . . . . . . . . . . . . . . . . . 47 3.1.8 Thermal Stability of Surface Layers . . . . . . . . . . . . . . . 47 3.2 Materials Properties Required for Better Wear Resistance . . . . . . 48 3.2.1 Adhesive Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.2.2 Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 3.2.3 Erosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 3.2.4 Surface Fatigue Wear. . . . . . . . . . . . . . . . . . . . . . . . . . 50 3.2.5 Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 3.2.6 Fretting Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3.3 Selection of Materials for Surface Engineering. . . . . . . . . . . . . . 51 3.3.1 Iron Base Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3.3.2 Cobalt Base Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3.3.3 Nickel Base Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 3.3.4 Copper Base Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 3.4 Structure and Wear of Material . . . . . . . . . . . . . . . . . . . . . . . . . 52 3.4.1 Ferrous Metals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 3.4.2 Carbon Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 3.4.3 Alloy Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 3.4.4 Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 3.4.5 Hadfield Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Contents ix 3.4.6 Gray Cast Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3.4.7 White Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3.4.8 Chromium Irons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3.4.9 Non-ferrous Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3.4.10 Cobalt Base Alloys and Composites . . . . . . . . . . . . . . . 64 3.4.11 Nickel Base Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 3.4.12 Thermal Barrier Coating. . . . . . . . . . . . . . . . . . . . . . . . 67 3.4.13 Functionally Graded Materials (FGM). . . . . . . . . . . . . . 69 3.5 Common Materials for Surface Modifications for Specific Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 3.6 Common Materials and Their Typical Applications . . . . . . . . . . 71 4 Surface Engineering by Changing the Surface Metallurgy . . . . . . . . 73 4.1 Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4.2 Transformation Hardening Methods. . . . . . . . . . . . . . . . . . . . . . 74 4.2.1 Flame Hardening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 4.2.2 Induction Hardening. . . . . . . . . . . . . . . . . . . . . . . . . . . 75 4.2.3 Laser Beam Hardening. . . . . . . . . . . . . . . . . . . . . . . . . 78 4.3 Re-meltingofBaseMetalorModifiedSurfacesUsingLaserand TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 4.4 Plastic Deformation-Based Approaches . . . . . . . . . . . . . . . . . . . 82 4.4.1 Shot Peening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 4.4.2 Burnishing and Contour Rolling . . . . . . . . . . . . . . . . . . 85 4.4.3 Friction Stir Processing. . . . . . . . . . . . . . . . . . . . . . . . . 86 5 Surface Engineering by Changing the Composition . . . . . . . . . . . . . 91 5.1 Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 5.2 Carburizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 5.2.1 Solid Carburizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 5.2.2 Liquid Carburizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 5.2.3 Gas Carburizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.2.4 Cyaniding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.3 Nitriding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 5.4 Plasma Carburizing and Plasma Nitriding. . . . . . . . . . . . . . . . . . 100 5.5 Surface Modification by Changing Chemical Composition . . . . . 101 5.5.1 Laser Alloying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 5.6 Surface Modification Using Diffusion-Based Processes (PVD, CVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 5.6.1 Vacuum Deposition . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 5.6.2 Ion Implantation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 5.6.3 Sputtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 5.6.4 Ion Plating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109