1. Surface Treatment for Automotive
Components
Materials and Manufacturing Processes for Automobiles (AME 2513)
Module Leader Dr. Srikari S
Department Dept. of AAE
Santosh S BBB0912001
Pruthvi VJ BBB0912004
Bharath IG BBB0912005
Raj Bharath M BYB0912007
Submitted by : Rajbharath.M(BYB0912007)
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2. Introduction
Manufacturing
Surface
Treatment
Finished
Product
Figure 1: Different stages of product development [Author]
Need for surface treatment
Benefits of surface treatment
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3. Types of Surface Treatment
Surface
Treatment
Surface Surface Surface hardening - Top surface layer
Hardening Coating infused with dopants.
Surface coating - New layer is coated
Case hardening, Chemical vapour on the surface.
Mechanical deposition,
surface treatment. Plating.
Figure 2: Types of Surface Treatment [Author]
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4. Case Hardening
Chemical structure manipulation by diffusing the atoms of
alternate elements.
Different types includes:
Figure 3: Different case hardening techniques [1]
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5. Nitriding
Nitrogen is diffused into the surface of the component being treated.
Nitriding Temperature: 500-600°C [2]
2NH3 ▲ 2N + 3H2 [2]
Figure 4: Schematic diagram of nitriding apparatus [2] Figure 5: Microstructure of nitrided component [3]
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6. Figure 6: Effect of case depth on hardness [4] Figure 7: Effect of nitriding time on case depth [2]
Process Capabilities [5]
Nitriding was adopted to increase the
strength of the crank shaft.
Figure 8: Nitrided crank shaft [5]
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8. Carburization produces a hard, wear resistant layer on the surface.
Typically, case hardens low carbon steel.
Figure 9: Carburizing process [6]
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9. Quenched microstructure [6]
Carbon Ferrite
Etching: Carburized gear
Figure 10: carbon diffusion [6]
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10. Applications
Fig 11: Carburized Steering Pinion [7] Hydraulic power steering
Fig 12: Carburized spur gear [13]
Transmission
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11. Induction hardening
Fig 14: Process overview [8]
Eddy current Fig 15: Quenching[12]
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12. Applications
Fig16:Simultaneous dual frequency
Fig 17: Sprocket – under induction hardening [10]
(SDF) – Green Hardening (for
gears). [9]
Induction hardening is characterized by precise energy metering.
Ultra low power consumption.
Short process times.
Targets surface layer alone.
Save energy and reduce rework effort. SDF
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14. Shot Peening
Overlapping indentations are produced on the surface.
The surface of the component is plastically deformed, which induces
the compressive stress on the surface.
Fatigue strength increases by 25% - 50%.
Figure 18 Shot peening Process [14]
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15. Case Study
Gear tooth Bending fatigue on a AXOD of Ford Taurus (1981)
Figure 19 Weibull analysis of Life v/s Failure [15]
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16. Laser Peening
The surface of the work piece is subjected to laser shocks.
As a result of which compressive stress is induced in the component,
thus improving the fatigue life.
Specifications: Laser intensity - 100-300 J/cm2
Pulse duration - 30 seconds
Figure 20 Laser Peening Working [16]
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17. Case Study
Laser Peening emerging applications for Engine Components
Reduce material cross-section and improve fuel efficiency.
Retard erosion inside fuel injector tip and reduce emissions.
Fuel injector tip Figure 21 Comparison of Laser peening [17]
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19. Electroplating
Electroplating is carried out to impart properties such as wear
resistance, corrosion resistance and other similar properties.
Chromium, nickel, cadmium, copper, zinc and tin are commonly
plated materials.
Anodizing, galvanizing, chrome plating.
Figure 22 : Chrome plating [18]
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20. Galvanization process
Figure 23: Galvanization process [19]
Cathodic protection
Figure 24: Cathodic protection [20]
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21. Figure 25: Anti-corrosion treatment for BIW [21]
Anti-corrosion treatment for BIW
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22. Benefits / Enhancement
Possible enhancements in the components manufactured:
Improved fatigue endurance limit.
Better wear resistance.
Higher strength.
Ability to withstand bending loads for a longer time.
Better corrosion resistance.
Better surface finish delays crack propagation.
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24. References
[1] Anon., Surface Treatment, Coating and Cleaning,
http://www.ielm.ust.hk/dfaculty/ajay/courses/ieem215/lecs/9_surfacetreatment.pdf,
retrieved on 29.12.2012.
[2] Kenneth G. Budinski and Michael K. Budinski., (2009) Engineering Materials: Properties
and Selection, 9th edition, Prentice Hall Publishers.
[3] Mumin Sahin, Ceyhun Sevil., (2011) "Investigation of properties of ion-nitrided AISI 304
austenitic-stainless steel", Industrial Lubrication and Tribology, Vol. 63 Iss: 5, pp.359 – 366.
[4] Anon., Heat Treatment Properties, http://www.tohokusteel.com/en/pages/kirin1.htm,
retrieved on 29.12.2012.
[5] Anon., Double the Strength, http://www.nitriding.co.uk/double-strength-please!,
retrieved on 29.12.2012.
[6] Hiroshi Yamagatta – “Science and technology of materials” [pg 180 onwards].
[7] “Hardness and case depth analysis through optimization techniques”
http://shodhganga.inflibnet.ac.in/bitstream/10603/1259/12/12_chapter%203.pdf
[8] Induction hardening - http://www.ustudy.in/node/4157
[9] Mark davis – “Gear hardening goes green”
http://www.eldec.de/fileadmin/00_Dateien/PDF/Veroeffentlichungen/0909_GearSolutions.p
df
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25. [10] Daewei hating machine co., ltd - http://www.dw-inductionheating.com/hardening-
induction-heating-applications.html/hardening-induction-heating, retrieved on
29.12.2012
[12] Industrial heating -
http://directories.industrialheating.com/Articles/Cover_Story/d08079c356cb7010Vgn
VCM100000f932a8c0, retrieved on 29.12.2012
[13] Thermex metal treating ltd - http://www.thermexmetal.com/carburizing-
carbonitriding, retrieved on 29.12.2012
[14] Mordern Mechanical Surface treatment.,(2006) Volker Schulze, Wiley-VCH
[15] Adam J. Vahratian, Robert P. Garibay., Application of Statistically capable Shot
Peening Automotive Components Design,
http://www.shotpeener.com/library/pdf/1993146.pdf, retrieved on 29.12.2012.
[16] Laser-assisted materials processing lab
https://engineering.purdue.edu/LAMPL/research_peening.html, retrived on
29.12.2012
[17] H.L.Chen, Lawrence Livermore National Laboratory , “Laser Peening - A Means
to Strengthen Metals”
[18] Anon., Chrome plating alternatives, http://www.rowantechnology.com/Tech-
Info.htm, retrieved on 30.12.2012
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26. [19] Anon., Zinc coatings and thin organic coatings, Coating process,
http://www.arcelormittal.com/automotive/saturnus/sheets/catalogue.pl?id_
sheet=N&language=EN, retrieved on 30.12.2012
[20] Anon., Zinc coatings protecting steels, Cathodic protection [pg. 7],
http://www.galvanizingasia.com/pdfs/ZincCoatingProtectingSteel.pdf,
retrieved on 30.12.2012
[21] Anon., “The inside story of how BMW's are made...” ,
http://www.usautoparts.net/bmw/bmw/assembly/painting.htm,
retrieved on 30.12.2012
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