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Surface Treatments & Engineering Metrology & Instrumentation Group 8 ME 260 Fall 2005 11/30/05

Surface Treatments & Engineering Metrology & Instrumentation Group 8 ME 260 Fall 2005 11/30/05. Kurt Sorenson Derek Benavidez Colin Evans Steven Best. Introduction. Surface Treatments Why? Types Cleaning Mechanical Measurements Standards Types Dimensioning.

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Surface Treatments & Engineering Metrology & Instrumentation Group 8 ME 260 Fall 2005 11/30/05

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  1. Surface Treatments & Engineering Metrology & InstrumentationGroup 8ME 260Fall 200511/30/05 Kurt Sorenson Derek Benavidez Colin Evans Steven Best

  2. Introduction • Surface Treatments • Why? • Types • Cleaning • Mechanical Measurements • Standards • Types • Dimensioning

  3. Why use a surface treatment? • Improves durability • Controls Friction • Reduces Adhesion

  4. Why use surface treatment? (cont) • Improves Lubrication • Rebuild Surfaces • Aesthetics

  5. Types of Treatments • Mechanical Surface Treatments • Mechanical Plating & Cladding • Case Hardening • Thermal Spraying • Vapor Deposition • Laser Treatments

  6. Mechanical Surface Treatments • Peening • Shot Peening • Laser Shot Peening • Water-jet Peening • Ultrasonic Peening • Roller Burnishing • Explosive Hardening

  7. Mechanical Plating & Cladding • Mechanical Plating • Cladding • Laser Cladding

  8. Case Hardening and Hard Facing • Case Hardening • Hard Facing • Spark Hardening

  9. Thermal Spraying • Combustion Spraying • Thermal Wire Spray • Thermal Metal-Powder Spray • Plasma Spray

  10. Vapor Deposition • Physical Vapor Deposition • Vacuum Deposition • Sputtering • Chemical Deposition • Ion Platting

  11. Physical Vapor Deposition

  12. Sputtering

  13. Chemical Vapor Deposition • Thermochemical Process • Cutting Tools • Thicker • Tedious

  14. Ion Implantation & Diffusion Coating • Particulates penetrate substrate • Modifies surface properties • Increases hardness • Improves durability • Masking capability

  15. Laser Treatments • Heating • Melting • Vaporization • Peening

  16. Electroplating, Electroless Plating,and Electroforming • Electroplating • Workpiece (cathode) is plated with other metal (anode) through a water-based electrolytic solution • A SLOW Process!!! • 75 micrometers/hour • Solution must be replenished • Sacrificial anode • Additional salts of metal

  17. Electroplating, Electroless Plating,and Electroforming • Operation Sequence • Chemical Cleaning • Acid Bath • Application of a Base Coat (Optional) • Final Electroplating • Rinse Tanks • Common Plating Metals • Nickel • Cadmium, Copper • Tin, Zinc

  18. Electroplating, Electroless Plating,and Electroforming • Electroless Plating • Chemical Reaction • More Expensive $$ • Uniform Thickness • Electroforming • Metal-fabrication • Metal electrodeposited on a mandrel

  19. Conversion Coatings • Anodizing- • The workpiece is the anode in an electrolytic cell • Coloring- • Alters color of metals, alloys, and ceramics • Conversion of surfaces into chemical compounds: oxides, chromates, and phosphates

  20. Hot Dipping • Workpiece is dipped into molten metal • Zinc- galvanized-steel sheet • Tin- food containers • Hot-dipped Galvanizing line

  21. Porcelain Enameling; Ceramic and Organic Coatings • Enamels- fuse a coating material by heating to 425 to 1000. • Ceramic coatings- Intense temp applied • Organic coatings- Wide range of properties: flexability, durability, color, texture…

  22. Diamond Coating and Diamond-Like Carbon • Techniques • Chemical vapor deposition • Plasma-assisted vapor deposition • Ion-beam-enhanced deposition • Diamond Properties • Hardness, wear resistance, thermal conductivity

  23. Surface Texturing & Painting • Texturing Techniques • Etching • Electric Arcs • Lasers • Atomic oxygen • Paint Classification • Enamels • Lacquers • Water-based paints

  24. Cleaning of Surfaces • 3 types • Mechanical Cleaning • Physically disturb contaminants • Electrolytic Cleaning • Abrasive bubbles aid in contaminant removal • Chemical Cleaning • Solution • Saponification • Emulsification • Dispersion • Aggregation

  25. Engineering Metrology and Instrumentation Metrology refers to the measurement of any type of dimensions (length, thickness, diameter, angle, etc.) Focus on Dimensional Tolerance (functionality, interchangeability, cost)

  26. Describing Quality of Instruments • Resolution- the smallest difference in dimensions that an instrument can detect. • Precision- the instruments ability to give repeated measurements (thermal expansion affects precision, standard measuring temperature is 200 C). • Accuracy- The ability of a measurement to match the actual value of the quantity being measured.

  27. Types of Measurement and Instruments Used

  28. Types of Measurement and Instruments Used

  29. Common Analog Instruments A caliper gage with a vernier A vernier

  30. (c) (a) The Micrometer Analog Micrometer Digital Micrometer

  31. Angle-Measuring Instruments Bevel Protractor Vernier for angular measurement

  32. Angle-Measuring Instruments Sine Bar Gage blocks are added until the top surface is parallel to the surface plate. The angle is calculated using trig. relationships.

  33. Comparative Length Measurement Multiple-Dimension Gaging

  34. Electronic Gages Measuring Bore Diameters Vertical Length Mesauring Instrument

  35. Laser Scan Micrometer

  36. Straightness Measurement

  37. Interferometry for Measuring Flatness Optical Flat is a glass disk or fused-quartz disk with parallel flat surfaces. A light beam with one wavelength is aimed at the surface at an angle and splits into two beams. The number of fringes relates the distance between part and flat.

  38. Interferometry for Measuring Shaped or Textured Surfaces Fringe pattern indicating a scratch on the surface. Fringes on a surface with two inclinations, the greater the incline, the closer the fringes. Curved fringe patterns indicate curvatures on the workpiece surface

  39. Measuring Roundness Measuring roundness using V-block and dial indicator

  40. Measuring Roundness Part supported on centers and rotated Circular tracing, with part being rotated on a vertical axis

  41. Measuring Profiles Dial Indicators Radius Gages

  42. Measuring Profiles Gear-Tooth Caliper Gear-Tooth Micrometer

  43. Horizontal-Beam Contour Projector Image is projected on screen at magnification of 100X or higher. Measurements made directly on screen.

  44. Gages Plug gages for holes Ring gages for round rods GO means smaller than desired size and should fit perfectly, if NOT GO gage also fits then tolerance is not met.

  45. Gages Snap Gage with adjustable anvils

  46. Gages Pneumatic Gage

  47. Modern Measuring Instruments and Machines Electronic gauges Laser Micrometers Laser Interferometry Photoelectric digital length measurement Coordinate-measuring machines (CMM)

  48. Electronic Gauges • Determine travel length by changes in electrical resistance, inductance, or capacitance. • A commonly used E-Gauge is the linear-variable differential transformer (LVDT) • Generally use a very accurate specified probe tip.

  49. Laser Micrometers • A laser beam scans a workpiece, generally at a rate of 350 times per second. • Generally capable of resolutionsas high as 0.125 µm (5 µin).

  50. Laser Interferometry • Used primarily to check and calibrate machine tools. • Also are used to compensate for positioning errors in CMM and CNC machines

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