INDUSTRIAL PROCESSES II INDEN 3313

1. INDUSTRIAL PROCESSES IIINDEN 3313 Lecture 4 – Completion of Finishing; Treatments, Coatings, and Cleaning Industrial Processes II

2. OVERVIEW • Return of Homework • Questions to Start/Errata • Finishing • Process Descriptions • Parameters/Impact on Surface Finish • Treatments • Coatings • Cleaning Industrial Processes II

3. QUESTIONSTO START ?? Errata -- Industrial Processes II

4. HONING • Illustration Groover Figure 26.19, p 675 Industrial Processes II

5. HONING • Comparison to Grinding • Universal Joints Enable Stone to “Follow the Hole” • Highest Pressure/Abrasion at Smallest Diameters • Precision Hole Size, Finish • Center Compliance Assured, Cross Hatched Pattern – Hold Lubrication in Hole • Process Parameters • Abrasive Material • Grit Size • Pressure Used • Adhesive Used (Bond) • Hone Speed Industrial Processes II

6. LAPPING • Illustration Kalpakjian, Figure 25.31, p.815 Industrial Processes II

7. LAPPING • Comparison to Grinding • Both Lap and Work Move (Same Grain Never in Same Location on Workpiece • Abrasives in Slurry • Low Pressure • Able to Move in Response to Cutting Forces • Process Parameters • Abrasive Material • Grit Size • Slurry Consistency • Lap/Work Speed Industrial Processes II

8. POLISHING • Description • Fine Abrasive Powders Are Used to Coat Fabric, Leather, Felt, … Disks or Belts • Coated Disk or Belt Rubbed on Surface to be Finished • Fine Abrasives Remove Material • Friction Heating Softens and Smears Surface Layers Industrial Processes II

9. POLISHING • Comparison to Grinding • Very Soft Backing Material (Cloth) • Fine Abrasives (May be in Slurry) • Low Pressure • Process Parameters • Abrasive Material • Abrasive Particle Size • Backing Material • Pressure Used Industrial Processes II

10. BUFFING • Description • Similar to Buffing with Softer Backing and/or Softer and/or Finer Abrasives • Also Known as “Compounding” from the term “Buffing Compound” • Extremely Fine Surface Finish Obtainable Industrial Processes II

11. BUFFING • Comparison to Grinding • Very Soft Backing Material (Cloth) • Very Fine Soft Abrasives (May be in Slurry) • Low Pressure • Process Parameters • Abrasive Material • Abrasive Particle Size • Backing Material • Pressure Used Industrial Processes II

12. ELECTRO-POLISHING • Description • Placement of Workpiece in Electrolytic Solution • Application of Electrical Potential to Workpiece • Ions (Charge) Collects on Outer Surface of Part • Ions Go Into Solution (Dissolve) • Highest Surface Goes Into Solution Most Rapidly Industrial Processes II

13. ELECTRO-POLISHING • Comparison to Grinding • Removal of Material via Electro-Chemical Means (NOT Shearing/Metal Cutting) • Process Parameters • Electrolyte Used • Strength of Potential (Voltage) • Duration of Applied Potential • Can Use a Similar Process With Metal Grinding Wheel – Grinding Fluid is Electrolyte and Known as Electro Chemical Grinding Industrial Processes II

14. FLOAT POLISHING • Illustration Kalpakjian, Figure 25.32, p.816 Industrial Processes II

15. FLOAT POLISHING • Comparison to Grinding • Pressure Supplied by Magnetic Forces • Magnetic (Metallic Abrasives) Pulled Onto Workpiece Via Strength of Magnetic Field • Permanent or Electro-Magnets Used • Used on Ceramic Ball Bearings • Pioneered at OSU • Process Parameters • Abrasive Material • Grit Size, Slurry • Strength of Magnetic Field • Rotational Speed Industrial Processes II

16. BARREL FINISHING • Description • Parts and (Dry Pellets) Abrasive are Placed into a Container • Container is Rotated • As Container Rotates the Parts Shift/Slide Against One Another (with the Abrasive Between Them) and the Weight of the Parts Provides the Pressure for the Abrasion Process. Industrial Processes II

17. BARREL FINISHING • Illustration Groover, Figure 32.2, p. 816 Industrial Processes II

18. BARREL FINISHING • Illustration Of Pellet Shapes Groover, Figure 32.3, p. 817 Industrial Processes II

19. BARREL FINISHING • Comparison to Grinding • Lower Pressure • Slower Speeds • Shaped (Loose) Abrasives • Process Parameters • Abrasive Material • Abrasive Pellet Shape • Ratio of Parts to Abrasive • Rotational Speed • Also Known as “Tumbling” Industrial Processes II

20. ABRASIVE FLOW • Illustration Kalpakjian, Figure 25.33, p.818 Industrial Processes II

21. ABRASIVE FLOW • Comparison to Grinding • Lower Pressure • Slower Speeds • Abrasive Slurry • Process Parameters • Abrasive Material • Abrasive Slurry “Stiffness” • Pressure Forcing Slurry Through/Around Part Industrial Processes II

22. ABRASIVE JET • Illustration Kalpakjian, Figure 26.20, p.847 Industrial Processes II

23. ABRASIVE JET • Comparison to Grinding • “Soft” Backing (Air) • Small Depths of Cut (Bounce Off) • Abrasive is “Loose” • Peens Surface • Process Parameters • Abrasive Material • Abrasive Particle Size and Shape • Angle of Incidence • Also Known as Sand Blasting, Bead Blasting Industrial Processes II

24. SURFACE TREATMENT AND COATING • Goals • Improve Hardness (Wear Resistance) • Reduce Adhesion • Improve (Retention) of Lubricants • Improve Corrosion Resistance • Barrier Methods • Insulation Methods • Improve Fatigue Resistance • Build-up/Restore Worn Surfaces • Modify Surface • Smoother or Rougher • Color Industrial Processes II

25. SURFACE TREATMENT • Definition • Changes Metallurgy (Crystalline Structure) of Metallic Parts Using Pressure or Heat • Types • Mechanical (Cold Working) • Shot Peen/Hammer Peening • Hit Surface with Ceramic or Steel Shot or Hammer • Roller/Ball Burnishing • Use Surface Rollers to Plastically Deform Surface • Explosive Hardening • Use High, Transient Force Application to Cold Work Surface Industrial Processes II

26. SURFACE TREATMENT • Types • Thermal • Flame and Induction Hardening • No Material Added, Smaller Grains at Surface • Heat and then Cool Surface/Part • Usually an “Air Quench” Process • Anneal • Heat/ Soften Surface via Annealing • Often Done in Furnace • Case Hardening • Material Added, Carburizing, Nitriding, ... • Heat To Assist in Diffusion into Surface then Cool Surface • Parameters • Temperature, Time, Pressure Industrial Processes II

27. COATINGS • Definition • Processes which Add Materials to the Base Component(s) • Types • Mechanical (Apply Particles onto Surface) • Cladding • Roll Thin Layer onto Base Metal (Alclad, Zn Coated Steel • Mechanical Plating • “Throw” Metal Particles/Powder onto Surface • Analogy – Snow Ball onto a Brick Wall • Painting Industrial Processes II

28. COATINGS • Types (cont.) • Thermal (Coat w/Molten Material) • Thermal Spraying (Metallizing) • Liquid Metal Spray Produced by Combustion/Heating to Melt Metal in Nozzle and use Escaping Gas to Expel Molten Metal at Speed onto (cool) Surface. • Parameters/Concerns • Temperature, Gas , Gas Pressures • Oxydation (vacuum) • Done at OKC Air Logistics Center to Rebuild Worn Jet Engines Industrial Processes II

29. COATINGS • Types (Cont.) • Thermal • Hard Facing • Harder Material Added to Surface • Melt a Filler Rod onto a Surface Rather Using an Electric Arc or Oxyfuel Heat Source • Often, Some Melting of Base Surface • (Hot) Dipping • Dip part to be Coated in Molten Metal • Galvanization (Zn Coating) • Enameling (Coat and Fuse with Heat) • Enameling of Steels, … • Glazing of Ceramics Industrial Processes II

30. COATINGS • Types (cont.) • Physical Vapor Deposition • Vacuum Evaporation • Evaporate metal to be deposited at high temperature • Let condense on cool part • Uniform Coating (Simple and Complex Shapes) • Parameters • Temperature Difference, Exposure Time • Sputtering • Use of ionized inert gas to bombard cathode, causing sputtering (ejection) of its atoms and subsequent condensation of the metal atoms on anode Industrial Processes II

31. COATINGS • Types (cont.) • Chemical Vapor Deposition • Thermochemical process – a reaction produces desired coating in an inert atmosphere • TiN Coating of Cutting Tools • Chemical • Electroplating, Plating, Electroforming • Deposition of ions from solution onto base • Electroplating, Electrical Current Used • Plating, No Current – Uses Reduction Reaction • Electroforming, Current, No Base Metal Coated • Parameters • Current Density, Voltage, Time • Part Shape (Affects Uniformity of Coating) Industrial Processes II

32. COATINGS • Types • Chemical (cont.) • Anodizing (Oxidizing Aluminum) • Produces porous oxide (hard) layer on surface via emersion of electrolytic cell in acid bath -- oxygen adsorption by metal – can add color (dyes) • Conversion Coating (Surface Reactions) • Naturally occurring oxides are formed on surfaces via chemical or electrochemical reactions; colors can be produced from some reactions (black oxides on iron steels) • Sol-Gels • OSU Research on corrosion resistance for aging aircraft Industrial Processes II

33. CLEANING • Definition • Removal of Contaminants from Surfaces • Dirt, Oils, Moisture, … • Types • Mechanical • Brushing (Wire) • Blasting (Abrasive Jet) • Tumbling • Steam • Ultrasonic Industrial Processes II

34. CLEANING • Types • Chemical • Solution (Dissolves Dirt into Solution) • Saponification (Convert Oils to Soap) • Emulsification (Suspend in Emulsion) • Dispersion (Reduce Concentration, Dilute) • Aggregation (Collect Particles, Remove Collection) • Pickling (Acid or Alkaline to Dissolve) Industrial Processes II

35. QUESTIONSOR CLARIFICATIONS ??? Industrial Processes II