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Surface Coatings & Surfacing Techniques

Engineering components can fail due to one or a combination of several mechanisms. They are: wear, corrosion, fretting, galling, erosion, cavitation or high temperature oxidation. In the majority of the cases, the component may be structurally sound but its surface properties have deteriorated or the clearances between mating parts have increased. The cost of replacing the part is usually much greater than the cost of the part itself. The increased cost of maintenance because of unwanted shut downs reduces profits.

The base material is usually chosen for its structural properties such as tensile strength, elasticity, ductility, density etc. But when the parts move relative to other mating parts, their surface properties such as hardness, galling resistance etc become crucial. It is nearly always impossible to match the combination of the structural properties and surface properties in a single metal or alloy.  This is where surface coating technology provides solutions by combining various base materials and coatings to give optimum core and surface properties.

 Sometimes technological progress and manufacturing efficiency may be constrained solely by surface requirements. For example, the fuel efficiency and power output of gas turbines or diesel engines are limited by the ability of key components to withstand high temperatures. However, it is often impractical, inefficient or uneconomical to manufacture components from a bulk material simply for its surface properties - far better to use a cheaper, more easily formed underlying material and coat it with a suitable high performance film. The resulting product performs better than the original and may cheaper.

Surface engineering is relevant to all types of products. It can increase performance; reduce costs and control surface properties independently of the substrate, offering enormous potential for:

• improved functionality
• the solution to previously insurmountable engineering problems
• the possibility to create entirely new products
• conservation of scarce material resources
• reduction of power consumption and effluent output

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Last modified: October 30, 2001