MANUFACTURING PROCESS I

S.E. PRODUCTION UNIT-V

1. Hot dipping / Galvanizing Process

Hot-dip galvanizing is the process of immersing iron or steel in a bath of molten zinc
to produce a corrosion resistant, multi-layered coating of zinc-iron alloy and zinc
metal. While the steel is immersed in the zinc, a metallurgical reaction occurs
between the iron in the steel and the molten zinc. This reaction is a diffusion
process, so the coating forms perpendicular to all surfaces creating a uniform
thickness throughout the part.

Figure 1: Model of the Hot-Dip Galvanizing Process

The hot-dip galvanizing process (Figure 1) has been used since 1742, providing
long-lasting, maintenance-free corrosion protection at a reasonable cost for decades.
The three main steps in the hot-dip galvanizing process are surface preparation,
galvanizing, and post-treatment. The process is inherently simple, which is a distinct
advantage over other corrosion protection methods.
1. Surface Preparation

Figure 2: Hanging of Steel Products

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

The purpose of surface preparation in the hot-dip galvanizing process is to obtain the
cleanest possible steel surface by removing all of the oxides and other contaminating
residues. Thorough surface preparation is paramount as zinc will not react with
unclean steel. In order to move the steel parts through the cleaning steps and
galvanizing bath, the articles are hung using chains, wires, or specially designed
dipping racks (Figure 2).
Cleaning steel to prepare for the hot-dip galvanized coating consists of three steps:

1.1 Degreasing
First the steel is immersed in a degreasing bath such as an alkaline caustic solution
to remove organic contaminants such as dirt, oil, and grease from the surface of the
steel. After degreasing the steel is rinsed with water.

Figure 3: The Pickling Tank

1.2 Pickling
Next the steel is pickled in a dilute solution of either hydrochloric or sulphuric acid
(Figure 3), which removes oxides and mill scale. Once all oxidation has been
removed from the steel, it is again rinsed with water and sent to the final step of the
surface preparation.

1.3 Fluxing
Finally, the steel is dipped in the flux. The purpose of the flux is to clean the steel of
all oxidation developed since the pickling of the steel and to create a protective
coating to prevent any oxidation before entering the galvanizing kettle. One type of
flux is contained in a separate tank, is slightly acidic, and contains a combination of
Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.
 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

zinc chloride and ammonium chloride. Another type of flux, top flux, floats on top of
the liquid zinc in the galvanizing kettle, but serves the same purpose.

After degreasing, pickling, and fluxing, the surface of the steel is a near white metal,
clean and completely free of any oxides or other contaminants that might inhibit the
reaction of the iron and molten zinc in the galvanizing kettle.

2 Galvanizing

Figure 4: Hot-Dip Galvanizing Kettle

Once the steel has been completely cleaned, it is ready for immersion in the zinc
bath. The galvanizing kettle contains zinc specified to ASTM B6, a document that
specifies any one of three grades of zinc that are each at least 98% pure.
Sometimes other metals may be added to the kettle to promote certain desirable
properties in the galvanized coating.

The galvanizing kettle (Figure 4), is heated to a temperature ranging from 820-860 F
(438-460 C), at which point the zinc is in a liquid state. The steel products are
lowered into the galvanizing kettle at an angle, and stay in the bath until the steel
heats to the bath temperature. Once the diffusion reaction of iron and zinc is
complete, the steel product is withdrawn from the zinc kettle. The entire dip usually
lasts less than ten minutes, depending upon the thickness of the steel.

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

Figure 5: Filing Zinc Drips

3 Post-Treatment
When the steel is removed from the galvanizing kettle, it may receive a post-
treatment to enhance the galvanized coating. One of the most commonly used
treatments is quenching. The quench tank contains mostly water but may also have
chemicals added to create a passivation layer that protects the galvanized steel
during storage and transportation. Other finishing steps include removal of zinc drips
or spikes, by grinding them off.

Applications of Galvanizing:

1. To galvanized sheet metal.

2. To galvanized house-hold items such as buckets, tubs and other containers.

3. To galvanized machine parts, tools, ships, tanks and wires.

4. Metal pipes and wires are most popular galvanized items which find application in
industrial use as well as in articles made for domestic use.

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

2. Electroplating Process

What is electroplating process?

The electroplating is an art of depositing a superior or more noble metal on a base

metal by means of electrolysis.

For example, metals like iron are coated with deposits of nickel or chromium by
electroplating to protect it from corrosion. Picture frames and machinery parts are
often chromium-plated to protect them from corrosion and at the same time to give
them a good appearance.

Cleaning Process

The surface on which process of electroplating is to be carried out must be polished

and free of grease, scale, rust and dirt.

In case, the object to be electroplated is not cleaned, polished and degreased, the
deposit formed may not well adhere to the base metal and is likely to peel off.

Oils and grease can be removed with the help of soaps, hot alkali solutions or
solvents like CTC and gasoline. Rust, scale and oxides can be removed with the
help of various acid, alkali and salt solutions mechanical abrasion and electrolytic
cleaning in hot alkali solutions.

The articles are rinsed or water dipped between every process of cleaning such as
physical cleaning, chemical cleaning, acid dips in order to prevent the carrying over
of one processing solution over to the other.

To meet this requirement in every plating shop, special rinsing tanks with running
water is extensively used. So ample supply of water with drainage facilities are to be
provided in a plating shop. From the above discussion it is clear that cleaning is one
of the most important electroplating process steps.

Electroplating Process Steps

In an electroplating process, the object to be electroplated is made the cathode (i.e.

connected to the negative terminal of DC source) in the solution of a salt of the
coating metal.

The articles which are to be electroplated are suspended into the plating solution.
The anode is also generally of the same metal. This arrangement is connected to a
DC power source.

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

(Cathode) (Anode) (Cathode) (Anode)

(Electrolyte) (Electrolyte)

Fig. Electroplating Process

When DC supply is applied to the two electrodes, current starts flowing through the
electrolyte. The metal ions begin to move towards the article and get deposited on it.
The voltage requirement is small usually of the order of 1 to 16 volts only.

Materials suitable for electroplating

Electroplating comes with several material capabilities. The materials used in the
plating (coating) process depend on the composition of the plating bath and the
deposition conditions. Here are the most commonly used materials:

 Nickel
 Black nickel/chromium
 Chromium
 Palladium or Palladium Nickel Alloy
 Gold
 Silver
 Copper
 Tin
 Platinum
 Ruthenium
 Cadmium
 Brass
 Zinc

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI
What is typical thickness of layers?

The thickness of the layers of the plate is determined by the shape of the metal
material. If the metal material is characterized by more sharp features, then
deposition is likely to be more dominating at the sharp features/ edges, due to the
direction of the electric field lines between the anode and cathode of the process. In
general, however, the layer of the plating has a thickness from 0.1 to 30 microns. In
maintaining uniformity of layering when using electroplating, the placement of the
anodes in the electrolyte is highly important.

What are the applications of electroplating?

Electroplating is used on:

  Silverware
  Jewellery
  Automobiles
  Motorcycles
  Hand and medical tools
  Light fixtures
  Steel bolts
  Nuts
  Washers
 Electrical connectors, and in many industries.

Silverware will resist wear longer when electroplated. Automobiles and motorcycles
have chrome plating on their steel parts. Chrome plating is added to the steel parts
of many hand tools and medical supplies in order to keep the tools from wearing.
Zinc is added to steel bolts, nuts and washers. And in many industries electroplating
is used for better functioning of the machinery, to prevent corrosion of the metals and
for decoration.

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

3. Burnishing process
Burnishing is a cold working super finishing process. In burnishing ball or
roller is pressed against the workpiece of the material due to which plastic
deformation of surface irregularities takes place and surface becomes smooth.
Quality of Surface plays a vital role in deciding the performance of a manufactured
product. The burnishing process is a chip-less machining process which induces
residual compressive stresses on the machined surface to improve surface qualities
like roughness, hardness, wear resistance, fatigue strength of the material. For
improving the surface qualities, there are various methods available. Burnishing can
be done on ferrous as well non-ferrous materials.

Classification Of Burnishing Processes Burnishing process can be typically classified

into two categories as follows:
a) Ball burnishing
b) Roller burnishing

Ball Burnishing: In this process the deformation element is hard ball. The material
used for ball are generally alumina carbide ceramic, cemented carbide, silicon nitride
ceramic, silicon carbide ceramic, bearing steel. In ball burnishing there is a point
contact between ball and work piece. Here the ball acts as tool in deformation of the
surfaces layer, for the specified normal force it gives high specific pressure,
additional fatigue strength, micro hardness & depth of work hardening layer as
compared to roller burnishing.

Roller Burnishing: Roller burnishing is a cold working process, which produces a

superior surface finish by the pure rotation of hardened rollers over a turned metal
surface. Whereas all machined surfaces consist of a sequence of up-downs (peaks-
valleys) of irregular height and spacing, the plastic deformation creates a
displacement of the material of the peaks which into the valleys. It results into a
mirror-like finish with work hardened, wear, corrosion and fatigue resistant surface.

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

Advantages of Burnishing Process:

 Improves the size and finish of revolution like cylinders and conical surfaces.

 Internal and external surfaces can be burnished.

 Improves surface hardness.

 Increases, wear-resistance, decreases fatigue and fights corrosion.

 It also eliminates the Grinding and Honing processes which can be costly.

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

4. Lapping Process
Lapping is a machining process in which two surfaces are rubbed together with an
abrasive between them, by hand movement or using a machine.

Types of Lapping
a. Hand lapping: In hand lapping process, the work piece is rubbed over the
lapping plate manually.
b. Machine lapping: The Rubbing action in lapping is done by use of machine.

How it works:
 Loose Abrasive Process-(LAP)
 Lapping Involves the Use of Abrasive Particles to Modify the Work-Pieces
 The Abrasive Particles are Mixed with a Water-Base or Oil Base Liquid. The
Combined Abrasive and Liquid are Called a “Slurry”, this is a Liquid Cutting
Tool
  The Slurry is Placed on a Rotating Motorized Platform Called a “Lap Plate”
 The Work-Piece is then Placed Against the Slurry on the Rotating Lap Plate
and the Surface of the Work-Piece is Modified
 Rolling/Sliding Action of Abrasive Grains Between Plate and Work piece

LAPPING PLATE

Lapping Process:
Lapping machines consist of 5 parts: the rotating table (called a lapping plate),
several retaining rings, the pressure plate, the slurry, and the machine itself.
The machine houses the controls, engine, coolant, filter, and other subsidiary
components for proper operation of the mechanism.
The lapping plate is the only thing that is turned by the motor--the conditioning
rings turn automatically as the plate itself turns. The plate is usually made of high-
quality soft cast iron, though copper and other soft metals may also be used. It may

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI
be anywhere from 12 to 144 inches in diameter and feature spirals, cross-hatches,
rings, or other shapes.
The retaining rings function as the workholding device. These rings distribute
the wear evenly across the lapping plate increasing its life, while also holding the
workpiece in place. Special rings may be fitted for cylindrical or especially long
pieces.
A pressure plate presses the pieces down in order to ensure abrasion occurs.
These may be simple lids or mechanically operated piston-like covers.
A slurry made by combining various abrasive materials such as diamond or
carbon with a liquid base like oil or water is fed between the lapping plate and the top
plate, and distributed evenly across the surface by the plate's rotation. The tiny
abrasives suspended in the liquid drag and tumble across the surface of the held
pieces, grinding away at any micro-irregularities in the part's surface.
When using lapping techniques it is possible to remove as little as 0.000002"
of stock. Typical stock removal after grinding is 0.002-0.0005".

Applications:
 Pump manufacturing: seal faces, vanes, impellers, body castings, rotating
 valves
 Hydraulics and pneumatics: castings, valve plates, seals, slipper plates,
cylinder bodies
 Transmission equipment: clutch plates, spacers, shims, gears
  Stampings & forgings: bosses, spacers, plates, type hammers
 Inspection equipment: micrometer anvils, test blocks, surface plates, optical
flats
 Aerospace parts: gyro components, lock plates, seals
 Printing equipment: new or reconditioned printing plates
 Cutting tools: tips, slitter blades

Advantages of lapping:
 Extreme accuracy of dimensions
 Correction of minor imperfections of shape
 Refinement of surface finish
 Producing close fit between mating surfaces
 It does not require the use of holding devices; therefore, no workpiece distortion
 occurs.
 Additionally, in normal lapping, less heat is generated than in most of other
finishing operations. This minimizes the possibility of metallurgical changes to
the machined parts.

Disadvantages or limitations of lapping:

 It is a slow process
 It is an expensive process

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

5. Honing Process:
Honing is a finishing process, in which a tool called hone carries out a
combined rotary and reciprocating motion while the workpiece does not perform any
working motion. Most honing is done on internal cylindrical surface, such as
automobile cylindrical walls. The honing stones are held against the workpiece with
controlled light pressure. The honing head is not guided externally but, instead, floats
in the hole, being guided by the work surface (Fig. 1). It is desired that
1. honing stones should not leave the work surface
2. stroke length must cover the entire work length.
In honing rotary and oscillatory motions are combined to produce a cross hatched
lay pattern as illustrated in Fig 2.

Cross hatch finish:

A "cross-hatch" pattern is used to retain oil or grease to ensure proper lubrication
and ring seal of pistons in cylinders. A smooth glazed cylinder wall can cause piston
ring and cylinder scuffing. The "cross-hatch" pattern is used on brake rotors and
flywheels.

Fig 1: Honing process

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

Fig 2: Cross hatch lay pattern

Because honing is a slower process than grinding, heat and pressures are
lower. This means that honing provides better size and geometry control. Hones are
incredibly accurate and can finish a part to within 0.2 microns.

Applications:

 Engine Cylinders
 Bearings
 Hydraulic valves
 Cartridge valves
 Fuel injectors
 Gears
 Gun barrels
 Connecting rods
 Engine blocks

Advantages:
Less complex or low cost fixtures.
 It is highly accurate.

 It can be used for both long and short bores.

 It maintains original bore centerline.

 Any material can be finished regardless its hardness.
Limitaions:
 Since honing is a high-precision process, it is also relatively expensive.

 Honing is a slow / time consuming process.

 Horizontal honing may create oval holes unless the work is rotated or
supported.

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

6. Polishing & Buffing:

Polishing and buffing are finishing processes for smoothing a workpiece's
surface using an abrasive and a work wheel or a leather strop.

Technically polishing refers to processes that use an abrasive that is glued to

the work wheel, while buffing uses a loose abrasive applied to the work wheel.
Polishing is a more aggressive process while buffing is less harsh, which leads to a
smoother, brighter finish. A common misconception is that a polished surface has a
mirror bright finish, however most mirror bright finishes are actually buffed.

Polishing is often used to enhance the appearance of an item, prevent

contamination of instruments, remove oxidation, create a reflective surface, or
prevent corrosion in pipes. In metallography and metallurgy, polishing is used to
create a flat, defect-free surface for examination of a metal's microstructure under a
microscope. Silicon-based polishing pads or a diamond solution can be used in the
polishing process. Polishing stainless steel can also increase the sanitary benefits of
it.

Polished Surface Functions:

 Enables sealing of high pressure gases and liquids

 Cosmetic purposes

 Enables the use of optical flatness measurement instruments

 Reduces the amount of surface and sub-surface damage

 Provides better uniformity of surfaces requiring epitaxial processes
or deposited materials

 Generates sharper edges on cutting tools

Applications:

Polishing may be used to enhance and restore the looks of certain metal parts or
object on cars and other vehicles, handrails, cookware, kitchenware, and
architectural metal. In other applications such as pharmaceutical, dairy, and specialty
plumbing, pipes are buffed to help prevent corrosion and to eliminate locations where
bacteria or mold may reside. Buffing is also used to manufacture light reflectors.

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

7. Tumbling process:

Barrel finishing, also known as barrel tumbling, is a surface improving

operation in which a mixture of parts, media and compounds are placed in a six - or
eight-sided barrel and rotated at a predetermined speed for the purpose of rounding
corners, deburring, grinding, descaling, deflashing, improving surface finish,
burnishing, polishing and radiusing parts in bulk. It works by tumbling parts in a
rotating barrel, thus creating friction by tumbling parts against each other and against
other materials, such as media and compounds.

Tumbling Highlights

  Parts can be finished less expensively than by hand.

  Many parts can be processed at one time.
  Requires very little handling.
  Parts are tougher and stronger after tumbling.
  Tumbling provides a certain amount of stress relief.
  Forgings and castings can be blended.
  Machine parts and stampings can be deburred and burnished to a high 
finish.

  On long runs, the systems can run overnight.
 Careful and proper machining of your parts will save tumbling time.

Fig. Hexagonal barrel tumbling machine

Abrasives / media used in tumbling:

 Ceramic

 Plastic

 Aluminium oxide

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI
 Steel balls

 Wood pegs

Advantages of the tumbling process:

 The speed, the processing times are very short compared to traditional
technologies, even though everything depends on the types of work pieces.

 The flexibility, it operates with both small quantities and large quantities of
pieces.

 The simplicity, the machines are small and easy to use.

 The costs, the use of these systems reduces costs by replacing other
complex machining with inaccessible costs.

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI

8. Metal Spraying Process:

Metal Spraying or The Combustion Wire Thermal Spray Process is basically
the spraying of molten metal* onto a surface to provide a coating. Material in wire
form is melted in a flame (oxy-acetylene flame most common) and atomised using
compressed air to form a fine spray. When the spray contacts the prepared surface
of a substrate material, the fine molten droplets rapidly solidify forming a coating.
This flame spray process carried out correctly is called a "cold process" (relative to
the substrate material being coated) as the substrate temperature can be kept low
during processing avoiding damage, metallurgical changes and distortion to the
substrate material.

This flame spray process has been extensively used in the past and today for
machine element work and anti-corrosion coatings. Thermal spraying can provide
thick coatings (approx. thickness range is 20 microns to several mm, depending on
the process and feedstock), over a large area at high deposition rate as compared to
other coating processes such as electroplating, physical and chemical vapor
deposition.

Metal or thermal spraying is a technology, which protects and greatly extends

the life of a wide variety of products in the most hostile environments and in
situations where coatings are vital for longevity. The variety of metallised coatings is
vast but can be broken down into two main categories. These include finishing
coatings, such as anti-corrosion or decorative coatings, and engineering coatings
such as wear resistant and thermal barrier coatings.

Fig: Schematic Diagram of Metal spraying / The Combustion Wire Thermal Spray Process

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.

 MANUFACTURING PROCESS I
S.E. PRODUCTION UNIT-VI
Common materials Sprayed:

 Zinc and aluminium for anti-corrosion cathodic coatings on steel

 Nickel/aluminium composite wire for bond coats and self-bonding coatings
  Molybdenum for bond coats
 Molybdenum for hard bearing applications, excellent resistance to
 adhesive wear, used on piston rings, syncromesh cones and journals.
 High Chromium steel for many applications requiring hard and wear
resistant coating
 Bronzes, babbitt for bearing applications
 Stainless steels, nickel and monel for anti-corrosion and wear
 Aluminium, nickel/aluminium for heat and oxidation resistance

Process Advantages:

 Low capital investment

  Simple to operate
 Wire form cheaper than powder
  Deposit efficiency very high
 Possibly still best for applying pure molybdenum coatings for wear resistance. 
 Portable system
 Preheating facility built in, unlike arc spraying
 Possible to use system in areas without electricity supply

Process Disadvantages:

  Limited to spraying materials supplied in wire or rod form

 Not capable of the low oxide, high density and high strength coatings of
plasma

Surface finishing processes and coating PREPARED BY:- PROF. VARPE N. J.