NEWER MATERIAL AND

PROCESSING

TOPIC :VAPOR DEPOSITION

& ION IMPLANTATION
 DEPOSITION
Applying a thin film on a surface range
from nano meters to micro meter
Thin film is deposited on substrates.
Different techniques are used for deposition
PVD ,CVD, sputtering, electroplating &
coating
PHYSICAL VAPOR
DEPOSITION (PVD)
Thermal evaporation
Sputtering
Laser sputtering
Ion Plating
Cluster-Beam

CHEMICAL VAPOR
DEPOSITION (CVD)
Reaction mechanisms
PHYSICAL VAPOR DEPOSITION (PVD)

Michal faraday used PVD in 1838

The material in solid form is either heated
until evaporation (thermal evaporation) or
sputtered by ions (sputtering).
In the last case, ions are generated by a
plasma discharge usually within an inert gas
(argon).
This allows to vary the energy and intensity
of ions reaching the target surface.
PHYSICAL VAPOR DEPOSITION
 Physical coating process involve, condensation
& evaporation of material
 PVD is used for high melting point & low vapor
pressure materials
 PVD is carried out high temperature and
vacuum
 The physical vapor deposition technique is based
on the formation of vapor of the material to be
deposited as a thin film.
MORPHOLOGY OF PVD
 High temperature is
required to vaporize the
material
 vacuum of different ranges
is used which depends on
the mean free path required
in the system
 APPLICATIONS:
PVD methods are commonly used in followings:

 circuit & IC fabrications.

 Aerospace in TBC & transparent coatings.
 Reflectors and optics
 PVD TECHNIQUES
 Evaporative deposition
* electron beam vapor deposition
* Pulsed laser deposition
 sputter deposition
 Ion induced deposition
 Cathode arc deposition
EVAPORATIVE DEPOSITION
 Resistive heating method is
used
 Deposition is performed at
high temperature & low
vacuum
 vacuum decreases the
content of contamination
 voltage & current is
manually controlled.
 PULSED LASER DEPOSITION
 High power laser is used
for deposition
 Argon or neon is used for
inert atmosphere
 High vacuum is formed

 Laser is focused by lens,

target decides the position
of the deposition
 SPUTTER DEPOSITION
 Sputtering works on the
bases of momentum
principle formed by the
collision of the atoms and
molecules.
 Plasma glow ion
acceleration or radioactive
 Emitting is used to
evaporate material
 Argon gas is used for inert
atmosphere
CATHODE ARC ION DEPOSITION
 In this process ions are
deposited on the
substrates.
 This process is used for IC
fabrication , micro circuit
printing nono printing or
pattering
 It will be discussed in
detail with nano pattering.
 ADVANTAGES
 Environment friendly then paint &
electroplating.
 More than one PVD technique can be used
for coating.
 Usually topcoats are not required.

 Good strength and durability

DISADVANTAGES
 Cooling system are required
 Mostly high temperature and vacuum
control needs skill & experience
 PVD coated materials has no chemical
interaction with the surface
 CHEMICAL VAPOUR DEPOSITION

 Chemical vapor deposition (CVD) is a chemical

process used to produce high quality, high-
performance, solid materials.

 The process is often used in semiconductor industry to

produce thin films
 REACTION MECHANISMS
 Mass transport of the reactant in the
bulk
 Gas-phase reactions (homogeneous)
 Mass transport to the surface
 Adsorption on the surface
 Surface reactions (heterogeneous)
 Surface migration
 Incorporation of film constituents
 Desorption of by-products
 Mass transport of by-products in bulk
CHEMICAL VAPOUR DEPOSITION
 Chemical vapor deposition (CVD) is
a chemical process used to produce high
quality, high-performance, solid
materials
ENERGY SOURCES FOR DEPOSITION:
 Thermal
 Plasma
 Laser
 Photons
 THERMAL CHEMICAL VAPOR
DEPOSITION

 A synthesis method where a substrate is

placed in a heated atmosphere (600--800
deg. C) and exposed to one or more volatile
precursors, which react or decompose on
the surface to produce a deposit.
PLASMA-ENHANCED CHEMICAL VAPOR
DEPOSITION (PECVD)
 A chemical vapor deposition process used
to deposit thin films from a gas state
(vapor) to a solid state on a substrate.
 Chemical reactions are involved in the
process which occur after creation of a
plasma of the reacting gases.
 The plasma is generally created by radio
frequency (RF) (alternating current (AC))
frequency or direct current (DC) discharge
between two electrodes
 LASER CHEMICAL VAPOR
DEPOSITION (LCVD)
 Uses a focused laser beam to locally heat the
substrate and drive the CVD deposition
reaction
 Several different deposition reactions and
substrates have been examined as a function
of intensity and irradiation time using a
CO2 laser source: Ni on SiO2, TiO2 on SiO2
PHOTON-INDUCED CHEMICAL VAPOR
DEPOSITION
 laser was used to excite and dissociate gas
phase SiH4 and N2O molecules in contrast
to earlier work with incoherent merucry
lamp.
 Achieved 20 times the deposition rate,
limited the dissociation volume to a
localized region, and minimized the direct
impingement of UV photons on the
substrate.
 PVD VS CVD
 PVD (Physical Vapor Deposition) and CVD
(Chemical Vapor Deposition) are two
techniques that are used to create a very thin
layer of material into a substrate.
 They are used largely in the production of
semiconductors where very thin layers of n-
type and p-type materials create the necessary
junctions.
 The main difference between PVD and CVD is
the processes they employ.
 PVD only uses physical forces to deposit the
layer while CVD uses chemical processes.
 ION IMPLANTATION
 Ion implantation is low-temperature process by
which ions of one element are accelerated into a
solid target by changing the physical, chemical,
or electrical properties of the target.
 Ion implantation is used in semiconductor
device fabrication and in metal finishing as well
as in materials science research.
 The ions can alter the elemental composition of
the target . Ion implantation cause also
chemical and physical changes when the ions
on the target at high energy.
NEWER MATERIALS AND
PROCESSING
NEWER FORMING PROCESSES

Topic: Super plastic Forming

Rubber forming

PRESENTED BY
SUBJECT HANDLING STAFF
N.BALAJI
17ME319
Dr.K.MAHADEVAN
M.TECH PDM
HEAD OF THE DEPARTMENT
PEC
 SUPERPLASTIC FORMING

DEFINITION:
 A process for shaping super-plastic materials, a unique class of
crystalline materials that exhibit exceptionally high ductility
with neck-free elongation.
 In specific, SPF is a hot forming process in which sheets of
superplastic grade aluminum are heated and forced onto or into
single surface tools by air pressure.
 Superplastic materials may be stretched in tension to
elongations typically in excess of 200% and more commonly
in the range of 400–2000%.
 There are rare reports of higher tensile elongations reaching
as much as 8000%. The high ductility is obtained only for
superplastic materials and requires both the temperature and
rate of deformation (strain rate) to be within a limited range.
Superplastic forming (SPF) process:
 The superplastic forming process having the sheet metal to
be formed and it placed on SPF die (or) mold, the die is
representative of final part to be formed.
 Simple or complex shapes can be formed

 During the super plastic forming process the elevated

temperature will keep the Sheet metal stress very low.
 During forming process the sheet metal and press tooling are
heated together and then high pressure gas is applied. In that
case, the sheet metals are plastically deformed into desire
shape of die cavity.
 SCHEMATIC OF THE SUPERPLASTIC-LIKE
FORMING PROCESS:

( a ) heating and clamping,

( b ) hot drawing stage
( c ) gas forming stage.
SUPER PLASTIC FORMING PROCESSES
 Cavity Forming
This forming process is suitable for the manufacturing of parts
with smooth, convex surfaces.
 Bubble Forming

The bubble forming technology is particularly suitable for

parts with high forming depths.
 Diaphragm Forming

The diaphragm-forming method (DFM) can be used to reduce

the tensile flow stress generated in a specific alloy matrix
composite during deformation.
PRODUCTION PROCESS: SPF

Need presses 1000,

3000and 8000kN

SPF/HGPF allows
complex shape
design with High-
strength alloys
APPLICATIONS
AEROSPACE - LIGHTWEIGHT LAMINAR
STRUCTURES

SPF parts in Al alloy

 Lip Skins
 Engine Nacelle Skins
 Bulkheads
 Lamp Drums
 Wing Tips
 Winglets
 Leading Edge Ribs
 Access Door Inner Skins
 Equipment Covers
 Facia panels
 Acoustic Panels

SPF/DB parts in titanium alloy

AUTOMOTIVE - ENCLOSURES, BODY IN WHITE,
CHASSIS STRUCTURES
 Door Inners
 Bodysides
 Door Rings
 Enclosure assemblies
 Tunnels
 B Pillars
 Cantrails
 Roof Structures
 Bulkheads
 Footwells
 Exterior Body Panels
SPF parts in Al alloy
RAIL - CAB STRUCTURES, INTERIOR PANELS, DOORS AND
SEATING
 Cab Skins
 Cab Structures
 Cab Desks
 Inter End Skins
 Inter End Canopies
 Interior Window Masks
 Interior Doorway Panels
 Cab Interiors
 Door Systems

SPF parts in Al alloy, from Superform website

Additional sectors of application

Application in sports

Application in arts
Application in furniture
PRODUCTION PROCESS: DIFFUSION
BONDING
VESSEL MANUFACTURING
ADVANTAGES
 Complex shapes are easily made

 Flexibility in design.

 Low applied stress for forming HSLA materials.

 Low capital cost on equipments.

 Effective material utilization and savings.

 DISADVANTAGES

 Inferior creep resistance

 Very slow process.

RUBBER FORMING
RUBBER PAD FORMING

 Rubber pad forming (RPF) is a metalworking process

where sheet metal is pressed between a die and
a rubber block, made of polyurethane.
 Under pressure, the rubber and sheet metal are driven into
the die and conform to its shape, forming the part.
 The rubber pads can have a general purpose shape, like a
membrane. Alternatively, they can be machined in the shape
of die or punch.
 Rubber pad forming is a deep drawing technique that is ideally
suited for the production of small and medium-sized series.
 The disadvantage of regular deep drawing is that expensive tools
consisting of an upper and lower mold are needed.
 Once these tools have been made, the variable costs are low,
which makes regular deep drawing very suitable for large and very
large numbers of products.
 RUBBER FORMING

1.Bottam of the press

2.Lower die

3.Sheet metal

4.Rabber pad

5.Top of the press

Advantages of rubber pad forming process:
• The soft rubber placed on the top punch and will not
damage or scratch the sheet metal
• Accurate dimensions are obtained and time
consumption is less
• Requires only one punch to manufacture of sheet
metal
• Any of shape can be formed in one process cycle
• Tooling cost will be low
• Uniform pressure is exerted over the surface of blank.
Disadvantages of rubber pad forming sheet
metal:
• Require long time
• Limit the number of parts
• Large force required
• Soft tool is deformed during the process.
• Complex shape part formed limited
• The soft tool is wear also.
Application of rubber pad forming
sheet metal:
• Steel alloys
• Air craft industry
• Aluminium alloy
 NEWER MATERIAL AND
PROCESSING

TOPIC :HOT DIPPING

HOT-DIP
 Hot-dip is the process of dipping fabricated steel
into a kettle or vat containing molten zinc.
 The process is simple which provides a distinct
advantage over other corrosion protection methods.
HOT-DIP GALVANIZATION
 Hot-dip galvanization is a form of galvanization.
 It is the process of coating iron and steel with zinc
which alloys with the surface of the base metal when
immersing the metal in a bath of molten zinc at a
temperature of around 840 °F (449 °C).
 Hot dipping is a process in which a metal
substrate is immersed in a molten bath of a
finished product metal.
 The most common substrate metals are steel
and iron and the common coating materials
are zinc, aluminum, tin and lead.
CHARACTERISTICS
Hot-dip metallic coatings can be considered to have
excellent long term corrosion resistance property
when properly sealed
1. The coating functions as a barrier providing
shielding to the base material.
2. 2. The coating may provide sacrificial galvanic
protection.
3. Typically 65 - 150 microns thick ( 1 mm = 1000
microns)
HOT-DIP GALVANIZATION
THE HOT DIP GALVANIZING PROCESS

 Loading – jigging
 Degreasing
Hot caustic
 Pickling
Hydrochloric acid
 Pre-fluxing

 Hot dip galvanizing Zinc am. chloride

 Quenching
Molten zinc

Dichromate
DEGREASING

 Solvent degreasing is a process used to prepare a

part for further operations such as electroplating or
painting.
 Typically it uses petroleum, chlorine, or alcohol
based solvents to dissolve the machining fluids and
other contaminants that might be on the part.
PICKLING

 Pickling is a metal surface treatment used to remove

impurities, such as stains inorganic contaminants
rust or scale from ferrous metals, copper precious
metals and aluminum alloys.
 A solution called pickle liquor which usually
contains acid, is used to remove the surface
impurities.
PRE-FLUXING

 The cleaning cycle usually consists of a degreasing

step, followed by acid pickling to remove scale and
rust, and fluxing
 Which inhibits oxidation of the steel before dipping
in the molten zinc.
 The dry process is accomplished by pre-fluxing in a
zinc ammonium chloride solution.
HOT DIP GALVANIZING

Hot-dip galvanization is a form of galvanization. It is

the process of coating iron and steel with zinc,
which alloys with the surface of the base metal when
immersing the metal in a bath of molten zinc at a
temperature of around 840 °F (449 °C).
QUENCHING
 After hot dip galvanized steel item is removed from
the galvanizing bath, it is immediately quenched in a
sodium dichromate solution
 The dichromate quenching cools the item so that it
can be quickly handled the surface of the galvanized
coating to maintain its bright appearance.
HOT DIP GALVANIZING PROCESS
 The steel is immersed in molten zinc (temp 4500C)
 The clean steel surface reacts with the molten zinc to
form a zinc-iron alloy which is very strongly bonded
to the surface
 The hot dip galvanized coating forms in 3-5
minutes, depending on the steel thickness.

Free zinc layer

Galvanized coating
Alloy layers
Steel
Micrograph - 100 X
Quenching:
After hot dip galvanized steel item is removed
from the galvanizing bath, it is immediately
quenched in a sodium dichromate solution
The dichromate quenching cools the item so that it
can be quickly handled and conditions the surface of
the galvanized coating to maintain its bright
appearance.
Dichromate quenching will reduce white rusting
problems. White rust forms when rainwater reacts with
newly galvanized steel to form zinc hydroxide.

Poor storage or HDG steel will also promote white

rust.
COATING COMPARISONS
Compared to zinc electroplating (ZEP)and continuous
galvanizing (CG), hot dip galvanizing (HDG) is better
HDG is thicker and will last over 50 years or more
without rusting
HDG is harder and is 5 times more abrasion resistant
than ZEP and CG
HDG coats all external and internal surfaces and
edges. All CG coatings have cut, exposed edges after
processing.
COATING THICKNESS OF
COATINGS ON
GALVANIZED PRODUCTS

Z350 Gal. sheet

100
90
80
70
60
50
40
30
20
10
0
ADVANTAGES
 hot-dip galvanizing does provide a longer service
life than competing protective coatings.
 Hot-dip galvanizing provides uniform coatings on
these surfaces, because the process develops the zinc
coating by way of a metallurgical reaction.
 The zinc coating drastically reduces corrosion and
prevents minerals from depositing inside the product
 Galvanized steel is more flame resistant than PVC
piping and is stronger than aluminum piping.
 APPLICATIONS
 Pressed steel water tanks
 Power generation & transmission

 Infrastructure development

 Telecommunication towers

 Building and construction

 PONDICHERRY ENGINEERING
COLLEGE

NEWER MATERIAL PROCESSING

Topics: Surface coating - Hardfacing , Thermal
Spraying.

Presented by Subject staff

Gidla Vinay Dr. Mahadevan
17ME320 HOD & Professor
1st yr M.Tech(PDM) Mechanical Engg Dept.
PEC. PEC
WWear:
EAR
Wear is defined as a progressive deterioration
through loss of material due to prolonged or
overly frequent use.

For user, this entails:

• Reduced lifetime and productivity.
• Increased risks to personnel.
• Higher energy consumption and lower
yield.

Ex: Adhesion(friction), Abrasion, Erosion,

Cavitation etc.
 TYPES OF WEAR
low and moderate stress
abrasion/Low impact :
Result of particles rubbing/sliding
on the substrate. As pressure from
these abrasives is low, they don’t
change size and don’t break up.

High stress abrasion/Under

pressure:
Occurs in equipment where the
abrasive is compressed between two
surfaces. The abrasive is then broken
into many pieces(chipping).

Severe abrasion/Gouging/High
impact:
Combination of low, moderate and
high abrasion combined with
impact. Large chips and scratches.
Adhesion:
When two metal bodies rub each other
and material is transferred from one
substrate to the other, this is known
as “adhesion wear”.
Occurs under conditions of high
temperature, high pressure and
friction.

Erosion:
This occurs when solid particles or
drops of liquid strike a surface at high
speed.
Rate depends on the angle of attack
and at which it is projected.

Fretting:
Caused when there is recurrent
rolling or sliding action between two
components. Under such conditions a
sudden loss of material, in the form of
pitting or chipping will be observed.
Ex: gear teeth, rails, roller presses.
Thermal fatigue:
This type of fatigue refers to wear
generated by thermal cycle loads on the
base metal.
When metal is repeated heated or
cooled, expansion and contraction
occurs.
Ex : Forge tools.

Cavitation:
Occurs in turbulent liquids in contact
with a solid surface.
Cavities are formed in the liquid and
implode, creating wear.
Cavitation erosion.

Combined wear ?
SURFACE COATING
An economic method for the production of materials ,
tools and machine parts that required the desired
surface properties such as corrosion, erosion and wear
resistance.

Different coatings are used to achieve the different

properties.

Some methods:
Hard facing
Thermal spraying
Vapor deposition
Ion implantation
Hot dipping
 WHY SURFACE COATINGS?

Principle of “Better-faster-
cheaper”

Either the entire component

can be coated or just the area
prone to attack, which ever
best fulfills the requirements

Chrome plated steel pelton turbine nozzle needle

after service
SURFACE PROPERTIES
Depends on service environment
 Wear

 Corrosion resistance

 Thermal insulation

 Electrical insulation

 Improved aesthetic appearance

Usually a combination is present

HARDFACING TERMINOLOGY

Rebuilding: Restoration of a part to its initial

dimensions when its geometry has been changed by
wear.

Buffer layer: overcome problems of incompatibility

between substrate and cladding.
HARDFACING
Hardfacing is the deposition of a surface layer by
welding, which is harder than the base material. Its
purpose is to give wear resistance.

Preventive hardfacing
Hardfacing
Remedial hardfacing

Characterized by
→ Soundness
→ Toughness
→ Environmental stresses like corrosion and high
temperatures
CHOOSING THE HARDFACING PROCESS

Size and shape

Function of the State of repair
component

Accessibility Base metal

composition Number
BENEFITS OF HARDFACING
Following benefits can be obtained
 Reduced maintenance

 Reduced operation costs

 Lower repair costs

 Extended equipment lifetime

Process types
 Gas tungsten Arc welding process
 Shielded metal arc welding
 Flux cored arc welding
 Submerged arc welding
Gas Tungsten Arc welding process:

 In TIG process, an electric arc is produced between a

refractory tungsten electrode and the part.
 A metallic filler wire may or may not be used.

 The weld pool is protected from oxidation by an inert

atmosphere(often argon).
Shielded metal Arc-welding(covered electrode):

 The consumable electrode is composed of a solid core

wire and a flux covering.
 An electric arc creates a weld pool between the
electrode core and the part.
 The slag produced by the fusion of the coating protects
the molten metal against oxidation, and can contribute
to the deposit’s chemical analysis.
Submerged Arc welding process:

 Molten metal is generated by an electric arc between a wire

and the part, beneath a “blanket” of powdered flux.
 The electric arc is not visible and the welding flames are
mostly absorbed by the flux layer.
 Supports only to flat welding positions on plated and rolls.
 Very high deposit rates.
Gas Shielded Metal Arc Welding Process:

 Molten metal is obtained by creating an electric arc

between a wire electrode(solid or tubular cored) and
the base metal.
 Metal Inert Gas(MIG)-Metal Active Gas(MAG)
 Easy to automate
Flux cored wires:
 Improve fusion characteristics.
 Protect the molten metal against excessive oxidation.
 Offer a wider range of alloys that can be deposited.
 COMPARISON

Process Type Precautio Weld pool Dilution Typical

Name ns protectio deposit
n rate
Gas Manual/Au Electric arc Gas 5-15% 0.5-1.5kg/h
tungsten tomatic 1.1-3.3lb/h
arc welding
Shielded Manual Electric arc Slag 15-30% 1.0-3.0kg/h
metal arc Baking 2.2-6.6kg/h
welding
Gas Semi- Electric arc Gas 15-35% 3.0-
shielded automatic / 10.0kg/h
metal arc Automatic 6.6-22lb/h
welding
Submerged Automatic Flux Slag 30-50% 5.0-
arc welding Baking 20.0kg/h
11.0-44lb/h
Dilution:

Dilution affects the chemical composition of the

deposit, hardness, and quality.
During welding some of the base metal dissolves
into the weld pool, diluting it.

𝐵
% Dilution = ∗ 100
𝐴+𝐵

During surfacing operations, dilution should be limited

to optimize deposit characteristics, whilst ensuring a
good fusion with the substrate.
THERMAL SPRAYING
“Thermal spray is a generic term for a group of
processes in which metallic, ceramic, cermet, and
some polymeric materials in the form of powder,
wire, rod are fed to a torch or gun with which they
are heated to near or somewhat above their
melting point”.

Projected against the surface to be

coated(substrate).
PRINCIPLE OF THERMAL SPRAYING

Schematic diagram of thermal spray coating process

CLASSIFICATION OF VARIOUS THERMAL SPRAY PROCESSES
PLASMA SPRAY

 DC electric arc generated, plasma gas(He,H2,N2 or

mixtures) acts as spraying heat source
 Copper anode-tungsten cathode

 Plasma plumes temperature can reach 16000 k

 Powder accelerated about 200m/s

 Generation of amorphous calcium phosphate and bio

calcium phosphate.
ELECTRIC ARC WIRE SPRAY(WAP)

 Two consumable wire electrodes connected to high DC

source for arc generation
 Can also be carried using inert gases or in controlled
atmosphere
 Substrate temperature can be very low

 The process is energy efficient

FLAME SPRAY

 Use combustible gas as a heat source to melt the

coating material.
 Spray gases-Acetylene, propene, methyl-acetylene-
propadiene (MAPP) and hydrogen along with oxygen.
 Mostly sprayed manually
 Flame temperature and characteristics depend on
oxygen-to-fuel ratio.
 A wide variety of materials can be deposited in rod,
wire or powder form as coatings using this process.
HIGH VELOCITY OXY-FUEL SPRAY(HVOF)

 Uses combination of oxygen with various fuel gases

like hydrogen, propene, propylene, kerosene.
 Spray powder is used.
 Flame temperature varies in range 2500c-3200c based
on combination.
 Different from flame spray
COMPARISON OF SEVERAL COMMON
THERMAL SPRAY PROCESSES

Process Coating Heat Flame Gas Porosity Coating

Material Source Temp velocity % Adhesio
form C m/s n
MPa
Plasma Powder Plasma 12000- 500-600 2-5 40-70
Spray Flame 16000
Wire Arc Wire Electric 5000- <300 5-10 28-41
Spray Arc 6000
Wire Wire Oxy-Fuel 3000 <300 5-10 14-21
Flame combustio
n
HVOF Powder Oxy-gas 3200 1200 1-2 >70
Fuel
combustio
n
 ENERGY COMPARISON OF THERMAL SPRAY
PROCESSES

 Thermal energy–attainable flame temperature

 Kinetic energy–function of gas velocity
APPLICATIONS
Hard chromium alternative
Nose gear
Wear and corrosion
Thermal sprayed HVOF coating

Medical implants
Hip implant
Vacuum plasma process
Gas turbines
Stationary and flight gas
turbines.
Thermal sprayed coating.
High temp corrosion resistance,
thermally insulating coatings,
repair of super alloy
components.

Salvage and restoration

Repair procedures to restore
components to their dimensions
CASE STUDY
COMPANY PROFILE
Thermico GmbH & Co.KG, a German-based company,
develops, produces and distributes robot-based coating
centers.
They specialize in plasma and high velocity flame spray
systems that provide coatings for a wide range of products
from aircraft turbine blades to Teflon® frying pans.

CHALLENGE
Thermico required a new extraction system to handle the dust
and fumes from the plasma and HVOF spray systems that
were being installed in their new premises.

APPROACHED COMPANY:
Camfil Air Pollution Control (APC)
SOLUTION:
Camfil APC addressed the issue by supplying one of their
ATEX compliant Farr Gold Series® GS40 dust collectors,
complete with a supply air system.

PRODUCT INFORMATION
Product: Farr Gold Series® dust
collector
Size: GS40 ATEX Compliant
Air Volume: 30.000 m3/hr
Application: Thermal spray
processes, HVOF, plasma
Customer: Thermico GmbH &
Co.KG, Dortmund, Germany
Installation date: January 2011
 Results
 Successful handling of thermal spray dust and fumes
was done.
 Additionally an energy saving setup that incorporated
a heat exchange system was installed.
 Thermico was delighted with the solution which
provides their workforce with a safe working
environment meeting all legislative requirements,
whilst saving on energy costs and ensuring
sustainability.
 An interesting fact

According to Centers for Disease control and Prevention,

in 2014 alone there have been approximately 7,19,000
knee replacements and 3,32,000 hip replacements.
 PONDICHERRY ENGINEERING
COLLEGE

ELECTRON BEAM WELDING &

DIFFUSION BONDING
STAFF IN CHARGE By
Dr. K.MAHADEVAN M.E. PH.D,
Rampragash
PROFESSOR & HOD,
m.Tech Pdm (mechanical)
MECHANICAL
101 DEPARTMENT,
17me326
PEC.
 102

HISTORY

 Developed by an German Scientist Karl–

Heinz steigerwald in 1949
 Steigerwald developed the first practical
EBW which began operation in 1958
 American inventor James T. Russel has
also been credited with designing and
building the first electron beam welder
 103

ELECTRON BEAM WELDING:

Definition:
A Fusion welding process in which
similar or dissimilar – metals ,alloys are fused
together by focusing a beam of high velocity
electron onto work piece either under near
atmospheric or at vacuum chamber.

Principle:
The electron’s Kinetic energy is
transformed into heat energy when it strikes
the surface of the work piece.
SCHEMATIC 104

DIAGRAM:
 105

MAJOR COMPONENTS OF EBW:

 Electron gun ( anode, cathode& grid)

 Electromagnetic focusing lens

 Deflection coil

 Vacuum pump
CLASSIFICATION OF EBW
MACHINES:
By
accelerating By machine
By pressure
voltage concept
 Conveyor
High voltage  High vacuum
 machine
machine machine
(10-3to 10-  Clock system
(Up to150 kV)
6Torr)  All-purpose
 Low voltage
 Fine vacuum EBW
machine (Up machine
to 60kV)  machine
(25 to 10-3Torr)
 Local vacuum
 Atmospheric
machine (NV-  machine
EB welding)  Mobile vacuum
1 atm = 760 torr  machine 106
 Micro and fine
 welding machine
 107

WORKING:
 Current is applied to the cathode filament gets heated
up to 2000 Celsius.

 The scattered electron beams are attracted by anode

particle

 For acceleration of electrons a high voltage input of

about 10KV to 150KV is applied to the electrons.

 Now the electrons are focused by an magnetic lens for

converging of electron beams to the weld spot

 The deflection coil is For precise welding spot ,in

which the beam is positioned with a symmetrically
 108

ENERGY DISSIPATION IN EBW:

 109

PENETRATION OF ELECTRON BEAM:

 110

PHYSICAL PROPERTIES OF ELECTRON:

 Mass (m) = 9.1 X 10−31 kg
 Negative charge(e) = 1.6 X 10−19 C (coulomb)

Rate of energy input to the work

piece

Where
v- beam accelerating voltage ,v
I- beam current ,A
P-beam power ,W
v- travel speed ,mm/s
n- fusion efficiency
111
 COMPARING EBW WITH SIMILAR 112

WELDING PROCESSES:
PARAMET TIG PLASMA LASER EB
ER
Power input 2kW 4kW 4kW 5kW
to
W-P
Total power 3kW 6kW 50kW 6kW
used
Traverse 2mm/s 5.7mm/s 16mm/s 40mm/s
speed
Positional Good Good Yes Require Requires
welding penetration penetration optics to mechanism to
move the move the
beam beam
Distortion Nominal Nominal Small Minimum
shrinkage significant in significant in Minimum Minimum
 113

ADVANTAGES:
 Thin and thick plate welding (0,1 mm bis 300
mm)
 extremely narrow seams (t:b = 50:1)

 low overall heat input => low distortion =>

welding of
 completely processed components

 high welding speed possible

 No flux or shielding gas required

 high process and plant efficiency

 114

DISADVANTAGES:
 . electrical conductivity of materials is required
 high precision of seam preparation

 beam may be deflected by magnetism

 Safety concern: EBW generates x-rays

 Rapid solidification rates can cause

 cracking in some materials

 115

APPLICATIONS:
 Precision Aerospace Gears Weld

 Joint Geometry : radial circumferential weld

 Rotate at high speeds and operate at high loads,
require virtually defect free welds.
 116
 Turbocharger impeller weld

 Turbine blade repair weld

 117

 almost all steels

MATERIALS :
 aluminium and its alloys

 magnesium alloys

 copper and its alloys

 titanium

 tungsten

 gold

 material combinations (e.g. Cu-steel, bronze

steel)

 ceramics (electrically conductive)

 118

DIFFUSION BONDING:

Definition:
A solid-state welding process, wherein
coalescence of the faying surfaces is
produced by the application of pressure and
temperature to carefully cleaned and mated
metal surfaces so that they actually grow
together by atomic diffusion.
SCHEMATIC REPRESENTATION OF 119

DIFFUSION BONDING:
 The first stage is to achieve intimate metal to metal
contact between the two pieces to be diffusion welded.
120

This is done by the application of pressure that

deforms the substrate roughness and disrupts and
disperses the above mentioned surface layers and
contaminants.
 The pressure applied in diffusion welded ranges from
350 to 700 kg/cm2.
 The second stage involves diffusion and grain growth
to complete the weld and ultimately eliminate the
interface formed in the previous stage. The second
stage induces complete metallic bonding across the
area of contact.
 In order to increase diffusion rate, moderate heating
temperatures are used.
 Third stage involves elimination of voids in the
interface layer of the metals
 121

MICRO STRUCTURE VIEW :

 122

PROCESSES:
 123

DIFFUSION BONDING METHODS:

 Gas pressure boding
 Vacuum fusion bonding
 Eutectic bonding
 124

GAS PRESSURE BONDING:

 Parts to be joined are placed together in intimate

contact and then heated to around 815 Celsius .
During heating, an inert gas pressure is built up
over all the surfaces of the parts to be welded.

 Non ferrous metals are joined with the help of gas

pressure bonding method.
VACUUM FUSION BONDING:
 Parts to be joined are pressed together 125

mechanically or hydraulically. A hydraulic press

used for diffusion welding resembles that
employed in forging and is equipped to pressurize
from three directions.

 Heating is carried out the same way as in gas

pressure bonding.

 Process is carried out in vacuum chamber.

 Pressure and temperature for this kind of

diffusion bonding is approx. 1150 Celsius and 700
 126

EUTECTIC FUSION BONDING:

 It is a low temperature diffusion welding process.

 A thin plate of some other material is kept

between the pieces to be joined.

 As the pieces are heated to a elevated

temperature, the filler material diffuses and
forms an eutectic compound with the parent
metals.
 127

DIFFUSION BONDING PARAMETERS:

 Temperature

 Pressure

 Time

Temperature:

 It affects plasticity, diffusivity, recrystallization

 Ranges from 0.5Tm to 0.7Tm

 128
Pressure:

 Assures consistency of bonding between the work piece

 Pressure to maintained at optimum range because

plastic deformation occurs apart the interfacing layer

Time:

 When temperature increases simultaneously time

reduces to weld

 It ranges from few minutes to hours.

ADVANTAGES:
 Welded having essentially the same physical, 129

chemical and mechanical properties as the base

metal can be produced.

 Heat treating operations can be incorporated

during the bonding cycle.

 Continuous, leak tight welds can be formed.

 The process is well suited for welding dissimilar

metals and ceramics.

 Numerous welds can be made simultaneously.

 Weldability is largely independent of material

thickness.
 130

DISADVANTAGES:

 Diffusion welding requires a relatively long,

time consuming thermal cycle.

 With dissimilar materials, difficulties due to

time / temperature / pressure requirements
are frequently encountered.

 Diffusion welding is not classified as a mass

 production process.
APPLICATION: 131

 Fabrication of reactor components in atomic

energy industries.

 Fabrication of honeycomb, rocket engines,

helicopter rotor hub, turbine components,
etc., in aerospace missile and rocketry
industries.

 Two controversial aerospace vehicles have

brought diffusion bonding into the light e.g.,
B-1 bomber and space shuttle.

 Fabrication of composite materials.

 PONDICHERRY ENGINEERING COLLEGE

SPECIAL METAL JOINING PROCESSES

ULTRASONIC WELDING AND FRICTION WELDING

Subject Handling Presented by

Staff Magesh K
Dr.K.Mahadevan 17ME325
Head of the Dept
I yr M.Tech. Product Design and Manufacturing
Mechanical
Engineering
 WELDING

SOLID
FUSION
STATE
WELDING
WELDING

Examples Example
SMAW s
SAW FRW
EBW USW
EXW
SPECIAL METAL JOINING PROCESS
 Also called MISCELLANEOUS WELDING PROCESS
 These processes are used for improved weld quality and
human comfort
 Both friction welding and ultrasonic welding

comes under SOLID STATE WELDING

SOLID STATE WELDING -PRINCIPLE

If two clean surfaces are brought into close contact with
each other under sufficient pressure, they form bonds and
produce a joint.
PHENOMENA INVLOVED
 Diffusion
Transfer of atoms at the interface
 Pressure

 Relative Interfacial Movements

 VARIOUS SPECIAL METAL JOINING
PROCESSES

 Ultrasonic welding (USW)

 Friction welding (FRW)

 Explosive Welding (EXW)

 Electron Beam Welding (EBW)

 Diffusion Welding OR Diffusion Bonding(DFW)

 Laser Beam Welding (LBW)

 Thermit Welding (TW)

 Forge Welding (FOW)

 Induction Welding (IW)

 ULTRASONIC WELDING
 SOLID STATE WELDING PROCESS
 In USW, the coalescence is produced by the local
application of high frequency vibratory energy as the
work parts are held together under high pressure
PROCESS

Stresses
involved

• Static Normal
Stress
•Tangential
Shear stress
KEY POINTS TO BE NOTED
 Electrode is called ‘Sonotrode’
 No fusion or melting

 Temperature at the weld zone = 1/3 to 1/5 of Tm.

However, for joining thermoplastics, relatively
lower temperature is used
 Dissimilar metals can be welded with USW
(Bimetallic strips)
ULTRASONIC SEAM WELDING
 PARAMETERS
PARAMETER OPTIMUM RANGE
Frequency 10-75 kHz
Period of contact at the less than 1 second
interface
Thickness •0.005 to 1 mm for steel
•Upto 3 mm for
Aluminium
•Upto 10 mm for
materials like organic
glass, PVC,
Polyethylene, Vinyl
Chloride, Polystyrene
Force • maximum of 3000N
 BASIC RELATIONS
 E = PxT
E -Energy input
P - Power
T - Time
 P= F x V

F -Force
V - Speed of movement of tool
 APPLICATIONS

Polymers used in
car components Medical Apllications
 OTHER APPLICATIONS OF USW
 Air craft construction
 Building of transistors

 Fine wire assemblies

 Bimetal electrical contacts

 Welding of Aluminium foil for packaging

requirements
FRICTION WELDING

 Heat required for

welding is generated
through friction between
the faying surfaces
 It is a Solid state
welding process
 Subjected to axial force
and torque
 KEY POINTS TO BE NOTED
 Oxides and other contaminants at the interface
are removed by the radially outward movement
of the hot metal at the interface
 The rotating member must be clamped securely
to the chuck or collect to resist both torque and
axial forces without slipping
 The pressure at the interface and the resulting
friction produce sufficient heat for a strong joint
to form
ANALYSIS
UPSET LENGTH
The upset length is the distance the two
pieces move inward during welding after
their initial contact
FRICTION WELDING
REAL TIME PICTURE
SIZE AND SHAPE OF THE WELD
Size depends on
• The amount of heat generated.

• Thermal conductivity of the

materials.
• Mechanical properties of the
materials being joined at elevated
temperatures
Shape depends on
• Rotational speed and Axial pressure
applied
• Generally solid and tubular shafts
MODIFICATIONS OF FRW
 Inertia Friction Welding
 Linear Friction Welding ( W/P need not be
circular)
 Friction Stir Welding

Inertia Friction Welding Linear Friction Welding

 FRICTION STIR WELDING

•In Friction Stir Welding, (developed in 1991), a

third body is rubbed against the two surfaces to be
joined
•In FRSW, electrode is also called as ‘Mechtrode’
FRICTION STIR WELDING
REAL TIME PICTURE
 PROCESS VARIABLES
 Rotational speed
 Forging pressure

 Time for heating

 Time for braking

 Time for forging

PARAMETERS AND MATERIALS
USED
PARAMETERS FRW / IFRW LFRW FRSW

Size Steel solid rod Rectangular Probe – 5 to 6

– <100mm sections as mm dia and 5
Steel Pipes - < large as 50mm mm height
250mm x 20mm W/P – 1 mm
to 50 mm
75 mm thick
Al plates

Surface speed of 15m/s 25 Hz 15 m/s

rotating member (amplitude + or
/ Frequency - 2 mm)
Pressure Applied 100 MPa for 240 mm2

Temperature 230 to 260 ºC

 BASIC RELATIONS
 Friction force (F) depends on Area of contact (A)
and applied load (L)
F = αA + μL
 If applied pressure is very high, Area is negligible
and can be neglected
F = μL
μ – Coefficient of friction (<0.3)
H = 2PK/nR x102 W/mm2
H – Heat generated W/mm2;
K – constant (mm2/min2)
N – speed (rpm)
R – Work Radius (mm)
 Space Crafts Apple iMAC

Train Bodies Marine Vessels

 APPLICATIONS

Gear Lever Piston Rods

Pump Shafts Engine Valves

VALVES
NEWER MATERIALS
&
PROCESSING

1.Electro Hydraulic Forming

&
2.Magnetic Pulse Forming

Presented by

K.Karthikeyan

1st yr M.Tech [PDM]

PEC
 ELECTRO HYDRAULIC FORMING
 A sudden electrical discharge in the form
of sparks is produced between the
electrodes and this discharge produces a
shock wave in the water medium.
 This shock wave deforms the work plate
and collapses it into the die.
 The characteristics of this process are
similar to those explosive forming. Here
the chemical explosive is replaced by a
capacitor bank, which stores electrical
energy.
CIRCUIT DIAGRAM
CONTINUATION

 The capacitor is charged through a

charging circuit.
 The energy released here is much
lesser than that released in explosive
forming.
 This process is also known as Electro
discharge or Electro shape or Electro
spark forming.
PROCESS CHARACTERISTICS
 Standard off distance must be optimum.
 Capacitor used : The energy of the
pressure pulse depends on the size of
capacitor.
 Transfer medium : usually water is used.
 Vacuum : The die cavity must be
evacuated to prevent adiabatic heating of
the work due to a sudden compression of
air.
 The capacitor bank is capable of
producing 5-25 kv and can store energies
upto 100kJ.
ADVANTAGES

 Pressure and Electrical energy is

easily controlled.
 Safer in handling than the explosive
materials.
 More suitable if the work size is
smaller than the medium.
 Thin plates can be formed with
smaller amounts of energy.
DISADVANTAGES
 Suitable only for smaller works.
 Need for vacuum makes equipment
more complicated.
 Proper SOD is necessary for effective
process.
 Each discharge of electrodes creates the
high voltage discharge in the fluid
results in vaporization of electrodes and
may creates the surface defects.
 The fluid vessel generally drained and
replaced for each vessel.
APPLICATIONS

 Reduces capital investments.

 Used in low volume Aerospace
applications.
 In Automobile section car doors are
manufactured.
 Complicated profiles in miniature
and fancy equipment's for electronic
industry are manufactured.
2. MAGNETIC PULSE FORMING PROCESS

 The electrical energy stored in a

capacitor bank is used to produce
opposing magnetic fields around a
tubular work piece, surrounded by
current carrying coils.
 The coil is firmly held and hence the
work piece collapses into the die
cavity due to magnetic repelling
force, thus assuming die shape.
DIAGRAM
ADVANTAGES

 Suitable for small tubes.

 Operations like collapsing, bending,
and crimping can be easily done.
 Electrical energy applied can be
precisely controlled and hence the
process is accurately controlled.
 This process is safer compared to
explosive forming.
 Wide range of applications.
DISADVANTAGES

 Applicable only for electrically

conducting materials.
 Not suitable for large work pieces.
 Rigid clamping of primary coil is
critical.
 Shorter life of the coil due to large
forces acting on it.