DESIGN AND ANALYSIS OF CHAIN SPROCKET

BY USING NICKEL COATED

 ABSTRACT

In this study, nickel was coated as bonding layer on the sprocket, one of which was
coated with nickel by PVD coatings process. In addition, the sprockets were tested
with micro hardness and wear as ASTM testing procedure. The measurements
showed that although of the coated sprocket were exposed to higher friction of
wears and the compared to the original sprocket and nickel coated sprocket. In this
coated sprocket to improve the hardness, wear and corrosion resistance
 Chapter-1
INTRODUCTION
 Chapter-1

INTRODUCTION

INTRODUCTION OF COATINGS

protective coatings

Protective coatings are used in oil and gas storage, transmission and distribution
network to prevent steel structures against corrosion. Steel structures like trains,
ships, automobiles, airplanes, underground buried gas pipelines, fuel storage tanks
etc require the use of protective coatings. The importance of a coating can be
judged from the fact that it can hardly be ignored in any corrosion protective
scheme. Protective coatings are unique specialty products which represent the most
widely used method of corrosion control.

They are used to give long term protection under different corrosive
conditions. The function of a protective coating or lining is to separate two highly
reactive materials; to prevent corrosive environment species from contacting the
reactive underlying steel structure. This is to say that a coating or a lining acts as
a barrier to prevent either chemical compounds or corrosion currents from
contacting the substrate . Corrosion protection of over-ground and under-ground
steel structures with the help of organic coatings are one of the most proven
methods. Other methods include Cathodic Protection (CP), environmental
modification, material selection and design. If the resistivity of electrolyte is
increased and the electron flux is retarded, the rate of corrosion is decreased. By
applying coatings of high resistivity, such as epoxies, vinyls, chlorinated rubbers,
etc. the flow of electric current to the metal surface is impeded. Also the higher the
thickness of a coating, the higher would be its electrical resistance.
A much higher resistance to the current flow would, therefore, be offered. Thus
increasing the electrical resistance of metals by coating offers an excellent
method of corrosion prevention. Another method to prevent corrosion is by the
use of inhibitors. This can be achieved by using inhibitive pigments, like zinc
chromate, red lead and zinc phosphate in coatings. An alternative method is to use
a metal more anodic than iron, such as zinc. This is done by using zinc-rich
coating. The zinc metal prevents the corrosion of iron by releasing electrons into
the iron surface. Thus, coatings are an effective method to control corrosion.

Purposes of a coating

A coating serves many purposes. Some of these are presented as below:-

 Protection of steel structures from the environment by acting as a barrier

between the substrate and the aggressive environment, such as the marine
and industrial environments.
 Control of solvent losses.
 Control of marine fouling; certain constituents in coating control
growth of mildew and marine fouling in seawater.
 Reduction in friction (coating reduces friction between two contacting
surfaces).
 Pleasant appearance; certain types of coatings provide a pleasant
appearance and produce attractive surroundings.
 Change in light intensity; by selection of appropriate coatings the light
intensity in rooms and buildings can be varied as desired.
 Visibility; many combinations of colors because of their visibility
from large distances are used on television and radio towers to warn
air craft.
  Modification of chemical, mechanical, thermal, electronic and optical
properties of materials.
 Application of thin coatings on low-cost substrates results in increased
efficiency and cost savings.

Coating as a means of corrosion control

First attempts to control steel structures corrosion relied on the use of coating
materials and the reasoning that if the substrate could be isolated from contact with
the surrounding earth, no corrosion could occur. This concept is entirely reasonable
and logical. Furthermore, a coating would be completely effective as a means of
stopping corrosion if the coating material:-Is an effective electrical insulator, Can
be applied with no breaks whatsoever and will remain so during the
backfilling process, and Constitutes an initially perfect film that will remain so
with time. Although coatings by themselves may not be the one perfect answer to
corrosion control, they are extremely effective when properly used. Most operators
plan coatings and Cathodic Protection (CP) for all their steel structures like oil and
gas transmission pipelines as a matter of course. A properly selected and applied
coating will provide all the protection necessary on most of the pipeline surface to
which it is applied. On a typical well-coated pipeline this may be better than 99%
and, along with the CP, may give total protection.

Characteristics of coatings

NACE Standard RP0169-96 Section 5: Coatings, is a comprehensive guide to pipe

coatings, and is required reading for a better understanding of their importance.
This standard lists the following desirable characteristics of coatings:-
Specifications of a coating

Specifications may be prepared in light of the recommendations of the coating

manufacturer with relevant modifications as may be dictated by conditions
applicable to the particular project and requirements of the coating system. Areas
to be covered by specifications may include the following:-

 Cleaning the steel surface

 Priming, if required
 The coating materials to be used and (if more than one material) the order in
which they are to be applied
 Total thickness with permissible tolerances
 Specifications applicable to the particular materials to be used, such as
application temperature and thickness, tension (for tapes or wrappers), and
other items of a similar nature
 Handling requirements for coating materials, such as storage provisions
and maintenance of dry and clean conditions Inspection requirements
Procedure for repair of coating defects

BASICS FOR REJECTION OF UNACCEPTABLE COATING

Requirements for handling and transporting the coated pipe Details of coating field
joints when factory coated pipe is used Backfilling requirements Modern coatings
are mainly of barrier type among which organic coatings are being extensively
used in oil and gas storage/transmission and distribution due to ease of application.
They have excellent barrier and fairly quick drying properties besides being cost
effective. The study of water uptake in an organic coating easily provides
knowledge about the interaction between water molecules and polymer.
Classification of a coating may help in understanding its degradation mechanism
and ultimate corrosion underneath coating at an early stage.

CLASSIFICATION OF COATINGS

According to their ability to resist corrosion, coatings can be classified into four
main categories namely barrier coatings, conversion coatings, anodic coatings, and
cathodic coatings. A brief description of these coatings is given as follows:-
Barrier coatings

Barrier coatings are of four types including organic coatings, inorganic coatings,
anodic oxides, and inhibitive coatings.

Organic Coatings

Epoxy, polyurethane, chlorinated rubber and polyvinyl chloride coatings serve as a

barrier to water, oxygen, and ions. They prevent initiation of any cathodic reactions
at the coating-substrate interface. Their barrier properties can be further enhanced
by addition of suitable inhibitors, like chromate, in the primer.

Inorganic Coatings

These include coatings like ceramics and glass. Glass coatings are virtually
impervious to water. Cement coatings are impervious as long as they are not
mechanically damaged.

Anodic Oxides

A layer of Al2O3 is produced on aluminum surfaces by electrolysis. As the oxides

are porous, they are sealed by a solution of potassium dichromate so as to
minimize coating porosity.
Inhibitive Coatings

Inhibitors are added to form surface layers which not only serve as a barrier against
the hostile environment but also prevent substrate corrosion in neutral or alkaline
media.

Conversion coatings

In case of conversion coatings, the surface metal is converted into a compound

having the desired porosity to act as a good base for coatings Phosphate and
chromate coatings are examples of conversion coatings.

Anodic coatings

In case of steel substrates, they are also known as sacrificial coatings. They protect
the substrate at the expense of the metallic coating applied. The zinc coatings
protect the substrate by acting as a sacrificial anode for the steel which is cathodic
to zinc.

Cathodic coatings

In such types of coating, the metals which are deposited are electropositive to the
substrate like copper coated steel wherein copper (0.337 Volts) is positive to steel
(-0.440 Volts). Electroplated coatings are generally pore-free and discontinuities
are not observed. Since organic coatings have been the focus of attention during
this research work, a brief review of literature on organic coatings is presented

Organic Coatings

Corrosion protection by organic coatings is accomplished through either a barrier

function or an inhibitive function. The barrier function is achieved by blocking the
entrance of water, oxygen and ions towards the substrate while the inhibitive
function is achieved by modification of the aqueous environment as it moves
through the coating film. The purpose of an organic coating is to promote,
enhance, and maintain a passive or a protective layer on the reactive metal
substrate. The two main types of coatings that have been studied during the course
of this work have been Fusion Bonded Epoxy (FBE) coatings for external
protection of pipelines buried under soil and two-pack polyamide epoxy coatings
used as internal lining of fuel storage tanks. Their brief description is as follows:-

FBE coatings systems can be divided into two main categories namely:-

 FBE single, or multiple coating systems these coatings initially consist of

100% solids thermosetting powders. When electro statically spray applied to
a preheated pipe, the FBE powder material melts flows, gels and cross-links,
forming a tough durable coating.
 Dual-layer FBE systems consist of two differently formulated FBE powders
applied consecutively. The second layer usually is tougher, and has better
temperature and/or mechanical resistance. Liquid coatings can also be
applied over FBE to impart mechanical resistance. 3-layer polyethylene
coating system
 It is similar to the non-FBE 3-layer polyethylene except an FBE primer is
used in lieu of the liquid epoxy primer. After FBE application, a co- or ter-
polymer an hydride grafted adhesive is applied to bond the polyethylene to
the FBE, followed by application of the polyethylene by wrapping, powder
spray and cure, or extrusion.
 Fusion-bonded epoxy (FBE is considered a superior coating material for
underground oil/gas transmission pipeline protection since it has excellent
adhesion to steel, good chemical resistance, low oxygen permeability, and
good flexibility.
  There are many factors that may affect the long-term performance of a
coating. One of them is its formulation while another may be the surface
preparation of the steel substrate before application of a coating. Improved
adhesion will enhance the FBE/CP performance. Adhesion comes from
mechanical, polar-polar (i.e. hydrogen bonding) and chemical bonding to the
substrate.

The use of two or more layers of FBE coatings provides much greater versatility
to oil/gas pipeline coating-protection-system capability. The primary layer is
typically a coating material designed as part of a corrosion protection system.
That means it has good initial adhesion and maintains adhesion after
exposure to hot water or other environmental factors. For underground
pipeline service, it also must resist cathodic disbondment.

The top layer can provided many different attributes, depending on

coating-system requirements. It can provide protection against mechanical
damage - e.g., impact, abrasion, and gouge. Coated steel pipes are exposed to
different types of conditions while being transported from the coating applicator
plant to finally being buried under ground. These could result into coating
damage in the form of holidays, disbondment and delamination leading to
premature failure of the coating substrate system.

SPROCKET COATINGS

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even

sprockets that mesh with a chain, track or other perforated or indented material.
The name 'sprocket' applies generally to any wheel upon which radial projections
engage a chain passing over it. It is distinguished from a gear in that
Sprockets are never meshed together directly, and differ from a pulley in that
sprockets have teeth and pulleys are smooth.

A coating is a covering that is applied to the surface of an object, usually

referred to as the substrate. The purpose of applying the coating may be decorative,
functional, or both. The coating itself may be an allover coating, completely
covering the substrate, or it may only cover parts of the substrate. An example of
all of these types of coating is a product label on many drinks bottles- one side has
an all-over functional coating (the adhesive) and the other side has one or more
decorative coatings in an appropriate pattern (the printing) to form the words and
images. Paints and lacquers are coatings that mostly have dual uses of protecting
the substrate and being decorative, although some artist paints are only for
decoration, and the paint on large industrial pipes is presumably only for the
function of preventing corrosion.

Functional coatings may be applied to change the surface properties of the

substrate, such as adhesion, wet ability, corrosion resistance, or wear resistance. A
major consideration for most coating processes is that the coating is to be applied
at a controlled thickness, and a number of different processes are in use to achieve
this control, ranging from a simple brush for painting a wall, to some very
expensive machinery applying coatings in the electronics industry. A further
consideration for 'non-all-over' coatings is that control is needed as to where the
coating is to be applied. A number of these non-all-over coating processes are
printing processes. Many industrial coating processes involve the application of a
thin film of functional material to a substrate, such as paper, fabric, film, foil, or
sheet stock. If the substrate starts and ends the process wound up in a roll, the
process may be termed “roll-to-roll” or "web-based" coating. A roll of substrate,
when wound through the coating machine, is typically called a web.
 Chaptet-2
LITERATURE REVIEW
 CHAPTET-2

LITERATURE REVIEW

Biermann, A. Peukera, P. Kersting, H. -J. Maier, K. Möhwald, P. Knödler, M.

Otten, Development and Analysis of Microstructures for the Transplantation of
Thermally Sprayed Coatings‖ has presented thermally sprayed coatings and
tribological surfaces are a point of interest in many industrial sectors. They are
used for better wear resistance of light weight materials or for oil retention on
surfaces. It is necessary to coat the cylinder liners to ensure wear resistance. In
most cases, the coating is sprayed directly onto the surface. Previous research has
shown that it is possible to transfer these coatings inversely onto other surfaces.
This was achieved with plasma sprayed coatings which were transplanted onto
pressure-casted surfaces. Mr. Atul A. Sagade, Prof. N.N. Shinde, Prof. Dr. P.S.
Patil, Effect of receiver temperature on performance evaluation of silver coated
selective surface compound parabolic reflector with top glass cover has presented
the experimental results of the prototype compound parabolic trough made of G.I
and silver coated selective surface.
.
From the sprocket components based on heat transfer mechanism. Mainly
the results of convective heat transfer coefficient & radiative heat transfer
coefficient are compared with practical values. This paper concludes that the
material has large influence on convective & radiative heat transfer & to avoid
thermal cracks temperature should be within optimum range. Amol A. Apte and H.
Ravi has analyzed finite element prediction on thermal performance of sprocket&
stresses in a sprocket system. Validation of sprocket design is carried out through
CAE/FEA. The procedure for prediction of thermal performance of sprocket is
developed & it correlate with test data available for the recently available design &
it applied to the new sprocket design.M.Rama Narasimha Reddy, K.Harshavardhan
Reddy, N.Balaji Ganesh has analyzed structural & thermal analysis of sprocket. In
this work they compare the results for stainless steel & carbon steel & result
obtained is that both the materials has stress value less than yield stress but thermal
gradient of carbon steel is more than stainless steel so carbon steel is better than
stainless steel.O.S.I. Fayomi , O.O.

Joseph a, M.P. Mubiayi c, B.M. Durodola d, O. Gabriel has analyzed the

effect of Zn-MgO deposition prepared through direct electrolytic co-deposition on
mild steel. The experiment was conducted at current density between 0.5 and
1A/cm−2. The morphologies of the coated surfaces were characterized using
Atomic Force Micro- scope (AFM), high resolution Nikon Optical Microscope
(OPM) and Scanning Electron Microscopy attached with Energy Dispersive
Spectrometer (SEM/EDX). The corrosion behavior was studied using linear
potentio- dynamic polarization method in 3.5% simulated environment.

The phase change was evaluated using X-ray Diffract gram (XRD).Y.
ReyesVidal a,1, R. Suarez-Rojas a, C. Ruiz a, J. Torres, Alia Méndez b, G. Trejoa
has analyzed The safety of heavy equipment is directly determined by the quality
of heavy-duty sprocket which is a basic component transmitting motion and power.
However, local overheat of tooth surface, non-homogeneous hardness and micro
cracking are observed due to the skin effect, corner effect, and annular effect
during traditional induction hardening of sprockets with conventional circular
coilM. Szociński, K.Darowicki has analyzed that polyvinyl zinc-rich coating
exposed to 97% relative humidity atmosphere for 40 days. Condition of the coating
and evolution of its protective properties were determined with the novel AFM-
based approach capable of providing surface profiles, local dc current maps as well
as local impedance spectra. The proposed technique allowed insight into the local
changes of coating topography and electrical Properties accompanying a transition
from purely electrochemical to barrier mechanism of protection.
 Chaptet-3
COATINGS AND METHODS
 Chapter-3

COATINGS AND METHODS

TYPE OF COATING MATERIALS

1. Nickel
2. Chromium
3. Yttrium oxide
4. black oxide
5. zinc

TYPE OF COATING

1. Pvd coating

2. Cvd coating

PHYSICAL VAPOUR DEPOSITION (PVD)

The basic PVD processes fall into two general categories: sputtering and
evaporation. The application of PVD techniques ranges over a wide variety of
applications from decorative, to high temperature superconducting films. The
thickness of the deposits can vary from angstroms to millimeters. Very high
deposition rates (25µm/sec) have been achieved with the advent of electron beam
heated sources. A very large number of inorganic materials metals, alloys In
physical vapor deposition (PVD) processes, the coating is deposited in vacuum by
condensation from a flux of neutral or ionized atoms of metals. Several PVD
techniques are available for deposition of hard coatings. Among them, cathodic arc
vapor (plasma or arc ion plating) deposition, magnetron sputtering (or sputter ion
plating), and combined magnetron and arc processes are the most widely used
techniques to deposit various hard coatings.

These PVD processes differ with respect to the type of evaporation of the
metallic components and the plasma conditions employed during the deposition
process. The transition of the metallic component (to be deposited) from a solid to
a vapor phase (in which metal atoms are ionized in different ways) may be
performed by heating of an evaporation source (as in cathodic arc) or by sputtering
of a target (as in magnetron sputtering). Cathodic arc and magnetron sputtering
techniques allow evaporation of metals with different melting points such as Ti and
Al from a Ti–Al alloy cathode/target.

The PVD arc evaporation process employs higher energy input than the
PVD sputtering process. In the case of arc evaporation, a small limited cathodic
area is evaporated with a very high energy arc that quickly moves over a spot on
the metal surface to be evaporated. The plasma generated consists of highly
ionized metal vapor. In the case of sputtering, atoms are ejected mechanically from
a target by the impact of ions or energetic neutral atoms.

 The high micro-hardness provides excellent abrasion resistance, and allows

the cutting edge to stay sharper for longer
 The lowered Coefficient of Friction means there is less resistance during the
cut; therefore, less heat is generated heat build-up being another major factor
in cutting edge break down
 The lowered Coefficient of Friction also means the chips generated during
the cutting process are evacuated more efficiently; therefore, the heat that is
generated does not have as much time to transfer from the chip to the tool –
more heat stays in the chip
  The lowered Coefficient of Friction will reduce machining noise and the
load placed on spindle motors
 The lack of chemical affinity between various coatings and work pieces will
reduce material “pick-up,” another leading cause of cutting edge
breakdown. For example, when cutting titanium with a ZrN coated end mill,
the titanium has no chemical affinity towards ZrN; therefore, you will
experience almost no “pick-up.”
 The lowered Coefficient of Friction creates a free-cutting tool – this may
reduce or eliminate burrs and help to improve the surface finish or machined
parts.
Chemical vapour deposition or CVD is a generic name for a group of processes
that involve depositing a solid material from a gaseous phase and is similar in
some respects to physical vapour deposition (PVD).PVD differs in that the
precursors are solid, with the material to be deposited being vaporised from a solid
target and deposited onto the substrate.

CVD COATINGS

TYPES OF CVD PROCESSES

CVD covers processes such as:

 Atmospheric Pressure Chemical Vapour Deposition (APCVD)

 Low Pressure Chemical Vapour Deposition (LPCVD)
 Metal-Organic Chemical Vapour Deposition (MOCVD)
 Plasma Assisted Chemical Vapour Deposition (PACVD) or Plasma
Enhanced Chemical Vapour Deposition (PECVD)
 Laser Chemical Vapour Deposition (LCVD)
  Photochemical Vapour Deposition (PCVD)
 Chemical Vapour Infiltration (CVI)
 Chemical Beam Epitaxy (CBE)

CVD WORK
Precursor gases (often diluted in carrier gases) are delivered into the reaction
chamber at approximately ambient temperatures. As they pass over or come into
contact with a heated substrate, they react or decompose forming a solid phase
which and are deposited onto the substrate. The substrate temperature is critical
and can influence what reactions will take place.

SELECTION OF SPROCKET

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even

sprockets that mesh with a chain, track or other perforated or indented material.
The name 'sprocket' applies generally to any wheel upon which radial projections
engage a chain passing over it. It is distinguished from a gear in that Sprockets are
never meshed together directly, and differ from a pulley in that sprockets have
teeth and pulleys are smooth.
Manufacturing processes for sprocket

There are several methods that could be used to manufacture sprocket. The
methods include milling, hobbing, powder metallurgy, sintering, and steel casting.
The selection of a particular process is hinged on the sprocket material, equipment
availability and cost. A hobbing machine is a milling variant used to cut sprockets,
gears, and splined parts using a specialist cutting tool known as hob. The hob is a
cylindrical cutting tool that features a series of helical rows of teeth. The hobbing
machine features two spindles, one of which holds the work piece and the other the
hob. Both spindles rotate at a set ratio while the hob is advanced into the work
piece to cut the teeth. Cutting toothed parts on a hobbing machine is a cheap yet
accurate method of production of a wide range of products including worm gears,
ratchets, involute gears, and helical gears. In most cases, the manufacturing process
to be used greatly lies on the facility available. Though, hobbing remains one the
best methods that could be used, in this work universal milling machine was used.
The operation layout of the manufacturing process is shown in Fig

PROBLEM IDENTIFICATION

A coating serves many purposes. Some of these are presented as Protection of

steel structures from the environment by acting as a barrier between the substrate
and the aggressive environment, such as the marine and industrial environments.
Control of solvent losses. Control of marine fouling; certain constituents in
coating control the growth of marine fouling in seawater. Reduction in friction
(coating reduces friction between two contacting surfaces).

Pleasant appearance; certain types of coatings provide a pleasant appearance

and produce attractive surroundings. Change in light intensity; by selection of
appropriate coatings the light intensity in rooms and buildings can be varied as
desired. Visibility; many combinations of colors because of their visibility from
large distances are used on television and radio towers to warn aircraft.
Modification of chemical, mechanical, thermal, electronic and optical properties
of materials. Application of thin coatings on low-cost substrates results in
increased efficiency and cost savings.

SELECTION OF COATING MATERIALS

NICKEL COATINGS

The technology of electroplating of nickel has been extensively developed,

particularly through the last five decades, to make possible the efficient production
of a broad range of industrial coatings for both decorative and functional
applications. Electroplated nickel is commercially important with upwards of
150,000 tonnes deposited annually worldwide. This widespread use reflects the
useful properties of nickel as a coating and its versatility.

A feature of is by modifying the composition of the electrolyte and the operating

conditions, the properties and appearance of nickel can be customised to meet
specific needs. Electroplated nickel is used extensively to enhance the utility, value
and sales appeal of consumer goods and manufactured products. Other nickel
coatings are used to improve the physical properties such as wear resistance, heat
resistance or corrosion resistance. In many important applications, the nickel
coatings serve the dual role of providing a bright decorative coating and Imparting
improved corrosion resistance or other functional properties.

Nickel coating process by which nickel is built up by electro deposition onto

a suitable mandrel and subsequently removed to produce a nickel product which
corresponds precisely to the shape and texture of the original substrate. This
Handbook has been prepared to provide practical information on the operation and
control of nickel plating processes. The basics of electroplating are addressed and
is focussed on the operation of the plating bath. Information is included on the
composition of plating solutions, correct control of anodes, trouble-shooting and
practical operation. Quality aspects and specifications are discussed to ensure that
coatings meet the required performance standards.

PROPERTIES VALUE

Thermal conductivity 93.9 W/(m·K)

Young's modulus 279 GPa

Bulk modulus 160 GPa

Poisson ratio 0.21

SELECTION OF COATING PROCESS

PHYSICAL VAPOUR DEPOSITION (PVD)

In physical vapor deposition (PVD) processes, the coating is deposited in vacuum

by condensation from a flux of neutral or ionized atoms of metals. Several PVD
techniques are available for deposition of hard coatings. Among them, cathodic arc
vapor (plasma or arc ion plating) deposition magnetron sputtering (or sputter ion
plating), and combined magnetron and arc processes are the most widely used
techniques to deposit various hard coatings.

These PVD processes differ with respect to the type of evaporation of the
metallic components and the plasma conditions employed during the deposition
process. The transition of the metallic component (to be deposited) from a solid to
a vapor phase (in which metal atoms are ionized in different ways) may be
performed by heating of an evaporation source (as in cathodic arc) or by sputtering
of a target (as in magnetron sputtering).

Cathodic arc and magnetron sputtering techniques allow evaporation of

metals with different melting points such as Ti and Al from a Ti–Al alloy
cathode/target. The PVD arc evaporation process employs higher energy input than
the PVD sputtering process. In the case of arc evaporation, a small limited cathodic
area is evaporated with a very high-energy arc that quickly moves over a spot on
the metal surface to be evaporated. The plasma generated consists of highly
ionized metal vapor. In the case of sputtering, atoms are ejected mechanically from
a target by the impact of ions or energetic neutral atoms. As may be noted from
Table 1, the cathodic arc process generates the highest quantity of ionized target
atoms, 50–100%, followed by anodic arc ion plating in the range of 5–40%. The
quantity of ionized atoms is rather low for magnetron sputtering.

The significance of metal ionization rates can be described as follows: The

energy during the deposition of coating depends on the atomic masses of the
participating ionized atoms, which in turn controls momentum transfer. The total
atomic mass of participating ions is highest in the case of the cathodic arc
deposition process due to the ability to evaporate large percentage of metallic ions
from cathodes (highest ionization rate).

This leads to high deposition energy, and a dense coating. In addition, the
ion plating effectiveness (defined as the potential to coat the substrate surface in
micro scale) of the cathodic arc deposition technique is higher than that of
conventional magnetron sputter techniques. Cathodic arc deposited coatings also
exhibit a higher level of adhesion to the substrate due to the effect of ion
bombardment or ion etching. During bombardment, high-energy metal ions
generated from the cathode bombard the substrate surface kept at a high negative
bias of 500–2000 V.

In addition to cleaning and heating the substrate, energetic metal ions during
ion bombardment knock off some metal atoms from within the substrate or may
penetrate the substrate lattice to angstrom levels. This leads to defects and
roughness on the substrate at an atomic level, and the atomic level of roughness is
believed to be responsible for the improved adhesion of the coating. Target
poisoning and very low ionization rates are the two drawbacks of conventional
magnetron sputtering process. Conventional sputtering techniques were modified
to improve ionization rates.

High ionization magnetron sputtering techniques, and allow deposition of

hard coating at a much higher ionization rate than conventional sputtering
techniques. Sputtered coatings generally have a columnar structure and a smooth
coating surface without the presence of macro particles, a typical problem of arc
evaporation. The main disadvantage of the cathodic arc process is the formation of
macro particles. Macro particles (or macro droplets) are the result of droplet
formation during arc evaporation of low melting point materials (e.g. aluminum in
the case of black oxide coating). It is also believed that very fast evaporation
during the cathodic arc process produces excess atoms that are not completely
ionized before they arrive at the substrate surface.

The property requirements for coating vary widely from application to

application. The target/cathode ratio, coating micro hardness and microstructure of
the coatings are among the most important properties that determine the wearing
resistance of hard coating for cutting tools. A rating of the properties for various
PVD coating techniques is difficult because they depend on coating system,
deposition processes and parameters.

However, the target composition, substrate temperature, bias voltage, gas

flow and ion bombardment rates are most important parameters in case of CAE
process. Whereas magnetron Power, ion current density, substrate bias, gas
pressure, target composition and substrate temperature were found to be most
influential parameters in the case of magnetron sputter deposition. These
parameters directly affect the mechanical, tribological, structural and thermo-
oxidation properties of coating. The choice of base material also plays an
important role for actual industrial application. Various industrial tools and dies
were used to deposit various coatings such as TiN, TiCN, TiC, (Ti,Al)N, black
oxide and etc. cermets and high speed steels are the most common tool materials
used in industries for various types of machining operations, namely drilling, metal
cutting, milling and turning. The process involved four steps:

 Evaporation
 Transportation
 Reaction
 Deposition


Evaporation

During this stage, a target, consisting of the material to be deposited is bombarded

by a high energy source such as a beam of electrons or ions. This dislodges atoms
from the surface of the target, ‘vaporizing’ them. Stage. For the above examples,
the reactive gases may be oxygen, nitrogen and methane.

Transport
This process simply consists of the movement of ‘vaporized’ atoms from the target
to the substrate to be coated and will generally be a straight line affair.

Reaction
In some cases coatings will consist of metal oxides, nitrides, carbides and other
such materials. In these cases, the target will consist of the metal. The atoms of
metal will then react with the appropriate gas during the transport stage. For the
above examples, the reactive gases may be oxygen, nitrogen and methane. In
instances where the coating consists of the target material alone, this step would
not be part of the process.

Deposition
This is the process of coating build up on the substrate surface. Depending on the
actual process, some reactions between target materials and the reactive gases may
also take place at the substrate surface simultaneously with the deposition process.

PVD USES

PVD coatings are deposited for numerous reasons. Some of the main ones are:

• Improved hardness and wear resistance

• Reduced friction
• Improved oxidation resistance
EXPRIMENTAL TESTING
 Chapter-4

MECHANICAL PROPERTY TESTING

TYPE OF TESTING

1. KNOOP HARDNESS
2. Wear test

1. Knoop hardness

The Micro hardness test method, according to ASTM E-384, specifies a range of
loads using a diamond indenter to make an indentation that is measured and
converted to a hardness value. There are two types of micro hardness indenters, a
square base pyramid shaped diamond used in a Vickers tester and a narrow
rhombus shaped indenter for a Knoop tester.
Typically, loads are very light, ranging from a few grams to one or several
kilograms. The term micro hardness refers to static indentations made with loads
not exceeding 1 kgf. The procedure for testing is very similar to that of the
standard Vickers hardness test, except that it is done on a microscopic scale with
higher precision instruments. Precision microscopes used to measure the
indentations, have a magnification of approximately X500, and measure an
accuracy of +0.5 micrometers

PIN ON DISC WEAR TESTER

Surface engineering point of view, wear test is carried out to evaluate the potential
of using a certain surface engineering technology to reduce wear for a specific
application, and to investigate the effect of treatment conditions (processing
parameters) on the wear performance, so that optimized surface treatment
conditions can be realized. In a pin-on-disc wear tester, a pin is loaded against a
flat rotating disc specimen such that a circular wear path is described by the
machine. The machine can be used to evaluate wear and friction properties of
materials under pure sliding conditions.

Either disc or pin can serve as specimen, while the other as counter face. Pin with
various geometry can be used. A convenient way is to use ball of commercially
available materials such as bearing steel, tungsten carbide or alumina (Al2O3) as
counter face, so that the name of ball-on-disc is used.
ADVANTAGE
 Chapter-5

ADVANTAGE

 Improved corrosion protection

 Improved abrasion resistance
 No dimensional changes
 Improved lubricity
 Reduces light glare and reflection
 No welding fumes
APPLICATION
 Chapter-6
APPLICATION

 AUTOMOBILE INDUSTRIES COMPONENTS

CONCLUSION
 Chapter-7
CONCLUSION

PVD coatings are generally used to improve hardness, wear resistance and
oxidation resistance. The effect of the nickel coating on performance
characteristics were conducted on wear resistance chain sprocket. The micro
hardness and wear rate behavior of the resultant deposition were investigated
with the following Increasing of nickel percentage causes decreasing the wear
rate. The major conclusions drawn from these experiments are as the coated
sprocket was exposed to higher friction of wears and the compared to the original
sprocket and nickel coated sprocket. In this coated sprocket to improve the
hardness, wear and corrosion resistance
REFERENCE
 Chapter-8

REFERENCE

 M.G. Jacko: Physical and Chemical Changes of Organic Sprocket Pads in

Service, Wear 46, (1978), 163–175.
 J.M. Herring: Mechanism of Brake Fade in Organic Brake Pad Linings,
Society of Automotive Engineers Transaction, Paper 670146, (1967).
 B.J. Briscoe, I. Ramirez and P.J. Twiddle: Friction of Aramid Fiber
Composites, in: Proceedings of the International Conference on Sprockets
for Commercial Vehicles, the Institution of Mechanical Engineers, UK,
(1988), 15 29.
 A.P. Batakis and J.W. Vogan: Rocket Thrust Chamber Thermal Barrier
Coatings, NASA Contract Report 1750222, (1985).
 D.L. Houck: Thermal Spray: Advances in Coatings Technology,
Proceedings of the National Thermal Spray Conference, ASM
International, (1987).
 R.C. Tucker: ASM Handbook: Surface Engineering, Vol. 5, ASM
International, Materials Park, OH, (1994), 497–509.
 H. Herman: Thermal Spray Coatings, Metallurgical and Ceramic Protective
Coatings, Chapman & Hall, London, (1996), 261–89.