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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
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
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
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
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
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
FBE coatings systems can be divided into two main categories namely:-
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.
SPROCKET COATINGS
LITERATURE REVIEW
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
1. Nickel
2. Chromium
3. Yttrium oxide
4. black oxide
5. zinc
TYPE OF COATING
1. Pvd coating
2. Cvd coating
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.
CVD COATINGS
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
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
NICKEL COATINGS
PROPERTIES VALUE
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).
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.
Evaporation
Transportation
Reaction
Deposition
Evaporation
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:
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
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
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