Department of Mechanical Engineering

College of Engineering and Design

Silliman University

Surface Engineering

In Partial Fulfillment of the Requirements in ME 56-Materials Science and Engineering for ME

Submitted to:

Engr. Louie Pierre O. Equio

Faculty of the College of Engineering and Design

Department of Mechanical Engineering

Silliman University

Submitted by:

Gador, Dartagnan Brandt M.

Manlucot, Xamwell John A.

Grajo, Rafael M.

Jumalon, Eirl Joshua M.

March 2024
Surface Engineering

Surface engineering is about altering the surface properties of a material to improve how

it performs and functions. Surface engineering involves a range of methods like coating, thin

film deposition, heat treatment, and surface hardening to enhance material surface properties for

wear resistance, corrosion protection, hardness, and other specific needs. Engineers use surface

engineering principles in a wide range of applications, from vital components in automotive and

aerospace structures to common household items like paints and varnishes. Surface engineering

is crucial for meeting the specific requirements of different industries, such as transportation and

household applications. It plays a vital role in shaping today’s products to fulfill the ever-

evolving needs of modern industries..

Importance of Surface Engineering

Surface engineering plays a crucial role in extending the service life and optimizing the

performance of components across various industries, including automotive, aerospace,

manufacturing, energy, and biomedical sectors. By tailoring surface properties, engineers can

enhance the material's suitability for specific applications while preserving the bulk material's

inherent properties. This results in extended lifespan and decreased maintenance expenses for

components and structures. Surface engineering plays a crucial role in enhancing energy

efficiency, promoting environmental sustainability, and achieving economic savings through the

optimization of machinery efficiency and the reduction of environmental impact from material

degradation. The enhancement of surface properties holds a vital role in innovation and

technology advancement.
Surface Engineering Techniques

1. Coating Technologies

a. Paints and Varnishes - These coatings act as a barrier, preventing direct

exposure of the underlying material to environmental elements such as moisture,

oxygen, and pollutants. By forming a protective layer, paint and varnish help

inhibit the corrosive processes that can degrade the material over time.

Additionally, both have a significant contribution in terms of aesthetic appeal of

the material as a whole.

b. Electroplating - Electroplating is a surface engineering technique that involves

depositing a thin layer of metal onto a substrate through an electrochemical

process called electrolysis. It creates a protective metal layer on the subject,

significantly enhancing its corrosion and wear resistance. Chromium, nickel, tin,

zinc, and cadmium are often used to plate copper, iron, and steel objects. Like

paints and varnishes, electroplating also enhances the aesthetic appearance.

c. Anodizing aluminum - is an electrochemical process to convert the metal surface

into an anodic oxide finish that is durable and highly corrosion resistant. The

anodic oxide structure originates from the aluminum and is composed entirely of

aluminum oxide. In simplest terms the aluminum oxide is grown from the

underlying aluminum substrate. It has a highly ordered structure that is well suited

for coloring and sealing. Unlike paint or plating, the finished anodized surface

will not chip or peel. Additionally anodized aluminum has good electrical

insulation properties which makes it advantageous for electrical applications.

grounds of pigments are electrically charged and sprayed into parts. An

electrostatic gun is typically used for this method. This applies an electrical

charge to the powder being sprayed, causing the particles to become positively

charged. The parts to be coated are grounded, giving them a negative charge.

Thus, the positively charged powder will be able to adhere to the negatively

charged part. Powder coating is environmentally friendly, cost effective, and

offers a variety of colors and finishes, including matte, gloss, metallic, and

textured. This flexibility enables this technique to be applicable across various

industries including automotive, appliances, furniture, electronics, tools and

equipment, etc.

2. Thin Film Deposition

Vapor Deposition - Are used to deposit thin layers of material or films onto a base

material called a substrate such as glass or silicon wafers. In theory any material can have

a thin film deposited onto its surface. In this process, the substrate will be exposed to one

or more vaporized sources, along with other stimuli which will cause a thin film to

deposit on the surface of the substrate. There are films that have unique electrical

properties which are commonly used for various parts in our gadgets such as

microprocessors and other electrical components. There are also water-resistant films,

dust resistant, corrosion resistant, and many other types, depending on the chemistry of

the vapors used and the operating conditions.

the chamber with the substrate. Through physical processes such as heating, the

solid material forms vapor which will in turn coat the surface of the substrate.

b. Chemical Vapor Deposition - Instead of forming vapors from a solid material

within a chamber, gasses are pumped into it from an external source which react

and cause the thin film to deposit.

3. Heat treatment - Heat treatment is a process that uses controlled heating and cooling to

modify the crystalline structure of metals and metal alloys. Depending on the material and

treatment process, heat treating can provide numerous benefits, including enhanced hardness,

increased temperature resistance, greater ductility, and improved material strength. Heat

treatments are a critical aspect of metal fabrication processes, as they allow the materials to gain

desirable physical and mechanical properties without altering the shape of the product.

a. Carburizing - Carburizing is a process used in metallurgy and materials science to

increase the carbon content of the surface layer of a metal object, typically steel. The

purpose of carburizing is to enhance the surface hardness and wear resistance of the metal

while maintaining a tough and ductile core.

b. Nitriding- Nitriding is a surface hardening process used in metallurgy to improve the

wear resistance, fatigue strength, and corrosion resistance of metal components, primarily

steel. Unlike carburizing, which introduces carbon into the surface layer, nitriding

introduces nitrogen.

c. Tempering- is a heat treatment process used to improve the toughness and ductility of

hardened metals, particularly steel, after they have been quenched. Quenching involves

rapidly cooling the metal from a high temperature to room temperature to achieve high
 hardness, but this often results in increased brittleness. Tempering helps alleviate this

brittleness by reducing the hardness slightly while enhancing other mechanical

properties.

4. Surface Hardening - Each surface hardening method has its advantages and is chosen based

on factors such as the material being treated, the desired properties of the finished component,

and the specific application requirements. Surface hardening processes are widely used in

industries such as automotive, aerospace, manufacturing, and machinery to improve the

performance and durability of metal parts subjected to wear and friction.

a. Induction Hardening- Induction hardening is a surface hardening process used to

selectively harden specific areas of metal components, typically made of steel. It's highly

efficient and allows for localized heating, which minimizes distortion and reduces the

need for subsequent machining operations. Induction hardening is commonly used in the

automotive industry for components like gears, shafts, and camshafts, as well as in other

applications where localized hardening is required to improve wear resistance and extend

the life of metal parts. Its advantages include fast heating, precise control over the

hardened areas, and minimal distortion compared to other hardening methods.

b. Flame Hardening- Flame hardening, also known as flame heating or flame surface

hardening, is a heat treatment process used to harden the surface of metal components. It

is particularly suitable for large or irregularly shaped parts that cannot be easily treated

using other hardening methods. The process involves localized heating of the surface of

the metal followed by rapid quenching to achieve the desired hardness. It is commonly

used in applications where localized hardening is required, such as the teeth of gears,

bearing surfaces, and other critical wear areas of metal components. It offers advantages
 such as flexibility in heating patterns, relatively low equipment cost, and suitability for

large and irregularly shaped parts. However, it may produce more distortion compared to

other hardening methods like induction hardening.

5. Shot peening- Shot peening is a cold working process used to improve the surface properties

of metal components, particularly to increase their resistance to fatigue and stress corrosion

cracking. It involves bombarding the surface of the metal with small, round particles called shot,

which are typically made of steel, ceramic, or glass. Shot peening is commonly used in industries

such as automotive, aerospace, and manufacturing to improve the durability and performance of

metal components subjected to cyclic loading or harsh environmental conditions. It is

particularly effective for increasing the fatigue life of components such as gears, springs, and

turbine blades.
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Protolabs. (2022, August 17). What is powder coating and how does it work?. YouTube.

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Karia, P. (2023, February 19). 5 Types of Surface Hardening Process. ThePipingMart Blog.

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