Table Of ContentA GUIDE TO
SURFACE ENGINEERING
TERMINOLOGY
General Editor: EUGENIUSZ TYRKIEL
Consulting Editor: PETER DEARNLEY
THE INSTITUTE OF MATERIALS
IN ASSOCIATION WITH THE IFHT
Book no. 575
First published in 1995 by
The Institute of Materials
1 Carlton House Terrace
London SWlY 5DB
Technical publication produced
under the auspices of the
International Federation for Heat Treatment
and Surface Engineering (IFHT)
All rights reserved
© 1995 The Institute of Materials
Graphics © 1994 R A. Dearnley
ISBN 0 901716 64 2
Typeset by The Institute of Materials
from disks supplied by P. A. Dearnley
Halftone origination by
Bourne Press, Bournemouth
Printed and bound in the UK by
Bourne Press
About the Editors
Professor Tyrkiel is in the Institute of Materials Science, Technical University of Warsaw,
Poland and is former Chairman of the IF1HT Terminology Committee.
Dr Dearnley is in the Department of Chemical & Materials Engineering, University of
Auckland, New Zealand and is on the editorial panel of the journal Surface Engineering
published by The Insitute of Materials.
Disclaimer
No responsibility is assumed by the publisher or Editors for any injury and/or damage to
persons or property as a matter of products liability, negligence or otherwise, or from any
use or operation of any methods, products, instructions or ideas contained in the material
herein. Reference to any commercial organisation, process or product contained herein
does not represent an endorsement or recommendation by the publisher or Editors.
Editor's note
When referring to sub-atmospheric pressures, the torr (1 mm Hg) has been used
throughout. It should be noted that 760 torr = 1 atm. = 1.03323 kg mnr2 = 14.6959 p.s.i
Also 1 bar = 105 Pa = 0.986923 atm.
Introduction
The International Federation for the Heat Treatment of Materials was founded in 1971. The name was
modified in 1986 to International Federation for Heat Treatment and Surface Engineering, but the
acronym IFHT was retained.The objective of IFHT is to serve as the premier organisation for facili-
tating and promoting the international exchange of information in the science and technology of heat
treatment and surface engineering. Its particular strength is its effectiveness as a forum uniting science
and industry.
Surface Engineering is now accepted as a discipline in its own right. Although founded in humble
origins, it presently enjoys a high level of technical sophistication. The technology which made this
possible has largely come of age within the past 20 years. Surface Engineering has successfully
transcended the 'patch-up technology' mind-set of the 1950s and 1960s, and is presently becoming
increasingly linked with design and manufacture.
The IFHT has long been recognised as a leader in the promotion of internationally unified termi-
nology in the field of heat treatment as reflected in the publication of a 'Multilingual Glossary of Heat
Treatment Terminology' by the Institute of Metals (now The Institute of Materials) in 1986.
The IFHT in adopting the modern discipline of surface engineering has sought to provide an
equally authorative 'Guide to Surface Engineering Terminology' based on the definition,
'Surface engineering involves the application of traditional and innovative surface
technologies to engineering components and materials in order to produce a compos-
ite material with properties unattainable in either the base or surface material. Fre-
quently, the various surface technologies are applied to existing designs of engineer-
ing components but, ideally, surface engineering involves the design of the compo-
nent with a knowledge of the surface treatment to be employed'
The eminent multilingual materials scientist Eugeniusz Tyrkiel was invited to steer a Terminology
Committee which initially solicited many terms from various industrial and academic experts from
around the globe.Dr Peter Dearnley in his role as Consulting Editor has added further terms and
shaped the material into a unified work. He is accountable for the presentation style and the illustra-
tions therein. The work strives to be more than a mere collection of definitions. Wherever possible he
has expanded the entries to provide greater technical detail and, where appropriate, cited further
references and application examples. It is hoped that the book will serve as an informative quick-
reference guide that will prove valuable to the expert and non-expert alike. I trust it will stimulate a
wider appreciation and participation in the discipline of surface engineering.
Finally, I would wish to thank Professor Tyrkiel and his international team as well as Dr Dearnley
and his family who sustained him through out his busy editorial task to provide an invaluable guide to
surface engineering terminology.
Professor Tom Bell
University of Birmingham
March 1995
Surface Engineering
Surface engineering is now widely established as part of the concept of integrated compo-
nent design and manufacture.The rapid development of the surface modification technologies
allowing its successful implementation have resulted from cooperation between disciplines
ranging from metallurgy to vacuum and plasma science, microanalysis, and nanotechnology.
Since its inception a decade ago, shortly after the original formulation of the concept, Surface
Engineering has kept readers informed of developments by reflecting this multidisciplinary
character. Embracing science, technology, and engineering from an international perspective,
the journal addresses the interests of designers, manufacturers, and end users of engineering
components as well as researchers in the relevant fields.
In addition to refereed research papers, expert reviews assessing the state of the art, and the
technical note format designed to allow rapid publication, Surface Engineering includes an
extensive News and features section, providing updates on new products and equipment
together with company news and profiles of leading companies and research establishments.
Industrial case studies provide validated examples of the practical application of surface
engineering. Conference reports, book reviews, and a comprehensive diary of forthcoming
events are regular features and each issue contains a selection of abstracts from current liter-
ature of interest to readers.
Key state of the art surveys and research studies reflecting the development of the discipline
published since the journal first appeared include:
Kinetics of the gaseous nitrocarburising process J. Slycke and L. Sproge
Oxygen probes for controlling nitriding and nitrocarburising atmospheres S. Bohmer,
H.-J. Spies, H.-J. Berg, and H. Zimdars
Nitrocarburising and its influence on design in the automotive sector C. Dawes
Environmentally harmless plasma thermochemical processes F. Hombeck and T. Bell
Optimising ion implantation conditions for improving wear, fatigue, and fretting fatigue
of Ti-6A1-4V J.E. Elder, R. Thamburaj, and RC. Pattnaik
Engineering the surface with boron based materials RA. Dearnley and T. Bell
Comparison of laser hardfacing with conventional processes RJ.E. Monson and
W.M. Steen
Microstructure, wear resistance, and stability of cobalt based and alternative iron based
hardfacing alloys S. Atamert and J. Stekiy
Filtered arc evaporation RJ. Martin
Assessment of coating adhesion J. Valli, U. Makela, and A. Matthews
Assessment of coating hardness RJ. Burnett and D.S. Rickerby
Quality assurance assessment of thin films SJ. Bull, D.S. Rickerby, and J.T. Gent
Published quarterly by The Institute of Materials, Surface Engineering is the designated
journal of the UK Surface Engineering Society. For further information, subscription
details, or a sample copy of the journal, please contact: Marketing Department, The
Institute of Materials, 1 Carlton House Terrace, London SWlY 5DB, tel. 0171-839 4071,
fax 0171-839 2078.
Contents
About the Editors ......................................................................... 5
Disclaimer .................................................................................... 5
Editor's Note ................................................................................ 5
Introduction .................................................................................. 7
Surface Engineering .................................................................... 8
Ablation to Autocatalytic Plating ............................................. 9
Babbitting to Burnt Surface ...................................................... 20
Cadmium Plating to Cyaniding ................................................ 30
DC Diode PAPVD to Durability ................................................. 43
EBPVD to Explosive Flame Spraying ...................................... 49
Facing by Welding to Fusion Hard Facing Alloys .................. 60
Galfan to Grit Blasting .............................................................. 63
Hard Chromium Plating to Hypersonic Powder
Spraying .............................................................................. 72
Ihrigising to IVD ......................................................................... 80
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vi Contents
Jet-Kote to Knoop Hardness .................................................... 85
Lacquering to Lubrication ........................................................ 86
Machining Charts to Multi-stage Nitriding .............................. 93
Nanoindentation Hardness to Nuclear Reaction
Spectrometry ....................................................................... 100
Opacity to Oxynitrocarburising ................................................ 106
Pack Aluminizing to Pyrolytic Plating ..................................... 108
Quench-hardened Layer to Rutherford Backscattering
Spectrometry ....................................................................... 124
S-phase to Surge Plating .......................................................... 132
Tafel Equation to Two-pot Tinning ........................................... 147
Ultramicrohardness to Underplate ........................................... 158
Vacuum Carbonitriding to VPS ................................................ 160
Washing to Working Properties ............................................... 164
XPS to X-ray Diffraction ............................................................ 167
YAG Laser to Zirconia Oxygen Sensor .................................... 169
Bibliography .............................................................................. 171
Colour Pages ............................................................................. A
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A
ablation. Vapourization or sublimation of a solid surface. Usually achieved by irradiating
a solid surface with a high power density laser, plasma or electron beam.
ablative coating, (i) a special coating of limited durability applied to early types of re-entry
space vehicles. The coating enables the space vehicle skin to remain relatively cool since
most heat is consumed during heat of vapourization; (ii) a sacrificial coating applied to a
metal to enable laser shock hardening. See shock hardening.
abradability. Proneness of a material to undergo abrasion.
abrasion. Material loss (wear) of a surface due to micro-scale cutting/shearing by imping-
ing high hardness particles or grit. Also see three body wear and erosive wear.
abrasion resistance. See abrasive wear resistance.
abrasive blast cleaning. Also termed blast cleaning or abrasive blasting. A mechanical
cleaning technique whereby a surface is exposed to the abrasive action of a stream of metal-
lic or ceramic particles borne by high a velocity fluid (often air or water).
abrasive blasting. See abrasive blast cleaning.
ABRASIVE WEAR
DEBRIS
HARD PARTICLE
BEARING
MATERIAL
P. A. Dearnley, 1994
abrasive wear. Wear taking place by the mechanism of abrasion. A process which
involves hard, fine particles, cutting through or ploughing over a relatively ductile
bearing surface during sliding contact, thereby removing material from the surface
(diagram). The abrasive particles maybe suspended in a fluid. Also see three-body wear.
abrasive wear resistance. Ability of a material to withstand abrasion.
acid cleaning. Chemical cleaning in which an acidic solution is applied.
acid descaling. Acid immersion process aimed specifically at the removal of oxide scale;
also known as pickling in the steel industry where it is applied to hot rolled material prior to
cold working. Also see: alkaline cleaning, alkaline descaling and alkaline deruster salts.
acrylic coat. Thermoplastic or thermosetting polymeric coating containing an acrylic poly-
mer as the binder. They demonstrate good mechanical properties and high corrosion resist-
ance. Thermoplastic variants are applied to cold rolled aluminium and steel sheet forms.
activated reactive evaporation (ARE). One type of plasma assisted physical vapour depo-
sition (PVD); first popularised by Bunshah et al in the 1970's for the reactive deposition of
ceramic coatings. The process is based on reactive ion plating. An anode is placed above an
electron beam evaporation source enabling a high population of metal ions to be created
(through electron-neutral atom/molecule collisions); the ions subsequently bombard the
(usually) negatively biased substrates. This technique is one method of producing a sup-
ported glow dischage. However, it has failed to take hold as a significant industrial process;
being superseded by the triode ion plating method.
activation analysis. See NRA.
activation overpotential. Part of the overpotential (polarisation) that exists across the elec-
trical double layer at any electrode-electrolyte interface, which governs the rate of the elec-
trode reaction by changing its activation energy.
activator. Commonly an alkali metal halide, an ammonium halide or alkali metal carbon-
ate, which when added to a pack medium, serves to facilitate mass transfer from the source
solid to the surface. For example, barium and calcium carbonates are added to hard wood
charcoal to facilitate carbon transfer in pack carburising. NH Cl serves a similar purpose in
4
pack aluminising and pack chromising. Another term for an activator is "energiser".
active medium. An essential component of a laser. See laser.
additon agent or additive. A material added to an electroplating solution to modify its
operational characteristics or the properties of the resulting electrodeposit.
adherence/adhesion. A qualitative term representing the ability of a coat to form an inti-
mate and durable attachment to a substrate. Chemical or metallurgical bonding across the
coat/substrate interface offers the best adherence, although some improvement in adher-
ence is offered by mechanical interlocking achieved by roughening the substrate surface
(e.g., by grit blasting) prior to deposition. The latter is a common surface preparation prior
to application of thermal spray coatings, like plasma sprayed ceramics.
adhesive (or adhesion) strength. Stress required to pull off or loosen a coating from its
underlying substrate.
adhesive (or adhesion) strength tests. Several tests exist, but interpretation remains diffi-
cult. Such tests are not to be compared with established mechanical tests, like uniaxial
tensile testing of bulk samples or indentation hardness. Available tests include scratch adhe-
sion tests, indentation adhesion tests, peel and bend tests. Simpler tests involve applying a
tape or glued rod end to the coated surface, which is subsequently pulled away causing
partial or complete coating detachment; by knowing the force required to cause separation
and the contact area under load, the stress to cause failure is calculated. Unfortunately,
failure is not always at the coat-substrate interface; in such cases, the result does not equate
to coating bond strength. Hence, caution is always necessary in interpreting results. Also
see scratch adhesion test.
ADHESIVE
WEAR
SURFACE 1
SURFACE 2
(i) (ii)
P. A. Dearnley, 1994. WEAR DEBRIS
adhesive wear. A mechanism of wear involving localised welding together of micro-aperities
during sliding contact, as for example between two bearing surfaces; such micro-seized
contacts subsequently fail through micro-shearing or tearing causing the removal of surface
material (wear). Debris particles can range in size from a few hundred micrometers to sig-
nificantly less than one micrometer. Some tribologists now regard the term 'adhesive wear'
to be redundant. A more common mode of wear debris creation (diagram) has recently been
