The Concept Of Surface Engineering
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part I
General Fundamentals of Surface Engineering
© 1999 by CRC Press LLC
chapter one
The concept of surface engineering 1.1 The term ”surface engineering” The word engineering stems from the French language (s’ingenier - to contemplate, rack one’s brains, strain oneself, exert oneself) and in the past had one meaning, while presently it has several meanings, all fairly close. In the past it was a skill; presently it is mainly a science relating to the design of shape or properties of materials and their manufacturing processes. Originally engineering encompassed the art of building fortifications, strongholds and other elements of defense systems. In 18th - 19th century Europe we see the beginnings of differentiation between military and civilian engineering. In more modern times the concept of engineering embraced the art of design and construction of all types of structures (with the exception of buildings) and various engineering branches were distinguished: civil, hydro-, maritime, sanitary, forestry. After World War II, the influence of Anglo-Saxon countries caused the spread in Europe of the US - born concept of social engineering. Quite recently, a new branch of science, termed environmental engineering, came into existence. It was also during this last century, especially after World War II, that the term engineering was broadened to encompass some areas of human knowledge, more particularly those connected with applied research, e.g. the science of unit operations used in the chemical and related industries and the subsequent development of chemical equipment (chemical engineering), or the applied science drawing on the theoretical achievements of genetics in the breeding of animals, cultivation of plants and in medicine (genetic engineering). Created and in use are such concepts as: biomedical engineering, electrical engineering, reliability engineering, programming engineering, communications engineering, aerospace engineering, process engineering, mechanical, ion beam, corrosion and other types of engineering. The early 70s saw the importation from the US to Europe of the concept of material engineering, created in the 60s and embracing the “scientific discipline dealing with the investigation of the structure of materials, as well as improvement and the obtaining of new materials with predicted and reproducible properties.” (Scientific and Technical Lexicon, WNT, Warsaw 1984).
© 1999 by CRC Press LLC
Departments, chairs, institutes and even entire faculties of material engineering have sprung up. It follows from the above definition that materials engineering deals with the investigation of the structure of and the design of different materials, including composites. It does not follow, on the other hand, although it cannot be excluded, that materials engineering deals specifically with problems of enhancement or modification of surface properties of materials. It is probably due to this that the new term surface engineering1 was coined for the first time in England in the 70s. In the early 70s the Surface Engineering Society, affiliated with the Welding Institute in Abington, was inaugurated. At first, it focused mainly on various aspects of welding and thermal spraying and gradually it broadened its scope of interest. Next, the Wolfson Institute for Surface Engineering was created at the University of Birmingham, initially concerned mainly with problems stemming from surface diffusion treatments and their connection with vacuum technology, gradually broadening the range of activity to other methods of formation of surface layers. The year 1985 saw the first edition of the quarterly “Surface Engineering”, published by the Wolfson Institute for Surface Engineering jointly with the Surface Engineering Society. As of 1987 another quarterly of a scientific-research and technical nature was published under the same title, as the combination of two periodicals: “Surfacing Journal International” and “Surface Engineering”. This quarterly deals with thermal spraying technologies, layer formation by PVD and CVD, electron and laser beam hardening, ion implantation, shot peening, surface alloying by conventional and plasma processes and generally with technologies of surface layer formation and with some coating technologies. Problems of coatings, especially paint, plating and other types, are dealt with by other periodicals (e.g., “Surface and Coatings Technology”, “Coatings”, “Metalloberfläche” and “Metal Finishing”). In October 1986, at the V International Congress of Heat Treatment of Materials in Budapest, the name of the International Federation for Heat Treatment of Materials, by then in existence for over 10 years, was changed to International Federation for Heat Treatment of Materials and Surface Engineering. For obvious reasons, both the Federation as well as Congresses convened under its auspices prefer mostly problems connected with heat treatment and, to a lesser degree, other problems connected with surface engineering. Over the past most recent years, many international conferences, meetings and discussions devoted to surface engineering and its connections with other fields of science and technology were organized.
1)
This term was later translated into French (l’ingenierie de surfaces), Russian (inzhinerya poverkhnosti), and German (Oberflächeningenierie) but to this day used in these languages only sporadically.
© 1999 by CRC Press LLC
1.2 Scope of topics forming the concept of surface engineering Surface Engineering is almost as old as structural materials used by man. From the beginnings of time until the early 70s of our century, mankind has worked on the development of surface engineering, although not aware of the concept. The term of surface engineering, in use in the world for over ten years, remained undefined and its topical scope is still the subject of discussions, especially on the aspect of definitions. In various ways, attempts have been made to define and to conduct a broader discussion of selected problems of surface engineering, especially those viewed through the techniques of formation covered by this scope [1, 4]. Various book and handbook type publications presented different, chronologically older technologies, within the scope of surface engineering. There was a lack of publications dealing with the newest methods of manufacturing. Earlier, generally the concept of surface enginnering was understood as solely different techniques of forming superficial layers prior to the beginning of service. Nothing was said about the formation of superficial layers during service, about research and propertiers or about modeling of these properties for concrete examples of application. Even newer literature does not present a modern approach to the overall concept of surface engineering [5, 6]. Today, such narrow understanding of surface engineering does not suffice. In fact, this would be a far-reaching simplification. For this reason, it was broadened during the years 1993-1995 to include problems of utilization of superficial layers, as well as problems of their design [3, 4]. Based on research conducted since the 80s, as well as available scientific and technical literature, the following topical scope and a definition of surface engineering are proposed: Surface engineering is a discipline of science, encompassing: 1) manufacturing processes of surface layers, thus, in accordance with the accepted terminology - superficial layers and coatings, produced for both technological and end use purposes, 2) connected phenomena, 3) performance effects obtained by them. Surface engineering encompasses all scientific and technical problems connected with the manufacture of surface layers prior to end use or service (technological layers) or during service (service-generated layers), on or under the surface (superficial layers) or on a substrate (coatings), with properties differing from those of the material which may be introduced to the surface of the core in the form of gas, liquid or solid (Fig. 1.1). It also includes research of connected phenomena and of potential and usable properties of surface layers, as well as problems connected with layer design.
© 1999 by CRC Press LLC
Fig. 1.1 Schematic representation of the area of activity of surface engineering.
Fig. 1.2 Scientific and technical activity adding up to create surface engineering.
Thus, surface engineering encompasses the total field of research and technical activity aimed at the design, manufacture, investigation and utilization of surface layers, both technological and for end use, with properties better than those of the core, such as mainly anti-corrosion, anti-fatigue, anti-wear and decorative. Other applications include properties such as optical,
© 1999 by CRC Press LLC
thermophysical, electrical, magnetic, adhesive, ablation, passivation, inhibition, catalytic, biocompatibility, diffusion and others. In the meaning as defined above, surface engineering has a lot in common with fundamental and applied (technical) science. Surface engineering draws inspiration from (Fig. 1.2): 1) Fundamental sciences: physics, chemistry, partially mathematics and constitutes their application to material surface; 2) Applied (technical) sciences: – sciences dealing with materials science and material engineering, with special emphasis on heat treatment, – construction and use of machines, with special emphasis on material strength, primarily fatigue, tribology and corrosion protection, – electrical engineering, electronics, optics, thermokinetics, the science of magnetism, etc. The object of material science and material engineering - the material constitutes the fundamental substance, the surface properties of which are improved, enhanced and controlled by surface engineering. The knowledge of material substrate or core structure is the basic condition of producing layers on it. Methods of formation (producing) surface layers are included in the area of machine building, as manufacturing methods. The properties of surface layers produced are evaluated by methods used in surface engineering, as well as in investigation and use of machines. These methods are used predominantly in areas such as: tribology, corrosion protection, material strength, etc. Some methods of designing of surface layer properties, used in surface engineering, are also derived from - besides mathematics - material engineering and machine building. This pertains primarily to material strength and tribology. The utilization of surface layers or their production during the course of service belongs to the area of machine service and takes into account, first and foremost, problems of tribology and corrosion protection.
References 1. Bell, T.: Surface engineering, past, present and future. Surface Engineering, Vol. 6, No. 1, 1990, pp. 31-40. 2. Burakowski, T.: Metal surface engineering - status and perspectives of development (in Russian). Series: Scientific-technical progress in machine-building. Edition 20. Publications of International Center for Scientific and Technical Information - A.A. Blagonravov Institute for Machine Science Building Research of the Academy of Science of USSR, Moscow, 1990. 3. Burakowski, T., Rolinski, E., and Wierzchon, T.: Metal surface engineering (in Polish). Warsaw University of Technology Publications, Warsaw, 1992.
© 1999 by CRC Press LLC
4. Burakowski, T.: A word about surface engineering (in Polish). Metaloznawstwo, Obróbka Cieplna, Inzynieria Powierzchni (Metallurgy, Heat Treatment, Surface Engineering), No. 121-123, 1993, pp. 16-31. 5. Tyrkiel, E. (General Editor), and Dearnley, P. (Consulting Editor): A guide to surface engineering terminology. The Institute of Materials in Association with the IFHT, Bourne Press, Bournemouth (UK), 1995. 6. Stafford, K.N., Smart, R. St. C., Sare, I., and Subramanian, Ch.: Surface engineering: processes and applications. Technomic Publishing Co. Lancaster (USA) - Basel (Switzerland), 1995.
© 1999 by CRC Press LLC
General Fundamentals of Surface Engineering
© 1999 by CRC Press LLC
chapter one
The concept of surface engineering 1.1 The term ”surface engineering” The word engineering stems from the French language (s’ingenier - to contemplate, rack one’s brains, strain oneself, exert oneself) and in the past had one meaning, while presently it has several meanings, all fairly close. In the past it was a skill; presently it is mainly a science relating to the design of shape or properties of materials and their manufacturing processes. Originally engineering encompassed the art of building fortifications, strongholds and other elements of defense systems. In 18th - 19th century Europe we see the beginnings of differentiation between military and civilian engineering. In more modern times the concept of engineering embraced the art of design and construction of all types of structures (with the exception of buildings) and various engineering branches were distinguished: civil, hydro-, maritime, sanitary, forestry. After World War II, the influence of Anglo-Saxon countries caused the spread in Europe of the US - born concept of social engineering. Quite recently, a new branch of science, termed environmental engineering, came into existence. It was also during this last century, especially after World War II, that the term engineering was broadened to encompass some areas of human knowledge, more particularly those connected with applied research, e.g. the science of unit operations used in the chemical and related industries and the subsequent development of chemical equipment (chemical engineering), or the applied science drawing on the theoretical achievements of genetics in the breeding of animals, cultivation of plants and in medicine (genetic engineering). Created and in use are such concepts as: biomedical engineering, electrical engineering, reliability engineering, programming engineering, communications engineering, aerospace engineering, process engineering, mechanical, ion beam, corrosion and other types of engineering. The early 70s saw the importation from the US to Europe of the concept of material engineering, created in the 60s and embracing the “scientific discipline dealing with the investigation of the structure of materials, as well as improvement and the obtaining of new materials with predicted and reproducible properties.” (Scientific and Technical Lexicon, WNT, Warsaw 1984).
© 1999 by CRC Press LLC
Departments, chairs, institutes and even entire faculties of material engineering have sprung up. It follows from the above definition that materials engineering deals with the investigation of the structure of and the design of different materials, including composites. It does not follow, on the other hand, although it cannot be excluded, that materials engineering deals specifically with problems of enhancement or modification of surface properties of materials. It is probably due to this that the new term surface engineering1 was coined for the first time in England in the 70s. In the early 70s the Surface Engineering Society, affiliated with the Welding Institute in Abington, was inaugurated. At first, it focused mainly on various aspects of welding and thermal spraying and gradually it broadened its scope of interest. Next, the Wolfson Institute for Surface Engineering was created at the University of Birmingham, initially concerned mainly with problems stemming from surface diffusion treatments and their connection with vacuum technology, gradually broadening the range of activity to other methods of formation of surface layers. The year 1985 saw the first edition of the quarterly “Surface Engineering”, published by the Wolfson Institute for Surface Engineering jointly with the Surface Engineering Society. As of 1987 another quarterly of a scientific-research and technical nature was published under the same title, as the combination of two periodicals: “Surfacing Journal International” and “Surface Engineering”. This quarterly deals with thermal spraying technologies, layer formation by PVD and CVD, electron and laser beam hardening, ion implantation, shot peening, surface alloying by conventional and plasma processes and generally with technologies of surface layer formation and with some coating technologies. Problems of coatings, especially paint, plating and other types, are dealt with by other periodicals (e.g., “Surface and Coatings Technology”, “Coatings”, “Metalloberfläche” and “Metal Finishing”). In October 1986, at the V International Congress of Heat Treatment of Materials in Budapest, the name of the International Federation for Heat Treatment of Materials, by then in existence for over 10 years, was changed to International Federation for Heat Treatment of Materials and Surface Engineering. For obvious reasons, both the Federation as well as Congresses convened under its auspices prefer mostly problems connected with heat treatment and, to a lesser degree, other problems connected with surface engineering. Over the past most recent years, many international conferences, meetings and discussions devoted to surface engineering and its connections with other fields of science and technology were organized.
1)
This term was later translated into French (l’ingenierie de surfaces), Russian (inzhinerya poverkhnosti), and German (Oberflächeningenierie) but to this day used in these languages only sporadically.
© 1999 by CRC Press LLC
1.2 Scope of topics forming the concept of surface engineering Surface Engineering is almost as old as structural materials used by man. From the beginnings of time until the early 70s of our century, mankind has worked on the development of surface engineering, although not aware of the concept. The term of surface engineering, in use in the world for over ten years, remained undefined and its topical scope is still the subject of discussions, especially on the aspect of definitions. In various ways, attempts have been made to define and to conduct a broader discussion of selected problems of surface engineering, especially those viewed through the techniques of formation covered by this scope [1, 4]. Various book and handbook type publications presented different, chronologically older technologies, within the scope of surface engineering. There was a lack of publications dealing with the newest methods of manufacturing. Earlier, generally the concept of surface enginnering was understood as solely different techniques of forming superficial layers prior to the beginning of service. Nothing was said about the formation of superficial layers during service, about research and propertiers or about modeling of these properties for concrete examples of application. Even newer literature does not present a modern approach to the overall concept of surface engineering [5, 6]. Today, such narrow understanding of surface engineering does not suffice. In fact, this would be a far-reaching simplification. For this reason, it was broadened during the years 1993-1995 to include problems of utilization of superficial layers, as well as problems of their design [3, 4]. Based on research conducted since the 80s, as well as available scientific and technical literature, the following topical scope and a definition of surface engineering are proposed: Surface engineering is a discipline of science, encompassing: 1) manufacturing processes of surface layers, thus, in accordance with the accepted terminology - superficial layers and coatings, produced for both technological and end use purposes, 2) connected phenomena, 3) performance effects obtained by them. Surface engineering encompasses all scientific and technical problems connected with the manufacture of surface layers prior to end use or service (technological layers) or during service (service-generated layers), on or under the surface (superficial layers) or on a substrate (coatings), with properties differing from those of the material which may be introduced to the surface of the core in the form of gas, liquid or solid (Fig. 1.1). It also includes research of connected phenomena and of potential and usable properties of surface layers, as well as problems connected with layer design.
© 1999 by CRC Press LLC
Fig. 1.1 Schematic representation of the area of activity of surface engineering.
Fig. 1.2 Scientific and technical activity adding up to create surface engineering.
Thus, surface engineering encompasses the total field of research and technical activity aimed at the design, manufacture, investigation and utilization of surface layers, both technological and for end use, with properties better than those of the core, such as mainly anti-corrosion, anti-fatigue, anti-wear and decorative. Other applications include properties such as optical,
© 1999 by CRC Press LLC
thermophysical, electrical, magnetic, adhesive, ablation, passivation, inhibition, catalytic, biocompatibility, diffusion and others. In the meaning as defined above, surface engineering has a lot in common with fundamental and applied (technical) science. Surface engineering draws inspiration from (Fig. 1.2): 1) Fundamental sciences: physics, chemistry, partially mathematics and constitutes their application to material surface; 2) Applied (technical) sciences: – sciences dealing with materials science and material engineering, with special emphasis on heat treatment, – construction and use of machines, with special emphasis on material strength, primarily fatigue, tribology and corrosion protection, – electrical engineering, electronics, optics, thermokinetics, the science of magnetism, etc. The object of material science and material engineering - the material constitutes the fundamental substance, the surface properties of which are improved, enhanced and controlled by surface engineering. The knowledge of material substrate or core structure is the basic condition of producing layers on it. Methods of formation (producing) surface layers are included in the area of machine building, as manufacturing methods. The properties of surface layers produced are evaluated by methods used in surface engineering, as well as in investigation and use of machines. These methods are used predominantly in areas such as: tribology, corrosion protection, material strength, etc. Some methods of designing of surface layer properties, used in surface engineering, are also derived from - besides mathematics - material engineering and machine building. This pertains primarily to material strength and tribology. The utilization of surface layers or their production during the course of service belongs to the area of machine service and takes into account, first and foremost, problems of tribology and corrosion protection.
References 1. Bell, T.: Surface engineering, past, present and future. Surface Engineering, Vol. 6, No. 1, 1990, pp. 31-40. 2. Burakowski, T.: Metal surface engineering - status and perspectives of development (in Russian). Series: Scientific-technical progress in machine-building. Edition 20. Publications of International Center for Scientific and Technical Information - A.A. Blagonravov Institute for Machine Science Building Research of the Academy of Science of USSR, Moscow, 1990. 3. Burakowski, T., Rolinski, E., and Wierzchon, T.: Metal surface engineering (in Polish). Warsaw University of Technology Publications, Warsaw, 1992.
© 1999 by CRC Press LLC
4. Burakowski, T.: A word about surface engineering (in Polish). Metaloznawstwo, Obróbka Cieplna, Inzynieria Powierzchni (Metallurgy, Heat Treatment, Surface Engineering), No. 121-123, 1993, pp. 16-31. 5. Tyrkiel, E. (General Editor), and Dearnley, P. (Consulting Editor): A guide to surface engineering terminology. The Institute of Materials in Association with the IFHT, Bourne Press, Bournemouth (UK), 1995. 6. Stafford, K.N., Smart, R. St. C., Sare, I., and Subramanian, Ch.: Surface engineering: processes and applications. Technomic Publishing Co. Lancaster (USA) - Basel (Switzerland), 1995.
© 1999 by CRC Press LLC
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