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Surface finishing is a broad range of industrial
processes that alter the surface of a manufactureditem to achieve a certain property. Currently, the
trend is towards surface treatments. Surface
engineering techniques are generally used to
develop a wide range of functional properties,
including physical, chemical, electrical, electronic,
magnetic, mechanical, wear-resistant and
corrosion-resistant properties at the requiredsubstrate surfaces.
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In t roduct ion
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In general, coatings are desirable, or even
necessary, for a variety of reasons including
economics, material conservation, unique
properties, or the engineering and design flexibility
which can be obtained by separating the surface
properties from the bulk properties. Surfaceengineered products thus increase performance,
reduce costs, control surface properties
independently of the substrate and medium, thus
offering an enormous potential in the finishingIndustry.
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Electro depositing of metals is a very
significant industrial process. Electroplatingis both an art and science .It entailed
adhering a thin metal coating to an object by
immersing it into an electrically charged
solvent containing the dissolved plating
metal. Electroplating served a number of
functions, such as protecting from corrosion
and wear, decoration, and electricalshielding. Anodizing most closely resembles
standard electroplating.
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Anodizing or anodizing is an electrolytic
passivation process used to increase the
thickness of the natural oxide layer on the surface
of metal parts. Anodizing increases corrosion
resistance and wears resistance, and provides
better adhesion for paint primers and glues thanbare metal. Anodic films are most commonly
applied to protect aluminium alloys.
The aim of this handbook is to give the reader a
perspective on several metal surface treatmenttechniques which are generally followed in the
finishing Industry.
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This is a unique compilation and it draws together
in a single source technical principles of surfacescience and surface treatments technologies of
plastics, elastomers, and metals along with various
formulae of bath solutions, current density, deposit
thickness, manufacturing processes, various
ingredients used in these processes. It is a very
useful guide for the readers, engineers, scientists,
practitioners of surface treatment, researchers,students, entrepreneurs and others involved in
materials adhesion and processing.
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Brushing
DeburringBuffing and Polishing Equipment
3. Mass Finishing MethodsVibratory Finishing Equipment
Centrifugal Barrel Finishing
Parts to Media Ratios
Mass Finishing Media and Compounds
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4. ElectropolishingThe Electropolished Surface
Types of Metal Electropolished
Electropolishing Equipment
5. Solvent CleaningSolvent CleaningDiphase Cold Cleaning
Stability
Materials of Construction
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Design Consideration
Location of Vapour Degreaser
Shutdown Procedure
Choosing a Vapour Degreasing Solvent
Water Removal
6. Alkaline CleaningSoils
Machining and Forming Oils Alkaline Descalers
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7. Oxide RemovalOxide Removal from Copper Alloys
Equipment for Pickling and Bright Dipping
II. TYPICAL PROCESSING AND OPERATING
SEQUENCES
8. MetalsPretreatments
Preliminary Treatment
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Final Treatment
Low-Carbon Steel
High-carbon and Low-Alloy Steels
Stainless Steels
Cast IronsCopper and Copper-Base Alloys
Zinc-Base Die Castings
Magnesium and Its Alloys
Lead and Lead AlloysPowder Metal Compacts
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Less common Metals
Intermediate Electrodeposited Coating as Basis Metal
Surface
9. PlasticsPlating
Electroless Plating
10. Wastewater Control and TreatmentWater Supply
Water and Chemical ConservationChemical and Water Recovery
Evaporative Recovery
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Reverse Osmosis
Electrodialysis
Ion ExchangeWaste water Treatment-Segregation and
Collection
Hexavalent Chromium Reduction
Pretreatment
Neutralization
Flocculation
Special Treatment Methods
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Solids Management
Maintenance
11. Plating Bath Compositions and Operating
Conditions
Effects of HydrogenStripping and Salvaging of Defective Plated Items
III. TESTING ELECTRODEPOSITED COATINGS
12. Thickness Tests
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Microscopic-Optical Methods
Double-Beam Interference Microscope,
InterferometryMagnetic Method
Eddy Current
Mass per Unit Area
Weight Gain MethodX-Ray Methods
Beta Backscatter (BBS)
Microresistance Technique
13. Corrosion Tests
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Outdoor Exposure Tests
Electrolytic Corrosion (EC) Test
14. InspectionFactors in Visual Inspection
Arriving at a Standard of Acceptability
Degree of Finish
Inspection of Coloured and Other than Bright
FinishesInspection Equipment
Inspection Personnel
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IV. SURFACE PROTECTION AND FINISHING
TREATMENTS
15. Phosphate Coating Processes Amorphous Phosphate Coatings on Aluminum
Surfaces
Process CyclesDiscussion of Process Steps in Practical Procedures
Immersion Processes
Spray Processes, with Solution Recirculation
Design Features
Simplified and Specialized Processes
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16. Chromate Conversion CoatingsMetals Commonly Chromated
Control of Electroplating Solutions
Coatings for Conversion Coatings
17 Sulfuric and Chromic Acid Anodizing of
AluminiumSulfuric Acid Anodizing
Colouring
Power Supply
Coating PropertiesChromic Acid Anodizing
Processing Steps
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Electrolyte Maintenance
Deisgnation System for Anodic Coatings Anodizing and Surface Conversion Treatments
for Magnesium
Pickling
Tank Equipment for Cleaning Acid Pickling Anodizing Processes
18. Electroplating Formulae of Various
Electroplating and Allied Chemicals
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Electroplating not alluminium
Gold Electroplating
Iron Electroplating
19. Principles of ElectroplatingPolarisation
20. Properties of Electroplating 428Conducting Salts
Plating Quality
21. Electroplating or Coatings on Silver,Copper and leadsCoating of Silver
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Alkaline Bath
Plant and Machineries Details for Electroplating Baths
Salts
22. Conservation of Materials and Energy in
Electroplating Industries with Effluent
TreatmentRegeneration and Recovery Techniques Applications
for Waste Water Treatment
Techniques for Uniform Metal Distribution Chemicalswill exceed the costs associated with purchasing
Choice of Finish and Process
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Plating From Low Concentrated Solutions at
Room Temperatur
23 Black Chrome Plating for Solar EnergyConversion
Hull Cell Studies
Effect of Plating Time on Optical Properties
24 Pickling of MetalsChemical and Electrolytic Pickling Compared
Tin and Lead Additions
Regeneration of Pickling Solutions
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25 Pickling Conditions and Solution
CompositionsPickling of Cast Iron
Pickling in Salt Baths
Pickling of Copper and Copper Alloys
Pickling of Copper AlloysPickling of Aluminium
Acid or Cold Pickling
Pickling of Magnesium
Pickling of Silver
Pickling of Titanium
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26 Cadmium Plating
27 Cobalt Plating
28 Copper PlatingCoppering by Simple Immersion
Bath Preparation
29. Iron Plating
30 Nickel PlatingNickel fluoborate bath
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Precautions
Semi-Bright Nickel Plating
Stabilisers
Barrel Nickel PlatingHeavy Nickel Plating
Nickel Electroforming & Electrotyping
31 Silver Plating Application of silver Plating
32 Gold ElectroplatingStripping Gold
Current-Density, 0.15 Ampere
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Gold Baths for Hot Gilding
Tanks for Gold Baths
For Gold-Plating in the Cold Bath the Process Is As
Follows
Gold Thread
Methods of Plating Stainless Steel
33 Nonelectrolytic Metal Coating ProcessesNon-Catalytic Chemical Methods
Maintainence of Immersion and Contact Baths
Sensitizing for Chemical Reduction
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34 Vapour-Phase MethodsVacuum Evaporation
Coating PropertiesSputtering
Range of Applicability
Apparatus Configuration
Ion PlatingChemical Vapour Deposition (CVD)
Apparatus Configuration
35 Catalytic MethodsCatalytic Chromium Plating
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The Operation of Electroless Copper Baths
Electroless Copper Treatment Sequence
Solution Formulations Analysis of Deposit
Corrosion Resistance of Deposits
Applications for Electroless Nickel
Boron Nickel Alloys
36 ElectroformingMandrel Types and Materials
Mandrel Design and Fabrication
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Preparation of Mandrel Surfaces
Electroforming Solutions and Deposit Properties
Control of Electroforming ProcessesMachining and Final Finishing of the Electroform
37. Industrial Anodising of Aluminium and its
Alloys Impurities and Bath Control
38. Environmental-Regulatory Restrictions,
Response of Paint Industry and Eco-Friendly
Coating Enactment of Rule 66 on the Use of
Organic Solvents
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Strategy of Paint Industry
Powder Coatings
39 Plating of Precious MetalsSilver Plating
Operating Conditions
Materials of Construction
Maintenance and Control of Solutions
40. Control of Electroplating Solutions UsingHull
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Cell Studies
Hull Cell
Case Studies using Hull Cell
Current Efficiency Test
41 Corrosion and their Preventive
Measures and Pollution Control
ConsiderationThe Mechanism of Basic Corrosion
Protection of Intergranular Corrosion
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