
Introduce practical engineering coatings, from corrosion and wear considerations to electrodeposited zinc, galvanizing, nickel, chromium, and thermal spray options, plus coding-based design selection.
Explore how corrosion initiates on metal surfaces. Explain galvanic corrosion, barrier and sacrificial protection, and how galvanic series and delta V influence coating performance.
Explore mechanical wear and surface fatigue, including abrasive, adhesive, surface fatigue, and corrosion wear, and how coatings boost wear resistance through hardness and barrier films.
explores hydrogen embrittlement, the electroplating process, and RoHS environmental regulations, highlighting pre-coating stress relief, baking, and factors like flux density that control coating thickness.
Master electrodeposited zinc coating fundamentals, standards and definitions, thickness ranges, compatible substrates, color and post-treatments, and how testing influences corrosion resistance in real-world parts.
Learn hot dip galvanizing for low alloy steels and cast irons, detailing thickness 35–150 microns, four-layer zinc-iron coating, long-term corrosion resistance up to 5–50 years, and relevant ASTM standards.
Explore hard chromium coatings for engineering applications, detailing substrates, surface preparation, thickness ranges, and the coating's exceptional wear resistance, corrosion resistance, and low friction.
Discover engineering nickel coatings per AMS 290 standards, their thickness-dependent corrosion resistance, electrical conductivity, magnetic properties, and practical use in automotive trims and electrical contacts.
Explore decorative chromium coatings: a multi-layer system with copper undercoat, nickel layers, and a micro discontinuous chromium topcoat that delivers bright luster and corrosion resistance on steels and aluminium alloys.
Learn how decorative chromium coating on plastics is electrodeposited, with copper and nickel undercoats and a chromium topcoat, achieving strong adhesion through etching and palladium activation.
Explore electroless nickel coatings, an autocatalytic nickel-phosphorus alloy that provides excellent corrosion and wear resistance, uniform deposition on diverse substrates, and solderability, with heat-treatment impacts.
Discover electroless nickel on plastics, used as an under plate for plating and for abrasion and corrosion resistance. Learn about surface etching, palladium nucleation sites, and low-temperature solutions.
Examine electrodeposited silver coatings for engineering applications, guided by ASTM B700 and ISO 4521. Explore properties including corrosion resistance, wear, solderability, electrical and thermal conductivity, and anti-tarnish treatments.
Explore electrodeposited gold coatings for industrial use, guided by ASTM B488 and AMS 2422 standards. Learn about thickness, hardness, corrosion resistance, underplates, and applications in electrical contacts and motor brushes.
Phosphate conversion coating provides a paint-base surface defined by tc 490 and mil-spec 16 to 32 for low alloy, galvanized steels, and cast irons, with corrosion resistance and wear reduction.
Explore thermal spray coatings, including flame, arc, plasma, and detonation gun processes, and learn surface preparation, bonding, porosity, sealing, and finishing for wear and corrosion resistance.
Explore anodizing of aluminium alloys, a controlled electrochemical process that thickens the oxide layer to boost corrosion resistance, wear properties, and decorative finishes.
Examine chromate conversion coating for aluminum alloys, a low-cost surface passivation applied by immersion, brushing, or spraying that improves paint adhesion and offers color variants with moderate corrosion resistance.
Passivation of corrosion resistant steels cleans surfaces by removing free iron, enhances the protective chromium-rich film, improves corrosion resistance, is not wear resistant, and is typically under one micron thick.
Explore black oxide coating for steels, carbon steels, corrosion resistant steels, and cast irons with mild corrosion protection via post plating preservative oil treatment and thickness up to 2.5 microns.
Use a practical table to preliminarily select coatings by substrate compatibility and key functional attributes. Review covers common coatings from zinc to thermal spray, outlining corrosion, wear, and cost considerations.
This course will provide you practical knowledge at field of engineering coating selection and definition during mechanical development process based on required attributes for product functionality. The course is structured in parts. The logic behind the partition based on understanding that correct application of coating will be achieved by utilizing why, what, how strategy.
Why : understand why coating is required/beneficial for the particular application.
What: evaluate main attributes of the coating which enables required functionality.
How: select most appropriate coating based on required functional attributes & define fully to attain those attributes from the supplier at consistent manner.
1. Part 1 (Why)- introduce you to basics of: corrosion, mechanical wear and fatigue, embrittlement, electroplating process and environmental topics.
2. Part 2 (What & How) - discussion of main technical attributes of common engineering coatings:
· Electrodeposited Zinc (Zn) & Hot Dip Galvanizing ( Zn)
· Hard & decorative chromium ( Cr) on metals & plastics
· Engineering Nickel (Ni)
· Electroless Nickel (Ni) on metals & plastics
· Electrodeposited Silver (Ag)
· Electrodeposited Gold (Au)
· Phosphate conversion coating
· Thermal spray (Plasma, HVOF,...)
· Anodize
· Chromate conversion coating ( Alodine)
· Passivation
· Black oxide
3. Part 3 (What) - summary and preliminary coating selection tool based on main coating's attributes. The tool present coatings with its main attributes as catalogue for more efficient preliminary selection.