Surface Protective Coatings And Heat Treatment processes used in

Engine Division HAL Bangalore

Presented by: K.G. Appaiah
Chief Manager-Mfg.Insp

Aero Engine is mainly divided into two portions. Cold end & Hot end.
75 % of parts are coated with some coating.
Material science has reached its pinnacle.
Now surface coatings are the order of the day

Protective coatings are divided into Three categories:

Conversion coatings
Overlay coatings
Diffusion coatings

Conversion coatings :
Chromating on Magnesium alloy parts
Anodising on Aluminium alloy parts. Anodising (Chromic acid / Sulphuric acid)
Hard anodising for abrasive resistance.
Phosphating / Black oxide coating on steel parts.

Chemical composition of the Chromating bath:

Solution A:
Ammonium sulphate
Ammonium Dichromate
Potassium Dichromate
Manganese sulphate
Solution B:
Sodium Dichromate
Manganese sulphate
Magnesium sulphate

: 30 g/l
: 15 g/l
: 15 g/l
: 10 g/l
: 80-120 g/l
: 40- 60 g/l
: 50-120 g/l

Application:
To increase the corrosion resistance of the Mg. alloy parts
As base for organic paint application because it provides excellent nonporous bonding surface for all paints that have good molecular adhesion.
Corrosion protection is proportional to thickness upto certain point.

Process:
Immerse in the prepared part in a solution-A bath maintained at a temperature of 90-100
deg.C for 10 to 30 mts when the pH is 3.6 to 4.0 and water wash and oven dry and protect in an oil
paper till the part is taken for further processing.
Similarly, if solution B is used for chrome-manganese treatment then immerse the prepared
part in solution-B maintained at pH value of 3.0 to 6.0 and depending on the temperature the
immersion time varies.

Brief on Anodizing:
Anodizing is a conversion coating of the surface of aluminum and its alloys to porous
aluminum oxide. Since the part acts as an anode in an electrolytic cell, it is called anodizing. There
are three types of anodizing processes viz chromic acid anodizing, Sulphuric acid anodizing and
hard anodizing.
Alloy elements more than 7% and/or copper more than 5% in material, requires sulphuric
acid anodizing instead of Chromic acid anodizing.
Properties:
Increase corrosion resistance when it is sealed either in hot water or in
solution.

dichromate

Improve decorative appearance.

Increase abrasion resistance
Increase paint adhesion
Improve adhesive bonding
Improve lubricity
Provide electrical insulation (dielectric)
Permit subsequent painting
Detection of surface flaws
Increase emissivity of Aluminum. When dyed black the film has excellent heat absorption up
to 230 deg.C

PHOSPHATE COATING
Phosphate coating is the treatment on iron, steel and even aluminium with a dilute solution
of phosphoric acid and other chemicals in which the surface of the metal, reacting chemically with
the phosphoric acid media is converted to an integral, mildly protective layer of insoluble crystalline
phosphate.
Composition of Phosphate Coating bath:
Bath containing 5% v/v of aqueous solution of Granodine 101 or 111 maintained at
temperature of 98-100 deg.C. Before use of the bath, the bath must be aged by a addition of 1 kg
degreased steel wool per 450 liters of solution.
Properties:
Phosphate treatment on ferrous parts for corrosion prevention.
The phosphate coating produced provides a good key for normal low temperature paints or for the
retention of oil base corrosion preventions and with some proprietary solution improves the antiscuffing properties of sliding surfaces.
Inspection:
Phosphate coating shall be uniform and matt in appearance No un-treated patches or flaky
and uneven deposits are acceptable. Shows minor variation in colour due to previous surface
treatments. Superficial powdery deposits on the surface shall be removed by light brushing. It shall
be free from such residues of the phosphating solution as may initiate deterioration of the
supplementary finish or pre-mature corrosion. Coating weight shall be 7.5 g/Sq.M.
Overlay coatings

Organic paints
Inorganic paints
Ceramic paints
Organic paints on Aluminium, Mg alloys (Castings)
Inorganic paints on Steel parts Outer casings & Discs
Ceramic paints on Nickel base alloys Hot end parts.

SERMETEL COATINGS:
Introduction:
Among the unique family of inorganic coatings capable of resisting temperature extremes,
corrosion and abrasive attack, Sermetel is unequaled in its experience with high performance
coatings. Sermetel inorganic coatings and processes provide economical, long lasting, thin film
protection on ferrous and non-ferrous metals used in severe and hostile environments. Sermetel is
completely dis-similar from paints. Sermetel coatings and processes develop an un-equaled
chemical and metallurgical bond when properly applied and cured on prepared substrates.
This tenacious interface is flexible, unaffected by age, and resistant to thermal, mechanical
and chemical abuse. Basically Sermetel has three different types namely Sermetel W, Sermetel 709

and Sermaseal 570A. Sermetel W is slurry comprised of an acidic chromatic/phosphate binder and
dispersed aluminum particles. Sermetel 709 is same as Sermetel W but thin version. Sermaseal
570A is a seal coating over Sermetel W and Sermetel 709.
PL-134 Ceramic paint:
Resistant against thermal fatigue
Indigenously developed. Application: Vapour gutters, Microturbo stators Adour.
PTAE-7 engine turbine wheel
Plasma coatings :
Wear, erosion, corrosion, Fretting wear resistant coatings.
Metallisation:
Abradable & wire spraying.
Plasma coatings by plasma gun.
Metallisation by oxy-accetylane gun.
Thermal Barrier coating Plasma
These coatings are applied for repair scheme also.
PLASMA COATINGS:
Plasma spray is one of the technologies used for application of metallic material and
ceramic material on prepared metallic components of all types of alloys viz aluminum, magnesium,
steel, nickel base, cobalt base alloys.
DIAMOND JET COATING:
Advantages:
Diamond jet coating is a better choice compared to Detonation gun coating due to its
commercial availability and continuous characteristic. It is more flexible and easy to operate and
provides very dense coatings.
Properties:
It produces a dense coating less than 0.5 volume percent porosity and well bonded.
Its bonding strength is greater than 10000 PSI.
It has excellent high temperature wear resistance.
The coating hardness will be 600-900 VPN.
Application:
LP Turbine blade-Adour
Turbine air seal rings
Turbine baffle dampers, Turbine inner nozzle support
Fuel rod mandrels
Hot crushing rolls
Steam turbine vanes and buckets.
D-Gun coating for high wear / Fretting wear resistant coatings.
Materials: Chromium carbide / Nickel chrome powders. Tungsten carbide powder, etc,
Ex.:
Adour LPT & HPT blades.
HVOF Gun coating alternate to D-Gun coating.
DETONATION GUN COATING.
The detonation spray coating unit mainly consists of double walled barrel one meter long
tube of 1 in diameter combustion chamber and powder feeder, apart from control panels to regulate

the gas flows and operation. The overall set-up also includes an appropriate manipulator to hold the
work piece and control its movements.
The process involves injection of fuel and oxygen gas into combustion chamber. Injection of
powder and nitrogen gas. Gas detonation and powder acceleration. Chamber ventilation. The above
cycle is repeated at a predetermined frequency to achieve the desired coating thickness.
Advantages of detonation spray coating process:
Low substrate temperature
No distortion on substrate
No change in microstructure of the substrate
High bond strength coating > 10,000 Psi.
High density microstructure < 1% porosity.
Smooth surface finish
Controlled residual compressive stress
Better wear, abrasion and corrosion resistance.
Application:
Chromium carbide/Nickel chrome powder (75/25) coating by detonation gun system is on
shroud end faces of Adour LP turbine blades to protect against high temperature fretting wear.
COBALT-CHROMIUM CARBIDE METALLO- CERAMIC COATING.
Introduction:
Cobalt-chromium carbide is a composite coating and is deposited using electrolytic plating
route. The process comprises of plating cobalt and chromium carbide particles of 2 to 5 micrometer
size simultaneously from a cobalt electrolytic -plating bath. The part to be plated is made as cathode
and cobalt chips work as anodes.
Process:
Plating of cobalt chromium carbide is achieved using a normal electro-plating system fitted
with a plate bumper. The plate bumper is made to move up and down in order to keep the fine
chromium carbide particles in suspension in the electrolytic bath. When the current is applied
between the anode and cathode, cobalt ions move from anode to cathode and in that process they
also carry fine chromium carbide particles resulting in co-deposition of cobalt and chromium carbide.
Advantages:
A versatile process capable of meeting a wide range of application requirements.
Coating is dense and non-porous, theoretical density 99.9%.
Capable of operating at temperatures upto 800C.
Bond strength is in excess of 70 N/mm2 (10000 Psi).
Blind faces and internal bores down to 6 mm can be plated.
Can be ground conventionally.
Surface finish as plated 0.4 to 0.6 micrometers CLA
Surface finish lapped 0.0125 micrometers CLA
Reduced counter face wear on many materials.
A cold process reducing component distortions to a minimum.
HARD CHROMIUM PLATING
Hard Chromium Plating is produced by electro-deposition from a solution containing chromic
acid (CrO3) and a catalytic anion in proper proportion. Chromium plating is hard and corrosion
resistant; it is also excellent wear resistant. Hard Chromium deposits are intended primarily to
increase the service life of functional parts by providing a surface with low coefficient of friction that
resists galling, abrasive, lubricated wear and corrosion. It is also used to restore dimensions of
undersized parts. Hard Chromium is normally deposited to thickness ranging from 2.5 to 500
microns.

NICKEL PLATING
The nickel plating process is used extensively for decorative, engineering and
electroforming purposes because the appearance and other properties of electrodeposited nickel
can be varied over wide ranges by controlling the composition and the operating parameters of the
plating solution.
ELECTROLESS NICKEL PLATING
Electro-less nickel plating is used to deposit nickel without the use of an electric current.
The coating is deposited by an autocatalytic chemical reduction of nickel ions by hypophosphite,
aminoborane or borohydride compounds.
Advantages:
Good resistance to corrosion and wear
Excellent uniformity
Solder-ability and braze-ability
Low labour costs.
Limitation:
Higher chemical cost than electro-plating.
Brittleness.
Poor welding characteristics due to contamination of nickel plate with nickelPhosphorus deposits.
Slower plating rate, as compared to electrolyte methods.
Reaction by products
Characteristics:
Electro-less nickel plating is produced by the controlled chemical reduction of nickel ions
onto a catalytic surface. The deposit itself is catalytic to reduction, and the reaction continues as
long as the surface remains in contact with the electro-less nickel solution.
Electro-less nickel solutions are blends of different chemicals, each performing an important
function, electro-less nickel solution contain:
A Source of nickel, i.e. nickel sulfate
A reducing agent to supply electrons for the reduction of nickel. Energy i.e. heat
Complexing agents to control the free nickel available to the reaction.
Buffering agents to resist the PH changes caused by the hydrogen generated
during
deposition
Accelerators to help increase the speed of the reaction.
Inhibitors (stabilizers) to help control reduction.
CADMIUM PLATING:
Cadmium plating is used to protect steel and cast iron against corrosion, because cadmium
is anode to iron, the underlying ferrous metal is protected at the expense of cadmium plating. It is a
thin coating the thickness is less than 25 microns. It is seldom used as undercoating for other metals
and its resistance to corrosion by most chemicals is low.
It has natural lubricity
Cadmium has excellent electrical conductivity and low contact resistance.
Non corrosive fluxes can be used to produce top quality soldered sections.
Steel that is coated with cadmium can be formed and shaped because of the
Ductility of the cadmium.
Cadmium is highly toxic. Health, safety and environmental concerns are driving

the reduction or elimination of its use for many applications.

SELECTRON (BRUSH) PLATING:

Selectron plating also called as brush plating is carried out by applying an electrolyte on to
the prepared surface by a hand held anode or stylus, which incorporates an absorbent wrapping for
applying the solution to the work piece (cathode). A direct current power pack drives the
electrochemical reaction, depositing the desired metal on the substrate.
Other surface modification
Processes:
PVD, CVD coatings,
Titanium Nitride coatings,
Laser cladding / modifications etc. are very widely used
Diffusion Coatings
(Indigenously developed In-house)
a) Aluminizing
b) Al-Si diffusion coating
c) Sermalloy-J coating
d) Pt-Aluminide coating
Applications: Turbine Blades / Turbine wheels
Surface coatings are all considered as sacrificial coatings, because they suffer from hostile
environment protecting base metal.
Advantage Enhancement of life of component , Recoating / Re-claiming of parts, there by cost
reduction, Replacement of parts are avoided.
PROCESS FLOW CHARTS
Organic Paint Application
Degrease / Metal cleaning
Chromate / Anodising (Mg /Al)
Apply Primer by Spray gun
Bake at 100-200 Deg C range
Mix paint thoroughly
Check viscosity
Apply paint by Spray gun
Air Dry
Bake at 190-200 Deg C for Hr
Inspect
Sermetel Paint Application
Degrease - Mask Abrasive Blast Clean with dry Air Mask Mix Sermetel W
thoroughly - Check viscosity Apply by spray gun Air dry Apply Second coat Air Dry Oven
Dry at 190 Deg C for Hr Bake at 350 Deg C for 1 Hr. and 560 Deg C for 1 Hr. Check thickness
and surface finish
Glassbead peen (Burnishing) Abbrasive Blast Apply Sermoseal 570A Air Dry Oven
Dry at 190 Deg C for Hr. Bake at 350 deg.c for 1hour. Inspect
Thickness of coating is 50 100 microns for Sermetel W 8-10 microns for Sermoseal 570A
Plasma / D-Gun Coating
Degrease

Mask
Abrasive blast
Clean with Dry Air
Mask
Apply Bond Coat (Plasma)
Apply Over Coat (Plasma)
Apply Coat D-Gun
Check Thickness / Quality

Aluminising / Al-Si Diffusion Coating

Degrease
Blast
Clean with dry air
Mask
Pack in powder
Load into furnace at temp.
Inlet argon
Soak for required time
Cool and clean the parts
10 % Ardrox Ultrasonic cleaning
Wash in cold water
5 % Citric acid cleaning
Wash in Cold water & Hot water
Air Dry
Diffusion Heat treatment
Check thickness and Quality
Aging
Platinum Aluminide Coating
Degrease
Mask
Blast
Remove Mask and Re-mask
Electrolytic Alkaline Cleaning
Acid Etching
Wash in Hot / Cold Water
Platinum plating
Wash in Cold / Hot Water
Dry & Inspect Thickness & Quality
High Temp. Diffusion Aluminising
10 % Ardrox Ultrasonic cleaning Wash in cold water
5 % Citric acid cleaning Wash in Cold water & Hot water
Air Dry
High Temp. Diffusion
Inspect Thickness & Quality
Aging
HEAT TREATMENT PROCESSES
All metallic parts in Aero Engine will under go some type of Heat treatment to achieve
required properties specified in drawing / specifications.
All metallic parts in Aero Engine will under go some type of Heat treatment to achieve
required properties specified in drawing / specifications.
Heat treat processes
1.
Annealing Steel

2.
3.
4.
5.

6.
7.

Normalising, Hardening & Tempering steels

Stress Relieving for all types of materials.
Solutionising & precipitation (Aging) heat treatment for Al, Mg, Ti, & Ni base
Surface hardening processes
a) Gas carburising
b) Gas nitriding
c) Cyaniding
De-embrittlement Heat treatment
Baking / curing of painted parts

alloys

Annealing
Heating the steel to 900 deg C and followed by furnace cooling. (Muffle / vacuum). Material
softens. Hence any forming and machining, Welding can be done easily.
Normalising, Hardening & Tempering
This process is applicable to carbon steels / alloy steels to achieve required properties & for
Machining.
Normalising: Heating to 900 deg C - hold Air cool (Muffle / vacuum)
Result: Uniform microstructure / chemical composition distribution.
Hardening: To achieve required hardness. Heating to 850 deg C hold oil quench / Gas quench in
muffle / Neutral salt bath / Vacuum Furnace respectively.
Result: Transformation to Martensitic structure. Hard & Brittle. Material in strained
Condition.
Tempering: Heating to 550 600 deg C for 1 to 2 hrs followed by air cooling (Air circulating furnace)
Result: Reduction in Brittleness. Required hardness / ductility achieved.
Stress Relieving: Heating to temperature less than or equal to tempering temperature, hold for 1-2
hrs and air cool. Induced stress due to machining, cold forming or welding is removed. Applicable for
any material.
Solutionising & Aging (Precipitation)
Aluminium: Heating to 505 to 525 deg C for required duration in air circulating
Furnace & water quenching / Brine quenching etc.
Result: All the constituents will go to solid solution.
Ex: Copper in Aluminium remains in Solid solution.
Conditions: Soft, easy to machine/ form etc.
Aging: (a) Natural Aging
(b) Artificial Aging (Precipitation)
Natural Aging takes place at room temp in 48 hrs.
Artificial Aging takes place at elevated temp. at 150-200 C for 16 Hrs.
Result: Copper precipitates as CuAl2
Inter-metallic compound in grain boundary and attain mechanical properties.
Hardness
: 120 150 BHN
Tensile Strength : 40-42 Kgs / mm2
Elongation
: 10% Minimum
Titanium and Nickel Base alloys also will undergo solutionising & aging to get mechanical
properties & High temp. Properties viz creep & stress rupture properties.
Solutionising: At 950 deg C for Ti- alloys, at 950-1150 deg C for Ni -Base alloys
Aging: 550 700 deg C for Ti- alloys
700 - 850 deg C for Ni- Base alloys
Surface Hardening Processes
(a)
Gas carburising: Introduction of additional carbon onto surface of components viz gears /
shafts etc., and hardening and tempering is called
case hardening.

Temperature
: 900 to 925 deg
Duration
: Depends on Thickness
Surface hardness : Rc 60 min (Some times Rc 57 acceptable)
Core hardness
: Rc 32-36 & Rc 36-43
Application
: Gear teeth, Bearing diameter, Shafts etc.,
Purpose
: Wear resistant, Increase fatigue with tough core for
resistance to shock load
b) Gas Nitriding: Introduction of Nacent Nitrogen onto surface of steel components at temperature
less than tempering temp of part. The Nacent Nitrogen combines with alloying elements viz Cr, V,
Mo, etc., forms respective nitrides and become hard surface to a depth required.
Nitriding temp : 490 505 deg C
Duration
: 12 ,24, 48,72 etc.,
Cyaniding:
Introduction of carbon and Nitrogen onto surface of the component. This is done in a salt
bath containing sodium cyanide, sodium chloride bath. Heated to 870 deg C and dipping the parts
for a period of 15-20 minutes to achieve case depth of 0.20 mm max
Then hardened and tempered 820 deg C Oil quench / salt quench at 190 deg c Air cool
140 150 deg C for 2 hrs. Air cool in air circulating furnace. Hardness: Rc 58- 61 Surface
Rc 32- 36 Rc 36- 43 Core
Quality Control Checks:

All furnaces and ovens are to be in calibrated condition.

Periodically to be calibrated including thermocouples.
Temperature Controller, Temperature recorder, over temperature controls is required to
every furnace.
Whenever test piece requirements are given in drawing, they have to be processed along
with parts.
Daily check / Annual calibration of Hardness testing machines is a must.
After Hardening & Tempering, Hardness to be checked & record (Rockwell, Vickers or
Brinnel methods.)
For surface hardening processes the following specimens to be processed & checked.

Gas carburising:
Spy Test specimen For case depth, quality, hardness
Gear cut specimen (Simulated T.P.) Case depth, quality, hardness
Carbon potential test specimen Percentage of carbon on surface
Retained Austenite test specimen To check for retained austenite in the case
Nitriding:
Spy Test specimen For case depth, quality, hardness
Impact test specimen toughness, Temper Embittlerment
Cyaniding:
Spy Test specimen Case depth, quality & Hardness
Neutral salt used for Hardening to be checked periodically
Cyanide content to be checked before use.
Quenching oil to be checked for contamination & acidity periodically
Trichloro- ethylene to be checked for contamination & acidity.