AN INTRODUCTION TO COMPOSITE CHROMIUM PLATING

(CPC) ON CAST IRON PISTON RINGS

INTRODUCTION

SHRIRAM PISTONS & RINGS LTD. PLOT NO. A-4 TO A-7, MEERUT ROAD INDUSTRIAL AREA,
GHAZIABAD, 201003, PHONE – 0120-2724861 - 67
ELECTROPLATING: - This is a branch of Electrochemical Engineering
dealing with application of Electrolytic Coating of One metal over other
metallic or non-metallic surface to give certain properties which enhance the
latter’s performance in terms of Appearance, Corrosion resistance,
mechanical properties such as reduction in friction & metallurgical
properties such as Hardness.

PRINCIPLE OF ELECTROPLATING: Basic fundamental principle of

electroplating is based on ‘Faraday’s laws of electrolysis’.

Faraday’s law states:-

In an electrolytic cell, the mass deposited on the cathode is directly

proportional to amount of current passing through the cell & the time for
which the current is allowed to pass.

Hence M  I x T (Where M – Mass of metal deposited at cathode &

T – Time of passing of current through Cell)

Therefore, M = Z x I x T (Where Z – Electrochemical Equivalent for a given

Electrolyte)

CPC COATING: - It is a process of embedding ceramic particles in the

matrix of metallic deposits of Chromium on the outer surface of Nodular
Grey Cast Iron Top Compression Piston Rings in the form of multiple layers
using Electrolytic process. Unlike ordinary Hard Chromium Plating process,
this coating technology is five times better in performance such as Friction,
Anti-Scuffing properties, Micro-hardness & life.

At Shriram, Ring plant & R&D has indigenously developed this technology
in July’ 2010 & set up a fully Automatic state of art facility in C2D1 Ring
plant in Dec’2010 under the guidance of M/S Riken Corporation, Japan.

 In a piston ring/ cylinder wall tribological system, hard chrome

coating is known for good wear resistance, so long as the thermal
and/or mechanical engine load do not exceed certain limit.
 Engine manufacturers are demanding that the thermal and/or
mechanical loading capabilities of the chrome coating should be
improved.
 Chromium-ceramic coating meets this requirement

SHRIRAM PISTONS & RINGS LTD. PLOT NO. A-4 TO A-7, MEERUT ROAD INDUSTRIAL AREA,
GHAZIABAD, 201003, PHONE – 0120-2724861 - 67
At present the major customers of CPC Rings are:-

1. Tata Cummins Ltd. (Pune & Jamshedpur)

2. Ashok Leyland Ltd. (Banglore)
3. Mahindra & Mahindra Ltd.
4. Eicher, Koel, MSI, Rami, Diamler Chrysler etc.

Photo – CPC Layers with Microcracks embedded with Ceramic particles

INPUT RINGS CHRACTERSTICS: Generally rings required to be CPC

Coated are Sharp Edge Profile Grounded Key Stone. However, there are
other categories as well such as Non-Profile Grounded Keystone Rings &
Semi Inlaid CPC Rings.

PROCESS – All CPC Rings are subjected to following sets of operations:

Casting –> Splitting –> Side Face Grinding –> Cam Profile Turning –>
Boring –> CNC Profile Turning –> Rough Gap Grinding –> Visual
Inspection –> Demagnetization -> Vibrofinishing –> Top – 2 Alignment ->

SHRIRAM PISTONS & RINGS LTD. PLOT NO. A-4 TO A-7, MEERUT ROAD INDUSTRIAL AREA,
GHAZIABAD, 201003, PHONE – 0120-2724861 - 67
Mandrel Clamping –> Lacquer Application & Cleaning –> Dry Sand
Blasting –> Loading –> Etching –> Ultrasonic Smut Removal –> CPC
Coating –> Unclamping –> Demagnetization –> Neutralization –>
Inspection & Testing –> Boring –> Side Face Grinding –> Gap Edge
Chamfering –> Profile Grinding –> Asymmetrical Honing –> Finish Gap
Grinding –> Beldering –> Washing –> Visual Inspection –> Key Stone
Grinding –> Visual Inspection –> Parkerizing –> Stamping –> Visual &
dimensional Inspection –> Quality Assurance Sample Inspection –>
Packaging – >Despatch To Godown –> Final Despatch To Customer

SHRIRAM PISTONS & RINGS LTD. PLOT NO. A-4 TO A-7, MEERUT ROAD INDUSTRIAL AREA,
GHAZIABAD, 201003, PHONE – 0120-2724861 - 67