Surface Coating Methods for

Metal Surfaces
SHRISTI SINGH
2018UGMM051
 CONTENTS

• Abstract
• Benefits of Surface Coatings
• Common Surface Coating
Techniques
• Galvanizing
• Electrochemical Coatings
• Vapor Deposition
• Conversion Coatings
• Thermal Spraying

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 ABSTRACT

Mostly special surface treatments are needed for metal surfaces, especially steels’ surfaces,
in order to have the desired optimum properties. There are various techniques for surface
treatment methods but the most common one is surface coating. Steels require further
surface coatings for enhanced corrosion resistance, wear-resistance, and surface hardness.
The coating methods differ for different applications. The most common surface coating
techniques have been discussed further in this presentation.

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 Benefits of Surface Coatings

 Abrasion-resistant coatings prevent wear and add durability.

 Protection against chemicals, prevents corrosion and contamination.
 Certain coatings acts as a barrier to current and prevents the part beneath from
static build.
 Certain coatings may act as a thermal barrier.
 Gives a sleek surface finish and provides an aesthetic appeal.

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 The vapor deposition methods
It is the process of applying a utilize vaporization and It applies a consumable as a spray of
protective zinc coating to steel or condensation processes for finely divided molten or semi-molten
iron, to prevent rusting. making thin-film layers.  droplets to produce a coating.

Electrochemical Vapor Conversion Thermal

Galvanizing
Coatings Deposition Coatings Spraying

They use the electrostatic properties of It is a chemical or electro-chemical

different metals which can be either in treatment that involves spraying or
solution as ions or can be as sheet dipping the desired material through the
metals. additional substance to create a
coating. 

Common Surface Coating Techniques

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 Galvanization
The galvanizing process has three major steps: surface preparation,
galvanizing process, and post-surface treatment. There are two types of
galvanizing methods: hot-dip galvanizing and electro-galvanizing.

• Hot dip galvanizing (LEFT nail in the Figure) involves coating iron

or steel with a layer of zinc by immersing the metal in a bath of
molten zinc at a temperature of around 450 °C.

• Electro-galvanization (RIGHT nail in the Figure) involves

electroplating, running a current of electricity through a
saline/zinc solution with a zinc anode and steel conductor.
 Electrochemical Coatings
Electrochemical coatings use the electrostatic properties of different metals which can be either in
solution as ions or can be as sheet metals. The electrochemical coatings are divided into two parts-
electrodeposition methods and electroless coatings.

• Electroplating systems consist of anodes cathodes and electrolytes. A direct current is passed
from the system for liberation or deposition of the ions. It may involve electrorefining
processes, electrowinning processes, or molten salt processes. Different metal ions can be
coated through the base metal which is used as the cathode in the system.

• In this electroless method, the desired surface is first cleaned and after immersed in a
solution. The surface is etched by the ions in the solution and ions located on the surface.

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 Vapor Deposition
It utilize vaporization and condensation processes for making thin-film layers. The desired metal is first
evaporated and then condensed onto the target surface. It may be classified as- chemical vapor deposition
(CVD) and physical vapor deposition (PVD).
• Chemical Vapor Deposition (CVD) is a process in which the substrate is exposed to one or more
volatile precursors, which react and/or decompose on the substrate surface to produce the
desired thin film deposit.
• Physical Vapor Deposition (PVD) involves physically depositing atoms, ions or molecules of a
coating species on to a substrate. There are three main types of PVD- thermal evaporation,
sputtering and ion plating. Thermal evaporation uses the heating of a material to form a vapor
which condenses on a substrate to form the coating. Sputtering involves the electrical generation
of a plasma between the coating species and the substrate. Ion plating is essentially a
combination of thermal evaporation and sputtering.

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 Conversion Coatings
It consists of spraying or dipping the desired material through the additional substance. They
develop the corrosion resistance of the surface by additional substances such as chromium or
phosphate. Conversion coatings can be classified as chromating, phosphating, and anodizing.

• In chromating process the base metal is dipped into a solution with chromium ions. Chromate
coatings have self-healing properties.
• In the phosphating method, metal surfaces are dipped into the phosphoric acid solution, or
solutions are sprayed onto the metal surfaces. 

• In the anodizing method, a protective film is formed by the base metal. 

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 Thermal Spraying
Thermal spraying is a generic category of coating processes that
apply a consumable as a spray of finely divided molten or semi-
molten droplets to produce a coating. It is distinguished by its
ability to deposit coatings of metals, ceramics and polymers in
layers of substantial thickness, typically 0.1 to 10mm, for
engineering applications. Almost any material can be deposited
so long as it melts or becomes plastic during the spraying
operation. At the substrate surface, the particles form 'splats' or
'platelets' that interlock and build up to give the coating. The
bond between a thermally sprayed coating and the substrate is
primarily mechanical, and not metallurgical or fused.