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Courses » Fundamentals of Surface Engineering: Mechanisms,Processes and Characterizations

Fundamentals of Surface Engineering: Mechanisms,Processes and Characterizations

ABOUT THE COURSE:

The course content is designed to have systematic and comprehensive understanding on various aspects related with surface engineering of metallic components for enhanced tribological life. It is proposed to include fundamental mechanisms of wear such as adhesive, abrasive, erosive, cavitation, corrosion etc., governing laws, materials properties importance for improved wear resistance under different wear conditions, materials increased tribological life, processes for engineering surfaces of three board categories a) regulating the micro-structure without changing chemical composition b) modification of chemical composition of near surface layers and c) developing of films, coating, and cladding on the. Methods of characterization needed for evaluating the metallurgical and mechanical and tribological properties and performance of engineered surfaces shall also be presented. Presentations will be supported with case studies for effective communication of concepts and procedures. Case studies will be taken up regarding surface engineering of various metal systems like ferrous and non-ferrous metals using different approaches discussed.

Important For Certification/Credit Transfer:

Weekly Assignments and Discussion Forum can be accessed ONLY by enrolling here

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Note: Content is Free!

All content including discussion forum and assignments, is free


Final Exam (in-person, invigilated, currently conducted in India) is mandatory for Certification and has INR Rs. 1100 as exam fee.





INTENDED AUDIENCE: UG and PG Student, Research Scholar & Practicing Engineers

CORE/ELECTIVE: Elective

UG/PG: PG/Research

PREREQUISITES: NIL

INDUSTRY SUPPORT: Mining, Hydropwer, Cement and Manufacturing

1047 students have enrolled already!!

ABOUT THE INSTRUCTOR:


Dr. D K Dwivedi obtained BE (mechanical engineering) , in 1993 from GEC Rewa, ME (welding engineering) from Univ. of Roorkee in 1997 and PhD in Met. Engineering from MNIT, Jaipur in 2003. He has about 9 years teaching experience at NIT Hamirpur and 12 years at IIT Roorkee of subjects related with manufacturing at UG level and welding engineering related subjects at PG level including failure analysis of welded joints. He has undertaken work of failure investigation valves, penstocks, bridges for many private and public sector industries especially in hydropower sector. He has published more than 100 research papers in SCI/SCIE indexed journals and undertaken 16 sponsored research and 50 industrial consultancy projects. Instructor has authored two books entitled Production and Properties of Cast Al-Si Alloys with New Age International, New Delhi (2013) and Surface Engineering with Springer, New Delhi (2018).

COURSE LAYOUT:

Week 1  : Introduction 
I. Introduction and need of surface engineering 
II. Surface/sub-surface regions and properties of importance for surface engineering 
III. Surface properties and their modification 
IV. Classification of surface modification techniques I
V. Classification of surface modification techniques II

Week 2  : Introduction 
I. Comparison of surface modification techniques and scope of surface engineering 
II. Scope of surface engineering I
III. Surface properties on wear and friction resistance I
IV. Surface properties on wear and friction resistance II
V. Surface properties on wear and friction resistance III

Week 3  : Surface damage 
I. Issues and application of surface modification 
II. Surface damage: type and categories 
III. Surface damage: Adhesive wear I
IV. Surface damage: Adhesive wear II
V. Surface damage: Classical law of adhesive wear and abrasive wear

Week 4   : Surface damage 
I. Surface damage: Abrasive wear I
II. Surface damage: Abrasive wear II
III. Surface damage: Erosive wear
IV. Surface damage: Melting wear and corrosive wear
V. Surface damage: Diffusive wear and evaluation of surface damage  

Week 5  : Materials for wear resistant applications 
I. Properties and mode of wear 
II. Metal systems
III. Thermal barrier coatings 
IV. Functionally graded materials and other materials  
V. Surface modification techniques: Principle of controlling surface metallurgy 

Week 6  : PROCESSES FOR CONTROLLING WEAR: STRUCTURAL MODIFICATION 
I. Surface modification techniques: Controlling surface metallurgy I
II. Surface modification techniques: Controlling surface metallurgy II
III. Surface modification techniques: Controlling surface metallurgy III
IV. Surface modification techniques: Controlling surface metallurgy IV
V. Surface modification techniques: Changing surface composition 

Week 7  : PROCESSES FOR CONTROLLING WEAR: COMPOSITION MODIFICATION
I. Surface modification techniques: Carburizing I
II. Surface modification techniques: Carburizing II
III. Surface modification techniques: Carburizing and Cyaniding 
IV. Surface modification techniques: Nitriding 
V. Surface modification techniques: Plasma carburizing  & plasma nitriding 

Week 8  : PROCESSES FOR CONTROLLING WEAR: COMPOSITION MODIFICATION
I. Surface modification techniques: Vacuum based surface modification I
II. Surface modification techniques: Ion implantation and ion plating  
III. Surface modification techniques: Sputtering and Ion beam assisted deposition 
IV. Surface modification techniques: Chemical vapour deposition and boronizing 
V. Surface modification techniques: Laser alloying 

Week 9  : PROCESSES FOR CONTROLLING WEAR: COMPOSITION MODIFICATION & WELD SURFACING 
I. Surface modification techniques: Laser nitriding and developing surface layer 
II. Surface modification techniques: Fundamentals of surface modification by weld surfacing and thermal spraying 
III. Surface modification techniques: Fundamentals of surface modification by weld surfacing 
IV. Surface modification techniques: Weld surfacing processes
V. Surface modification techniques: Weld surfacing I  

Week 10  : PROCESSES FOR CONTROLLING WEAR: COATINGS & CLADDING 
I. Surface modification techniques: Weld surfacing II
II. Surface modification techniques: Weld surfacing III
III. Surface modification techniques: Laser cladding 
IV. Surface modification techniques: Principle of thermal spraying 
V. Surface modification techniques: Flame spraying 

Week 11  : PROCESSES FOR CONTROLLING WEAR: COATINGS & OVERLAYS
I. Surface modification techniques: Improving the performance of flam spray coating 
II. Surface modification techniques: HVOF and Detonation spraying 
III. Surface modification techniques: Cold spraying, arc spraying 
IV. Surface modification techniques: Plasma spraying, electroplating, electroless plating   
V. Characterization of modified surfaces: Surface roughness and thickness I

Week 12  : PROCESSES FOR CONTROLLING WEAR: COATINGS & CHARACTERIZATION 
I. Characterization of modified surfaces: Surface roughness and thickness II
II. Characterization of modified surfaces: Thickness and soundness 
III. Characterization of modified surfaces: Soundness and mechanical properties
IV. Characterization of modified surfaces: Metallography  
V. Characterization of modified surfaces: Wear behavior 


SUGGESTED READING MATERIALS:

ASM Handbook, Surface Engineering, ASM, (1995) Ohio D K Dwivedi, Surface Engineering: Enhancing life of tribological component, Springer (2017) New Delhi  Jamal Takadoum, Materials and Surface Engineering in Tribology, Willey (2007), London A W Batchelor et al., Materials Degradation and its control by surface engineering, Imperial College Press, (2006), London Tadeusz Burakowski, Tadeusz Wierzchon, Surface engineering in metals, CRC Press (1999) London
CERTIFICATION EXAM :
  • The exam is optional for a fee.
  • Date of Exams : October 28 (Sunday)
  • Time of Exams : Morning session 9am to 12 noon; Afternoon session: 2pm to 5pm
  • Exam for this course will be available in both morning & afternoon sessions.
  • Registration url: Announcements will be made when the registration form is open for registrations.
  • The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published.

CERTIFICATION:

  • Final score will be calculated as : 25% assignment score + 75% final exam score
  • 25% assignment score is calculated as 25% of average of  Best 8 out of 12 assignments
  • E-Certificate will be given to those who register and write the exam and score greater than or equal to 40% final score. Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Roorkee.It will be e-verifiable at nptel.ac.in/noc.