Metals and surface treatments – an overview

What is surface treatment in industry?

Industrial surface treatment is a process where a surface of a workpiece is treated to improve or change its mechanical, chemical or visual properties.

Surface treatments can be carried out in various ways, such as etching, electroplating, powder coating, heat treatment, structural change and thermal coating. The purpose of surface treatment is to improve the service life and efficiency of the workpieces. Surface treatment can also help to lower costs by reducing maintenance requirements and ensuring protection against corrosive influences.

What are the advantages of surface treatments?

Surface treatments have many advantages, for example:

• They can protect the surface from corrosion, dirt and wear.
• They can prolong the life of the material or product.
• They can reduce moisture absorption.
• They can reduce friction and wear.
• They can improve the appearance and look.
• They can enable a surface to be kept clean easily.
• They can improve thermal and sound insulation.

What types of surface treatment are available?

There are a variety of surface treatments used for different applications. These include:

• Paint: This is one of the most common surface treatments.
• Coatings: This treatment can take the form of powder coatings, electroplating and electrophoresis.
• Tempering: This treatment is used to make the surface smoother and stronger, making it more resistant to wear and tear.
• Heat treatments: This treatment is used to increase the strength and hardness of the surface by heating it and then cooling it down.
• Polishing: This treatment is used to make the surface smoother and glossier.
• Surface treatments with chemical agents.

Surface treatment with dissolved materials

Anodizing

Anodizing is a surface treatment where an anodized coating is applied to the surface of a metal object. This layer prevents corrosion and improves the function and appearance of the object.

Anodizing is a process where a layer of aluminium oxide is applied to a metal surface. This layer protects the metal from oxidation and increases durability. Anodizing can be used on many different metals, including aluminium, steel, copper and magnesium.

Nitriding

Nitriding is a thermal treatment where a metal is treated with nitrogen using heat and pressure. This treatment gives the metal increased hardness, improves wear resistance and increases resistance to corrosion. Nitriding is often used on steel, iron, brass and aluminium.

Tinning

Tinning is a technique in which a metal, usually zinc, is applied to another metal. It is often used to protect metal parts from corrosion, especially in humid environments. Zinc is used as a tinning material as it is a very good corrosion inhibitor and has a long service life.

Galvanising

Galvanising is a process where metal surfaces are coated with a layer of zinc. This method is often used on steel and iron, but can also be applied to other metallic surfaces such as aluminium or copper. Galvanised metal surfaces are resistant to acid rain, salty air and other environmental conditions that can lead to corrosion.

Chromating

Chromating is a surface treatment process. It involves applying a layer of metal or metal alloy to the surface of a material to protect, enhance its appearance or modify it. It is typically applied to metal surfaces to improve their corrosion resistance and protect them from oxidation.

Chemical nickel plating

Chemical nickel plating is a surface treatment technique used to apply a layer of nickel to a metal surface. The nickel applied provides a very smooth and hard surface that is resistant to corrosion and wear. This technique is a popular choice for industrial applications as it not only creates a smooth, visual appealing surface, but also a durable surface that offers long-term protection. Chemical nickel plating is normally used on metal parts such as bolts, screws, nuts, shafts, couplings and other fasteners.

Phosphating

Phosphating refers to a surface treatment where a phosphate layer is applied to a metal surface. This layer is used to protect the surface from corrosion and to give the surface a shiny appearance. Phosphate coating is often used on car parts, tools, machines and other metal surfaces.

Sol-gel

Sol-gel is a process for producing surface coatings where a solution of silicate or aluminate compounds is introduced into a pre-formed surface. This process is widely used in electronics, the automotive, textile and furniture industries, as well as the chemical industry. Sol-gel coatings are extremely thin, smooth, robust and corrosion resistant, making them particularly attractive for a wide range of applications.

Surface treatment with liquid materials

Thermal spraying

Thermal spraying is a type of surface treatment that involves applying a special resin in a powder blasting process. This procedure is often used to restore damaged surfaces and to improve durability and resistance to corrosion. Thermal spraying involves spraying a powdered material, normally consisting of a combination of metal powder and resin, onto the surface through a nozzle at high pressure. The heat generated by the pressure of spraying ensures that the resin and the metal powder bond together, creating a lasting barrier that protects the surface from dirt and water.

Plasticising

Plasticising is a surface treatment technique mainly used to prevent corrosion and improve surface hardness. This process makes the surfaces thinner and harder, which increases resistance to wear and corrosion. Plasticising involves applying a thin layer of metal or non-ferrous metal to a surface, creating a protective film that protects the surface from damage.

Electrophoretic dip coating

Electrophoretic dip coating is a type of surface treatment where an electrically charged paint is applied to a metal part. The paint is then dipped into a metal part by electrolysis, which coats the surface of the part with a thin layer of paint. The process provides an even and smooth finish, protecting the metal part from corrosion and wear.

Hot dip galvanising

Hot dip galvanising (also known as hot dipping) is a type of galvanic surface treatment carried out on a metallic surface. The process involves applying a thin layer of zinc dust to the metal by heating the surface with an alloy of zinc and copper. This process creates a corrosion-resistant layer that protects against oxidative damage. Hot dip galvanising is one of many surface treatment methods referred to as zinc or electroplating.

Dip coating

Dip coating is a specific type of surface treatment where a workpiece is immersed in a bath of paint, coating substance or other material to coat or protect it. This process can take a few minutes or several hours depending on the material and application.

Enamelling

Enamelling is a type of surface treatment where an enamel is applied to a metal surface to achieve a smooth, glossy surface. This glaze is then tempered using a special oven method to create a hard, durable surface. Enamelling is an extremely effective method of protecting a surface from corrosion, scratches, wear and other damage.

Bronzing

Bronzing is a surface treatment method where a metal surface is polished with a polishing agent, such as a polished metal dust. This method is used to achieve a smooth surface that is resistant to wear and corrosion. Some bronzed metal parts may have a higher gloss level than with other surface treatment methods.

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