Metals and surface treatments – An overview

What is industrial surface treatment?

Industrial surface treatment is a process in which the surface of a workpiece is machined to improve or change its mechanical, chemical or visual properties.

There are various ways to treat surfaces, such as etching, galvanizing, powder coating, heat treatment, microstructure modification and thermal coating. The purpose of surface treatment is to improve the lifetime and efficiency of workpieces. Surface treatment can also help reduce costs by reducing maintenance requirements and ensuring protection against corrosive influences.

What are the benefits of surface treatments?

Surface treatments have many benefits, for example:

• They can protect the surface from corrosion, dirt and wear.
• They can extend the life of the material or product.
• They can reduce moisture absorption.
• They can reduce friction and wear.
• They can improve the appearance and optics.
• You can easily keep the surface clean.
• You can use the heat- and improve sound proofing.

What types of surface treatments are there?

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

• Painting: This is one of the most common surface treatments.
• Coating: This treatment can be used in the form of powder coatings, galvanization and electrophoresis.
• Q&T: 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.
• Polishing: This treatment is used to make the surface smoother and shinier.
• Surface treatments with chemical agents.

Surface treatment with dissolved materials

Anodizing

Anodizing is a surface treatment in which an oxide film is formed on the surface of a metal object through anodic oxidation. This layer prevents corrosion and improves the functionality and appearance of the object.

Anodizing is a type of anodizing and is best known in connection with the surface treatment of aluminum alloys. The resulting anodized layer protects the metal from oxidation and increases durability.

Anodizing and technical anodizing can be used on various other metals besides aluminum. These so-called valve metals, including steel, titanium and magnesium, also form a protective oxide layer when anodized.

Nitriding

Nitriding is a thermal treatment in which a metal is treated with nitrogen using heat and pressure. This treatment gives the metal greater hardness, improves wear resistance and increases corrosion resistance. Nitriding is often used on steel, iron, brass and aluminum.

Tinning

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

Zinc galvanizing

Zinc galvanizing is a process in which metal surfaces are coated with a layer of zinc. This process is often used on steel and iron, but can also be applied to other metallic surfaces such as aluminum or copper. Zinc galvanized metal surfaces are resistant to acid rain, salty air and other environmental conditions that may lead to corrosion.

Chromating

Chromating is a surface treatment process. It involves applying a layer of metal or metal alloys to the surface of a material to protect, embellish or modify it. It is typically applied to metal surfaces to make them more corrosion resistant and protect them against oxidation.

Electroless nickel plating

Electroless nickel plating is a surface treatment technique used to apply a layer of nickel to a metal surface. The applied nickel provides a very smooth and hard surface that is corrosion-resistant and wear-resistant. This technique is a popular choice for industrial applications because it not only creates a smooth, beautiful surface, but also a durable surface that will provide protection for a long time. Electroless nickel plating is usually applied to metal parts such as bolts, screws, nuts, shafts, couplings and other fasteners.

Phosphating

Phosphating is a surface treatment in which 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 commonly used on automotive parts, tools, machinery and other metal surfaces.

Sol-Gel

Sol-gel is a process for producing surface treatments in which a solution of silicate or aluminate compounds are introduced into a preformed surface. This process is often used in electronics, automotive-, textile- and furniture industry as well as in the chemical industry. Sol-gel coatings are very thin, smooth, robust and corrosion-resistant, which makes them particularly attractive for a wide range of applications.

Surface treatment with liquid materials

Thermal spraying

Thermal spraying is a type of surface treatment in which a special resin is applied using a powder jet process. This process is often used to restore damaged surfaces and improve durability and corrosion resistance. In thermal spraying, a powdered material, usually a combination of metal powder and resin, is sprayed onto the surface through a nozzle at high pressure. The heat generated by the pressure during spraying causes the resin and metal powder to bond together, creating a permanent barrier that protects the surface against dirt and water.

Plasticizing

Plasticizing is a surface treatment technique mainly used to prevent corrosion and increase surface hardness. This process makes the surfaces thinner and harder, increasing resistance to wear and corrosion. Plasticizing is the process of applying a thin layer of metal or non-ferrous metal to a surface, creating a protective film that protects the surface against damage.

Electrophoretic dipping

Electrophoretic dipping is a type of surface treatment in which an electrically charged paint is applied to a metal part. The paint is then dipped into a metal part through electrolysis, coating the surface of the part with a thin layer of paint. The process allows for a uniform and smooth finish, protecting the metal part from corrosion and wear.

Hot dipping (hot-dip galvanizing)

Hot dipping (also called hot-dip galvanizing) is a type of electroplating surface treatment that is performed on a metallic surface. It is a process in which a thin layer of zinc dust is applied 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 dipping is one of many surface treatment methods known as zinc or galvanization.

Dip coating

Dip coating is a specific type of surface treatment in which a workpiece is dipped into a bath of a paint, coating or other material to cover or protect it. This process may take a few minutes or several hours, depending on the material and application.

Enameling

Enameling is a type of surface treatment in which a molten glass is applied to a metal surface to produce a smooth, shiny finish. This glaze is then cured using a special kiln method to create a hard, durable surface. Enameling is an extremely effective way to protect a surface from corrosion, scratches, wear and other damage.

Burnishing

Burnishing is a surface treatment process in which a ferrous metal surface is treated with an acidic or alkaline solution, the so-called burnishing agent. This is usually done by immersing the object to be burnished in an immersion bath. A chemical reaction creates a black oxide film which is not a coating but a material transformation.

This treatment creates a protective layer which improves protection against wear and corrosion.

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