Course 1 Surface Engineering and Thin Films 2025

Surface Engineering

• Focused on development of thin films and their applications.

• Rapidly growing field with significant technological advancements.

Surface Engineering Overview

• Definition: Applied thin film science, concentrating on design, processing, and characterization of thin films.

Benefits of Thin Films

• Enhanced Properties:

  • Hardness: Increases resistance to scratches and wear.

  • Young’s Modulus: A measure of the stiffness of a solid material.

  • Resistance to Plastic Deformation: Ability to maintain shape under stress.

  • Friction Coefficient: Reduced friction leading to improved efficiency.

  • Chemical Reactivity: Control over chemical interactions.

  • Electrical Properties: Enhanced conductivity or insulation as required.

  • Optical Properties: Improved light performance for various applications.

Applications of Thin Films

• Utilized in diverse fields such as:

  • Cutting Tools: Improved performance and durability.

  • Punches and Dies: Enhanced operational lifespan.

  • Medical Devices & Surgical Implants: Biocompatibility and performance.

  • Aerospace Components: Critical performance under stress.

  • Plastic Molds: Overall lifecycle improvement.

  • Decorative Accessories: Enhanced aesthetic appeal.

  • Firearms Components: Performance and safety.

  • Sporting Goods: Lightweight and durable materials.

  • Computer Hardware: Enhanced performance and reliability.

  • Plumbing Fixtures: Increased durability and maintenance.

  • Blades and Knives: Edge retention properties.

  • Marine Hardware: Corrosion resistance in challenging environments.

  • Eyeglass Frames: Aesthetic and functional improvements.

Historical Context of Gilding

• Oldest Arts: Gold beating techniques recorded over 5000 years ago.

• Ancient techniques involved melting gold using blowpipes and beating with stones.

  • Example: Illustration from Egyptian tomb at Saqqara (2500 B.C.) depicts early gold processing.

Gold Beating and Gilding Techniques

• Applications: Used for statuary, royal crowns, coffin cases, churches, and furniture (fine leaf samples from ~1500 BC).

  • Techniques have evolved from simple beating to complex layering systems.

  • Composite Structures: Gold sandwiched between layers of animal skins for durability.

Gilding Techniques

• Gilding: The application of a thin layer of gold to various surfaces including metals, wood, porcelain, and stone.

Gold Leaf Production Process (Sakuda)

• Process:

  • Melting and alloying of metals.

  • Casting into steel moulds.

  • Rolling passes to achieve desired thickness.

  • Beating and cutting into leaf formation.

• Result: Extremely thin gold foils for decorative purposes.

Mercury and Fire Gilding

• Used for decorating copper or bronze statues.

• Techniques:

  • Surface smoothing/polishing is crucial.

  • Copper dissolved in mercury forms a smooth surface for gold leaf bonding.

Depletion Gilding

• A technique derived from mechanical gilding, focusing on removing non-gold elements to leave pure gold behind.

• Practiced by Andean metalsmiths about 2000 years ago.

Electroplating Overview

• Definition: Process using electric current to deposit metal ions onto a substrate.

  • Key Metals: Chromium, Nickel, Copper, Zinc, Cadmium, Gold.

  • Process Examples:

    • Anode and cathode reactions driving deposition.

Surface Heat Treatments and Induction Heating

• Utilizes induction coils to heat conductive materials quickly.

• Applications in various processes including melting silicon and shaft hardening.

Carburizing Techniques

• Different methods: Gas, Vacuum, Liquid, and Pack Carburizing to enhance surface properties through controlled atmospheres.

Plasma Nitriding

• A method to enhance surface hardness via nitrogen incorporation.

• Deposition processes and equipment outlined for efficiency and effectiveness.

Development of Thin Films for Wear Resistance

• Three generations of thin films from basic polycrystalline monolayers to advanced nanocomposite films.

  • Key Innovatory Works: Various studies showcasing the evolution of film technology.

Structural Analysis and Atomic Force Microscopy (AFM)

• Techniques for characterizing thin films' physical and chemical properties and their structural dimensions.

Innovative Applications in Filtration

• Coated water filter papers show improved bactericidal effects through metal deposition combined with electrical power.

• Antibacterial performances compared across different sample conditions.