Coatings and Surface Treatments

Code:

M.EMAT016

Acronym:

RTS

Keywords
Classification	Keyword
OFICIAL	Science and Technology of Materials

Instance: 2023/2024 - 1S

Active?	Yes
Responsible unit:	Department of Metallurgical and Materials Engineering
Course/CS Responsible:	Master in Materials Engineering

Cycles of Study/Courses

Acronym	No. of Students	Study Plan	Curricular Years	Credits UCN	Credits ECTS	Contact hours	Total Time
M.EMAT	22	Syllabus	2	-	6	45,5	162

Teaching language

English

Objectives

The students are supposed to be given a wide range of notions concerning the most relevant coating and surface treatment techniques: Not only they are expected to get acquainted with the several alternative technologies but most of all they should be able to scientifically develop the concepts behind those processes of surface treatment, starting from the knowledge previously acquired in the subjects of “ Electrochemistry” and “Materials Degradation. By the end of the term the students should be able to choose the adequate alternatives of coatings and surface treatments and to critically judge them in technological , scientific, and financial terms.

Knowledge and compreension
The students should be able, when concluding this subject, to identify interpret and reproduce adequately subjects related with the theme of the material discussed. They should be able to manipulate as required tools, background knowledge in physics, chemistry, particularly electrochemistry and materials science that should enable them to provide well established opinions on the acquired knowledge.

Eng. Analysis
The students should be capable to deal with averagely complex problems and systems related with the area covered by this subject.
They should be able to establish a correct hierarchy of events within a process involving surface coatings and should present an open mind towards innovation in this field, and find adequate solutions based on the acquired knowledge, on their capability in terms of literature survey and on the capability to adapt them to specific circumstances.


Eng Practice

The students should be able to adapt some resources and tools to specific problems even with some degree of novelty, based on an engineering approach to finding technological solutions.
Therefore they should be able to stand with some degree of leadership to overcome problems and propose solutions taking into consideration risks, technical or otherwise, and cost/ benefit ratios.

The students should have a market guided perspective, considering alternatives solutions taking into consideration financial/ technical/ marketing viability, and should be able to present their case to an audience.

Transferable skills
The students should be able to read and speak in relatively fluent English so that they might be capable of acceding to the technical literature, and be prepared for the challenges of the global market, both in terms of finding job opportunities and of internationalizing their activities within their future jobs in companies

Learning outcomes and competences

The students should be capable of analizing questions related to surface treatments and coatings and apply this knowledge in industry, wirth the necessary transition of scale. They should also be capable of proposing materials and methods of application of coatings for specific industrial applications.

Working method

Presencial

Pre-requirements (prior knowledge) and co-requirements (common knowledge)

Chemistry ; Electrochemistry

Program

1- Introduction; Revision of concepts of electrochemistry and corrosion; Aims of surface coatings and treatments; Presentation of the several technologies and respective typical applications.
2- Surface preparation prior to the several surface treatments and coatings; grinding and polishing the surfaces, electrolytic polishing; Cleaning dust and particulate removal from the substrates’ surfaces. Available techniques; Degreasing and removal of physically adherent material; hot alkaline degreasing; cathodic degreasing. Surfactants and emulsions: vapour phase degreasing and ultrasound cleansing; Acid etch and removal of chemisorbed materials; grit blasting.
3- Passivation, conversion and temporary treatments; Cromating, phosphating, black oxidising, temporary coatings.
4- Anodising; mechanical polishing, electrolytic polishing, acid etch. Types of anodising solutions and respective films. Variables controlling the anodic film build-up process ( solution, pH, T, t, V, I, cathodes, electrolyte viscosity. Colouring and pores sealing; alternative methods; ac anodising applications and threats.
5- Electroplating; theory of electroplating and electro-crystallising; process technology and control; anodes characteristics, surface preparation, electroplating systems; coated films propertied and applications; alloy and composite plating, multi-layered coatings.
6- Electroless coatings; Formation of films, depositing on polymers
7- Hot dip galvanising; surface preparation and fluxes; continuous and discontinuous coating. Main phase equilibrium diagrams, properties and applications.
8- Non-metallic Coatings; vitreous enamelling, painting and lacquering, electrophoretic coating, thermal-lacquering.
9- Physical methods for coatings; diffusion coatings; CVD and PVD coatings, respective alternatives; CVD process characteristics and equipments, process kinetics, case studies TiN, TiC, Al2O3, DLC; PVD process, sputtering, ARE, ion plating; thermal flame processes, detonation and plasma spraying; physical principles, equipments, adhesion and bonding processes; applications
10- Ion implantation; physical principles of the process and required equipments; ion distribution over the substrate and effects on its properties; typical applications.
11- Case studies of application of different coating technologies.

Mandatory literature

Tratamentos de passivação e conversão e revestimentos temporários -, N
D.R. Gabe ; Introduction to metal surface treatments and protection, N

Complementary Bibliography

Luís Rocha ; Estudo experimental de Revestimentos de Zn e de Zn + 5% Al obtidos por imersão a quente, N

Teaching methods and learning activities

During the theoretico-practical sessions the proposed subjects are presented: at the early moments of each session a short revision of the concepts previously discussed, preparing the follow-up discussion : In general, and as a consequence of the existence of relatively small groups of students each year, some discussion and questioning takes place, allowing for the students to get easily acquainted with the subjects and their subtleties. The practical sessions allow the students divided in groups to produce practical works that lead to reports and a final presentations and discussions with the lecturer and other colleagues.

keywords

Technological sciences > Engineering

Evaluation Type

Distributed evaluation without final exam

Assessment Components

Designation	Weight (%)
Teste	75,00
Trabalho laboratorial	25,00
Total:	100,00

Amount of time allocated to each course unit

Designation	Time (hours)
Estudo autónomo	96,50
Frequência das aulas	32,50
Trabalho laboratorial	13,00
Apresentação/discussão de um trabalho científico	5,00
Elaboração de relatório/dissertação/tese	15,00
Total:	162,00

Eligibility for exams

The attendance at  lab classes is compolsive, with the bylaws of FEUP being applied regarding absences.75% of presences is required.

Calculation formula of final grade

Final mark calculation

Practical work – 25%
Theoretical minitests – 75%

Examinations or Special Assignments

not applicable

Internship work/project

not applicable

Special assessment (TE, DA, ...)

Final Examination

Classification improvement

The students are allowed to try to improve their marks by doing a final (recovery) exam where they can choose between substituting only one minitest or substitute  both minitests. The best mark prevails.

Observations

The division of the evaluation in 2 minitests has proved to be a very successful step in terms of focusing the students attention on this subject throughout the semester.The practical component of the work carried out in the lab is also very appelling to the students and helps them not only yo get a deeper knowledge but also at becoming increasingly interested in the subject and therefore in improving their marks.