Contributor contact details ........................................ ix Preface ............................................................ xi 1 Understanding surface wear in engineering materials ............ 1 R.J.K.Wood, University of Southampton, UK 1.1 Introduction ................................................... 1 1.2 Role of stress distributions in wear ........................... 2 1.3 Wear in tribocontacts .......................................... 6 1.4 Stress fields for coated systems .............................. 40 1.5 Conclusions ................................................... 48 1.6 References .................................................... 48 1.7 Appendix: Nomenclature ........................................ 55 2 Mechanical testing of coatings ................................ 58 N.M.Jennett and M.G.Gee, National Physical Laboratory, UK 2.1 Introduction .................................................. 58 2.2 Thickness ..................................................... 59 2.3 Fracture and adhesion testing ................................. 62 2.4 Scratch testing ............................................... 66 2.5 Instrumented indentation testing .............................. 68 2.6 Impact excitation ............................................. 73 2.7 Surface acoustic wave spectroscopy ............................ 73 2.8 Residual stress measurement ................................... 76 2.9 Conclusions ................................................... 77 2.10 References .................................................... 77 3 The range of surface coating methods .......................... 79 P.H.Shipway, University of Nottingham, UK 3.1 Introduction .................................................. 79 3.2 Basic classification of processes employed for coating ........ 80 3.3 Processes: coatings deposited on to the substrate ............. 81 3.4 Processes: coatings formed by reactions involving the substrate ................................................. 91 3.5 Comparison of the methods ..................................... 94 3.6 Future trends ................................................. 97 3.7 References .................................................... 98 3.8 Further reading ............................................... 98 4 Chemical vapour deposition methods for protection against wear ................................................. 101 D.W.Wheeler, Atomic Weapons Establishment, UK 4.1 Introduction ................................................. 101 4.2 The chemical vapour deposition process ....................... 102 4.3 Factors affecting the coating characteristics ................ 108 4.4 Advantages and disadvantages of chemical vapour deposition ... 110 4.5 Plasma-assisted chemical vapour deposition ................... 111 4.6 Hard coatings produced by chemical vapour deposition ......... 112 4.7 Conclusions .................................................. 132 4.8 Future trends ................................................ 135 4.9 Sources of further information ............................... 136 4.10 Acknowledgements ............................................. 137 4.11 References ................................................... 137 5 Physical vapour deposition methods for protection against wear ................................................. 146 S.J.Bull, University of Newcastle, UK 5.1 Introduction ................................................. 146 5.2 Fundamentals of physical vapour deposition ................... 147 5.3 Commercial physical vapour deposition processes .............. 156 5.4 Coatings for wear resistance ................................. 164 5.5 Applications ................................................. 171 5.6 Future trends ................................................ 178 5.7 References ................................................... 179 6 Electroless plating for protection against wear .............. 184 C.Ponce de Leon, University of Southampton, UK, C.Kerr, Tin Technology Ltd, UK, and F.C.Walsh, University of Southampton, UK 6.1 Introduction ................................................. 184 6.2 Electrolyte composition and operating conditions ............. 192 6.3 Characteristics of electroless deposits ...................... 195 6.4 Conclusions .................................................. 217 6.5 References ................................................... 219 6.6 Appendix: Professional associations .......................... 224 7 Electroplating for protection against wear ................... 226 R.G.A.Wills and F.C.Walsh, University of Southampton, UK 7.1 Introduction ................................................. 226 7.2 Electrodeposited metallic coatings ........................... 232 7.3 Electrodeposited composite coatings .......................... 240 7.4 Anodised coatings on light metals ............................ 241 7.5 Conclusions and further reading .............................. 241 7.6 References ................................................... 245 7.7 Appendix: Professional associations .......................... 247 8 Thermal spraying methods for protection against wear ......... 249 J.M.Guilemany and J.Nin, Universitat de Barcelona, Spain 8.1 Introduction ................................................. 249 8.2 Thermal spray process fundamentals ........................... 256 8.3 Coating structures ........................................... 266 8.4 Post-spray treatments ........................................ 272 8.5 Structure-property relationships ............................. 272 8.6 Industrial applications ...................................... 283 8.7 Unsuccessful coatings and applications ....................... 288 8.8 Future trends ................................................ 290 9 Welding surface treatment methods for protection against wear ................................................. 302 B.G.Mellor, University of Southampton, UK 9.1 Introduction ................................................. 302 9.2 Welding processes suitable for hardfacing .................... 303 9.3 Nature of the deposit ........................................ 310 9.4 Hardfacing materials ......................................... 315 9.5 Hardfacing alloy selection ................................... 360 9.6 Hardfacing process selection ................................. 361 9.7 Distortion and residual stresses ............................. 366 9.8 Successful and unsuccessful applications ..................... 369 9.9 Conclusions .................................................. 370 9.10 References ................................................... 370 10 Laser surface treatment methods for protection against wear ................................................. 377 H.C.Man, Hong Kong Polytechnic University, Hong Kong, PR China 10.1 Introduction ................................................. 377 10.2 Operation principles ......................................... 377 10.3 Lasers for laser surface engineering ......................... 380 10.4 Advantages and limitations of laser surface engineering ...... 381 10.5 Applications on ferrous alloys ............................... 382 10.6 Applications on aluminium alloys ............................. 383 10.7 Applications on titanium alloys .............................. 386 10.8 Conclusions .................................................. 388 10.9 References ................................................... 390 11 Future trends in surface coatings for protection against wear ................................................. 392 A.O.Kunrath, D.Zhong, B.Mishra and J.J.Moore, Colorado School of Mines, USA 11.1 Introduction ................................................. 392 11.2 Coating materials ............................................ 392 11.3 Coating architectures ........................................ 394 11.4 Smart systems ................................................ 399 11.5 New processes ................................................ 401 11.6 Conclusions .................................................. 408 11.7 References ................................................... 408 Index ........................................................ 415