Surface Coating Technology

(Teknologi Pelapisan Permukaan)

1
 Application of Thin Film Coating
Thin-film Category Typical Application
• Optical Reflective/antireflective coatings
Interference filters
Decoration (colour, luster)
Memory discs (CDs)
Waveguides
• Electrical Insulation
Conduction
Semiconductor devices
Piezoelectric drivers
• Magnetic Memory discs

• Chemical Barrier to diffusion or alloying

Protection against oxidation or corrosion
Gas/liquid sensors
• Mechanical Tribological (wear resistant) coatings
Hardness
Micromechanics
• Thermal Barrier layers
Heat sinks

2
 PELAPISAN CVD DAN PVD

Metoda pelapisan permukaan dengan cara mengendapkan logam atau

senyawa logam ke permukaan komponen melalui fasa uap didalam
bejana tertutup. Dua cara, yaitu: melalui dekomposisi/reaksi kimia
disekitar permukaan komponen (CVD) atau peristiwa kondensasi
fisika (PVD)

Kondisi vakum /
bertekanan rendah Fasa uap

3
 TUJUAN PELAPISAN
Memperbaiki:
--Sifat ketahan aus, dari perkakas potong, bantalan ✓
--Konduktivitas listrik, dari komponen elektronik
--Sifat optik, dari bahan kaca dan plastik
--Ketahanan korosi, dari komponen industri kimia

S/D 35 X

UMUR PAKAI PERKAKAS MENINGKAT

Perbandingan Relatif

LEBIH BAIK DIBANDINGKAN

METODA LAINNYA
S/D 15 X
Umur Pakai

S/D 3 X

Tanpa Perlakuan panas Perlakuan CVD/PVD

perlakuan konvensional permukaan

4
 CVD vs PVD

CVD : --Proses pengendapan senyawa / unsur terjadi akibat

reaksi dekomposisi kimia akibat aktivasi termal di seputar
komponen yang dilapis
--Temperatur perlakuan lebih tinggi
--Efek distorsi 
--Aplikasi lebih terbatas

PVD : --Proses pengendapan senyawa / unsur terjadi akibat peristiwa

kondensasi fisika
--Temperatur lebih rendah
--Efek distorsi 
--Aplikasi lebih luas

5
PELAPISAN CVD
(aplikasi tribologi)

6
JENIS-JENIS PROSES CVD

• PROSES TERMAL CVD ✓

• PROSES PLASMA CVD ✓
• PROSES LASER CVD
• PROSES CLOSED REACTOR CVD (PACK CEMENTATION)
• PROSES CHEMICAL VAPOUR INFLITRATION
• PROSES METAL-ORGANIC CVD

7
 Peralatan Proses Thermal CVD
THERMAL CVD

Reaktor

Suplai Lilitan kawat

gas
Komponen

Pengukur Penetral Pompa

alir gas vakum

Gas Reaktan H2

8
 Peralatan Proses Thermal CVD
RF PLASMA CVD

Input from shielded radio-frequency power

Electrode Electrode
Silicon wafers

Heater Heater

To vacuum pump Rotating s

shaft To vacuum pump
and exhaust and exhaust
Magnetic drive

Input gases
9
 Urutan Langkah Proses CVD
1. Source-gas
supply 1. Gasseous fluids flow to the reactor.
2. Forced convection due to a pressure gradient.
2. Forced
convection 3. Free convection due to buoyancy of hot gas.

3. Free 4. Gas movement by diffusion due to viscous friction

Transport and
convection as closed to the substrate.
homogeneous
reaction 5. Gas adsorption by the surface of substrate.
4. Gas-phase
5. Gases are thermally activated sourrounding
diffusion the substrate surface and lead to reactions
producing e.g. chemical compounds.
5. Adsorption
7. Desorption of gaseous by-products.
6. Surface reaction
8. Formation and growth of thin film occur by means
Deposition
of producing a physical/metallurgical structure.
7. Desorption
8. Film composition Note: Excessive gas-phase reactions could produce
And structure particles of film material and these settle out as powder.

10
Contoh Reaksi Fasa Gas dan Permukaan

11
 Lapisan CVD Aplikasi Tribologi
Material Kekerasan Temperatur dan
Lapisan (VHN) Tekanan Proses
TiC 3200 900-1200 ºC < 200 torr
TiN 2000 550-950 10-70 torr
TiCN 2500 700-900
Al2O3 2100 850-1100 ~50 torr
WC 2400 400-1000
SiC 2500
TiB2 3300
VC 2600 Keunggulan:
Si3N4 2800 kekerasan 
B4C 3000
Stabilitas ikatan kimia 
Koefisien friksi 

12
REAKSI DEPOSISI PADA PERMUKAN
-- Pirolisis atau dekomposisi termal
Ni(CO)4 = Ni + 4 CO
--Reduksi
WF6 + 3H2 = W + 6HF
-- Oksidasi
SiH4 + O2 = Si O2 + 2H2
--Hidrolisa
Al2Cl6 + 3CO2 + 3H2 = Al2O3 + 3CO + 6HCl
--Pembentukan karbida
TiCl4 + CH4 = TiC + 4HCl
--Pembentukan nitrida
TiCl4 + 1/2N2 + 2H2 = TiN + 4HCl
--Ko-reduksi
TiCl4 + 2BCl + 5H2 = TiB2 + 10HCl

13
 APLIKASI CVD HARD COATINGS

Jenis perkakas Material Umur pakai rata-rata Perbaikan

non-lapis lapis
(stroke)
Draw die D2 20.000 1.500.000 75X
Cut off tool M2 150 1000 6,3X
Trim die M2 11.000 100.000 9,1X
Thread rolling die D2 100.000 1000.000 10X
Form tool M2 4950 23.000 4,6X
Extrusion punch M2 2000 70.000 35X
Tap M2 3000 9000 3X
Class C hob M2 1500 4500 3X
Drill M2 1000 4000 4X
Minting collars D2 200.000 1.000.000 5X

14
CONTOH KOMPONEN YANG DILAPISI

15
 FOTO PENAMPANG LAPISAN

Pahat bubut
Keuntungan:
--umur pakai 20X
--kecepatan potong
--dapat memotong material
Ti, Al yang sulit dibubut.

Kekerasan 2000 VHN

Lapidan TiN

16
KARAKTERISTIK PROSES CVD
KEUNGGULAN
--Dapat melapisi substrat dengan bahan refraktori
dibawah temperatur lelehnya atau temperatur sinter
--Densitas lapisan mecapai theoretcal density
--Orientasi dan ukuran butiran dapat dikontrol
--Proses dapat dilakukan pada kondisi mencapai tekanan atmosfir
--Ikatan lekat terhadap substrate memadai
--Komponen berlubang geometri kompleks dapat dilapis

KETERBATASAN
--Aplikasi terbatas pada substrat yang memiliki kestabilan
struktur pada temperatur meningkat
--Beberapa gas reaktan beracun (hazardous & toxic)
--Memerlukan energi proses yang besar, sehingga sering dijumpai
efisiensi proses rendah dan biaya tinggi

17
PYHSICAL VAPOUR DEPOSITION (PVD)

Kondisi vakum 10-6 - 10-1

Temperatur < 500°C
Pelepasan atom Pengendapan atom
(evaporasi) (deposition)

18
DASAR KLASIFIKASI PVD :
--Pertama, berdasarkan jenis sumber penguapannya

--Kedua, berdasarkan apakah terjadi:

• reaksi kimia dari fasa gas menuju ke permukaan substrat
• penembakan ion pada permukaan substrat
• peningkatan aktivitas kimia gas reaktan melalui ‘electric discharge’

19
 KLASIFIKASI PROSES PVD
Process designation Source Chemical Activation Ion Substrate
Reaction of gas bombardment
Thermal Atom ejection Ion beam of substrate
evaporation (sputtering) generation
Vacuum coating
Reactive evaporation
Activated reactive
evaporation

Sputter coating
Reactive sputtering
Reactive bias sputtering

Ion plating
Reactive ion plating
Biased activated reac-
tive evaporation

Primary ion beam

deposition
Secondary ion beam
deposition
Ion implantation 20
PRINSIP THERMAL EVAPORATIVE
Material pelapis diuapkan pada bejana bertekanan vakum (10-2 – 10-5 torr)
Tekanan makin rendah kecepatan penguapan meningkat
Temperatur fasa uap dari berbagai jenis logam
pada tekanan 10-2 torr


Metal Temperature C
Ag 1030
Al 1220
Au 1400
Cd 265
Co 1520
Cr 1400
Cu 1260
Fe 1480
Hf 2400
Ni 1530
Mo 2530
Pb 715
W 3230
Zn 345
21
 METODA THERMAL
EVAPORATIVE
•Terdiri dari dua jenis : resistance heated dan electron
beam heated vacuum evaporation source
• Sesuai untuk material dengan Tuap < 1600 C

• Sulit untuk aplikasi material senyawa akibat kecenderungannya berdisosiasi

• Untuk benda kerja dengan bentuk permukaan yang tidak datar

diperlukan pergerakan agar tercapai pelapisan yang uniform.

• Untuk pelapisan senyawa digunakan metoda reaktif (ARE)

dengan memasukkan gas (O2, NH3, Ch4) ke bejana vakum

• Proses sederhana investasi relatif rendah dibandingkan teknik

PVD lainnya

22
 APLIKASI THERMAL
EVAPORATIVE COATINGS

Application
Electronic components
Interference films on camera and microscope
lenses
Coloured interference coatings
Transparent coatings, eg alumina, silica dioxide,
on polycarbonate windows and eye-glasses
MCrA1Y coatings on gas turbine vanes and
blades (M=Co, Ni or Fe)
Aluminium coating of steel strip
Nickel coating of perforated steel strip
Coating of interior and exterior car trim
Purpose
Manfufacturing procedure
To reduce reflection and glare
for decoration, absorption of solar energy, control
of heating, eg of satellite.
Tinting, to reduce heat and glare
To give abrasion resistance
For increased resistance to sulphidation and oxidation
For use in can manufacture
For use in alkaline batteryu manufacture
For decoration

23
 THERMAL EVAPORATION SOURCE
Resistance heated
evaporation source Electron beam heated vacuum
Sesuai untuk material dengan Tuap < 1600 C evaporation source

Substrate Substrate

Vapor Vapor
stream (VACUUM) stream (VACUUM)
Source Boat

water
Focused Water-cooled crucible
electron
beam
H.T. supply +
-
Filament and High V>DC
shield Low A
Filament
Boat supply supply
Low V > AC Low V AC
High A High A 24
PROSES ACTIVATED REACTIVE EVAPORATION
(ARE PROCESS)

Thermal evaporation source: electron beam

Substrate
Electrode
+
Reactive gas Plasma
injection

Coating flux Power

Supply

Pressure
Electron
barrier beam
evaporator

Vacuum pumps

25
JENIS PROSES VS KECEPATAN PELAPISAN
Coating rates of refractory compounds by reactive and
activated reactive evaporation

Coating process Coating rate Compound type

Reactive < 0.2 Oxides : Al, Si, Ti

Nitrides : Al, Nb, Ta,W
Activated reactive
*Outside < 0.2 Oxides : Al, Si, Ti
Nitrides : Al
*Inside 1.5 -10 Nitrides : Ti
Carbides : Hf,Nb,Ta,
Ti,V,Zr

26
TEMPERATUR SUBSTRAT VS KECEPATAN DEPOSISI

Effects of substrate temperature on rate of deposition

and hardness of TiC on tantalum

Substrate Thickness of Rate of Deposit

temperature deposit deposition hardness
oC m m/min HV0.05

520 100.0 3.3 2710

610 93.0 3.1 2330
830 67.5 2.6 2955
1080 37.5 2.2 4110
1120 30.0 2.15 4160
1450 55.0 1.85 3890

27
Temperatur Substrat Vs Struktur Lapisan

• Kenaikan temperatur substrat akan menyebabkan struktur menjadi

recrystallised-columnar grain dengan densitas tinggi.
• Tekanan meningkat menggeser pembentukan struktur tersebut
diatas ke temperatur substrat yang lebih tinggi

28
 PROSES SPUTTER COATING
Pressure 10-3 - 10-1 torr
Applied potential 500 V

Working
gas
_
Target

Potential: 0,5-5 kV
_
Coating rate: 0,5-5 m + _
Use of magnetron adapted +
with rf supply increases 10 cm or less Power
coating rate up tp 100 m Plasma
Supply

Substrate

Vacuum pumps
29
 PROSES ION PLATING DENGAN
CARA BIAS SPUTTERING
Cooled vacuum
chamber Window Hot enclosure
Vent
Resistance
Negative potential
heater
is applied to the
workpiece producing Cathode
ion bombardment to it (source)
Insulator
Substrate Cathode
- power
supply

Shield

Purifier
Pump Gas
Bias
+
30
- Bias
KARAKTER LAPISAN DAN APLIKASI

Microhardness of TiN and ZrN produced by reactive sputtering

HV Bulk
Coating Thicknes Load
m gf Hardnes
Optical SEM HV

9.5 100 3238 3359 2000

TiN
9.5 200 2663 2391 2000

ZrN 11.0 100 3342 2628 1500

11.0 200 2358 2663 1500

Friction coefficient of TiN coatings on cast iron substretes

Time, h 0 2 5 10 20

Uncoated 0.09 0.10 0.10 0.08 0.08

Electrodeposite Cr 0.11 0.12 0.11 0.09 0.09
SputtereTiN 0.15 0.12 0.10 0.09 0.08
Ion Plated TiN 0.11 0.10 0.10 0.10 0.10
31
 KARAKTER LAPISAN DAN APLIKASI

Wear
(m) Wear behavior of TiN coatings on cast iron substrate
12

10
Uncoated

8
Cr
6 Plated

TiN sputtered
2
TiN ion plated

0 2 4 6 8 10 12 14 16 32
Time (h)
 KARAKTER LAPISAN DAN APLIKASI

Coefficient Coefficient
of friction of friction
0.6 LEAD 0.6 GOLD

0.4 0.4

0.2 0.2

0 0
0 -1 1 10 100 0 -1 1 10 100
Film thickness (m) Film thickness (m)
33
 KARAKTER LAPISAN DAN APLIKASI

Laju keausan akibat implantasi nitrogen

Wear rate Relative decrease

(cm3/cm sliding distance) in wear rate
10-6

40
Unimplanted

30
En 40B steel
10-7 En 40B steel pin-on-disc
pin-on-disc

20
Implanted
10-8 2x1017 N/cm2
50 KeV

10
10-9

0
0.1 1.0 10 1016 1017 1018
Load (kg) Dosis N/cm2 (50 keV)
34
 KARAKTER LAPISAN DAN APLIKASI

Aplikasi pada industri perkakas

Tool Material Implanted species Factor of improvement

Injection Moulding for tools Cr-plated steel N 10

Injection screw for plastic Nitrided-steel N 10-15

Feed wear pads & bushes Steel N 10-15

for plastic machinery

Tools for metal extrusion Steel, stellite, N 6

cemented carbide

Thread cutting dies M2 steel N 5

Hot rolls for non ferrous rod H13 N 5

Dies for copper rod Cemented carbide C 5

Wire drawing dies Cemented carbide C 2

35
Ring press tool for steel Cemented carbide N 10
 PPROSES ION PLATING DENGAN
SISTEM MULTIPLE ARC

Plasma
Natural Reactive
gas gas

Substrate
Evaporator
Evaporated
Cooling material Vacuum
Material pump

Power Supply
36
 PROSES ION PLATING

Water cooling Pirani garage

for cathode
Rubber seal

Gauze shield

Glass jar
Specimen
(cathode) Metal shield

Variable high Base plate

voltage supply Penning
gauge
Low voltage Baffle Air
d.c.filament valve and
diffusion inlet
containing pumping
evaporant system Roughing Argon
line inlet 37
Thermal Spray
Coating

38
 Klasifikasi Thermal Spray Coating

It involves projection of molten or semimolten particles against the surface

of material (substrate) to be coated by use of various techniques, such as :

• Conventional combustion (flame spraying) Old

• Electric arc spraying

• Plasma spraying
• High-velocity oxy-fuel (HVOF)
• Detonation (D-gun) New

39
 Urutan dan Karakteristik Proses
Machining
Berfungsi untuk mempersiapkan ketebalan
lapisan yang diperlukan

Cleaning
Membuang kotoran nyang melekat dipermukaan
seperti: gemuk, minyak, dan kotoran
Surface Roughening
Membuat grooving dengan kedalaman 0.5 mm
atau lebih agar pelekatan lapisan maksimum
Bond Coat
Memperkuat daya lekat lapisan terhadap
substrat (precoating Mo, Ni-Al)
Dapat diterapkan ke berbagai jenis material
dengan alternatif beberapa bahan pelapis
Bermacam bentuk komponen dapat dilapisi
tergantung kondisi spray gun
Namun terdapat kelemahan seperti:
adanya porositas, dan ikatan difusi
secara metalurgis hampir tidak ada,

Preheating
Memanaskan substrat s/d 100-150 °C agar
proses pelekatan lapisan-substrat optimum

40
 Contoh Struktur Lapisan

Dikutip dari Thermal Spray Coating Applications in The Chemical Process Industries,
R.P. Krepski, 1993

Base Metal

Skematik struktur lapisan Struktur lapisan tribolite

hasil semprot logam (metal spraying). (iron-based powder)
pada permukaan baja

41
Bentuk Spraying Gun
(Sesuai Metoda Penyemmprotan)
Melted Particles
Unmelted Powder

Atomising Gas Melted Particles

Melted Particles
Atomising Gas

Unmelted Powder Melted Particles

42
 Karakteristik Beberapa Jenis Thermal Spray Coating

Heating Method Combustion Electric Arc

Process Powder Wire D-gun Wire Plasma Plasma
(40 KW) (80 KW)

Gas Temp. (approx.) ºK 3000 3000 4000 5000 15000 15000

Particle velocity (approx.)m/s* 35 200 800 200 300 500
Bond strength N/mm2 45 45 145-360 45 45-120 60-145
Porosities % 2 10 1 10 2 1
Materials sprayed Metals Metal wires Metal, cermet, Metal wires Metal, cermet and ceramic
ceramics ceramic rods ceramic powders powders
Rate od depostion kg/hr 2-9 6(metal) 1(ceramic) ~1 15 1-5 1-5
Cost basic equip. (approx) £ 3600 4500 - 10000 upto 75000
Typical coating thickness 0.75 1.25 0.25 1.25 0.25 0.25

*varies with particle size and density

43
 Perkembangan Thermal Spray Coating

Metoda Inovasi Teknologi Hasil/Tampilan

Plasma Chamber Spray

• Inert Gas Minimum Oxidation
• Low Pressure Minimum Porosity
Inductively Coupled Uniform Melting
Water-Stabilised Plasma High Spray Rate
Underwater Spraying Rapid Quench

Arc-Spray Inert Gas Atomisation Reduced Porosity

(wire) Chamber Spray Reactive Metals
Single Wire Deposit Efficiency
Cored Wire Feed Hard Wear Coatings

D-Gun Super D Gun Residual Compressive Stress/

Smooth Finish

44
 Conventional Combustion Spraying
It makes use of conventional oxy-fuel combustion to melt the feeds (powder or wire), and thus,
consequently producing liquid droplets that will be sprayed onto the surface of components being coated.

Combusting gas, up to 3000 ºC : • oxy-acetylene flame,

• propane hydrogen,
• natural gas,
• methylacetylene-propadiene

This conventional method commonly uses powder feeds due to simple, compact, and light weight
equipment handling. The flame spraying will both melt and direct the feeds to the substrate. This cause
such characteristics, compared to other methods, as:
• Low droplet velocity
• Inferior coating in terms of porosity bond strength.
• It is used only for general maintenance and applications.

45
 Conventional Combustion Spraying
Contoh Material Pelapis
Jenis serbuk,

Coating Nickel Base Alloy Nickel Aluminium Aluminium Bronze

Composition, % Al 5.5 Al 5 Cu 85
Mo 5 Ni 95 Al 15
Ni bal
Hardness, HV 140 120 95
Bond streng to grit blasted 35 (5000) 20 (3000) 14 (2000)
Steel, N/mm2 (psi)
Density, g/ml 7.2 7.2 6.5
Porosity % <2 2 <5
Maximum service temp. oC 800 800 230
Thickness, mm typical 2.5 None 2.5
Cost, £/kg 42 22 33
Special feature Expensive material but used on used mainly as a bond coat, Can Mixture of elemental powder
account of high bond strength be used as a single coating to give which react on spraying to
for reclamation work on difficult moderate wear resistance up to give good bond. Used mainly
geometries. 800oC. Poor corrosion resistance. As build upcoating on copper
Can be machined to fine finish alloys. Good machining
Moderate wear resistance. Characteristics.
Moderate wear resistance.

Lanjutan di halaman berikut

46
 Conventional Combustion Spraying
Contoh Material Pelapis
Jenis serbuk, pe+han C, B, Si, menurunkan titik
leleh sehingga mengakibatkan terjadinya
proses fusi terhadap substrat 
Coating Nickel base coating (hard) Nickel base coating (soft) cobalt base coating Nikel base alloy with
WC particles

Composition, % Cr 13.5 Cr 10.0 Ni 28 (WC/80% Ni) 35

C 0.75 C 0.45 Cr 18 Cr 11.00
B 3.00 B 2.00 B 3.0 C. 0.5
Si 4.25 Si 2.25 Si. 3.5 B 2.5
Ni bal Ni bal Co bal Ni bal
Hardnes, HV 700 400 520 950 (WC particles 2000)
Density, g/ml 7.8 8.2 8.5 10.2
Porosity, % 0 0 0 0
Melting Point, oC 1040 1110 1120 1025
Thicknes, mm
Upper limit 1.75 1.75 1.75 None
Lower limit 0.25 0.25 0.25 0.25
Cost, £/kg 13.5 13.5 27 51
Abrasive wear resistance 0.35 0.20 0.30 0.75
relative to plasma sprayed
WC/12% Co= 1
Special features standard hard facing material. Moderate wear resistance. Good sliding wear Outstanding wear
Must be ground. Excellent wear Good impact properties. Resistance.Low Resistance. Coating can
and corrosion resistance. Can be machined with WC coefficient of friction. be ground and lapped
tools Retains hardness at to fine finish. Expensive
elevated temperature material

47
 D-Gun Process
(Combustion Process)
The process is essentially a combustion method but it makes use of spark plug to ignite gas mixtures
and thereby accelerating the particles speed impinging the substrate.

This method imrpoves the impinging velocity of droplets (800 m/sec) as compared to conventional combustion
Thus producing as low as ½ -1% porosity of the layers.
Gas mixture is ignited 4-9 times per sec.
The operation is remotely controlled from console Powder
Spark plug
3000 K
Applied for highly abrasive condition.
N2 Acetylene O2 distance 5-10 cm
Typical coating materials normally used for this method
are either oxides or carbide-metal cermets such as:
Designation LA2 LA1 LW IN40 LCIB
Composition % Al2O3 WC 91 WC 85 Cr3C2 (65) Ni-Cr (35)
Hardness VHN 1100 1300 1050 700
Bond strength N/mm2 70 140 140 140
Porosity % 2 ½ ½ 1

48
 Arc Wire Spraying and Plasma Spraying
(Electric)
Arc Wire Spraying
The process makes use of two wires continuously fed in to the gun. An electric arc is then struck
between the wires and thus producing melts which is then atomised by the the gas or air.
The deposition reate is very high (~12 kg/hr for stainless steel)
Mostly applied for coating by metals/alloys such: as steels and copper alloys, with thick coating

Plasma Spraying
This is similar to arc wire method which makes use of electric power to melt coating articles
(normally powder), but the H2 / N2 / Ar /He are added into the gun and ionised by electric discharge
to cause protective atmosphere and increased temperature of arc (H2 and N2 4000 – 8000 ºK,
Ar 15000 ºK , He 20000 ºK)

This method produces a coating layer that its characteristics (interfacial bonding, porosity,
and grain structure) between thermal spray and D-gun.

It can be applied to various materials of ferrous, non ferrous, and polymeric to be.coated with
Metals/oxide/carbide

49
 Jet-Kote Process

The process is categorised as high velocity combustion system which uses plasma system
to prevent oxidation effect to the melting particles.

Firstly developed by Browning Corp. but was bought in 1982 by Cabot.

Gas mixture consists of oxygen+hydrocarbon(propylene) is burned under pressure 0.4-0.7 N/mm2

This produces quality comparable to D-gun method but its advantages are reduced noise level,
minimum oxidation effect, and relatively finer structure.

The most recent development of jet-kote

Process is Low Pressure or Vacuum
Plasma Spraying(LPPS or VPS).
This provide high temperature substrate
(1000 ºC) due to surface oxidation and
stress in coating are reduced. Thus
More adherant coating.

50
Effect of coating thickness on bond strength

Substrate-layer bonding mechanisms:

Mechanical Anchoring
Adhesive Bonding / Van der Waals secondary bonding
Short range diffusional bonding
Chemical bonding and, rarely
Metallurgical bonding with less possibility

51
Effect of substrate preheat temperature on bond strength

The lower bond strength above a certain

temperature is caused by increased
oxidation of the component surface

52
 Pelumasan

Gaseous, liquid, or solid matter that is :

introduced between two moving interfaces in order to reduce friction, to carry away
heat and debris generated during sliding process. It prevents a direct contact between
two metal surfaces.

53
 Klasifikasi Pelumas
Engine lubricants:
Gasoline engine oils
Diesel engine oils
Natural gas engine oils
Aviation engine oils
Two-stroke cycle engine oils
Alternate fuel engine oils
Nonengine lubricants:
Transmission fluids
Power steering fluids
Shock absorber fluids
Gear oils
Hydraulic fluids
Metal working fluids
Miscellaneous industrial oils
Greases
54
 Pelumasan Cair
1. Thick film lubrication: the total separation of asperities by a lubricant is caused by a fluid
pressure film which has thickness many times larger than the size of the lubricant molecules.

2. Thin film lubrication: asperities separation occurs by means of combination between

liquid pressure and molecularly thin lubricant film. Also called mixed lubrication.

3. Boundary lubrication: the entire separation is carried out by surface films of

molecularly thin liquids.

4. Hydrodynamic lubrication: at an increased speed of sliding or rolling a hydrodynamic

pressurized film separating two surfaces is formed due to wedging or squeezing the
lubricant through a convergent gap.

5. Hydrostatic lubrication: it uses an externally pressurized lubricant to generate

sufficiently thick film if surface velocities are not sufficient to generate hydrodynamic
lubrication.

6. Elastohydrodynamic lubrication: lubricant pressure causes elastic deformation of the

surfaces that is on the same order as the lubricant film thickness thus causing a combined
effect of lubrication. 55
 Hydrodynamic Lubrication
Wedging action : Squeeze action :
Thicker film at the inlet section can transport more tubricant Occors at a parallel gap where the slider moves downward
than thinner film at the exit section. However the entire film and normal to the surface. At an increased speed of sliding
velocity should be maintained constant throught the gap. This motion the hydrodynamic action by squeezing out the lubricant
consequently causes high pressure generated to balance the at both edges
condition, i.e.: pressure rises at the inlet to empede the velocity
and then decrease at the exit to enhance the velocity

Velocity

Inlet Exit
Velocity profile Velocity profile Velocity profiles
Relative pressure

Relative pressure
Inlet Exit Inlet Exit

56
 Sifat-sifat Oil Based Lubricant
Basic properties
Bulk modulus Filterability
Surface tension Compatibility
Thermal conductivity Seal
Electrical conductivity Paint
Heat capacity Flammability
Refractive index Rheology
Rheology Shear sterngth
Viscosity Pourability
Viscosity-pressure coefficient Permanent viscosity loss
Viscosity-temperature coefficient Tribology
Temporary viscosity loss Friction
Gravity Wear
Density Load carrying
pitting fatigue
Performance properties Solvency
Corrosion/rust Stability
Wettability Oxidative
Volatility Hydrolytic
Foaming/air release Thermal
Toxicity Detergency/dispersancy
Biodegradability
Miscibility 57
Thermal conductivity
 Kategori Pelumas Berdasarkan API
Applied to engine service
S categories (gasoline engine) :
SE i.e. improved protection against oxidation, high temperature deposits, rust
and corrosion
SF i.e. additives against high and low-temperature deposits, wear, and corrosion.
Improved oxidation stability and anti wear over SE.
SG i.e. meets CC category requirements. Improved anti wear, cleanliness, and
antithickening over SF.
C categories (diesel engine) :
CC i.e. lightly supercharged diesel engines and certain heavy-duty gasoline engine.
Additives against high-and low temperature deposits, rust, and corrosion.
CD i.e. satisfies requirements of supercharged diesel engines, even with high-sulfur
fuels. Additives against high-temperature deposits, rust and corrosion.

CD-II i.e. Severe duty service of supercharged two stroke engines. Satisfies CD
requirement and a supercharged two-stroke multicylinder engine 58
Hubungan Koefisien friksi Terhadap Rasio
Kecepatan Luncur - Tekanan Nominal

Boundary
Lubrication Full fluid film lubrication

Coefficient of friction

Sommerfeld number = Z N / P
Z, Lubricant viscosity
N, Rotational speed bearing
P, Nominal pressure

Sommerfeld number

59
Contoh Pelumasan Pada Bearing
Shaft dia. 50 mm
Surface fatigue could bearing life 104 hours
appear in this region

60
 Pelumasan Padat
Thin film composed of a single or multi solid constituents that has shear
strength much lower than surface to be protected. As the sliding occurs
the solid films will undergo plastic deformation or sometimes followed
by asperities melting to cause easy movement of two moving surfaces.

Common solid lubricants:

Molybdenum disulfide MoS2,
Polytetrafloroethylene PTFE,
Graphite, and
soft metals such as: brass, white metals, and bronze.

61
 Pilihan Material Untuk Aplikasi Keausan
Sliding Rolling
Unlub. Lub. Abra Unlub. Lub Three-body Fluid Drop Particle
Materials wear wear sion wear wear abrasion erosion erosion erosion
Structural alloys
-Surface treatments X X X X
-Hard surfacing X X X X X X
-Soft coatings X X X
Alloy steels X X X X X X
Tool steels X X X X X X
Stainless steels
-Precipitation hardened X X X
-Martensitic X X X X X X
Cast irons
-Graphitic X X X X X
-White X X X
High-temperature alloys
-Refractory materials X X X
-Superalloys X X X X
Copper –base alloys
-Bronze X X
-Beryllium copper X
Soft bearing alloys (babbitts X
Carbides X X X X X X X
Ceramics X X X X X X
Polymers
-Thermosets X
-Thermoplastics X X X
-Elastomers X X X X X
Carbons X
Lubricatings composites X X 62
Langkah Perancangan Surface Engineering
Untuk Komponen Dengan Aplikasi Tribologi
Define
application
Define
properties
required

Mechanical
design

Materials
selection

Engineer substrate
Engineer surface

Design
lubrication

Evaluate
Performance

63