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Syllabus
Surface Coating
1. AN OVERVIEW OF SURFACE COATINGS
1.1 Describe the purpose of surface coatings
1.2 Discuss the different types of surface coatings and their uses.
1.3 Describe the general properties of different surface coatings.
2. PRETREATMENT OF SURFACES
2.1 Identify types of surface contamination.
2.2 Discuss the advantages and disadvantages of solvent cleaning and alkaline water-based cleaning.
2.3 Discuss all the precautions that are necessary in operating a solvent degreaser, both from a safety and environment aspect.
2.4 Describe methods of pretreatment for most common metals.
2.5 Discuss safe pretreatments for high-strength steels.
2.6 Discuss pretreatments for aluminium alloys.
2.7 Discuss pretreatments for stainless steels and similar high-alloy steels.
2.8 Explain how to make up acid etchants for a variety of metals.
3. ELECTROCHEMICAL PROCESSES
3.1 Explain the processes of dissociation and ionisation.
3.2 Discuss the influence of changes in electrolyte temperature, metal concentration and agitation on reactions taking place in the cathode film.
3.3 Discuss the process of the crystal build-up on the cathode surface to produce deposits and its effect on stress and ductility.
3.4 Discuss Faraday’s Laws in relation to anode and cathode efficiency.
3.5 Explain the effect of variations in cathode efficiency on metal distribution.
3.6 Discuss the influence of deposition potential on the ability to electroplate into recesses and hollows.
3.7 Discuss the effect of pretreatment on adhesion and porosity.
3.8 Explain why some coatings are more porous than others.
3.9 Explain how pitting occurs.
3.10 Discuss the variation of coating hardness from metal to metal and its effect on wear resistance.
3.11 Discuss the deposition of alloy coatings and their uses.
3.12 Explain the meaning of autocatalytic deposition.
3.13 Describe the mechanism of autocatalytic deposition.
3.14 Discuss the various commercially available autocatalytic processes and their uses.
3.15 Describe the production and uses of alloy deposits and co-deposits.
3.16 Explain the simple chemistry of the replacement reaction.
3.17 Describe some of the common immersion plating solutions.
3.18 Describe a typical process for plating plastics.
3.19 Discuss some of the practical difficulties in plating plastics.
3.20 Discuss the various processes for blackening metals.
3.21 Discuss the range of processes for producing coloured films on various metals.
3.22 Explain the theory of anodising aluminium and its alloys.
3.23 Describe the process of sulphuric acid anodising.
3.24 Describe the process of chromic acid anodising.
3.25 Describe the process of hard anodising.
3.26 Discuss some of the practical problems encountered in anodising.
3.27 Explain the basic chemistry of phosphating.
3.28 Discuss the different types of phosphate coatings and their uses.
3.29 Explain the basic chemistry of chromating.
3.30 Discuss the techniques used for chromating different metals.
3.31 Explain the basic chemistry of oxidising.
3.32 Discuss the techniques for the control of solutions:
3.32.1 by regular routine plant inspections.
3.32.2 by routine chemical analysis.
3.32.3 by carrying out plating tests.
3.33 Discuss Statistical Process Control (SPC) by reference to a simple system.
3.34 Describe how to carry out a Hull Cell test.
3.35 Describe the layout of a manual plating line.
3.36 Discuss the principles of a plating plant layout.
3.37 Discuss the advantages & disadvantages of the return type automatic plant.
3.38 Discuss the advantages of a computer-controlled automatic plant.
3.39 Explain the main purpose of Health and Safety Legislation.
3.40 Describe the workings of COSHH.
3.41 Discuss the environmental impact of electroplating and how the requirements of legislation are met.
4. NON-ELECTROLYTIC COATING PROCESSES
4.1 Describe the following processes and have a knowledge of their advantages and limitations:
4.1.1 Hot Dipping Processes
4.1.1.1 Zinc galvanising
4.1.1.2 Hot dip tinning
4.1.1.3 Hot dip aluminium coating
4.1.2 Diffusion Coating Processes
4.1.2.1 ‘Sherardizing’ – (Zn)
4.1.2.2 ‘Chromising’
4.2 Describe the process for the thermal spraying of materials.
4.3 Discuss some of the uses of the thermal spraying technique.
4.4 List the different coatings that can be applied by thermal spraying.
4.5 Discuss the cladding of metals with metals and some of its applications.
4.6 Discuss the cladding of metals with plastics and some of its applications.
4.7 Describe the process of vitreous enamelling.
4.8 Discuss the pretreatment procedure for vitreous enamelling and the base metal requirements.
4.9 Discuss the range of applications of the vitreous enamelling process.
4.10 Discuss the process of vacuum metallisation by:
4.10.1 Evaporation.
4.10.2 Sputtering.
4.10.3 Ion plating
4.11 Describe the process of Physical Vapour Deposition (PVD)
4.12 Describe applications for PVD processes.
5. ORGANIC COATING
5.1 Define and explain the properties and uses of primers, primer-surfacers, primer-fillers, undercoats, topcoats, lacquers and varnishes.
5.2 Explain what is meant by convertible and non-convertible polymer systems.
5.3 Discuss the advantages and disadvantages of convertible and non-convertible systems, their properties and uses.
5.4 Discuss the main properties and uses of solvent-containing paints.
5.5 Discuss the properties and uses of reactive solvents.
5.6 Discuss the main properties and uses of emulsions and other types of dispersions.
5.7 Discuss the main properties and uses of water-based paints.
5.8 Discuss the main properties and uses of powder coatings.
5.9 Describe matt finishes and explain their main use and properties.
5.10 Describe wrinkle finishes and explain their main uses and properties.
5.11 Describe hammer finishes and explain their main uses and properties.
5.12 Describe metallic finishes and explain their main uses and properties.
5.13 Describe opalescent and pearlescent finishes and explain their main uses and properties.
5.14 Describe textured finishes and explain their main uses and properties.
5.15 Define the purposes of conversion coatings.
5.16 Discuss the chemistry of the phosphating of steel.
5.17 Describe the layout of a typical phosphating plant.
5.18 Distinguish between the types of phosphate coatings.
5.19 Discuss the properties of conversion coatings for aluminium and its alloys.
5.20 Discuss the advantages and disadvantages of paint spraying.
5.21 Describe the different types of spray painting techniques.
5.22 Discuss the advantages and disadvantages of dipping and flow coating.
5.23 Discuss the process of electrophoretic painting (electrocoating).
5.24 Describe spin dipping.
5.25 Describe the technique of fluidised bed application.
5.26 Explain the need for stoving.
5.27 Discuss the use of conventional thermal ovens:
5.27.1 Box ovens
5.27.2 Forced draught ovens
5.27.3 Tunnel ovens
5.27.4 Camel-back ovens
5.28 Discuss infrared curing.
5.29 Discuss ultra-violet and electron beam curing.
5.30 Describe the common tests for paint films.
5.31 Describe common film defects.
5.32 Discuss the causes of common paint film defects.
5.33 Identify the possible cures for common paint film defects.
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