Research task presentation, & PechKucha presentation

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1 Research task presentation, & PechKucha presentation p.2-20 Jeffrey nyoni

2 Metal coating processes, finishes, & application of graphics JEFFREY NYONI

3 Why include a finishing process on metals? Aesthetic quality's greater sense of value Protecting the metal from corrosion Making the product water repellent Improving abilities to insulate against electricity/ heat Improving resistant to wear/ fatigue (Evans, 2008)

4 Types of Metal Coating Electroplated Metal Coating Anodising Dipping & spraying Powder coating Plastic coating Enamelling Blueing

An example of this would be chromium plating used to enhance the properties of a simple bathroom tap,

5 Electroplated Metal Coating Electroplating is a electrochemical process allowing ions from the coating material to form on the base material, this giving it the finish of the coating metal. An example of this would be chromium plating used to enhance the properties of a simple bathroom tap, kitchen utensils and vehicle components. Metals coated this way: Chromium Copper Sliver Zinc Gold Tin (Evans, 2008)

Anodising Anodising is an electrochemical process used to make the surface of metals (aluminium specifically) more durable. Coloured dyes can be added for a decorative finish.

6 Anodising Anodising is an electrochemical process used to make the surface of metals (aluminium specifically) more durable. Coloured dyes can be added for a decorative finish. Its produced in an electrochemical cell (which is similar to electroplating) where a sulphuric acid solution is the electrolyte, the aluminium product as the anode and lead as the cathode. It is then finally finished with a lacquer. (A liquid made of shellac dissolved in alcohol, or of synthetic substances, that dries to form a hard protective coating for wood, metal) (Evans, 2008) Carabineers used by mountain climbers.

Polishing Quality and gloss of polishing are

which helps smooth the surface of the metal.

7 Polishing Quality and gloss of polishing are determined by customer specifications(requirements), polishing is done by an abrasive work wheel (handheld or machine worked) which helps smooth the surface of the metal. The polished surfaces normally go on to be anodized after polishing. (Aluminium Design. 2013)

Hot dip galvanizing Involves coating metals with other metals by

some sort, before this the material must be thoroughly cleaned and

(Evans, 2008) Examples of coating materials for this process are:

8 Hot dip galvanizing Involves coating metals with other metals by spraying or dipping them in conjunction with a heating system of some sort, before this the material must be thoroughly cleaned and fluxed. (Evans, 2008) Examples of coating materials for this process are: Zinc plating: a process achieved by dipping steel in molten zinc, heated to C. this being usually the first layer of car bodies

Powder coating Powder coating is a electrostatic method of applying paint to a product that has been statically charged.

An air gun is used to spray the powder evenly on the product surface.

two. When the product has been fully over coated it is then baked in an oven causing the powder to melt over the product which produces a

9 Powder coating Powder coating is a electrostatic method of applying paint to a product that has been statically charged. This process is dry where as the powder is used instead of the actual paint. An air gun is used to spray the powder evenly on the product surface. The metal product will be negatively charged while the powder is positively charged which results in a very strong attraction between the two. When the product has been fully over coated it is then baked in an oven causing the powder to melt over the product which produces a harder and tougher finish compared to conventional paints. (Evans, 2008) Products coated this way: Fridges Washing machines Dryers Gates Etc. This being a dry process, it is environmentally sound, no solvents or propellants are use and excess material from the coating can be recovered

be in powder state) and then dipping it in the polymer.

10 Plastic dip coating This type of coating is used on a range of products, it involves heating the metal above the softening point of the polymer (which will be in powder state) and then dipping it in the polymer. The polymer at this stage then adheres to the metal and cools down giving it a protective layer (Evans, 2008)

Enamelling Enamelling is when finely ground glass is formed into a water-based slurry, this is then sprayed on the metal product. E.g. components for cooker or for pressed steel baths.

11 Enamelling Enamelling is when finely ground glass is formed into a water-based slurry, this is then sprayed on the metal product. E.g. components for cooker or for pressed steel baths. The product is the fired making the coating a continuous layer of heat and scratch resistant material. (Evans, 2008) Better Heat Transfer Non-Stick Surface Very Durable Does Not React with Foods Constraints Not impact resistant resulting in chips on the top layer.

Blueing Blueing is a technique used to produced a protective surface for steels. Blueing is achieved by heating the steel component to around 300c and the quenching it in oil.

12 Blueing Blueing is a technique used to produced a protective surface for steels. Blueing is achieved by heating the steel component to around 300c and the quenching it in oil. The results of this is a fine oxide layer which protects against any environmental effects Constraints Blueing has limited success & will ware out meaning the process has to be repeated. This process can be done at home by people to naturally protect their knives, gun casing and metal pipes. (Evans, 2008)

13 Hot Blackening This process is where black oxide is applied on to a metal surface creating a matte black finish with high abrasion resistance. It is a high-temperature process in which the product is inserted into a series of tanks containing cleaners, caustics, and coolants. Hot blackening is most commonly used in the production of automotive parts, tools, and firearms. (Types of Metal Finishing. 2013)

14 Application of graphics Embossing Metal Engraving Laser engraving & etching Vinyl Screen Printing & tampon printing

Embossing: Textures that can be applied to metals.

passed through and the rollers emboss their pattern on the sheet.

15 Embossing: Textures that can be applied to metals. Rollers Embossing is a process done on rollers where the metal sheet is passed through and the rollers emboss their pattern on the sheet. This process is usually done after the metal has been finished Various embossing textures that can be applied. Examples where embossing has been used are staircases outdoors. Which usually have more grip and are not slippery in wet weather. (Zhenhuan trade.2013)

16 Metal engraving Metal engraving involves using a set of tools to engrave in the metal. This process is slow and is good for one off products. However for mass production a CAD machine engraving is faster and more accurate Computer aided machine engraving

placed on accurate template measure to size.

17 Laser engraving & etching. This process evolves using Computer aided design(cad) software to design logos, patterns or lettering which is then placed on accurate template measure to size. The programmed design is the exact pattern that will be followed by the controller in relation to the laser. At this point the design is printed and engraved on to the metal surface. This method is preferred by businesses overhand engraving because it is very accurate and reliable. (ehow.2013)

18 Vinyl On metal vinyl s done by the wet method which involve cleansing the surface of the metal and pressing the vinyl on the metal just like a sticker. Full video at ( embedded#!) Vinyl on aluminium.

Screen printing This method of printing is firstly done on a fine meshed screen but usually done on nylon nowadays. This is then exposed and developed photographically.

19 Screen printing This method of printing is firstly done on a fine meshed screen but usually done on nylon nowadays. This is then exposed and developed photographically. The screen is next fitted into a frame. Either manually or automatically, a squeegee is dragged along the screen to transfer the design onto the printing surface. Tampon printing This is a printing technique that makes it possible to use screen printing on both concave and convex surfaces (Aluminium Design. 2013) Lithography printing Digital printing pad

20 References Evans Brian, Potts Will (2008). AQA Design & Technology: Product Design (3-D Design) AS/A2. Cheltenham: Nelson Thornes. p Anatech. (). Metal coating. Available at: Accessed [17th Jan 2013]. TIGER Coatings: TIGER. A synonym for colours & effects [ONLINE] Available at: [Accessed 24 January 2013]. What are the Advantages of Enamelling? What are the Advantages of Enamelling?. [ONLINE] Available at: [Accessed 04 February 2013]. Aluminium Design Aluminium Surface Treatment - Aluminium Design. [ONLINE] Available at: [Accessed 04 February 2013]. Types of Metal Finishing Types of Metal Finishing. [ONLINE] Available at: [Accessed 09 February 2013]. Wood Powder Coating Process - MDF Finishing - BTD Wood Powder Coating Process - MDF Finishing - BTD. [ONLINE] Available at: [Accessed 04 February 2013]. The Anodising Process What is Anodising - How Anodising Works - The Anodising Process. [ONLINE] Available at: [Accessed 09 February 2013]. Types of Metal Finishing [ONLINE] Available at: [Accessed 11 February 2013]. Zhenhuan trade [ONLINE] Available at: [Accessed 09 February 2013]. ehow How Laser Engraving Works ehow.co.uk. [ONLINE] Available at: [Accessed 11 February 2013].

21 Design Exercise - Sketch sheets, Concept Proposal board/s. 750 Word rationale Jeffrey Nyoni p Word rationale - p.40

41 Rational The processes I have chosen to use on the chair are die casting, water jet cutting polishing and anodising. From my own research task I have chosen to use polishing and anodising. Staring off I have chosen a pink vein marble to use as the back of the chair, this due to its aesthetic qualities, it has a great finish, feel, its hard and strong. The marble block that will be used will be 1m by 125mm Instead of a solid marble block it will be cut to a aesthetic pleasing shape that will take shape of the human body to increase comfort and will also have designs cut out on the base. During the cutting process support cut-outs will be blended into the design, these cut-outs will be for the support castings that will help balance & strengthen the chair. However the bad side to this design are the cuts made, they may possibly make the chair uncomfortable, and to counter this sanding will be done to any sharp surface. Thick marble will be hard to cut therefore the most cost efficient way chosen to cut will be water jet cutting. Though it will be a slow process it will be precise in cutting the marble & design on the marble. Water jet cutting was chosen because it is capable of cutting large materials the likes of the marble block chosen it can also withstand cutting the thickness of the marble but will take some time cutting through it. Being a cost efficient method to cut out it does not need any extra tooling and is very ideal for making a chair that will cost quite a lot to manufacture. The only downside to this process is that it will leave the edges unfinished which will be fixed by faint sanding around the edges removing any sharp edges. For the chair legs die casting will be used, this being because it will be a cost efficient and fast manufacture once the tooling has been made. The manufacture of the tooling is not too expensive and will pay off when batch produce. However mass producing the marble will not keep up with the die-casting as it is limited to a low number produced each time and will be slow & expensive. This process is suitable but the manufacturing times conflicts. Aluminium will be most suitable as it will have extra strength properties and will be lightweight. I have chosen die casting because complex details can be added in the cast which will minimise the parts for the chair. The length of the aluminium fame will be 1.3m suitable for a laid back type chair. The hot chamber method will be used because it is better that the cold chamber method though it may suffer from heat related issues. The complex details that will need to be added to the die casting tooling will be screw holes for the support and holes for placing the seats. This will save time doing it all in one piece. Four more casting will need to be done, two for the front support and two for the back. The two supports will be relatively smaller, less noticeable to help with the aesthetic qualities, also ensuring the chair is properly balanced. As aluminium frames will be used I will use my own research methods for the finish which are first; polishing the aluminium after it has been die casted giving it a good clean and shiny finish. After polishing the aluminium will then be anodised, this done to make it more durable as it will be used outdoors, anodising will also help protect against harsh weather which makes it ideal for outdoor use. During the anodising process colours can be added to meet any client requirements. Anodising has a great and aesthetic pleasing finish and is not an expensive process. To finalise the chair satin finished mahogany will used as the seats due to the aesthetic quality and durability, the mahogany compliments the marble and aluminium which enhance the quality of the product. By doing this it will ensure that the chair looks and feels expensive ensuring customer satisfaction. in conclusion the chair manufacturing cost will be relatively high due to the processes used. The main aim of the aesthetics of the chair is to make the user know that they purchased a quality rich product. Possible down sides to the chair depending on the colour used to anodise the frames some colours may not compliment the marble. The chair overall will be prepared for bad out door weather and will last for a long time.

Surface Finishes. For woods metals and plastics

Surface Finishes. For woods metals and plastics Surface Finishes For woods metals and plastics Reasons for Surface Finishes Some kind of surface finish is always necessary for the following reasons Resistance to decay (Stopping the material from rotting