Courses » Surface Engineering for Corrosion and Wear Resistance Application

Surface Engineering for Corrosion and Wear Resistance Application


Wear and corrosion are the major causes of degradation of engineering components for structural applications. Among different ways of minimizing the probability of failure of components by wear or corrosion or improving its lifetime is by optimum designing of surface, may be termed as surface engineering. However, the properties achieved on the surface depend on the techniques to be applied, process parameters to be chosen and the surface characteristics (surface roughness, microstructure and composition) achieved thereafter. The present course encompasses (a) a brief introduction to the wear and corrosion and their classification, (b) surface microstructure and composition required for combating different modes of wear and corrosion, (c) classification and scopes of surface engineering, (d) principle of different modes of surface engineering, process parameters, advantages and disadvantages, (e) characterization and testing of surfaces and (f) engineering applications of surface engineering techniques. The course will offer training to the engineering students pursuing studies in the UG and PG level from Metallurgical engineering, mechanical engineering, materials science, physics and chemistry.

Metallurgical Engineering, Mechanical Engineering, Materials Science and Physics


UG/PG: UG and PG

PREREQUISITES: Materials Science and Engineering

INDUSTRY SUPPORT: Tata Steel, Jamshedpur, Tata Metallics, Kharagpur, R&D Center for Iron and Steel (RDCIS), Ranchi, Engineers from all the Integrated Steel Plants under Sail Authority of India Limited.

634 students have enrolled already!!


Professor Manna is a renowned academician and prolific researcher with wide ranging research interests concerning microstructure-property-parameter correlation in nanometric and amorphous solids, laser and plasma assisted surface engineered components, bainitic and ODS steel and nano-fluid. His significant contribution in the study of amorphous/nanocrystalline Al-alloys, nano-fluid and laser/plasma assisted surface engineering received intense attention from the scientific community and is highly lauded. His early contributions in moving boundary phase transformation are still widely cited. Professor Manna has over 300 publications in peer reviewed journals and proceedings. He has supervised over 20 PhD theses. While serving in the Metallurgical and Materials Engineering Department at IIT Kharagpur, Professor Manna developed several new research laboratories and facilities like plasma ion implantation and coating unit (DST, Tata Steel), Mechanical Alloying laboratory (DST, CSIR), Wear and erosion testing laboratory (CSIR, Tata Steel, DST), Electron bean joining facility (BRNS), Pulsed laser deposition and FE-SEM laboratory (DST), Nanofluid synthesis and characterization laboratory (ISRO), etc.

Prof. Dutta Majumdar is well known internationally for her research contribution in the field of Metallurgical and Material Engineering with focus on surface engineering and laser surface processing. She made fundamental contributions to a profound understanding of the metallurgy of rapid solidification of metals under the specific heat input of a laser source. Her works also concern a detailed structure-property correlation of laser surface modified metallic materials with a specific goal to improve certain engineering properties. She also stated a brief understanding of the mechanism of wear, corrosion and high temperature oxidation of the metastable microstructures developed in commercial metals and alloys due to laser processing. Extensive efforts were also made for the first time for the development of compositionally graded surface and nano-dispersed surface for thermal barrier and hot corrosion application by application of hybrid coating technology.


Week 1  :  Introduction to materials, surface, thermodynamics of surface, surface dependent engineering properties
Week 2  :   Common surface initiated engineering failure; mechanism of surface degradation (wear, corrosion and high Temp. Oxidation).
Week 3  : Role of microstructure and materials behavior in controlling the surface dependent failure of components, importance of surface engineering, classification and scope of surface engineering of Materials. Introduction to surface modification and coating techniques.
Week 4  :  Conventional surface modification methods: flame hardening, induction hardening, carburizing, nitriding, diffusion assisted surface alloying.
Week 5  :  Advanced surface modification methods: Laser, Plasma and electron beam assisted surface modification. 
Week 6  :  Surface Coating by Chemical/electro-chemical Routes Electro/electroless deposition, anodizing, micro-arc oxidation
Week 7  :  Surface Coating by Physical Routes: Physical vapor deposition (Thermal evaporation, sputtering and Ion Plating), pulsed laser deposition, cathodic arc evaporation.
Week 8  :  Surface Coating by chemical Routes: Chemical vapor deposition, laser assisted chemical vapor deposition.
Week 9  :  Hot dipping, (galvanizing, tinning, aluminizing, babitting, etc.)
Week 10  :  Thermal Spraying (flame spraying, HVOF spraying, wire arc spraying, kinetic spraying)
Week 11  :  Weld overlaying, laser surface cladding
Week 12  :  Surface characterization and Testing


•    Surface Engineering for Wear Resistances (Introduction and classification of Wear) By: K.G. Budinski Prentice Hall, Englewood Cliffs, 1988

•     Surface Engineering & Heat Treatment (Diffusion assisted surface alloying) By: P.H Morton I.I.T, Brooke field, (1991)

•     Protective Coating of Metals By: R.M. Burns & W.W. Bradley Reinhold Publication Corporation, N. York, 1928

•    Metals HandbookNinth Edition, Vol.5, Surface Cleaning, Finishing & Coating,

•     ASM, Metals Park Ohio, 1982. Metals HandbookNinth Edition, Vol.5, Surface Cleaning, Finishing & Coating, ASM, Metals Park Ohio, 1982.   
  • The exam is optional for a fee.
  • Date and Time of Exams: April 28 2019 (Sunday)  Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
  • Registration url: Announcements will be made when the registration form is open for registrations.
  • The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published.


  • Final score will be calculated as : 25% assignment score + 75% final exam score
  • 25% assignment score is calculated as 25% of average of  Best 8 out of 12 assignments
  • E-Certificate will be given to those who register and write the exam and score greater than or equal to 40% final score. Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Kharagpur.It will be e-verifiable at nptel.ac.in/noc.