Download - Ceramic and Cermet Coating With Advanced
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CIDETEC FOUNDATION-LOCALIZATION
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- RTD Foundation created in 1997
- Member of IK4 Technological Alliance
1405 researchers 2011: 103 M Turnover
- CIDETEC:
9 Laboratories in 5000 m2
115 Researchers, with 40% PhD and 90% Degree
2011 Turnover: 9,5 M
3 Technical Departments
Energy
Surface Finishing
New Materials
CIDETEC FOUNDATION
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CIDETEC FOUNDATION Kera-coat
Batteries Unit
Fuel Cells Unit
Coatings Unit
LIGHT ALLOYS ANODISATION (Al, Mg & Ti)
SOL-GEL COATINGS
ELECTRODEPOSITION COATINGS
Processes Unit
ELECTROPHORETIC DEPOSITION (EPD)
AESTHETIC SURFACE COLOURING
PHYSICAL TREATMENTS (Laser, PVD)
ELECTROCHEMICAL MACHINING (ECM)
ENVIRONMENTAL ELECTROCHEMISTRY
Nanotechnology Unit
Biomaterials Unit
Sensors & Fotonics Unit
Surface Finishing
New Materials Energy
SCALING-UP EPD PROCESSES
SPIN OFF
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KERACOAT
FACILITIES
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PROCESS &
PROTECTION
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CERAMIC COATING
Properties of ceramics CERAMIC COATING
CERAMIC COATINGS PROCESS
Corrosion/oxidation resistance Thermal Electrical Optical Magnetic Wear-resistant
Sol-gel
Vapour phase: PVD and CVD
Thermal Spray Process: LVOF, HVOF, VPS and APS
Laser
Electrophoretic deposition (EPD)
Electrophoretic deposition is a colloidal processing technique to deposit thin films and coatings on substrates. After EPD, the obtained coating, which is in fact still a powder compact, has to be densified by a heat treatment.
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CERAMIC COATING
Technique Thickness Coatings Materials
Temperature of work
Geometry of the pieces
Substrate Investment Process
Cost
PVD 2- 4 m Ceramic
and metal 200 500 C
Metal, glass and ceramic
4 3
CVD 6 9 m Ceramic
and metal 1000 C
Metal and ceramic
4 4
Plasma Thermal spraying
1- 5 m Refractory materials
600 C Metal and ceramic
4 3
HVOF >700m Ceramic 800 1000 C Metal and ceramic
4 3
EPD 1900 m Ceramic,
composite and cermet
25 C
Metal, ceramic and others
2 2
CERAMIC COATING PROCESS
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CERAMIC COATING BY EPD R+D
CERAMIC COATING BY EPD
ACCESIBILITY TO INTRINCATE SHAPES AND FLEXIBILITY
HIGH HARDNESS (> 700Hv)
HIGH CORROSION RESISTANCE FeCl3 > 72h at 50 C
Salt spray test > 1000 h
VARIABLE SINTERING TEMPERATURE .
(600 - 950 C) LOW ROUGHNESS (< 0.04 m)
VITREOUS FINISH
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CONDENSING HEATING BOILERS
Ceramic coating for acid environment corrosion protection in copper alloys
AERONAUTICAL AND AUTOMOTIVE COMPONENTS
Cermets coatings for high-precision special alloy mechanical components
Technical ceramic coating with improvement of mechanical and
tribological properties for tool steels
TOOL MACHINE
MEDICAL APPLICATIONS
Bioceramic coatings for dental implants
CERAMIC COATING BY EPD R+D
CERAMIC
COATING BY EPD APPLICATIONS
PIPE AND EQUIPMENT TO PETROCHEMICAL
AND CHEMICAL INDUSTRY
Inert barrier coating with advanced anticorrosive properties for austenitic stainless steels
AESTHETIC APPLICATIONS
Aesthetic and functional ceramic coating
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ALUMINIUM
CERAMIC
COATING BY EPD METAL
SUBSTRATES
TECHNOLOGICAL IMPROVEMENT OF DIFFERENT METAL SUBSTRATES SURFACE
COPPER
STAINLESS STEEL
CARBON STEEL CAST IRON
R+D IN DIFFERENT METAL SUBSRATES (BRASS,
TITANIUM)
CERAMIC COATING BY EPD R+D
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ELECTROPHORETIC DEPOSITION
Cold rolled austenitic
stainless steel tube
EPD Cell: Aqueous suspensions of non- commercial ceramic enamels (SiO2, Na2O, K2O, TiO2, etc.)
EPD PROCESS
Ceramic coating deposited over metal substrate
Thermal treatment
Outside coating
Inner coating
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CERAMIC COATING
PROPERTIES
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Thickness: Optical microscopy
Continuous and homogeneous coating. Thickness can be adjust modifying EPD
parameters based on final coating properties
COATING CHARACTERIZATION
MORPHOLOGYCAL
CERAMIC COATING PROPERTIES (R+D)
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Joining metal and ceramic : SEM
- Low density of cracks and bubbles - High joining between substrate and ceramic coating - The adhesion between coating and substrate is strong
COATING CHARACTERIZATION
Ceramic Coating
Substrate
Ceramic Coating
Substrate
MORPHOLOGYCAL
CERAMIC COATING PROPERTIES (R+D)
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Substrate Ceramic coating
Important decrease of roughness, avoiding corrosive
particles adhesion
COATING CHARACTERIZATION
MORPHOLOGYCAL Roughness: Profilometry and AFM
CERAMIC COATING PROPERTIES (R+D)
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F = 300.000mN/20s
C = ---
R = Same as load increase
C = ---
0.2 0.4 0.6 0.8 1.0 1.2 1.4h [m]
50
150
250
F [mN]
CERAMIC COATING IS HARDER THAN THE SUBSTRATE
COATING CHARACTERIZATION
MECHANICAL Hardness test
HARDNESS (HV)
84010 ELASTIC MODULUS EIT
(GPa)
87
CERAMIC COATING PROPERTIES (R+D)
THE IMPROVEMENT OF HARDENESS AND ELASTICITY IS POSSIBLE MODIFYING THE STRUCTURE AND COMPOSITION OF CERAMIC COMPOUNDS IN ORDER
TO CERAMIC COATING FINAL PROPERTIES REQUIRED
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MECHANICAL
COATING CHARACTERIZATION
Abrasion resistance
0 cycles 10000 cycles Mass loss for 10000 cycles:
wn = < w0 > - < wn >
Substrate
w10000 = 94.783 94.725
w10000 = 58 mg
Ceramic coating
w10000 = 119.377 119.374
w10000 = 3 mg
CERAMIC COATING PROPERTIES (R+D)
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High Stainless Steel Ceramic coating
5 cm
10 cm
15 cm
MECHANICAL
COATING CHARACTERIZATION
Impact resistance
NO CERAMIC COATING DETACHMENTS AT MEDIUM LOADS: GOOD ADHERENCE
Before After
CERAMIC COATING PROPERTIES (R+D)
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MECHANICAL
COATING CHARACTERIZATION
Thermal cycling (450C)
0 cycles 1 cycle 2 cycles 3 cycles 4 cycles 5 cycles 6 cycles
Air cooled
CERAMIC COATING PROPERTIES (R+D)
MODIFYING CERAMICS COMPOUNDS IS POSSIBLE TO
OBTAIN CERAMIC COATING WITH DIFFERENTS TEMPERATURE
RESISTANCE
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CORROSION RESISTANCE
-Pitting potential measurement:
- JIS G-0577:2005
- Conditions:
o Solution: 5% NaCl, 25 C
o Counter electrode: Platinum
o Reference electrode: Ag/AgCl
o The tested surface was fully immersed in test
solution for 2 h
o The test was conducted by potentiokinetic
method from natural electrode potential to 1
mA/cm2 of anodic current density
o Potential sweeping velocity: 1mV/s
COATING CHARACTERIZATION
CERAMIC COATING PROPERTIES (R+D)
-9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2
-0,4
-0,2
0,0
0,2
0,4
0,6
0,8
1,0
AISI 316L
Ceramic coating T153
E (
V)
vs. A
g/A
gC
l/K
Cl (3
,5M
)
log J (mA/cm2)
Ecorr Log Jcorr (mV vs Ag/AgCl) (mA/cm
2)
Stainless Steel -106 -2.54
Ceramic coating UNALTERED
CORROSION
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- Pitting Corrosion Resistance:
ASTM G48A
Method A-Ferric Chloride Pitting test:
o Conditions:
Solution: 10% FeCl3
Steps:
1. 24 hours in 10% FeCl3 at room temperature
2. 72 hours in 10% FeCl3 at 50 C
o Determination of weight loss:
Maximum 4g/m2 (Norsok)
COATING CHARACTERIZATION
CORROSION RESISTANCE
10% FeCl3
Stainless steel Ceramic coating
0 h (25 C)
72 h (50 C)
Weight Loss
(g/m2) >700 0
CERAMIC COATING PROPERTIES (R+D)
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- Crevice Corrosion Resistance:
ASTM G48A
Method B-Ferric Chloride Crevice Corrosion Test:
o Conditions:
Solution: 10% FeCl3 at 22 C
Steps:
1. Fasten TFE-fluorocarbon block and crevice to the
test specimen with rubber band
2. 72 hours in 10% FeCl3 at 22 C
3. Visual inspection
COATING CHARACTERIZATION
CORROSION RESISTANCE
block crevice
CERAMIC COATING PROPERTIES (R+D)
Stainless Steel Ceramic coating
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COATING CHARACTERIZATION
CORROSION RESISTANCE
CERAMIC COATING PROPERTIES (R+D)
- Seawater Corrosion Resistance (Offshore):
Conditions:
Solution: 3,5% NaCl at 22 C
Visual inspection after test
Seawater Corrosion Test
0 h
1000 h
2000 h
HIGH CORROSION
RESISTANCE FOR
OFFSHORE
APPLICATIONS
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CORROSION RESISTANCE
- Acid Corrosion Resistance :
Conditions:
Solution: 10% HCl at 22 C
Visual inspection after test
Acid Corrosion Test
0 h
1000 h
2000 h
LOST OF BRIGHTNESS
DURING THE TIMING
TEST, BUT THE CERAMIC
COATING CONTINUES TO
PROTECT THE METAL
SUBSTRATE
COATING CHARACTERIZATION
CERAMIC COATING PROPERTIES (R+D)
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CORROSION RESISTANCE
COATING CHARACTERIZATION
CERAMIC COATING PROPERTIES (R+D)
- Molten salt Corrosion Resistance :
Conditions:
Molten salt composition: NaNO3 + KNO3 (60/40)
Blocks of molten salts positioned over the ceramic
coating
46 cycles HEATING (8 hours at 400C)/COOLING
(air cooled)
Visual and optical microscopy inspection
Initial test
After 46 cycles /Before cleaning
After 46 cycles / Surface clean
SURFACE
UNALTERED
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R+D SOLUTIONS
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R+D SOLUTIONS FOR NEW DEMANDING MATERIALS
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R+D SOLUTIONS FOR NEW DEMANDING MATERIALS