2015.04 - ibc capabilities overview
Post on 24-Jan-2017
519 Views
Preview:
TRANSCRIPT
Materials and TechnologiesIBC Group | 902 Hendricks Drive, Lebanon, IN 46052 | www.ibccoatings.com
Capabilities OverviewApril 2014
Materials and Technologies2
Welcome to IBC
Materials and Technologies
Company Profile
• IBC Group consists of IBC Coating Technologies, Inc.; IBC Materials and Technologies, Inc.; and IBC-Sputtek, Inc.
• IBC is a privately owned surface engineering company established in 1996, with manufacturing and R&D capabilities located in Lebanon, Indiana, U.S.A. and Toronto, Canada
• IBC has about 70 employees and occupies approximately 80,000 square feet
• IBC serves a variety of industries – Aerospace, Defense, Gas Turbines, Oil, Automotive, Metal Forming, Die Casting, Forging, and others – by providing advanced surface treatment solutions in USA , Canada, Mexico, and Europe
• IBC develops and applies proprietary surface treatments to improve wear, corrosion, fatigue, and lubricity properties of components
• IBC uses build-up processes (Cold Spray, HVAF, Laser Cladding) in conjunction with surface treatments to provide repair solutions
• IBC’s surface treatments are used in a wide variety of applications with excellent results
3
Materials and Technologies
IBC Provides The Following Services
• Thin Film Coating– CeraTough-D™ Diamond Like Carbon (DLC)
coatings– High Energy PVD coatings (TiN, TiALN, CRN,
CRC, TIC, VC, Al2O3, SiO2, ZrO2, SiN)
• Nitriding– Ion Plasma Nitriding (DHIN)– Ion Plasma Ferritic Nitrocarburizing (DH-FNC) – Post-DHIN and FNC Oxidation (equivalent to
Plasox)– Salt Bath Nitriding (DHN) (equivalent to QPQ,
Melonite, Tufftride, etc.)
• Laser Cladding
• PLASMA ELECTROLYTIC OXIDATION OF AL, TI, MG –ALLOYS – CeraTough™ PEO coatings– Services and Equipment
• HEAT TREATING– Vacuum Heat Treat with up to 12 Bar Gas Quench– Annealing– Stress Relief– Aging– Carburizing– Solution Nitriding
• THERMAL DIFFUSION SURFACE TREATMENT– Boriding (DHB)– Tantalizing (DHTa) – Chromizing (DHC)– Aluminizing (DHA)– Vanadium Carbide (TDH)
4
Materials and Technologies5
IBC Equipment Size Capabilities
• Ion Plasma Nitriding & FNC with post oxidation (Dia 60” x 83” tall)
• S-phase Ion Plasma Carburizing, Nitrocarburizing, Nitriding(Dia 60” x 83” tall)
• Plasma-assisted DLC coatings with the ability to deposit thick 20-40 micron layers (Dia 60” x 83” tall)
• Thermal Diffusion coatings (Dia 100” x 120” Tall)
– Boriding
– Chrome Carbide (on carbon reach and austenitic alloys)
– Chrome Diffusion
– Aluminizing
– Tantalizing
– Vanadium Carbide
• PVD coatings ( 40”x40”x60”)
– Vanadium Carbide, Chrome Carbide, Chrome Nitride, etc.
• CeraTough™ - PEO Ceramic Coatings for lightweight alloys including Al, Ti, and Mg
• Vacuum Heat Treatment with up to 12 Bar Gas Quench (24”x24”x36”)
• Vacuum Carburizing and Carbonitriding (24”x24”x36”)
• Salt Bath and Gas Nitriding & Nitrocarburizing (Dia 40”x60”tall)
• Thermal Spray (Plasma, HVOF, HVAF, Cold Spray)
• Laser Cladding – 5000 LB weight limit, 12’ length, 8’ diameter
– WC-Cr-Co/ WC- Ni-Cr-B-Si
– CRC-NiCr
– Inconel 718, 625, Stellite, etc.
Materials and Technologies
CeraTough-D™ (DLC) Coating
Base
Metal
DLC
Coating
• DLC stands for Diamond-Like Carbon and is a nanocomposite coating that has unique properties of natural diamond-like low friction, high hardness, and high corrosion resistance
• CeraTough-D™ DLC coatings have the following characteristics:– High hardness
– Low coefficient of friction (0.02-0.15)
– High corrosion resistance
– Great adhesion to substrate material
– Fretting resistance
– Abrasive wear resistance
– Self lubrication in dry wear conditions
– Excellent release properties
– Electrical insulation
Materials and Technologies
CeraTough-D™ (DLC) Coating
• CeraTough-D™ Equipment Size Capability
– CAPVD Systems can fit parts that are less than 30”x 20”x20” with a weight limit of 500 LB
– PACVD Systems can fit parts in a 60” diameter and 82” tall chamber with a weight limit of 18,000 LB
• CeraTough-D™ DLC Coating applications include:– Cutting tools for Aluminum, Aluminum-Silicon Alloys, Powder Metallurgy Alloys
– Tools for metal forming and blanking
– Plastic molds and extrusion components for abrasion and corrosion resistance, good release, and antibacterial properties
– Hydraulic Components (cylinders, pistons, gear pumps, etc.)
– Valve Components (balls, gates, seats, actuators, housings, etc.)
– Automotive Components (crank shafts, cam shafts, gears, bearings, piston rings, tappets, wrist pins, fuel injectors, etc.)
– Pump components (impellers, diffusers, rotors, etc.)
– Mechanical seals
Materials and Technologies
Examples of DLC Coated Components
8
Filters for Plastic Recycling
Gears
CrankshaftsHydraulic Components
Hydraulic Rods for Mining Equipment
Forming Rolls
Materials and Technologies9
• IPN is a low-temperature (<1000°F) surface-hardening heat treatment that introduces nitrogen or nitrogen-carbon into the surface of steel & titanium alloys
• IPN imparts excellent wear, corrosion, and fatigue enhancement properties into the metal surface
• The diffusion layer thickness is 0.0001”-0.020“ depending on the type of material and process parameters
• Typical Microhardness: 600-1800 HV
Ion Plasma Nitriding/Nitrocarburizing
Materials and Technologies
• Impeller made of low-alloyed steel 1.7225/SCM4/4140 pre-hardened
• MPP nitriding for increased wear resistance
• Special pumps used in the paperindustry
• High-alloyed impeller made of Duplex Cr-Ni-steel
• PLASNIT® treatment: Surface hardness 1200HV
• Increased lifetime from 6 months to 20 months!
PLASNIT® Pump Components
Materials and Technologies
Plasma Nitriding of Crankshafts for 6-Cylinder Engines
Materials and Technologies
• An innovative Green Technology for cost-efficient production of gears and other transmission parts
Plasma Nitriding of Gears
Materials and Technologies
Ball valves during S-Phase treatment
S-Phase Surface Treatment
• S-Phase carburizing/ nitro-carburizing/ nitriding creates wear-resistant layers on austenitic, ferritic, duplex, and nickel alloys, promoting outstanding corrosion resistance
• S-phase treatment typically results in a layer up to 45µm thick and a microhardnessranging 1000-1400 HV
13
Materials and Technologies
0
50
100
150
200
250
1
Untreated
Hardened
H1324 hrs
LTPN
Molten Salt
Nitrided
Weight Loss after 0.5 hr. mg.
S-Phase (LTPN) Treatment of 17-4 PH Steel
14
Materials and Technologies15
• The DHN treatment is carried out at 800 -1100 oF for between two and eight hours
• The diffusion layer thickness is 0.001”-0.015”
• Microhardness is between 600-1300 HV
DHN – Salt Bath Nitriding
H 13 SS 304
M 2
Nitro-Carburized Layer
FX-2
Nitro-carburized layer
Materials and Technologies
Microhardness Distribution After Salt Bath Nitriding
500
600
700
800
900
1000
1100
1200
1300
1400
1500
0 0.002 0.004 0.006 0.008 0.01
Distance from the surface, Inch
Mic
roh
ard
ness,
HV
(100)
Series1 Series2 Series3 Series4
Die Material: H13
400
450
500
550
600
650
700
750
800
0 0.005 0.01 0.015 0.02 0.025 0.03
Distance from the surface, Inch
HV
300 24 Hours
6 Hours
12 Hours
36 Hours
Die Material: FX-2
Materials and Technologies
CeraTough™ Plasma Electrolytic Oxidation
• A new nano-structured ceramic surface treatment for Al, Ti, Mg, and other alloys
• Non-line-of-sight plasma process
• Conformal to surface via diffusion mechanism
• High hardness (800-2000HV)
• Low friction with outstanding wear performance
• High density (95%-99%+)
• No fatigue debit
• High corrosion resistance
• CeraTough™ is a Green Technology – no hazardous waste streams
Inside a PEO cell
CeraTough™-coated piston
Materials and Technologies
Advantages of CeraTough™ PEO
• No pretreatments required (NaOH soak, caustic etch, de-smutting, etc.)
• No sealing required
• No acids or hazardous byproducts to be scrubbed, vented, respirated, or remediated
• CeraTough™ process uses water-based electrolytes composed of low-concentration silicates, aluminates, metaphosphates, borates, and hydroxides
– These additives are low-cost, safe, and easy to maintain
– Fully spent electrolyte can be washed down the drain with no prior remediation or downstream monitoring
CeraTough™ eliminates OSHA & HAZMAT issues associated
with anodizing
Materials and Technologies
How are CeraTough™ Coatings Used?
• Advanced protection against wear, fretting, and galling
• Extreme protection against corrosion and chemical attack
• State-of-the-art thermal barrier coatings with controlled thermal conductivity
• High electrical insulation properties with controlled electrical and thermal conductivity
• Life extension of repairs parts in conjunction with additive manufacturing processes
- Cold spray
- Flame spray
- Laser cladding
- Laser welding
- Friction welding Al2O3 Coating on F357 Aluminum
Base Metal –Aluminum Alloy
CeraTough™ Al2O3 Coating
Materials and Technologies
ASTM B117 Corrosion Test Results:CeraTough™ vs. Hard Anodizing
0
16.25
32.50
Corrosion Pitting - # of pits after B117 salt spray 1344 hours
Ceratough-Al Hard Anodize
Corrosion Pitting: Number of Pits After 1344 Hours of B117 Salt Spray
CeraTough™-Al Hard
Anodizing
Materials and Technologies
CeraTough™ Wear Test Results
Test Method: M50 ellipsoid against test specimens, with oil
Baseline: 4340 steel
Samples: Ceramic Aluminum-Oxide (Al2O3) coated F357 Aluminum
M50 vs. CeraTough™
M50 vs 4340
CeraTough™ Coatings
provide 10X wear
improvement over lubricated
4340 steel
4340 exhibits substantial fretting & galling against M50
CeraTough™ exhibits
virtually no fretting & galling
against M50
Materials and Technologies
Taber Test Results Show 5X Less Wear Compared to Anodizing
Hard Anodized 355 Alloy CeraTough™ Coated 355 Alloy
Materials and Technologies
Vanadium Carbide TD Coating
• Greatly reduces galling, wear, and lubricant usage
• Reduces tooling cost by extending tool life by 5 to 15 times
• Increases press-up time and speed
• Improves part quality and surface finish
• Decreases maintenance time and expense
Materials and Technologies
TD Coatings Can Be Applied Two Different Ways
• Hot Process (TDH)
– Metallurgical bond ensures better adhesion
– Uniform VC thickness in deep holes
– Hardens most substrates during coating
– 1750 to 1900 °F deposition temperature
– Nanostructure on coating provides unmatched wear performance
• Cold Process (TDC)
– No distortion, tight tolerances maintained
– Unlimited number of re-coatings
– Diffusion bond insures superior strength
– 600 to 840 °F deposition temperature
– Nanostructure on coating provides unmatched wear performance
Materials and Technologies
Vanadium CarbideTD Coating
Materials and Technologies
DIFFUSION BORIDING
• Diffusion treatment that produces hard coatings with outstanding resistance to erosion, cavitation, abrasion, and corrosion
• Most iron, nickel, cobalt, and molybdenum alloys can be Borided
• Most applications are in the Oil & Gas, Mining, Refinery, and Agricultural fields
• IBC uses proprietary compositions to form deep cases that outperform many other coating solutions
• Cold Boriding process is under development at IBC R&D center
• Thousands of pump components coated at IBC have performed outstandingly in the most demanding of applications
26
Materials and Technologies
Deep Case Boriding
27
Niresist
M4 Tool Steel420 Stainless Steel
8620 Steel4140 Steel
1045 Steel
Materials and Technologies
Microhardness Distribution in Borided Layers
0
200
400
600
800
1000
1200
1400
1600
1800
2000
0 100 200 300 400 500 600 700
HV
Depth (um)
Supplied Sample
1045 Coated atIBC
4140 Coated at IBC
8620 Coated at IBC
M4 Coated at IBC
420 SS Coated at IBC
28
Materials and Technologies
Erosion Test Comparison of Boriding and Stellite 12
STELLITE 12 AFTER 5 MINUTES OF GRIT BLAST AT 90 PSI (1.00” form target)
BORONIZED PLATE AFTER 5 MINUTES OF GRIT BLAST AT 90 PSI (1.00” form target) – NO WEAR
Grit: size 20 - 30
29
Materials and Technologies
Boriding Corrosion Resistance
Data taken from ASM Handbook Volume 4
Materials and Technologies
Diffusion Chrome Carbide Coatings on Different Materials
31
• Diffusion Chrome and Chrome Carbide Coatings are widely used by IBC customers for pumps, valves, and other components to improve corrosion, wear, and cavitation resistance in the oil, food, aircraft, and other industries
• High hardness (800-2000 HV) and low coefficient of friction
Niresist Cast Iron H-13 Tool Steel
420 Stainless Steel Impeller
Materials and Technologies
Tantalum Diffusion Coating
Exposed to 10% Acetic Acid at 450 °F
Material Corrosion Rate (mpy)
Ti 6-4 2.2
316L 242
Ta-Surface Alloyed 316L 0
Exposed to 10% HCl, 10% Acetic Acid, 15 PSIA H2S at 450 °F
Material Corrosion Rate (mpy)
Ti 6-4 >41,341
316L >36,517
Ta-Surface Alloyed 316L 0
Data taken from Stainless Steel World
Properties
• Superb corrosion resistance
• Non-line-of-sight process
• High bond strength
• Uniform, pore-free structure
• Impervious to chemical attack below 302 °F
• Vulnerable only to hydrofluoric acid, acidic solutions containing the fluoride ion, and free sulfur trioxide
• High strength and ductility
• Thickness up to 0.002”
Tantalum Corrosion Resistance
Materials and Technologies
Aluminizing
Properties
• Corrosion resistance in extreme, high temperature environments
• Protects steel from attack by H2S, SO2, and SO3
• Can be applied to steels, stainless steels, and nickel alloys
• Case depths up to 0.015”
• Oxidation and Carburization resistance
Inconel 718 Substrate
Aluminized Layer
Materials and Technologies
Thermal Spray/ High Velocity Air Fuel (HVAF) Coatings
Fuel Combustion
in oxygen
Combustion in air
Methane 2810 1950
Propane 2820 1980
MAPP 2927 2010
Hydrogen 3200 2210
Adiabatic flame temperature (oC) of common gases@ a=1, 20oC, 1 Bar
Melting temperature of common metals: 1400-1700 oC
Gas velocity in de Laval nozzle
1000
1100
1200
1300
1400
1500
1600
0.4 0.5 0.6 0.7 0.8 0.9 1
Chamber absolute pressure, MPa
Vg, m/s
T=2300K T=2100K T=1900K
Materials and Technologies
HVAF Coating of 20,000 LB Turbine Rotor
35
Materials and Technologies
Tungsten Carbide HVAF Coating of Elbows
36
Materials and Technologies
Tungsten Carbide HVAF Coating of a Cyclone
37
Materials and Technologies
• Porosity: < 1%
• No unmelted particles or
inclusions
• Very uniform thickness
Microstructure of Tungsten Carbide HVAF WC-10Co-4Cr Coating
Materials and Technologies
Thermal Spray (HVAF) Microhardness Distribution
Materials and Technologies
Bond Strength – HVAF on 4130 Steel
Requirement:
Above 10,153 PSI – Glue Failure
# Tensile Strength, PSI
Failuremode
1 10557 Glue
2 8857 Glue
3 9244 Glue
4 10287 Glue
5 10874 Glue
Materials and Technologies
Mechanical Integrity ofHVAF Coating: 90 O Bend Test
Materials and Technologies
LASER CLADDING
• IBC Laser Cell has a 4kW IPG fiber laser with a head tail stock positioner that can hold up to 2000 kg and 12’ length
• Cell has a wide production window to clad a variety of metals
Materials and Technologies
CLADDING WEAR SLEEVE
• 1ST Layer
• 2ND Layer
Materials and Technologies
IBC LASER CLAD WC – NiCrBSi MATRIX
• WC hardness
1913 HV – 3900 HV
• Matrix average hardness
40 HRC
44
Materials and Technologies
Summary
• IBC Group is the leading supplier of surface treatment technologies for multiple industries
• We are committed to providing you with the best solutions to improve the life of your components
• We are located in the Crossroads of America in Indiana and are proud to serve US manufacturing needs
Materials and Technologies
Contact Information
• Phone: (765) 482-9802
• President/CEO: Solomon Berman
– sb@ibccoatings.com
• Vice President: Ashok Ramaswamy
– ashok@ibccoatings.com
• Address:
902 Hendricks Drive
Lebanon, IN 46052
top related