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coatings-event-presentation-7-alec-gunner-twi.pdf
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Ltd 2015 TWI Coatings and Surface in TWI
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Ltd 2015 Coatings & Surfacing in TWI More than 35 staffs (including 5PhD/EngDoc Students between 3 sites: • Cambridge (New materials, formulation, Plating, surface engineering(TSA, HVOF) • Sheffield (Laser cladding) • Middlesbrough (coating process, surface understanding & interpretation) Competences: Chemists, Materials Scientists, Material & Chemical Engineers...
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Ltd 2015 ENERGY SECTORS OF INTEREST AEROSPACE OIL&GAS CONSTRUCTION TEXTILE
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Ltd 2015 NEW MATERIALS / COATINGS Our Aim: to produce enabling technologies that will allow production of durable functional coatings Composition Structure Properties
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Ltd 2015 Technology Hot Topics Liquid coatings know-how Anti-Icing Coatings Optical coatings Conductive coatings Anti-Corrosion Protective coatings/primers Hydrophobic/Oleophobic coatings Anti-microbial coatings Extension of know-how through project work Cellulose enhancement Materials reinforcement Surface enhancement
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Ltd 2015 Controlling Surface Energy Aluminium Glass Textile Wood Polymer Deposition of functionalised silica nanoparticles onto the substrate Easy deposition: Dip coated or flow coated Dry oven or UV cure Solvent: IMS or others Silica content: 8-9% WCA on glass : 150° Super-hydrophobic properties result from dual-scale roughness and low surface energy
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Ltd 2015 Video
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Ltd 2015 WeldaPrime Self-repairable Zinc-free Weldable Anti-corrosion Primer for Steel Protection Project aim: To develop an anti-corrosion weldable, zinc free primer that lasts at least 1 year and that does not need grinding before welding or blast-cleaning before finishing. Rust develops on steel during transportation, handling and storage. Material waste and higher costs Coating development aspects: - Synthesis - Formulation - Deposition and curing - Testing - Demonstration Application of sol-gel derived materials to address: - Corrosion performance - Weld-through characteristics - Compatibility with the final top-coat (applied to the welded structure) - Low VOC and Zinc-free
9.
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Ltd 2015 ICE-FREE Ice accretion on high voltage power lines is a severe problem for power networks and it can cause insulator flashover, wire breakage and tower collapse Figure Hybrid high functional coating deposited on power lines to reduce ice accretion Development of durable easy to apply anti-icing polyurethane coating for aluminium overhead power lines (OHL)
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Ltd 2015 COEUS TITAN Figure 2 Epoxy resin blocks with and without ~50%wt of silica loading CoeusTitan is developing a gel-coat that will extend the life of composite moulds for the manufacture of plastic and composite components, with the associated cost saving. The addition of a proportion of silica nanoparticles into the epoxy resin matrix (~50%wt) can provide to the tool mould: • Thermal stability • Low surface energy (non – stick properties) • Higher mechanical robustness Figure 1 Low viscosity epoxy resin with ~50%wt in silica nanoparticles loading
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Ltd 2015 TEXSHIELD Environmentally Friendly and Durable Oil and Water Repellent Finish on Technical Textiles Providing a cost effective alternative treatment to C8-PFCs by reducing the total fluorine content in the treatment for the Textile industry. This treatment will allow textiles to have durable anti soiling/anti-staining properties. Creating additional functions such as anti-static and anti-microbial properties Chemical structure of C8-PFCs Different hydrophobi city depending of the type of surface
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Ltd 2015 CuVITO Nano-Structured Copper Coatings, based on Vitolane® technology, for Antimicrobial applications A molecular-scale cage structured silsesquioxane additive (Vitolane® technology) with a Copper nanoparticle. Copper inks on cotton sheet swatches. Development of anti-microbial coatings for textiles for public buildings using : Copper nanoparticles Vitolane-based functionalization Joint EC/Mexico project
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Ltd 2015 NATURAL NATURAL aims - to develop of the first generation of metrology standards that relate structural hierarchy to performance for nanostructured coatings. - to develop a robust, rapid and accurate methodology that allows the determination and prediction of the durability and performance of the coating for wind blade.
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Ltd 2015 SURFACE ENGINEERING Cold Spray Alumina Coatings Thermal Spray coatings HVOF Coatings Surface engineering - TopGun HVOF system used for ceramic coatings e.g: - Alumina - Zirconia - HA - Bearing surface applications - Ceramics (Al2O3, ZrO2…) - Zirconia based coatings Hydroxyapatite and other bioactive materials Process development to tailor coating properties and control phases - Can create composite, graded & multilayer coatings - Rapid build-up of metal deposits with minimal porosity and no oxidation - High pressure He or N2 mixtures - No melting of consumables
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Ltd 2015 Thermal spray coating of polymer composites – Aerospace Cold spray technology – Aerospace, Electronic, Biomedical H2 embrittlement testing (coated high strength alloys) – Aerospace, Oil & Gas Automated surface preparation (grit blasting) – All industry sectors Testing and characterisation of thin film, slurry, plating, thermal spray coatings – Oil & Gas High temperature coatings e.g. biomass, waste combustion, metal dusting– Power Generation Offshore applications for thermal spray Al (TSA) – Oil & Gas, Wind, Wave & Tidal Surface Engineering Hot Topics
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Ltd 2015 Recently Completed - Improved splash and tidal zone coatings for a 40-year design life (oil & gas, wind power). - Development of coatings for corrosion mitigation in biomass, waste-to-energy and other process plants (power generation). - CompoSurfTM coating technology for increased functionality of composite materials (aerospace) - Measuring the Effect of Cathodic Protection on the Performance of TSA Coatings at Elevated Temperature (oil & gas) Joint Industry Projects (JIP) Currently running
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Ltd 2015 TSB: Cold spray Al-B4C coatings for neutron capture (nuclear power). TSB: Development of photo-catalytic coatings for splitting H2O (using suspension spraying) (renewable energy). 22665 RGF/BIS: Automated application of 40-year life coatings for wind turbine structures (renewable energy) Recently Completed UK Collaborative Projects
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Ltd 2015 23506 FP7 Clean Sky: COMPOCOAT - coatings for composite gas turbine blades (aerospace) 23405 FP7 Thematic: CORSAIR - cold spray coatings and repair (aerospace) 23789 FP7 R4S: ACORN TSA / anti-fouling duplex coatings for wave & tidal energy generation devices (renewables) Current EU Collaborative Projects
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Ltd 2015 22407 Automated surface preparation methods for thermal spray coating (grit blasting) 22419 Further development of Cold Spray process - deposition of more challenging coating compositions (Ni718) 2012-2015 Core Research Programme (CRP)
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Ltd 2015 wear and corrosion protection using wet plating. ELECTROPLATING WET PLATING Electroplating (or 'electrodeposition') of metal films Electroless (or 'autocatalytic') deposition of metal films Anodising (oxide film growth on non- ferrous metals):conventional, PEO and Hard Anodising. Conversion coatings (usually phosphates/chromates of Fe, Zn, Mn) 'Hot-dip' coatings (eg. galvanising - using a bath of molten Zn)
21.
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Ltd 2015 Corrosion performance: Salt fog test (5% NaCl) 168 hrs 336 hrs • Plasma electrolytic oxidation (PEO) coatings show no signs of corrosion after 336 hrs exposure in 100% humid atmosphere with NaCl • Thus, thin (10 - 20 mm) PEO coatings on Al can provide effective barrier against corrosion attack in chloride environments Courtesy of WPAFB
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Ltd 2015 Examples of PEO applications for Aluminium Al wheels with PEO or PEO+PTFE coated teeth reduce wear against belts and chains. No lubrication required. Thermal barrier PEO coatings reduce temperatures in automotive piston crowns and improve overall engine performance. Al moulds with PEO+PTFE coating reduce adhesive wear during casting. Tool production costs also reduced. Source: www.keronite.com
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Ltd 2015 Coatings@twi.co.uk http://youtu.be/t1S1KaN95W8?list=UUVyzolRz84369 63AmklQM4Q THANK YOU
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