2015.04 - IBC Capabilities Overview

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

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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)

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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.


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


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


Examples of DLC Coated Components

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Filters for Plastic Recycling

Gears

CrankshaftsHydraulic Components

Hydraulic Rods for Mining Equipment

Forming Rolls


• 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


• 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


Plasma Nitriding of Crankshafts for 6-Cylinder Engines


• An innovative Green Technology for cost-efficient production of gears and other transmission parts

Plasma Nitriding of Gears


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

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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

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• 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


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


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


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


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


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


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


Taber Test Results Show 5X Less Wear Compared to Anodizing

Hard Anodized 355 Alloy CeraTough™ Coated 355 Alloy


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


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


Vanadium CarbideTD Coating


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

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Deep Case Boriding

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Niresist

M4 Tool Steel420 Stainless Steel

8620 Steel4140 Steel

1045 Steel


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

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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

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Boriding Corrosion Resistance

Data taken from ASM Handbook Volume 4


Diffusion Chrome Carbide Coatings on Different Materials

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• 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


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


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


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


HVAF Coating of 20,000 LB Turbine Rotor

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Tungsten Carbide HVAF Coating of Elbows

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Tungsten Carbide HVAF Coating of a Cyclone

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• Porosity: < 1%

• No unmelted particles or

inclusions

• Very uniform thickness

Microstructure of Tungsten Carbide HVAF WC-10Co-4Cr Coating


Thermal Spray (HVAF) Microhardness Distribution


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


Mechanical Integrity ofHVAF Coating: 90 O Bend Test


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


CLADDING WEAR SLEEVE

• 1ST Layer

• 2ND Layer


IBC LASER CLAD WC – NiCrBSi MATRIX

• WC hardness

1913 HV – 3900 HV

• Matrix average hardness

40 HRC

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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


Contact Information

• Phone: (765) 482-9802

• President/CEO: Solomon Berman

– [email protected]

• Vice President: Ashok Ramaswamy

– [email protected]

• Address:

902 Hendricks Drive

Lebanon, IN 46052

Documents

2015.04 - IBC Capabilities Overview