Transfair Presentation 4 ( 8MB)

A future design classic – Bright Chrome

Life Extension of tri-valent chromium passivation baths

Coffee and networking

Bonded lubricating coatings

Physical vapour deposition coatings

Terry Clarke; MacDermid Inc

Ashish Kulkarni; Shree Rasayani

Roy Harrison; Whitford Technologies

Kevin Cooke; Miba Coating Group

A Future “Design Classic”

- Bright Chromium

Alan Gardner

MacDermid: all rights reserved

What is a “Design Classic”?

• “Design Classics” are icons in the world of fashion and trend. They are easy to recognise yet are so familiar they become part of every day living. They often go unnoticed. They always remain true to their original concepts

• They are more often noticed when they have unexpectedly changed

• There endurance is due to qualities that cannot be easily measured and they don’t become classics overnight

• We are aware of them even without knowing the influence they have on our lives


Evolution not Revolution …

• During their evolution, design classics tend to

retain the key features that make them

appealing…

– Note the Coca Cola logo remains consistent


Change Vs Evolution

• Iconic Endurance

– An iconic design can change, yet its intrinsic appeal can remain or

even grow

– We remain attracted to its values despite these changes


How far can Evolution go…

• Surprisingly…providing the original concept

and values are clearly reflected in the product,

company or service we embrace changes


Image or Name …

• Design Classics can be recognised equally

effectively by images, names or services:

• Coca Cola

• Mini

• Starbucks

– The iconic form is not critical, but its values are


Sustaining Values …

• How many here are truly Design Classics….


Why Bright Chromium is Iconic…

• Iconic Designs

– Recognised without need for description

– Universally appreciated & valued

– Sustains Core Values/Principals/Virtues

– Not Diluted by Evolution

– Multi Lingual

– Imitations always compared to original

– They endure through almost all changes


Bright Chromium…Appeal

• In France & Italy…almost 50% of the chromium

electroplate is consumed by Fashion and Cosmetics


Bright Chromium…Fashion

• A true Design Classic is always in demand

despite changes in fashion and trend…


Bright Chromium…Innovation

• A true Design Classic is always in demand

even at the leading edge of innovation…


Bright Chromium…Technology

• A true Design Classic always delivers…even

when designs and technologies change


Bright Chromium…Enduring Value

• A true Design Classic can continue to enhance

value through many design generations

Bright Chromium Technology


Bright Chromium Advances…

Trivalent Hexavalent Deposition Modes


Bright Chromium Advances…

• Latest generation trivalent chrome systems

deliver the same unique metallic style but with

added benefits:

– Choice of colours

– Meet Environmental, HSE and Productivity needs

– Experienced worldwide applicator base

– Tough metallic films with high performance

– Can’t be matched by paints


Bright Chromium…Options

• Colour evolutions open new markets and opportunities

Bright Satin Dark


• TriMac

– TriMac trivalent chrome systems offer

colours plus high performance from

environmentally sound chemistry

– TriMacIII conventional chrome colour with

excellent performance

– TriMac RM a warm colour with maximum

“Russian Mud” corrosion performance

Bright Trivalent Systems …


Darker Trivalent Systems…

• Twilite

– The first chrome to break from tradition,

Twilite has been adopted worldwide as a

new look stylish chrome

– Twilite a cool darker shade that brings a

subtle new look to metallic chrome, also

provides excellent performance in

“Russian mud”, CASS and NSS


Very Dark Trivalent Systems…

• Galaxy

– Galaxy is rapidly gaining a reputation

amongst designers as the new look dark

chrome

– Galaxy’s cool blue/gray shade works well

with modern fabrics and textures, it also

gives performance to match standard

chromium

Specified by General Motors (M24)


The Satin Revolution…

• M-Satin …

– Satin chrome has sparked new opportunities in design studios. Stylish options in satin chrome include systems with highly consistent gloss and colour

– From the very light to dense and heavy, satin continues to win over designers in all application areas

– It has now started to appear on external automotive parts


Bright Chromium and Performance…

• Trivalent Chromium is solving the problem of Russian Mud !!! A BIG issue in some countries during severe winters…


The Future…is Bright !!!

Chromium continues to be specified by major OEM’s:

• Automotive demand is at its highest for 20 years

• Technology is improving to meet higher standards

• Environmental pressures are driving technology

• New finishes are attracting designers

• Bright Chromium on plastics is preferred route

• These are hallmarks of a “Design Classic”


Bright Chromium…Automotive

2012

1 China Nationals 11,400,000

2 Toyota 9,500,000

3 VW 8,700,000

4 GM 7,200,000

5 Hyundai 7,000,000

6 Renault-Nissan 5,700,000

7 Ford 5,100,000

8 FIAT-Chrysler 4,250,000

9 Honda 4,000,000

10 PSA 2,950,000

11 Suzuki 2,900,000

12 BMW 1,800,000

13 Daimler AG 1,750,000

100% of cars use Bright Chromium for plastic trim

Global Total = +60m units per year


BUT…Design Classics have Limits !!!

Noooooo !!!


Thank You…

For more information about our world of

“Fashion Finishes” see our web site

www.macdermid.com/industrial

www.macdermid.com/autotype

Life Extension Of Trivalent Chromium

Passivation Baths and Enhanced

Product Performance

A. S. Kulkarni

SHREE RASAYANI

INDIA

Overview

• About us

• Current status of Cr (III) passivations

• Expected changes or improvements

• Our solutions

• Future developments

About us

• Located in Nasik, India

• Manufacture and supply of formulations

• Customers in all regions of India

• Approvals from auto companies like Tata Motors

• Emphasis on surface treatment of Zn and Al

• Systems ISO 9001 certified

Current Status of Cr (III) passivations

• Fairly well established process worldwide

• Available in 2 main finishes – Light iridescent or

Silver and Black

• Applied successfully on Zn, Zn alloys and Al

alloys

• Use of a Sealer or Topcoat is almost universal

Current Status of Cr (III) passivations (cont.)

• 240 hours of salt spray life for Zn-Ni and 300 hours for Al is considered standard.

For Zn, 120 hours can be regarded as average.

• Sensitive to variations in pH, temperatures and presence of metallic impurities

• Formulations of comparable performance are available from various sources

Expected Changes or Improvements

From Finishers

• Higher coverage per litre of concentrate (cost reduction)

• More robust processes (tolerance to metallic impurities, poor water quality..)

• Formulations that can applied to different surfaces, easily and consistently

Expected Changes or Improvements

(cont.)

From End Users

• Improved corrosion protection and aesthetics

• Ability to withstand different environments

From Regulators

• Reduction in amount of effluent

• Restrictions on hazardous substances

Our Objectives

• Remove metallic impurities and rejuvenate the

passivation bath and maintain product quality

• Reduce the frequency of discard and hence

costs as well as quantity of effluents

• Improve the corrosion resistance of passivation

films significantly with minimal cost impact

• Study Co containing and Co free formulations

Our Solutions

• A membrane based process for removal of

dissolved metallic impurities like zinc, iron and

copper from Cr (III) based passivation baths

• Incorporation of nano sized ceramic particles in

the passivation film for significant improvement

in corrosion resistance

Effect of Metallic Impurities

• Spoil the aesthetics of components

• Reduce the rate of formation of passive film,

hence corrosion resistance

• Increase the load on effluent treatment plants

due to early discard of bath

• Effectively costing money

Effect of zinc concentration on corrosion

resistance H

ou

rs t

o w

hit

e R

ust

0

20

40

60

80

100

120

140

Co-free Co-based

Fresh solution

Zn 10 g/L

Schematic diagram of the purification system

Cr (III) passivation bath

MEMBRANE

Acid

Filter

Process and operating conditions

• Pressure: Slightly above atmospheric

• Temperature: 25 to 50 C

• Acid conc: 1 to 4 M (1:16 to 1:4 dilution)

• Flow rates: 12 to 400 litres per hour

• pH: 1.8 to 2.4 (Zn, Fe)

> 3.5 (Co, Cu)

Ion Exchange (Batch or Continuous)

Cr3+

Co2+ Zn2+ Fe2+

MEMBRANE

H+

H+ Zn2+ Fe2+

Cr3+ Co2+

Features of Ion Exchange Process

• Only metallic ions are exchanged

• Presence of –ve ions like nitrates, sulphates,

fluorides does not affect the rate of exchange

• The type of ions exchanged depends on pH –

simultaneous removal of different ions is

possible

• The rate of exchange depends on pH, flow rate

and surface area of the membrane

Features of Ion Exchange Process (cont.)

• Any mineral acid can be used

• Strength of the acid can be from 1M to 4M

• Process is fairly safe

• No special analytical instruments needed

• Can be operated on a batch or truly continuous

basis

Features of Ion Exchange Process (cont.)

Cr (III) solution

Acid

For extra capacity, membranes can be arranged in parallel

MEMBRANE

MEMBRANE

Comparison of transfer rates of Zn and Fe

0 10 20 30 40 50 600

5

10 [Zn]

[Fe]

Time (Minutes)

[Zn

] (g

/L)

0

200

400

600

800

1000

[Fe] (p

pm

)

Influence of Acid strength on rejuvenation

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.520

40

60

80

100

120T

ime

(m

inu

tes

)

Acid Strength (M)

Design Considerations

• Quantity of solution

• Rate of increase in Zn concentration

• Mode of operation

• Which acid?

• Strength of acid

• Space constraints

Plant Data (1000 litre soln. – 72 hrs working)

• 500 Kg of fasteners plated per hour

• 190 to 275 grams of Zn dissolved per hour

• Rate of metal removal was 175 grams per hour

• 15 litres of conc. Nitric acid consumed

• Effluent generated was 120 litres

Variation in Zinc concentration

1 2 3 4 5 60.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

[Zn

] (g

/L)

Day

Membrane operated in dual mode from day 4

Incorporating Ceramic nano-particles

Zn: 8 to 10 microns thick

Aqueous suspension of ceramic particles (size 10-12 nm)

added to the passivation

Temp: 30 to 35 C

pH: 2.0 to 2.8

Mild Steel

Zinc

Passivation

Incorporating Ceramic nano-particles (cont.)

This concept has been around for few years

• Is still not ‘mainstream’ technology

• Problems related to stability (gelling)

• Friction coefficient cannot be modified

• Application of topcoat increases cost

Manufacturing of ceramics helps us

overcome problems of cost and gelling

Corrosion performance of Co free process

Without ceramics (120 hours) With ceramics (192 hours)

Comparison of Co free & Co based processes H

ou

rs

0

50

100

150

200

250

300

350

400

450

Co-free Co-free withceramics

Co-based Co-basedwith ceramics

Effect of application of Sealer: Observations

by Tata Motors H

ou

rs t

o W

hit

e R

ust

Ceramic Loading per Litre

050

100150200250300350400450500

15 ml(Ac-Zn)

30 ml(Ac-Zn)

60 ml(Ac-Zn)

15 ml(Alk-Zn)

30 ml(Alk-Zn)

60 ml(Alk-Zn)

How expensive is it?

• The Passivation + Ceramics + Sealer process is

in use for last couple of years

• The cost of chemicals to our customers is around

4 to 5 pence per Kg of fasteners

Future Developments

• Separation of Al from Cr (III) solutions using

membranes

• Using ceramics to improve the performance of

Cr (III) passivations for Al

• Jointly working with Evonik to develop Cr free

coatings for galvanised surfaces using ceramics

Please visit the exhibition

Don’t forget the “Land Rover” Experience

Have a look at the Heritage Museum

Please be back for 3.45pm!

Bonded Lubricating Coatings

Steve Butler Director Automotive Technologies

Roy Harrison BSc, MIM

Technical Sales Manager

• Worldwide manufacturing

• Almost 50 years in bonded lubricating and release Coatings

• Coatings used by almost every car maker

• Global technical support

• Knowledge of Wear Mechanisms

• Knowledge of Tribology

• Understanding of Friction

• Philosophy of supporting innovation

What is a Bonded Lubricating Coating?

Contact surface

Tailored formulations

1

2

3

4 5

Weatherstrip seals Glassrun seals Pistons Fasteners Steering systems

Key Properties

Waterproofing and stain resistance

Key Properties

Waterproofing and stain resistance

Key Properties

Weathering

Key Properties

Weathering

Key Properties

Corrosion protection

Key Properties

Abrasion and wear reduction

Key Properties

Abrasion and wear reduction

Key Properties

Noise reduction and suppression

Key Properties

Noise reduction and suppression

Body Paint

Glass

Metal Appliq

ué

Plastic Trim

Closure Seal

Key Properties

Chemical resistance

Key Properties

Chemical resistance

Key Properties

Corrosion protection with lubrication

Key Properties

Freeze release

Key Properties

Freeze release

Key Properties

Colour identification and easy fitting

Key Properties

Controlled friction values

Key Properties

Reduce CoF Eliminate Stick Slip Reproducible results

Application Methods

Key Applications

Controlled friction values

What’s New?

Whitford reinvest 6% into R&D Always looking for Innovative opportunities Sol-gel with polymers

Where good ideas come to the surface

Sol gel

Sol gel - MATRIX

• Hybrid of organic and inorganic chemistry • Hard surface like porcelain enamel • Low CoF and good release at elevated

temperatures (300 – 500 oC)

http://www.google.co.uk/url?sa=i&rct=j&q=fire&source=images&cd=&cad=rja&docid=vE4Vls8jGSJ-2M&tbnid=Cws3W1uZwNumEM:&ved=0CAUQjRw&url=http://smehealthandsafety.co.uk/fire/&ei=dw96UcTQHsXdsgajjoGABA&psig=AFQjCNHWDMoHSWkCChgyXLu_M2jHwoXP8A&ust=1367040230833428

http://www.google.co.uk/url?sa=i&rct=j&q=hard+hammer&source=images&cd=&docid=Li5XkkQOIXwdzM&tbnid=OHoTCrfIzZ5QJM:&ved=0CAUQjRw&url=http://www.nuplacorp.com/product.php?id=193&ei=rRB6Uce3JNHEsgbV6YGYBw&psig=AFQjCNHA2rrEiMYOY_rFfa_0XW-BqSVouQ&ust=1367040543080865

How Best to Utilise Whitford’s abilities? How to make the most from Xylan coatings?

Involve Whitford and Xylan coatings in the

engineering process

Partnership

References

http://uk.wrs.yahoo.com/_ylt=A0WTf2wXxYpJx2UBN.xNBQx.;_ylu=X3oDMTBpZTByOGFiBHBvcwMyBHNlYwNzcgR2dGlkAw--/SIG=1louktoul/EXP=1233917591/**http:/uk.images.search.yahoo.com/images/view?back=http://uk.images.search.yahoo.com/search/images?ei=UTF-8&p=volkswagen logo&sado=1&rd=r1&SpellState=n-3027130588_q-xbukr9oWoMZvcEDqe4jtVwAAAA@@&fr2=tab-web&fr=yfp-t-501&w=250&h=250&imgurl=images.noticiasautomotivas.com.br/img/b/volkswagen-logo.jpg&rurl=http://www.noticiasautomotivas.com.br/volkswagen-linha-2009-semana-que-vem&size=24.8kB&name=volkswagen-logo.jpg&p=volkswagen+logo&type=JPG&oid=623d87d6225f0220&no=2&tt=23,069&sigr=12a30jre8&sigi=11r4pt5i5&sigb=15djlha9c

http://uk.wrs.yahoo.com/_ylt=A0WTf23J1IpJP8cAt7xNBQx.;_ylu=X3oDMTBqNzNhb3I1BHBvcwMyMQRzZWMDc3IEdnRpZAM-/SIG=1i93pm9bq/EXP=1233921609/**http:/uk.images.search.yahoo.com/images/view?back=http://uk.images.search.yahoo.com/search/images?p=suzuki+logo&js=1&ei=utf-8&y=Search&fr=yfp-t-501&xargs=0&pstart=1&b=19&ni=18&w=663&h=567&imgurl=www.istargazer.ca/suzuki/suzuki_logo1.jpg&rurl=http://www.istargazer.ca/suzuki&size=31.8kB&name=suzuki_logo1.jpg&p=suzuki+logo&type=JPG&oid=a78efd5db996beaa&no=21&tt=24,927&sigr=10vmtcv00&sigi=119e6r49j&sigb=13t6nkuol

http://www.fantom-xp.com/r/

http://uk.wrs.yahoo.com/_ylt=A0WTf2zDKotJvmUBp_FNBQx.;_ylu=X3oDMTBpdnJhMHUzBHBvcwMxBHNlYwNzcgR2dGlkAw--/SIG=1hfal5g21/EXP=1233943619/**http:/uk.images.search.yahoo.com/images/view?back=http://uk.images.search.yahoo.com/search/images?p=+chevrolet+logo&y=Search&fr=yfp-t-501&ei=utf-8&js=1&x=wrt&w=250&h=222&imgurl=www.all-chevy.com/Chevrolet Logo.jpg&rurl=http://www.all-chevy.com/Monte_Carlo.html&size=7.1kB&name=Chevrolet+Logo.jpg&p=chevrolet+logo&type=JPG&oid=39ac7e6ade9cdf00&no=1&tt=23,076&sigr=119ae4m6g&sigi=1166ocpqv&sigb=13bgvb1o4

http://uk.wrs.yahoo.com/_ylt=A0S0zvkT2fhKiBkBuatWBQx./SIG=12527eeat/EXP=1257908883/**http:/bentley.my-volkswagen.com/Bentley_logo.jpg

http://uk.wrs.yahoo.com/_ylt=A0WTf21orb1L_DcAACtWBQx./SIG=12gtt416k/EXP=1270808296/**http:/www.lamorocharepuestos.com.ar/images/logo_renault.jpg

http://uk.wrs.yahoo.com/_ylt=A0WTf223rb1LkE4AIqVWBQx./SIG=13f8mkhgg/EXP=1270808375/**http:/files.auto-top.eu/system_preview_detail_200003744-9501295fb5-public/porsche_logo.jpg

Dr K E Cooke TransFAIR 2013 – IMF, Gaydon

© Teer Coatings Ltd, 2013

TransFAIR 2013:

PVD Coatings for Hydrogen Economy Applications

Dr Kevin Cooke

R&D Technology Centre Manager

Teer Coatings Limited, Miba Coating Group



PVD Coatings for Hydrogen Economy Applications Introduction

• Motivation: Coatings for the Hydrogen Economy

• Miba Coating Group & Teer Coatings Limited

• The Magnetron Sputtering Process

• Industrial PVD Coating Technology

• Coatings for PEMFC Bipolar Plates

• Other potential applications:

Electrolysers: emissions reduction & fuel generation

• Towards Scale up

• Conclusions




“With a driving range and performance

comparable to ICEs, FCEVs are the lowest

carbon solution for medium/larger cars and

longer trips. These car segments account

for 50% of all cars and 75% of CO2

emissions, hence replacing one ICE with

one FCEV achieves a relatively high CO2

reduction.” McKinnsey & Co, Sept 2011

Motivation: the growing Importance of PEMFC for future FCEVs

“UK H2 Mobility: [UK] by 2030…annual

sales of more than 300,000” http://www.itm-

power.com/wp-content/uploads/2013/02/UK-

H2Mobility-Synopsis-of-Phase-1-Results-Feb-2013.pdf



Our Vision, Mission, Strategy and Goals

Miba 2015

Our Vision

No power train without Miba technology

Our Goals

Profitable core business growth. A new

business area provides the basis for at least

1 billion euros in sales.

Our Strategy

Global No. 1 in economically attractive and

technologically demanding market segments

Our Mission

Innovation in Motion - Miba technology

enables resource-efficient mobility

Our Values

Technological leadership

Life-long learning

Entrepreneurship

Passion for success

Technological Leadership

We develop superior technologies for the future.

Investments in R&D EUR 31 million

Research ratio 5% of sales

Employees in R&D

218

Patents

195 valid ones, thereof 20 new ones in 2011

Among Europeʼs Top 500 most research-oriented

companies

No. 6 of Austriaʼs

most research-oriented companies

Miba is driven by the Thirst for Knowledge and Dedication



Miba AG

______________________________________

Miba Sinter Austria GmbH

Vorchdorf, Austria ______________________________________

Miba Sinter Slovakia s.r.o.

Dolný Kubín, Slovakia ______________________________________

Miba Sinter USA LLC

McConnelsville, OH, USA ______________________________________

Miba Precision Components

(China) Co., Ltd.

Suzhou, China ______________________________________

Mahle Metal Leve Miba

Sinterizados Ltda. *

Indaiatuba, Brazil ______________________________________

Sintercom India Pvt. Ltd. *

Pune, India ______________________________________

Miba Deutschland GmbH

Fellbach/Wolfsburg, Germany ______________________________________

Miba France SARL

Meudon, France ______________________________________

Miba Italia s.r.l.

Mondovì, Italy ______________________________________

Miba Bearing Group ______________________________________

Miba Gleitlager GmbH

Laakirchen, Austria ______________________________________

Miba Bearings US LLC

McConnelsville, OH, USA ______________________________________

Miba Precision Components

(China) Co., Ltd.

Suzhou, China ______________________________________

Advanced Bearing Materials

LLC *

Greensburg, IN, USA ______________________________________

Miba Far East

Singapore ______________________________________

Miba Friction Group ______________________________________

Miba Frictec GmbH

Roitham, Austria ______________________________________

Miba Steeltec s.r.o.

Vráble, Slovakia ______________________________________

Miba HydraMechanica Corp.

Sterling Heights, MI, USA ______________________________________

Miba Drivetec India Pvt. Ltd.

Pune, India ______________________________________

Miba Deutschland

Schongau, Germany ______________________________________

New Technologies Group ______________________________________

Miba Automation Systems

GmbH

Laakirchen, Austria ______________________________________

EBG Elektronische

Bauelemente GmbH

Kirchbach, Austria ______________________________________

EBG Shenzhen Ltd. *

Shenzhen, China ______________________________________

DAU GmbH & Co KG

Ligist, Austria ______________________________________

DAU Thermal Solutions North

America Inc.

Macedon, NY, USA ______________________________________

EBG Resistors LLC *

Middletown, PA, USA ______________________________________

Miba Coating Group ______________________________________

High Tech Coatings GmbH *

Vorchdorf, Austria ______________________________________

Teer Coatings Ltd.

Droitwich, United Kingdom ______________________________________

Miba Coatings Trading

(Suzhou) Co., Ltd.

Suzhou, China ______________________________________

Miba Group 5 Core Segments

Production Site

Sales/Engineering Office

Miba Sinter Group

* All companies are 100% subsidiaries, except for High Tech

Coatings (50.1%), Advanced Bearing Materials (50%), Mahle

Metal Leve Miba Sinterizados (30%), EBG Resistors (70%),

EBG-Shenzhen (25%) and Sintercom India (26%).



Miba’s Global Network

20 Sites Worldwide

Sinter Group

Friction Group

New Technologies Group

Coating Group

Bearing Group



Now operating from three sites: Austria, UK & China

Miba Coating Group

Miba Coatings Trading

(Suzhou) Ltd.

Suzhou, China

Teer Coatings Limited

Droitwich, United Kingdom

High Tech Coatings GmbH

Vorchdorf, Austria

Polymer coatings

Electroplated overlays

PVD coatings

PVD coatings

PVD coating equipment

ISO9001:2008

TS16949

ISO9001:2008



Closed Field UnBalanced Magnetron

Sputter Ion Plating (CFUBMSIP)

Unbalanced field

Field lines “closed” with

another magnetron

Plasma confined around

substrates

Electrons and ion loss to

chamber walls minimised

Dense, adherent coatings

Ar

S

S

N

S

S

N

N S N

N S N

Sample Holder

Magnetron

Closed

Magnetic Field

Line



N

N

N

N

S

N N

N S S S

Front Elevation

Cross Section

B

B E

Position of Magnets

(behind target)

“Race Track”

(electron

confinement

in front of

target)

Target

Magnet Polarities

Electron

Electron/Plasma Confinement using

Magnets (Magnetrons)



Coatings for PEMFC Bipolar Plates Thin film Physical Vapour Deposited coatings are relevant

• PEMFC Bipolar Plates have multiple functions Electrical conductivity, flow field for gas distribution, water

clearance, structural stability, etc.

• Low interfacial contact resistance & high

corrosion resistance required

• Thin stainless steel foils (0.1mm or less) – save

weight & space (cf graphite) & economically

formed into channels, but relatively high ICR +

corrosion (= ICR↑ & risk of MEA poisoning)

• Coatings needed with low ICR & good stability

Noble metals, transition metal nitrides, carbon…



Coatings for PEMFC Bipolar Plates Importance of the BPPs

http://en.wikipedia.org/wiki/File:Fc

_diagram_pem.gif http://en.wikipedia.org/wiki/File:Pem.fuelcell2.gif

//upload.wikimedia.org/wikipedia/en/5/5c/Fc_diagram_pem.gif

//upload.wikimedia.org/wikipedia/commons/c/ce/Pem.fuelcell2.gif



Coatings for PEMFC Bipolar Plates

• In state-of-the-art PEMFC, ICR between the

materials contribute 55% of the total I2R losses,

dominating the ohmic loss contributions C.J. Netwall, et al, Journal of Power Sources 227, (2013) 137–144

• 10nm Au coating has been suggested to improve

ICR of stainless steel BPPs S. Hirano et al, Fuel Cell Seminar & Exposition October 18-21, 2010

• 100’s BPPs/stack, so 300,000 FCEVs/year could

need ~14kg of Au, even for 10nm coatings!

• Reducing Au required: Treadstone Technologies

nano-vias, covering only 1.1% of the surface area Stayapal et al, Flow Cell Workshop Washington, DC 3/7/2011

Why it has to be “nano”!



PVD Coatings for Hydrogen Economy Applications Chromium Nitride – CrN: Deposited by Reactive CFUBMSIP

Coating Characteristics

Thickness 2.5µm

Hardness 2,000 HV

Coefficient of friction 0.5

Properties

“Metallic” colour

Good oxidation resistance

Good performance in partially lubricated

contacts

Applications

F1 and high performance motorsport

Good adhesive wear properties vs non-

ferrous alloys

TEM cross section at

substrate interface

Ar

Cr

Cr

Cr

Cr

S

N

S

N S N

N S N

One axis Two axis

Three axis

S

N

S

N2



PVD Coatings for Hydrogen Economy Applications Graphit-iC™: Non-hydrogenated amorphous carbon coating

Metal doped carbon-based coating

Coating Characteristics

Thickness 2.5µm

Hardness 1,400 – 2,200 HV

Coefficient of friction 0.05 – 0.09

Properties

Very good in aqueous environments

High load bearing capacity

Applications

F1 and high performance motorsport

Fuel injection systems

Mechanical seals

Injection moulding tools

Ar

Cr

C

C

C

S

N

S

S

N

S

N S N

N S N

One axis Two axis

Three axis



PVD Coatings for Hydrogen Economy Applications Graphit-iC™: Non-hydrogenated amorphous carbon coating

1 to 3-nm sized graphite clusters in the

amorphous carbon

Yang et al, Surface and Coatings Technology,

142-144 (2001) 85-93

Wear testing, e.g.:

5mm Ø WC-8%Co

pin, 80N load,

200mms-1, 30mins

~10-17m3N-1m-1

Unlike a traditional “diamond like carbon”,

Graphit-iC™ is electrically conductive



PVD Coatings for Hydrogen Economy Applications Thin film coatings – benefits to interfacial contact resistance

111

16cm2 in area, total resistance

under a particular pressure;

usually 140Ncm-2

• Uncoated AISI316L plate : higher ICR value of ~900 mΩcm2;

• TiN coated plates : lower ICR value, in the range 80-170 mΩcm2 (as coated)

• C and Graphit-iC™ coatings : similar to 10 nm Au thin film, <10mΩcm2

• Duplex Graphit-iC™ FC2: low ICR & good corrosion resistance

[H. Sun et al, Thin Solid Films, 528 (2013) 199–204]

0.5µm FC2



PVD Coatings for Hydrogen Economy Applications Enhanced corrosion resistance

(H. Sun et al, Thin Solid Films, 528 (2013) 199–204)

• Thin (sub-micron)

duplex coatings,

such as Graphit-iC™

FC2, provide

enhanced corrosion

resistance.

• Potentiostatic

polarization

behaviour of coated

samples at 1 V/SHE

for 2 h in 0.5 M

H2SO4 at 70 °C.

0.5 µm FC2



PVD Coatings for Hydrogen Economy Applications Duplex nitride + carbon coatings for PEMFC BPPs

Carbon

Nitride

Stainless Steel

• PVD (CFUBMSIP)

produces smooth,

dense, highly adherent

layers with few defects.

• Duplex coatings such

as Graphit-iC™ FC2

combine the low ICR

and inertness of

carbon-based coatings

with corrosion

resistance and high

conductivity of

transition metal

nitrides.

• Image shows one

possible configuration

for illustration.

(H. Sun et al, Thin Solid Films, 528 (2013) 199–204)



Hydrogen via Electrolysis - Transport

• H2 from “on board” alkaline electrolyser (ITM Power)

• Improve combustion + exhaust after treatment: Emissions

• Powered by “waste” energy (e.g. regenerative braking)

• H2 optimises cold start (exhaust catalyst activation temp )

• H2 periodic injection to purge Lean NOx Trap (LNT)

On board alkaline electrolysis

http://www.itm-

power.com/wp-

content/uploads/2012/04/

CaseStudy5-

ImproveVehicleEmissions

.pdf



Hydrogen via Electrolysis - Transport

• Example: Walmart Balzac PDC, Fork Lifts

• H2 Fuel Cell technology (7 year forecast):

Operating Costs (cf batteries) $2.0M

GHG 530 tonnes of CO2 per year

Fuel generation via electrolysis

http://www.h2andyou.org/

pdf/walmart_forklifts.pdf

• H2 used in Balzac is

generated through

electrolysis, predominantly

hydro-electricity (Québec)

• H2 could also be generated

locally, from other renewable

sources (wind, solar, etc.)

• Future: H2 expected cost

competitive with diesel +

stable long term pricing!



E vs. Hg/HgO / V

-1.6 -1.4 -1.2 -1.0 -0.8 -0.6

j /

A c

m-2

-1.0

-0.8

-0.6

-0.4

-0.2

0.0

Ni

HSA Ni

NiAl

NiS

NiMo

(a)

PVD Coatings for Hydrogen Economy Applications Electrolysers – High Surface Area (HSA) coatings for increased activity

SEM image of PVD Hastelloy

(Ni~65%,Mo~29%)

[X.Zhang, presented at ICMCTF

2012, San Diego]

Steady state polarization curves for H2

evolution in 4 M NaOH at 333 K with a potential

sweep rate of 1 mV s-1

[D. Pletcher, X. Li & S. Wang, Int. J. Hydrogen

Energy 37 (2012) 7429–7435]

PVD conditions can be selected to produce dense, corrosion resistant interfaces

combined with high surface area electrode coatings for efficient electrolysis.



PVD Coatings for Hydrogen Economy Applications Towards scale up: from batch processing to serial production of coated plates

Coating equipment for different volume scenarios:

Equipment suitable for prototypes and lower volumes

Equipment for volumes up to 300k parts: In-line device with higher efficiency

compared to conventional batch equipment

~10 € m-2 both sides coated, fully utilized machine, for say 300,000 m2/year



PVD Coatings for Hydrogen Economy Applications In line, load-locked, semi-continuous processing concept




• PVD coatings are essential to protect and improve the

performance of multiple components vital to the Hydrogen

Economy.

• Stainless steel BPPs, e.g. for PEMFC, need lower ICR and

improved corrosion resistance.

• Economic “duplex” nano-structured coatings, such as

Graphit-iC™ FC2, can significantly reduce the ICR of

stainless steel PEMFC BPPs, and reduce corrosion.

• High Surface Area (HSA) coatings can enhance the H2

production rate from electrolysers and substitute for

expensive PGM catalysts..

• Industrial PVD technology will support pre-production batch

processing and future serial manufacturing requirements.

Summary & Conclusions




Thanks to colleagues at TCL, Droitwich:

• Hailin Sun

• Xiaoling Zhang

• Sue Field

• Joanne Hampshire

• Phil Hamilton

UK Technology Strategy Board & DECC support for:

• HydroGEN: Development of a Novel Low-Cost Alkaline

Hydrogen Electrolyser TSB File Ref 100590

• In Line Coating System Demonstration, TSB File Ref 100804

EPSRC/University of Birmingham:

• Phil Hamilton, Industrial CASE PhD

Acknowledgements



Acknowledgements


Contact:

[email protected]

+44(0)1905 827550

Thank you to the speakers

Thank you for attending

Please visit the exhibition

Don’t forget the “Land Rover” Experience

Have a look at the Heritage Museum

We look forward to seeing everybody tonight at the dinner or tomorrow at 9.00am

Documents

Transfair Presentation 4 ( 8MB)