2015.04 - IBC Capabilities Overview
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IBC Group provides various surface treatment and coating services including thin film coatings, nitriding, laser cladding, plasma electrolytic oxidation, heat treating, and thermal diffusion surface treatments. They have large equipment capable of treating components up to 100 inches in diameter. Some of their main coating types include diamond-like carbon coatings, ion plasma nitriding/nitrocarburizing, salt bath nitriding, CeraTough plasma electrolytic oxidation coatings, and thermal diffusion coatings like boriding, chrome carbide, and aluminizing. IBC serves industries such as aerospace, defense, oil and gas, automotive, and others.
2015.04 - IBC Capabilities Overview
- 1. Materials and Technologies IBC Group | 902 Hendricks Drive, Lebanon, IN 46052 | www.ibccoatings.com Capabilities Overview April 2014
- 2. Materials and Technologies2 Welcome to IBC
- 3. 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
- 4. 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
- 5. Materials and Technologies 5 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.
- 6. 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
- 7. 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
- 8. Materials and Technologies Examples of DLC Coated Components 8 Filters for Plastic Recycling Gears CrankshaftsHydraulic Components Hydraulic Rods for Mining Equipment Forming Rolls
- 9. Materials and Technologies 9 • 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
- 10. 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 paper industry • 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
- 11. Materials and Technologies Plasma Nitriding of Crankshafts for 6-Cylinder Engines
- 12. Materials and Technologies • An innovative Green Technology for cost-efficient production of gears and other transmission parts Plasma Nitriding of Gears
- 13. 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 microhardness ranging 1000-1400 HV 13
- 14. Materials and Technologies 0 50 100 150 200 250 1 Untreated Hardened H13 24 hrs LTPN Molten Salt Nitrided Weight Loss after 0.5 hr. mg. S-Phase (LTPN) Treatment of 17- 4 PH Steel 14
- 15. Materials and Technologies 15 • 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
- 16. 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 Microhardness,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 HV300 24 Hours 6 Hours 12 Hours 36 Hours Die Material: FX-2
- 17. 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
- 18. 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
- 19. 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
- 20. 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
- 21. 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
- 22. Materials and Technologies Taber Test Results Show 5X Less Wear Compared to Anodizing Hard Anodized 355 Alloy CeraTough™ Coated 355 Alloy
- 23. 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
- 24. 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
- 25. Materials and Technologies Vanadium Carbide TD Coating
- 26. 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
- 27. Materials and Technologies Deep Case Boriding 27 Niresist M4 Tool Steel420 Stainless Steel 8620 Steel4140 Steel 1045 Steel
- 28. 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
- 29. 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
- 30. Materials and Technologies Boriding Corrosion Resistance Data taken from ASM Handbook Volume 4
- 31. 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
- 32. 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
- 33. 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
- 34. 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
- 35. Materials and Technologies HVAF Coating of 20,000 LB Turbine Rotor 35
- 36. Materials and Technologies Tungsten Carbide HVAF Coating of Elbows 36
- 37. Materials and Technologies Tungsten Carbide HVAF Coating of a Cyclone 37
- 38. Materials and Technologies • Porosity: < 1% • No unmelted particles or inclusions • Very uniform thickness Microstructure of Tungsten Carbide HVAF WC-10Co-4Cr Coating
- 39. Materials and Technologies Thermal Spray (HVAF) Microhardness Distribution
- 40. Materials and Technologies Bond Strength – HVAF on 4130 Steel Requirement: Above 10,153 PSI – Glue Failure # Tensile Strength, PSI Failure mode 1 10557 Glue 2 8857 Glue 3 9244 Glue 4 10287 Glue 5 10874 Glue
- 41. Materials and Technologies Mechanical Integrity of HVAF Coating: 90 O Bend Test
- 42. 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
- 43. Materials and Technologies CLADDING WEAR SLEEVE • 1ST Layer • 2ND Layer
- 44. Materials and Technologies IBC LASER CLAD WC – NiCrBSi MATRIX • WC hardness 1913 HV – 3900 HV • Matrix average hardness 40 HRC 44
- 45. 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
- 46. 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