Ceramic coating for engines suits UAV use
Ceramic coating developed for Formula 1 and other motorsport engines, is also specified for the rotary engines in most of the world’s Unmanned Air Vehicles.
Apticote Ceramic 2000, the Poeton coating developed for Formula 1 and other motorsport engines and used by the winner of the 2004 European Kart Championship, is also specified for the rotary engines in most of the world’s Unmanned Air Vehicles (UAVs). The UK has a significant technology lead in this expanding market, which is estimated to be worth around GBP 2 Billion a year, with an annual growth rate of 12.5%. The UAV’s obvious benefits include no pilot so no risk to human life; no constraints on size or design; light weight; and continuous operation for more than one hundred hours.
Besides their military applications, UAVs are also used for civil projects such as agriculture, police surveillance, border control, and traffic and weather monitoring.
One of the world’s leading suppliers of power units for these craft is UAV Engines (UEL), which manufactures a range of lightweight rotary engines covering 20 to 120BHP (15 to 90kW).
Due to the unique, patented air-cooled rotor design, rotary engines have an exceptionally high power to weight ratio that makes them more compact, helps reduce mechanical friction and lowers fuel consumption.
Apticote Ceramic 2000 - a metal matrix coating system specifically developed for high performance automotive engine applications - is used to add high wear resistance and low friction properties to the trochoidal bores of the rotary engine housings.
A plasma sprayed coating of Apticote 800 is also applied to reduce wear in the engine seal tracks.
Poeton is also undertaking research and development work on coatings for other engine components.
Commenting for UEL a spokesman says they actively use Poeton coating expertise to improve engine operating characteristics under extreme climatic conditions, adding: ‘This work has successfully resulted in the introduction of a number of product enhancements with additional improvements nearing the end of the development phase.’ On the choice of coating he says its engineers are convinced that Apticote Ceramic 2000 makes a significant contribution to the performance of the engines, which have successfully passed a 150-hour severe duty FAR 33-type ground durability test, setting new standards for small ultra-lightweight unmanned aircraft engines.
Looking to the future, Poeton R and D director Keith Stevens says that to keep pace with future development UAV engines, guidance systems and other components will need a whole range of engineering coatings that can be applied to enhance the performance of light weight alloys of aluminium, magnesium and titanium.
High performance coatings replace ‘exotic’ metals
Coatings that are based on semi-crystalline thermoplastics, and provide high temperature, wear, corrosion and abrasion resistance, can replace hard to machine ‘exotic’ metals.
Victrex announced that it has licensed a worldwide network of electrostatic spray and dispersion coating formulators with a patented base recipe and unique powders to produce both powder and aqueous-based coatings made from VICTREX PEEK polymer. The formulators can modify the polyaryletherketone-based recipe to enhance specific properties such as abrasion resistance, lubricity, release and color. Each formulator offers the necessary processing and customer service support, technical literature and pricing of the VICTREX PEEK-based coatings.
The coatings are based on semi-crystalline VICTREX PEEK thermoplastics, which is widely regarded as having the best combination of properties for harsh environments.
These include: high temperature resistance and the retention of mechanical performance at high temperature; outstanding wear and abrasion resistance; chemical resistance; excellent fire, smoke and toxicity performance and good electrical properties.
According to Annette Forster, New Market Development Manager for Victrex, ‘When a thin layer of VICTREX PEEK-based coating is applied to a substrate, it confers all the performance properties associated with our high performance polymers.’ VICTREX PEEK-based coatings can provide substantial benefits over existing coatings as well as eliminate the need for costly, hard-to-machine exotic metals such as stainless steel or titanium.
Powders are formulated to produce durable, impact resistant pin-hole-free coatings from 15-20 mils using conventional equipment.
Forster said that ‘VICTREX PEEK-based coatings are under evaluation in analytical, semiconductor, and medical applications because they provide a lubricious, non-sloughing, and tough protective layer over metals, ceramics, and glass’.
‘They are also being evaluated in the food industry because of their FDA compliance and their superior chemical resistance to harsh cleaning fluids.’ VICTREX PEEK-based coatings are also ideal for coating components and substrates in industries that demand corrosion protection and wear resistance.
‘For parts such as agitators and vessels, coating for corrosion protection in aggressive environments may be the only cost-effective answer,’ said Forster.
VICTREX PEEK-based coatings are also a solution for components in ultra-pure water systems, chemical plants, and offshore oil installations.
Coatings are applied by spraying VICTREX PEEK-based powder with an average particle size of between 30 and 80 micron.
After application of the powder, parts are heated in an oven to around 752 deg F (400 deg C) at which point the powder melts to form a continuous film.
Air cooling of the liquefied film then causes it to solidify again.
This process is repeated to build up the required coating thickness on a variety of substrates including stainless steel and aluminum.
Victrex, is the sole manufacturer and supplier of Victrex polymer worldwide.
Spray-on chrome finish has wider usage
Conventional electroplated chrome can only be applied onto a limited range of plastics substrates, but now there is a process for spraying a finish that looks and feels like electroplated chrome.
Since expanding into new premises in 2004, Applied Coating technologies has continued to develop its finishing capabilities to meet customer expectations for a one-stop finishing source. Already supplying many industries with a wide range of high quality decorative finishes to plastics mouldings, requests were often received from existing customers for a ‘chrome’ paint finish. A chrome finish is usually applied using conventional electroplating techniques and offers a bright, mirror finish.
It is specified on a variety of everyday products, such as shower handsets and car door handles.
However, conventional electroplated chrome can only be applied onto a limited range of plastics substrates, such as ABS.
There are also constraints in terms of the size and geometry of parts that can be processed.
‘Applichrome’ is a process for spraying a finish that looks and feels just like electroplated chrome.
It is a process that has been developed in the USA and is being introduced in the UK by Applied Coating Technologies (ACT).
The finish can be applied onto virtually any plastics or metal substrate.
ACT is currently developing the process further to coat wood, ceramic and glass substrates.
The Applichrome process involves the following key steps: 1.
Application of an adhesion promoting primer.
Various primers have been developed and now even adhesion to difficult substrates such as polypropylene can be achieved.
2.
Application of bright metallic chrome finish.
Since the coating is applied by spraying, selective areas can be coated.
3.
Application of 2-pack polyurethane clear lacquer.
The lacquers provide chemical and wear resistance.
An added benefit is that the lacquer reduces finger marking, which can be a problem on conventionally plated parts.
The Applichrome process is carried out at low temperatures, typically below 60 deg C, so even thin wall plastics substrates can be coated.
The Applichrome process is not meant to be a direct replacement for conventional chrome electroplating and would generally be more expensive when compared to electroplated chrome.
However, it fills the niche requirement for chrome, where electroplating is not an option.
The process is current being evaluated on a number of projects in various industries, these include: * Interior and exterior automotive components.
* Domestic appliances.
* Bar top displays.
The development of the Applichrome process at ACT was in response to customer requirements for a one-stop shop finishing service.
The core business of ACT is EMI shielding coatings and decorative finishing of plastics mouldings.
Licence given to produce coatings
Victrex plc has announced that it has licensed Armourcote in the UK for the use of Victrex PEEK based dispersions to produce aqueous-based dispersions made from Victrex PEEK polymer.
Victrex has licensed Armourcote in the UK for the use of Victrex PEEK based dispersions which have a patented base recipe and are formulated with powders to produce aqueous-based dispersions made from Victrex PEEK polymer. Armourcote a major UK based coating company can modify the Polyarletheretherketone-based recipe to enhance specific properties such as abrasion resistance, lubricity, release and color. Armourcote offers the necessary customer and technical service support for the new Victrex PEEK-based coatings to ensure that the right coating system is specified.
Armourcote have many years experience of tailoring coatings for specific applications in all market segments and with the new Victrex PEEK dispersions can now offer solutions to coatings that are specified in the most demanding environments.
The coatings are based on semi-crystalline Victrex PEEK thermoplastic which is widely regarded as having the best combination of properties for harsh environments.
These include: high temperature resistance, the retention of mechanical performance at high temperature; outstanding wear and abrasion; chemical resistance; excellent fire, smoke, toxicity performance and good electrical properties.
According to Annette Forster, Market Development Manager for Victrex, ‘When a thin layer of Victrex PEEK-based coating is applied to a substrate, it confers all the performance properties associated with our high performance polymers.’ Victrex PEEK-based dispersion coatings can provide substantial benefits over existing coatings as well as eliminate the need for costly, hard-to-machine exotic metals like stainless steel or titanium.
Dispersions are formulated to produce durable, impact resistant pin hole free coatings from <25 microns - 100 microns using conventional equipment.
Cycle times are potentially reduced as Victrex PEEK dispersions can offer a one coat system where multiple coats of other less wear resistant systems may be required.
Forster said that: ‘Victrex PEEK-based coatings are under evaluation in analytical, semiconductor, and medical applications because they provide a lubricious, non-sloughing, and tough protective layer over metals, ceramics, and glass’.
‘They are also being evaluated in the food industry because of their FDA compliance and their superior chemical resistance to harsh cleaning fluids.’ Victrex PEEK-based dispersion coatings are also ideal for coating components and substrates in industries that demand corrosion protection and wear resistance.
‘For parts such as agitators and vessels, coating for corrosion protection in aggressive environments may be the only cost-effective answer,’ said Forster.
VictrexPEEK-based dispersion coatings are also a solution for components in ultra-pure water systems, chemical plants, and offshore oil installations.
Coatings are applied by spraying Victrex PEEK-based dispersions with an average particle size of between 10 and 25 micron.
After application of the powder, parts are heated in an oven to around 400 deg C at which point the powder melts to form a continuous film.
Air cooling of the liquefied film then causes it to solidify again.
This process can be repeated to build up the required coating thickness on a variety of substrates including stainless steel and aluminum.
Licence issued to produce special coatings
Victrex has licensed a worldwide network of electrostatic spray and dispersion coating formulators with a patented base recipe and unique powders to produce both powder and aqueous-based coatings.
Victrex announced that it has licensed a worldwide network of electrostatic spray and dispersion coating formulators with a patented base recipe and unique powders to produce both powder and aqueous-based coatings made from Victrex PEEK polymer. The formulators can modify the polyarletheretherketone-based recipe to enhance specific properties such as abrasion resistance, lubricity, release and color. Each formulator offers the necessary processing and customer service support, technical literature and pricing of the Victrex PEEK-based coatings.
The coatings are based on semi-crystalline Victrex PEEK thermoplastic which is widely regarded as having the best combination of properties for harsh environments.
These include: high temperature resistance and the retention of mechanical performance at high temperature; outstanding wear and abrasion; chemical resistance; excellent fire, smoke and toxicity performance and good electrical properties.
According to Annette Forster, New Market Development Manager for Victrex, ‘When a thin layer of Victrex PEEK-based coating is applied to a substrate, it confers all the performance properties associated with our high performance polymers.’ Victrex PEEK-based coatings can provide substantial benefits over existing coatings as well as eliminate the need for costly, hard-to-machine exotic metals like stainless steel or titanium.
Powders are formulated to produce durable, impact resistant pin hole free coatings from 15 - 25 mils using conventional equipment.
Forster said that ‘Victrex PEEK-based coatings are under evaluation in analytical, semiconductor, and medical applications because they provide a lubricious, non-sloughing, and tough protective layer over metals, ceramics, and glass’.
‘They are also being evaluated in the food industry because of their FDA Food Contact compliance and their superior chemical resistance to harsh cleaning fluids.’ Victrex PEEK-based coatings are also ideal for coating components and substrates in industries that demand corrosion protection and wear resistance.
‘For parts such as agitators and vessels, coating for corrosion protection in aggressive environments may be the only cost-effective answer,’ said Forster.
Victrex PEEK-based coatings are also a solution for components in ultra-pure water systems, chemical plants, and offshore oil installations.
Coatings are applied by spraying Victrex PEEK-based powder with an average particle size of between 30 and 80 micron.
After application of the powder, parts are heated in an oven to around 400 deg C at which point the powder melts to form a continuous film.
Air cooling of the liquefied film then causes it to solidify again.
This process is repeated to build up the required coating thickness on a variety of substrates including stainless steel and aluminum.
Website devoted to wear-resistant coatings
Offering much more information and more user-friendly than its predecessor, a Website shows how coatings can help to improve tool life, quality and improve process reliability.
The launch of the new website from Balzers brings with it many advantages and benefits to users of the company’s hard, wear resistant coatings. The redesigned site has much more information and more user-friendly than it predecessor. Among the new developments are links to Balzers Coating Guides, which offers an on-line source of relevant information to assist in the correct selection of coatings for specific applications.
Detailed information on applications suitable for Balzers’ wide range of Balinit coatings.
Specific examples of how coatings can help to improve tool-life, quality and improve process reliability are available on the site.
Further links give details of individual industry sectors, such as automotive, medical, aerospace, and food and pharmaceutical processing which can all benefit from the application of Balzers’ physical vapour deposition (PVD) coatings.
Resins help eliminate paint for furniture makers
A family of widely used conductive resins grades originally developed for European automotive manufacturers, are becoming equally successful in a new industry - office furniture.
GE’s Noryl GTX resins, a family of widely used conductive grades originally developed for European automotive manufacturers, are becoming equally successful in a new industry - office furniture. Specifically, Noryl GTX conductive resin is being used in powder-coated moulded plastics furniture, providing a host of design, aesthetic, environmental, and cost benefits compared to moulded-in colour, wet-painted parts, and even powder-coated metal. Among these are greater design freedom that helps enable part consolidation, lower weight than metal, and the elimination of paint solvents that can negatively impact the environment.
The two key properties required for successful powder coating are conductivity and high heat performance, both of which are features of Noryl GTX resins - a blend of polyamide (PA) reinforced with modified polyphenylene ether (MPPE) polymer technology.
In the powder coating process, a fine, dry electrically charged powder is sprayed on the plastics part surface, which holds an opposite charge.
The attraction between the charged powder and part results in an even coating.
The coated part is then cured at a high temperature to create a durable finish.
* finishing process that supports the environment - one of the most valuable benefits of GE’s Noryl GTX resin for powder-coating applications is that it helps eliminate conventional wet-paint systems, which typically have a high solvent content.
The powder-coating paint system contains no solvents that can cause harmful volatile organic compounds (VOCs) to be released into the environment.
Noryl GTX resin may also reduce costs by eliminating secondary operations, such as applying a conductive primer to non-conductive plastics parts.
Furthermore, companies can potentially avoid capital costs for VOC recovery systems which may be required with solvent-based paint systems.
* Greater design freedom - another important advantage from using powder-coated plastics for furniture is design flexibility that far surpasses that of metal.
Used for furniture components, GE’s Noryl GTX resins can be moulded into unique shapes that are highly conductive, providing exceptional coating adherence.
The powder coating process also yields exceptional colour depth, quality, and richness for a competitive differentiation.
Finally, plastics parts can now be powder-coated in the same process and with the same colour as metal parts for improved aesthetics avoiding the colour mismatch often seen between powder-coated metal and injection-moulded plastics.
‘Our customers are achieving great results by using Noryl GTX resins to elevate utilitarian office furniture into beautiful designs,’ said Kristi Dolan, product market leader, Noryl resin, Europe, GE Advanced Materials.
‘This versatile resin helps designers to achieve the same finish as on metal parts, but with the design freedom that plastics has to offer.’ * High Performance - GE’s Noryl GTX resins offer a number of outstanding performance characteristics, including high-temperature resistance that enables it to withstand the curing process, which requires temperatures from 180 deg C-200 deg C.
They also exhibit excellent chemical and impact resistance.
In addition to office furniture such as chairs and cabinets, applications for Noryl GTX conductive resins include lighting fixtures, appliances, and parts for vehicles including motorcycles and scooters.
Their use continues to expand in the global automotive industry, as well.
Modular car roof has high-gloss film, not paint
To achieve exceptional aesthetics and durability, a film rather than paint, was selected to help avoid harmful volatile organic compound emissions, associated with conventional paint.
When the new 2005 Opel Zafira compact van arrives in showrooms this summer, customers will be dazzled by the high gloss and rich color of its unique roof. To achieve exceptional aesthetics and durability, Opel selected GE’s Lexan SLX film for this complex part as a superior alternative to a traditional painted component. As part of GE’s ecomagination initiative to help customers solve tough environmental challenges, Lexan SLX film could help avoid harmful volatile organic compound (VOC) emissions, associated with conventional paint, to lessen the impact on the environment.
‘To make the Zafira roof design concept a reality, while helping to reduce VOCs for environmental compliance, we needed a fresh, new approach, and Lexan SLX film delivered,’ said Hans-Dieter Langer, exterior director, Plastics Engineering at Opel.
‘We are delighted with its many advantages over conventional painting, including an exceptional gloss level that matches the overall look of the roof’.
‘The Zafira is Opel’s first experience with this GE technology and we are confident that customers will be impressed with the look and performance of this roof module solution.’ Paint avoidance for VOC reduction - the Zafira roof module, which is developed and manufactured by Webasto AG, is back-molded using a polyurethane LFI substrate and pre-formed Lexan SLX film.
The multi-layer structure is infused with pigment, avoiding the requirement for priming or painting.
In comparison with a traditional painted system, which OPEL decided against, Lexan SLX film can help reduce VOC emissions.
VOCs, which have been shown to have a negative impact on air quality, are strictly regulated in Germany where Opel is headquartered.
In addition to helping reduce VOCs, replacing painted exterior components with lighter weight Lexan SLX film could potentially result in the production of more fuel-efficient vehicles.
As an example, body panels made of GE Advanced Materials resin, including Lexan SLX films, could be up to 40% lighter, compared to similar components made from painted metal.
Another potential benefit is water conservation from the elimination of waterborne paints.
High performance and eye-catching appearance - coupled with its potential environmental benefits, Lexan SLX film provides outstanding performance in demanding automotive applications.
It is exceptionally weatherable with good scratch and chemical resistance, extremely strong, and tested to withstand prolonged outdoor exposure.
But what customers will notice is the high-gloss finish and rich color.
For the roof module, with its extensive use of glass insets, Opel wanted a finish that would be highly polished.
With a gloss rating of 110 - far exceeding that of painted steel, for example - Lexan SLX film gives paint a run for its money.
‘As a centerpiece of the GE ecomagination initiative, Lexan SLX film can offer tremendous potential to manufacturers who are looking for a new solution to boost environmental compliance,’ said Kurt Schuering, executive director, GE Advanced Materials, Automotive.
‘We have worked closely with Opel and Webasto to validate the performance of this unique technology’.
‘A solution like Lexan SLX film not only addresses environmental challenges but also delivers top performance and shows that GE innovation is stronger than ever - and growing.’ GE offers other innovative materials with paint avoidance potential, including Xenoy, Geloy, and Valox resins that can be used in place of conventional paint systems.
* About GE Advanced Materials - GE Advanced Materials is a world leader in providing high-technology material solutions.
Headquartered in Pittsfield, Massachusetts, USA, its businesses include plastics, Ssilicones, quartz, automotive, specialty film and sheet, polymershapes, and sealants and adhesives.
GE (NYSE: GE) is Imagination at Work - a diversified technology, media and financial services company focused on solving some of the world’s toughest problems.
With products and services ranging from aircraft engines, power generation, water processing and security technology to medical imaging, business and consumer financing, media content and advanced materials, GE serves customers in more than 100 countries and employs more than 300,000 people worldwide.
For more information, visit the company’s Web site.
* About Opel - since its inception in 1862, Opel has set out to make technology affordable and widely available to a large segment of society.
This vision has remained constant from its roots and today remains at the heart of all automotive product development.
In 2004, some 1.6 million Opel and Vauxhall cars, commercial vehicles, and component sets were produced in nine production and assembly operations in six countries in Western and Central Europe.
Opel has a strong brand profile which rests on these three cornerstones: * Versatility and interior flexibility.
* Driving dynamics.
* Contemporary, distinctive design.
In Europe, Opel is investing EUR 10 billion in the period 2002 through 2006 for a new model offensive.
GM Europe Engineering with its headquarters in Ruesselsheim, OPELs International Technical Development Center, has the responsibility for the global compact car development as well as for global midsize car development within the entire GM corporation.
The new GME Design Center will also be located in Russelsheim and demonstrates the clear long-term vision for a successful design and development base
New finishing option is for hand tools
Manufacturers of hand tools have discovered a new option for black oxide finishing - low temperature black oxide - for an attractive, high quality, black finish.
Manufacturers of hand tools have discovered a new option for black oxide finishing - Tru Temp low temperature black oxide - for an attractive, high quality, black finish that provides long term corrosion protection. The Tru Temp finish protects tool surfaces of all types, including wrenches, sockets, pliers, screwdrivers, chisels, etc. with a non-dimensional deposit that does not interfere with the function of the tool.
The process provides branded hand tools with a deep black, protective finish that resists rust and also displays well in retail packaging.
The Tru Temp finish has already proven itself on high value tooling and machine components such as cutting tools, gears and power drive components, and meets military specifications MIL-DTL-13924 and AMS 2485.
Now this high level finish is available for consumer hand tools and is safe and economical to operate.
In contrast to other finishing methods, the Tru Temp process takes just 25 minutes of processing time with a chemical cost of only $0.01-0.02 per pound of finished work.
Small parts can be processed in bulk loads, larger parts in baskets or on racks.
Most existing tank lines can be retrofitted at low cost to accommodate the process, or new tank lines are available from Birchwood Casey in all sizes.
Because the Tru Temp process contains no EPA regulated chemicals, there is usually no need for waste treatment equipment.
In most sewer districts the rinse waters are considered sewerable as non-hazardous effluent.
This feature simplifies the installation and minimizes the capital investment needed to set up the process line.
Since the Tru Temp process operates at only 200F, it avoids the severe splattering and boilover hazards often seen with conventional hot oxide tanks.
The relatively mild solutions used in the process line also prevent the formation of red coatings and white salt leaching that often plague ordinary black oxide finishes.
Birchwood Casey offers sample part processing at No Charge.
TRU TEMP may be ordered online for immediate shipment
Paint/powder coating ovens monitored efficiently
A simple to use oven monitoring system offers temperature profiling and quality control for measuring that the paint and powder coating process is efficient and correct.
The new Grant oven monitoring system offers a complete solution to temperature profiling and quality control in the coatings industry! The new Grant OMK610 oven monitoring system is a simple to use, affordable and flexible solution for measuring that the paint and powder coating process is efficient and correct. Designed to accurately record the oven temperature profile with the same ease and speed of the original Grant paper recorder, the new OMK610 system sets new standards in temperature profiling. At the heart of the system is a new small compact 6 channel data logger that can be used with or without a PC.
It couldn’t be simpler to set-up and use; just power up the logger, connect the temperature probes, place in the thermal barrier and pass through the conveyor oven, making it very easy for production personnel to set-up without ever connecting to a PC.
Not only is it simple to set-up from the front panel but results can be printed immediately the data logger exits the oven giving an instant record for Quality Control purposes.
Just connect the data logger to a USB printer, press the print button and get an immediate report showing cure times, batch details and the actual temperature profile as a graph.
Once the report is printed the logger is ready to go through the oven again to monitor the next batch of products.
No need to download or clear the data.
The logger has enough memory to be passed through the process up to 8 times before needing to have its memory cleared from the front panel or be downloaded to a PC.
If more detailed analysis is needed then the data logger can be downloaded to a PC using the PaintView software, which has been designed specifically for the paint and finishing industries.
PaintView provides quick detailed analysis with user defined templates and reports along with an automatic cure calculation based on paint manufacturers specified cure temperature times.
This makes it easy for the user to make a rapid pass/fail decision on each batch of products for quality control purposes and produce reports for compliance and traceability.
Alternatively data can be exported into Excel or other third party quality control or analysis software.
Other key features include intelligent triggering ensuring only valid data is collected, a unique universal temperature probe that can measure both surface and air temperature and different definable temperature reading rates of up to 8 readings per second to suit different ovens and processes.
This flexibility allows the OMK610 monitoring systems to not only monitor the efficiency of the coating cure process but also to optimise the oven settings for maximum productivity, energy conservation and reduced costs.
The OMK610 comes as a complete kit comprising data logger, a small compact and light thermal barrier, temperature probes, transport case, software and USB cable.