IBC Capabilities Overview

03.2020

ISO9001:2015 Registered by EAGLE Registrations Inc. IBC Coatings Technologies | 902 Hendricks Drive, Lebanon, IN 46052 | www.ibccoatings.com This page may contain ITAR restricted data IBC Coatings Presentation rev:01 IBC’s Background

• Privately-owned surface engineering company • Aerospace, • Established in 1996 and located in Lebanon, Indiana • Oil and Gas, • Automotive, • 90+ employees and 100,000+ sq. feet • Metal Forming, • Development of surface treatments to improve wear, corrosion, fatigue • Die Casting, and lubricity properties • Forging, • and many more • Industrial-scale application of PVD, CVD, TD, and other coating processes IBC Provides The Following Services

• Thin Film Coating • Plasma Electrolytic treatments and – CeraTough-D™ Diamond Like Carbon (DLC) coatings coatings – PEO – plasma electrolytic coatings of Al, Mg, Ti – High Energy PVD coatings (TiN, TiALN, CRN, alloys CRC, TIC, VC, Al O , SiO , ZrO , SiN) – PED – plasma electrolytic diffusion coatings 2 3 2 2 – PEP- plasma electrolytic polishing • • – Ion Plasma Nitriding (DHIN) – Vacuum Heat Treat with up to 12 Bar Gas Quench – Ion Plasma Ferritic Nitrocarburizing (DH-FNC) – Vacuum – Post-DHIN and FNC Oxidation (equivalent to – Solution Nitriding Plasox) • Thermal Diffusion Surface treatments – Salt Bath Nitriding (DHN) (equivalent to QPQ, – (DHB) Melonite, Tufftride, etc.) – Tantalizing (DHTa) • Laser Cladding – Chromizing (DHC) – Aluminizing (DHA) • Micro-laser welding and repair – Vanadium Carbide (TDH) • CVD Coatings • Electro-spark deposition – Amorphous Chrome Carbide • HVOF/HVAF Coating Services

3 IBC Equipment Size Capabilities

• Ion Plasma Nitriding & FNC with post oxidation (Dia 60” • CeraTough™ Ceramic Diffusion Wear Coatings for lightweight ” alloys including Al, Ti, and Mg can fit component up to 48” x 83 tall) x48”x 120 “ and 2,000 LB weight limit. • S-phase Ion Plasma Carburizing, Nitrocarburizing, • Vacuum Heat Treatment with up to 12 Bar Gas Quench Nitriding (Dia 60” x 83” tall) (24”x24”x36”) and 1,200 LB weight limit in a load. ” ” ” • Plasma-assisted DLC coatings with the ability to deposit • Vacuum Carburizing and (24 x24 x36 ) thick 20-40-micron layers for components that can fit • Salt Bath and Gas Nitriding & Nitrocarburizing (Dia 40”x60” into Dia 60” x 83” tall, and up to 18,000 LB weight tall) capacity. • Thermal Spray (Plasma, HVOF, HVAF, Cold Spray) • High Energy PVD coatings system can deposit on – WC-Cr-Co components that can fit into Dia 48”x 48” tall chamber – CRC-NiCr with 5,000 LB weight limit. – Inconel 718, 625, Stelite, etc. • Thermal Diffusion coatings can be done for components • Laser Cladding – parts up to 5,000LB and 48” OD by that can fit Dia 100”x 120” tall chamber with 10,000 LB 120” long weight limit.

4 PVD Coating

5 RF & Magnetron Sputtering PVD

Designation Composition CeraTough-0601 DLC CeraTough-0603 Si-DLC CeraTough-0604 W-DLC CeraTough-0605 WC-DLC CeraTough-0606 Cr-DLC

CeraTough-0607 Ti-MoS2

• Hybrid Radio-Frequency and Magnetron Sputtering PVD (MSPVD) • Chamber supports 30” diameter, 40” height, and up to 3000 lbs • Multi-axis table rotation for uniform coatings on complex shapes • Ultra-low process temperature (<200°C) • Can apply coatings to almost any material, including polymers IBC’s PACVD Systems

Designation Composition DHIN Nitriding CeraTough-0701 Si-DLC (thin) CeraTough-0702 Si-DLC (thick) CeraTough-0710 Rainbow DLC Si-DLC for CeraTough-D-F food contact

• Plasma Assisted Chemical Vapor Deposition (PACVD) • Multiple furnaces with different dimensions to support a wide range of load sizes • Largest chamber supports 60” diameter, 83” height, and up to 18,000 lbs • Non-line-of-sight deposition • Low process temperature (<500°C) • Can apply Duplex Nitriding and DLC in one process DLC Coatings

• 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

tetrahedral amorphous carbon DLC coatings can have different Methods of DLC structures and properties that • Cathodic arc rely on the ratio of SP3 • Magnetron Sputtering (diamond) and SP2 (carbon) or other fillers like hydrogen, • Electron Beam Evaporation silicon, and metal in the layer. • PACVD • CVD

8 PVD/CVD Self-Lubricating Coatings

Hardness Thickness Designation Composition Dry CoF Uncoated (HV) (µm) CeraTough-0601 DLC 2500 0.1 2-4 CeraTough-0603 Si-DLC 2000 0.05 2-4 CeraTough-0604 W-DLC 1200 0.09 1 CeraTough-0605 WC-DLC 1600 0.1 1 CeraTough-0606 Cr-DLC 2000 0.1 2-4

CeraTough-0607 Ti-MoS2 700 0.04 1 CeraTough-0701 Si-DLC 1300 0.05 3-5 DLC-coated Steel CeraTough-0702 Si-DLC 1300 0.05 15-20 CeraTough-0710 Rainbow DLC 2500 0.05 0.5 CeraTough-D-F Si-DLC 1300 0.05 3-5

Bare experience rapid and severe galling in dry or poorly lubricated conditions. Self-lubricating DLC and Ti-MoS2 coatings prevent galling or fretting and maintain a smooth, clean interface. DLC Development C-130 Flight Actuator Program

Mean and Std Dev, Top Performing Coating Systems (>100,000 cycles) vs Baseline, 609 ksi, Test Freq. 33Hz 180000

160000

140000

120000

100000 5-8X Increase 80000

60000

40000

20000

0 1 2 3 4 5 6 7 8 9 Dry DLC Coatings Outperform Lubricated Baseline Corrosion Resistance of CeraTough-D TM (DLC) Coatings

Outstanding corrosion resistance of CeraTough-D TM (DLC) Coatings

13-8PH Stainless H1085

336hrs ASTM G85 Annex 4 B 117

11 Examples of DLC Coated Components

Filters for Plastic Recycling

Gears

Forming Rolls

Hydraulic Rods for Mining Equipment

Hydraulic Components Crankshafts

12 Cathodic Arc PVD

Designation Composition CeraTough-0101 TiAlCN CeraTough-0102 TiAlN CeraTough-0103 TiAlN/TiSiN CeraTough-0104 TiAlSiN CeraTough-0105 TiAlVN CeraTough-0106 TiCN CeraTough-0107 TiN CeraTough-0108 TiSiVN CeraTough-0201 AlCrN • Proprietary High Energy Cathodic Arc PVD (CAPVD) CeraTough-0202 AlCrTiSiN • Dual-chamber machine for high throughput • Each chamber supports 40” diameter, 45” height, CeraTough-0203 AlCrVN and up to 3000 lbs CeraTough-0301 ZrN • Multi-axis table rotation for uniform coatings on CeraTough-0401 VCN complex shapes CeraTough-0402 VTiSiCN • Low process temperature (<400°C) CeraTough-0501 CrCN • Nanostructured monolayers, multilayers, and duplex coatings can all be applied CeraTough-0502 CrN PVD Tribological Examples - No Lubrication

Wear and Coefficient of Friction Testing: ASTM G133 (Ball on Flat), No lubrication Parameters: 5 N load, 10 mm length, 5 Hz reciprocating, 1000 sec Ball Materials: 10 mm diameter 52100 steel and 6061 aluminum

Hardness Against 52100 Against 6061 Al Designation Composition (HV) COF Wear Rate COF Wear Rate Uncoated D2 Steel 650 0.55 42 0.59 232

Uncoated H13 Steel 500 0.76 64 0.41 117

Uncoated 8620 Carb. 700 0.75 70 0.55 150

CeraTough-0107 TiN 2500 0.50 7.7 0.43 4.0

CeraTough-0201 AlCrN 3000 0.52 4.9 0.42 4.6

CeraTough-0401 VCN 3500 0.49 2.9 0.46 4.9

Note: wear rates are in units of (mm3/Nm) x 10-7 PVD Tribological Examples - Poor Lubrication

Wear and Coefficient of Friction Testing: ASTM G133 (Ball on Flat), Poorly lubricated (1 drop of mineral oil) Parameters: 20 N load, 10 mm length, 10 Hz reciprocating, 1000 sec Ball Material: 10 mm diameter 52100 steel Designation Composition COF Wear Rate (mm3/Nm) x 10-7 Uncoated D2 Steel 0.1-0.2 (unstable) Not measurable (heavy galling) CeraTough-0401 VCN 0.09 0.19

Uncoated D2 VCN Coating

The wear track on uncoated D2 is much wider and obscured by galling, compared to the minor polishing wear of the VCN coating. PVD Erosion Resistance

IBC can apply hard, low-stress PVD multilayers up to 40 µm thick for superior erosion resistance. Examples are shown below for VAlCrSiN multilayers with a Test conditions hardness of 2000-2500 HV: Substrate: AM350 stainless steel Duration: 180 min. at max. power + 60 min. at approx. 65 % of max. power Abrasive: 120 µm sand Total amount: 1.3 lbs. Ingestion rate: 0.08-0.4 lb./min.

Calotest crater of a 39 µm VAlCrSiN coating on Waspaloy Turbine blades coated by IBC

ASTM C1624 scratch testing shows an excellent critical adhesion load of 135 N.

Parameters: ΔF=100-200 N, Δt = 60 s, 10 mm length Ion Plasma Nitriding/ Nitrocarburizing

• 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

17 PLASNIT® Pump Components

• 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!

18 Plasma Nitriding of Crankshafts for 6-Cylinder Engines

19 Plasma Nitriding of Gears

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

20 Bearings after Ion Plasma Nitriding

21 Salt Bath Nitrocarburizing DHQN – QPQTM, MELONITETM, TENNIFERTM, TUFFTRIDETM

• DHNQ is a thermochemical quench-polish-quench ferritic nitrocarburizing process to harden, strengthen, and improve the corrosion resistance of the surface of metal components. H 13 SS 304 • The DHN treatment is carried out at 1000 - 1100 Nitro-Carburized o Nitro-carburized F for between two and Layer eight hours layer

• The diffusion layer thickness is 0.001”- 0.015”

• Microhardness is between 600-1300 HV

M 2 FX-2

22 Typical Hardness after DHQN Processing

MATERIAL SURFACE HV1KG SURFACE HV10KG CORE HV1KG 1018 mild steel 400 300 200 4140 alloy steel 800 650 350 416 stainless steel 1000 600 300 H13 tool steel 1200 750 500

23 Microhardness Distribution After Salt Bath Nitriding

Die Material: H13 1500 1400 1300 1200 1100 1000 900 800 700

Microhardness, HV (100) 600 500 Die Material: FX-2 0 0.002 0.004 0.006 0.008 0.01 800 Distance from the surface, Inch Series1 Series2 Series3 Series4 750 700

650 24 Hours 6 Hours 600 12 Hours

HV 300 550 36 Hours 500 450 400 0 0.005 0.01 0.015 0.02 0.025 0.03 Distance from the surface, Inch

24 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

Ball valves during S-Phase treatment

25 S-Phase (LTPN) Treatment of 17- 4 PH Steel

mg. Weight Loss after 0.5 hr. 250 Untreated

200

150 Molten Salt Nitrided 100

Hardened 50 H13 24 hrs LTPN 0 1 26 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

27 TD Coatings Can Be Applied Two Different Ways

• Hot Process (TDH) • Cold Process (TDC) – Metallurgical bond ensures – No distortion, tight better adhesion tolerances maintained – Uniform VC thickness in deep – Unlimited number of re- holes coatings – Hardens most substrates – Diffusion bond insures during coating superior strength – 1750 to 1900 °F deposition – 600 to 840 °F deposition temperature temperature – Nanostructure on coating – Nanostructure on coating provides unmatched wear provides unmatched wear performance performance

28 Vanadium Carbide TD Coating

29 DIFFUSION BORIDING

• Diffusion treatment that produces hard coatings with outstanding resistance to erosion, cavitation, abrasion, and corrosion • Most , 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

30 Deep Case Boriding

Niresist 4140 Steel 8620 Steel

1045 Steel 420 Stainless Steel M4 Tool Steel

31 Boriding of 8620 components

32 Microhardness Distribution in Borided Layers

2000

1800 Supplied Sample 1600 1045 Coated atIBC

1400 4140 Coated at IBC

1200 8620 Coated at IBC

1000 M4 Coated at IBC HV 420 SS Coated at IBC 800

600

400

200

0 0 100 200 300 400 500 600 700 Depth (um)

33 Erosion Test Comparison of Boriding and Stellite 12

BORONIZED PLATE AFTER 5 MINUTES OF GRIT BLAST AT 90 PSI (1.00” form target) – NO WEAR

Grit: size 20 - 30 STELLITE 12 AFTER 5 MINUTES OF GRIT BLAST AT 90 PSI (1.00” form target)

34 Boriding Corrosion Resistance

Data taken from ASM Handbook Volume 4

35 Borided Components

Plungers Inserts

36 Diffusion Chrome Carbide Coatings on Different Materials

• Diffusion Chrome and Chrome Carbide Coatings are widely used by IBC customers for pumps, valves, and other components to Niresist H-13 Tool Steel improve corrosion, wear, and cavitation resistance in the oil, food, aircraft, and other industries • High hardness (800-2000 HV) and low coefficient of friction

420 Stainless Steel Impeller

37 Corrosion Testing in 10 % H2SO4

NiResist +CrC Before Immersion NiResist +CrC After Immersion 377 min

10% H2SO4 Sample 416 Uncoated 416 Boride NiResist Uncoated NiResist CrC Surface Area (mm2): 1074 1074 448 1004 Immersion Time (min) Mass (g) Mass (g) Mass (g) Mass (g) 0 20.7591 20.8216 10.7517 17.0522 35 20.6910 20.8173 10.7516 17.0517 97 20.4144 20.8146 10.7512 17.0523* 377 19.6957 20.8090 10.7504 17.0517

Corrosion Rate (g/mm2*min): 2.63E-06 3.11E-08 7.70E-09 1.32E-09 Corrosion Rate (g/cm2*y): 1.38E+02 1.64E+00 4.05E-01 6.94E-02 Corrosion Rate (mil/y): 6.79E-01 8.05E-03 1.99E-03 3.42E-04 Corrosion Testing in 10 % HCL

NiResist +CrC Before Immersion NiResist +CrC After Immersion 377 min

10% HCl Sample 416 Uncoated 416 Boride NiResist Uncoated NiResist CrC Surface Area (mm2): 1074 1074 448 1004 Immersion Time (min) Mass (g) Mass (g) Mass (g) Mass (g) 0 20.7816 20.8048 11.2884 14.4332 35 20.7383 20.7989 11.2879 14.4330 97 20.6934 20.7950 11.2876 14.4330 377 19.3833 20.7773 11.2853 14.4329

Corrosion Rate (g/mm2*min): 3.45E-06 6.79E-08 1.84E-08 7.93E-10 Corrosion Rate (g/cm2*y): 1.82E+02 3.57E+00 9.65E-01 4.17E-02 Corrosion Rate (mil/y): 8.93E-01 1.76E-02 4.75E-03 2.05E-04 Corrosion Testing Results

416 SS 416 +Boride NiResist NiResist +CrC

Prior to Immersion:

10% HCl (377 min):

10% H2SO4 (377 min): Tantalum Diffusion Coating

Tantalum Corrosion Resistance Properties Exposed to 10% Acetic Acid at 450 °F • Superb corrosion resistance Material Corrosion Rate (mpy) • Non-line-of-sight process Ti 6-4 2.2 • High bond strength 316L 242 • Uniform, pore-free structure Ta-Surface Alloyed 316L 0 • Impervious to chemical attack below 302 °F Exposed to 10% HCl, 10% Acetic Acid, 15 PSIA H2S at 450 °F • Vulnerable only to hydrofluoric acid, acidic solutions containing Material Corrosion Rate (mpy) the fluoride ion, and free sulfur Ti 6-4 >41,341 trioxide 316L >36,517 • High strength and ductility Ta-Surface Alloyed 316L 0 • Thickness up to 0.002” Data taken from Stainless Steel World

41 Aluminizing

Properties • Corrosion resistance in extreme, high temperature environments • Protects steel from attack by Aluminized H2S, SO2, and SO3 Layer • Can be applied to steels, Inconel 718 stainless steels, and nickel Substrate alloys • Case depths up to 0.015” • Oxidation and Carburization resistance

42 CVD Amorphous CrC - In Development

• Low temperature process (<400°C)

• Non line-of-sight process

• High corrosion and wear resistance

• Coating thickness from 1-50+μm

Hardness: 1400-2500 Vickers 43μm of CrC coating on A286 SS CVD Amorphous CrC - Uniformity on Complex Geometry

CrC layer on the flank of a thread CrC layer near the base of a thread

7500x SEM images of a CrC coated fastener thread. The layer is about 2 um on the flank, and about 1.5 um at the base. a-CrC Corrosion Resistance

8μm of CrC on A286 showed no evidence of corrosion after 423 hours of ASTM G85, Annex 4 (SO2 salt spray)

0 hours testing 423 hours testing a-CrC Corrosion Resistance HCl Immersion Corrosion

Immersion corrosion testing per ASTM G31 None of the coated fasteners showed signs of corrosion after 30 minutes. The images below show results after 18 hrs.

8740 Steel Fastener Weight Loss After HCl (15%) Submersion Weight Loss (mg) Sample 30 min 18 hrs

Uncoated 2.5 44.0

DLC (8 µm) 0 16.9

a-CrC (2 µm) 0 1.4

a-CrC (2 µm) + 0 0 Uncoated: dark DLC (8 µm): 5-10% a-CrC (2 µm): No visible a-CrC+ DLC: No visible DLC (8 µm) corroded surface surface pitting pits, low mass loss pits, no mass loss CeraTough™ Plasma Electrolytic Oxidation

• A new nano-structured ceramic surface treatment for Al, Ti, Mg, and other alloys Inside a PEO cell • 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 CeraTough™- • High corrosion resistance coated piston • CeraTough™ is a Green Technology – no hazardous waste streams

48 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

49 How are CeraTough™ Coatings Used?

• Advanced protection against wear, fretting, and galling • Extreme protection against corrosion and chemical attack CeraTough™ Base Metal – • State-of-the-art thermal barrier coatings with Al2O3 Coating Aluminum Alloy 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

50 ASTM B117 Corrosion Test Results: CeraTough™ vs. Hard Anodizing

CCorrosionorrosion Pi ttiPitting:ng - # o fNumber pits after Bof11 7Pits sal tAfter spray 13441344 h oHoursurs of B117 Salt Spray

32.50

16.25

0

CCeraTough™eratough-Al -Al HHardard An odize Anodizing

51 CeraTough™ Wear Test Results

M50 vs. CeraTough™

CeraTough™ Coatings CeraTough™ exhibits provide 10X wear virtually no fretting & galling improvement over lubricated against M50 4340 steel M50 vs 4340

Test Method: M50 ellipsoid against test specimens, with oil 4340 exhibits substantial fretting Baseline: 4340 steel & galling against M50 Samples: Ceramic Aluminum-Oxide (Al2O3) coated F357 Aluminum

52 Taber Test Results Show 5X Less Wear Compared to Anodizing

Hard Anodized 355 Alloy CeraTough™ Coated 355 Alloy

53 SH13000 PEO Coated Impellers

54 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

55 CLADDING WEAR SLEEVE

• 1ST Layer

• 2ND Layer

56 IBC LASER CLAD WC – NiCrBSi MATRIX

• WC hardness 1913 HV – 3900 HV • Matrix average hardness 40 HRC

57 Examples of Laser cladding repairs

Laser cladded turbo shaft Laser cladded cam lobs

58 Performance of Laser cladded agricultural components

• Standard components after two weeks

• Laser cladded components after two weeks with no wear signs

59 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

60 Contact Information

• Phone: (765) 482-9802 • President/CEO: Solomon Berman – [email protected] • Vice President: Ashok Ramaswamy – [email protected] • Address: 825 Hendricks Drive Lebanon, IN 46052

61