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IBC Capabilities Overview 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 • Nitriding • Heat treating – Ion Plasma Nitriding (DHIN) – Vacuum Heat Treat with up to 12 Bar Gas Quench – Ion Plasma Ferritic Nitrocarburizing (DH-FNC) – Vacuum Carburizing – Post-DHIN and FNC Oxidation (equivalent to – Solution Nitriding Plasox) • Thermal Diffusion Surface treatments – Salt Bath Nitriding (DHN) (equivalent to QPQ, – Boriding (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 Carbonitriding (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 Steel (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 steels 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
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