Transfair Presentation 4 (pdf file 8MB)
Transcription
Transfair Presentation 4 (pdf file 8MB)
A future design classic – Bright Chrome Terry Clarke; MacDermid Inc Life Extension of tri-valent chromium passivation baths Ashish Kulkarni; Shree Rasayani Coffee and networking Bonded lubricating coatings Roy Harrison; Whitford Technologies Physical vapour deposition coatings Kevin Cooke; Miba Coating Group A Future “Design Classic” - Bright Chromium Alan Gardner 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 MacDermid: all rights reserved 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 MacDermid: all rights reserved 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 MacDermid: all rights reserved How far can Evolution go… • Surprisingly…providing the original concept and values are clearly reflected in the product, company or service we embrace changes MacDermid: all rights reserved 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 MacDermid: all rights reserved Sustaining Values … • How many here are truly Design Classics…. MacDermid: all rights reserved Why Bright Chromium is Iconic… • Iconic Designs – – – – – – – MacDermid: all rights reserved 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 MacDermid: all rights reserved Bright Chromium…Fashion • A true Design Classic is always in demand despite changes in fashion and trend… MacDermid: all rights reserved Bright Chromium…Innovation • A true Design Classic is always in demand even at the leading edge of innovation… MacDermid: all rights reserved Bright Chromium…Technology • A true Design Classic always delivers…even when designs and technologies change MacDermid: all rights reserved Bright Chromium…Enduring Value • A true Design Classic can continue to enhance value through many design generations MacDermid: all rights reserved Bright Chromium Technology Bright Chromium Advances… Hexavalent MacDermid: all rights reserved Deposition Modes Trivalent Bright Chromium Advances… • Latest generation trivalent chrome systems deliver the same unique metallic style but with added benefits: – – – – – MacDermid: all rights reserved 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 Bright Satin Dark • Colour evolutions open new markets and opportunities MacDermid: all rights reserved Bright Trivalent Systems … • 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 MacDermid: all rights reserved 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 MacDermid: all rights reserved 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) MacDermid: all rights reserved 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 MacDermid: all rights reserved Bright Chromium and Performance… • Trivalent Chromium is solving the problem of Russian Mud !!! A BIG issue in some countries during severe winters… MacDermid: all rights reserved 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” MacDermid: all rights reserved Bright Chromium…Automotive 100% of cars use Bright Chromium for plastic trim 2012 MacDermid: all rights reserved 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 Global Total = +60m units per year 2,900,000 12 BMW 1,800,000 13 Daimler AG 1,750,000 BUT…Design Classics have Limits !!! Noooooo !!! MacDermid: all rights reserved Thank You… For more information about our world of “Fashion Finishes” see our web site www.macdermid.com/industrial www.macdermid.com/autotype MacDermid: all rights reserved 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 Hours to white Rust Effect of zinc concentration on corrosion resistance 140 120 100 Fresh solution Zn 10 g/L 80 60 40 20 0 Co-free Co-based Schematic diagram of the purification system Acid Filter MEMBRANE Cr (III) passivation bath 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+ H+ Cr3+ Co2+ MEMBRANE H+ Zn2+ Fe2+ 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.) MEMBRANE Cr (III) solution Acid MEMBRANE For extra capacity, membranes can be arranged in parallel Comparison of transfer rates of Zn and Fe [Zn] [Fe] 10 1000 600 5 400 200 0 0 0 10 20 30 40 Time (Minutes) 50 60 [Fe] (ppm) [Zn] (g/L) 800 Influence of Acid strength on rejuvenation 120 Time (minutes) 100 80 60 40 20 0.0 0.5 1.0 1.5 2.0 2.5 3.0 Acid Strength (M) 3.5 4.0 4.5 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 4.0 3.5 [Zn] (g/L) 3.0 2.5 2.0 1.5 1.0 0.5 0.0 1 2 3 4 5 6 Day Membrane operated in dual mode from day 4 Incorporating Ceramic nano-particles Passivation Zinc Zn: 8 to 10 microns thick Mild Steel Aqueous suspension of ceramic particles (size 10-12 nm) added to the passivation Temp: 30 to 35 C pH: 2.0 to 2.8 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 450 400 350 Hours 300 250 200 150 100 50 0 Co-free Co-free with ceramics Co-based Co-based with ceramics Hours to White Rust Effect of application of Sealer: Observations by Tata Motors 500 450 400 350 300 250 200 150 100 50 0 15 ml 30 ml 60 ml 15 ml 30 ml 60 ml (Ac-Zn) (Ac-Zn) (Ac-Zn) (Alk-Zn) (Alk-Zn) (Alk-Zn) Ceramic Loading per Litre 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 • Almost 50 years in bonded lubricating and release Coatings • Worldwide manufacturing • Global technical support • Coatings used by almost every car maker • Knowledge of Tribology • Knowledge of Wear Mechanisms • Understanding of Friction • Philosophy of supporting innovation What is a Bonded Lubricating Coating? Contact surface Tailored formulations 2 4 5 3 1 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 Closure Seal Plastic Trim Glass Metal Appliq ué 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) 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 TransFAIR 2013: PVD Coatings for Hydrogen Economy Applications Dr Kevin Cooke R&D Technology Centre Manager Teer Coatings Limited, Miba Coating Group Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 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 Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications Motivation: the growing Importance of PEMFC for future FCEVs “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 “UK H2 Mobility: [UK] by 2030…annual sales of more than 300,000” http://www.itmpower.com/wp-content/uploads/2013/02/UKH2Mobility-Synopsis-of-Phase-1-Results-Feb-2013.pdf Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 Miba 2015 Our Vision, Mission, Strategy and Goals 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 Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 Technological Leadership Miba is driven by the Thirst for Knowledge and Dedication 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 Group 5 Core Segments Miba AG Miba Sinter Group Miba Bearing Group Miba Friction Group New Technologies Group Miba Coating Group ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ Miba Sinter Austria GmbH Vorchdorf, Austria Miba Gleitlager GmbH Laakirchen, Austria Miba Frictec GmbH Roitham, Austria High Tech Coatings GmbH * Vorchdorf, Austria ______________________________________ ______________________________________ ______________________________________ Miba Automation Systems GmbH Laakirchen, Austria Miba Sinter Slovakia s.r.o. Dolný Kubín, Slovakia Miba Bearings US LLC McConnelsville, OH, USA Miba Steeltec s.r.o. Vráble, Slovakia ______________________________________ ______________________________________ ______________________________________ Miba Sinter USA LLC McConnelsville, OH, USA Miba Precision Components (China) Co., Ltd. Suzhou, China Miba HydraMechanica Corp. Sterling Heights, MI, USA ______________________________________ Miba Precision Components (China) Co., Ltd. Suzhou, China ______________________________________ Mahle Metal Leve Miba Sinterizados Ltda. * Indaiatuba, Brazil ______________________________________ ______________________________________ Advanced Bearing Materials LLC * Greensburg, IN, USA ______________________________________ ______________________________________ Miba Drivetec India Pvt. Ltd. Pune, India ______________________________________ Miba Deutschland Schongau, Germany ______________________________________ Miba Far East Singapore ______________________________________ ______________________________________ EBG Shenzhen Ltd. * Shenzhen, China Teer Coatings Ltd. Droitwich, United Kingdom ______________________________________ Miba Coatings Trading (Suzhou) Co., Ltd. Suzhou, China ______________________________________ ______________________________________ DAU GmbH & Co KG Ligist, Austria ______________________________________ DAU Thermal Solutions North America Inc. Macedon, NY, USA EBG Resistors LLC * Middletown, PA, USA ______________________________________ ______________________________________ Miba Deutschland GmbH Fellbach/Wolfsburg, Germany Production Site ______________________________________ Sales/Engineering Office Miba France SARL Meudon, France * 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%). ______________________________________ Dr K______________________________________ E Cooke EBG Elektronische Bauelemente GmbH Kirchbach, Austria ______________________________________ ______________________________________ Sintercom India Pvt. Ltd. * Pune, India Miba Italia s.r.l. Mondovì, Italy ______________________________________ TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 20 Sites Worldwide Miba’s Global Network Sinter Group Bearing Group Friction Group New Technologies Group Coating Group Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 Miba Coating Group Now operating from three sites: Austria, UK & China High Tech Coatings GmbH Vorchdorf, Austria Teer Coatings Limited Droitwich, United Kingdom Polymer coatings Electroplated overlays PVD coatings PVD coatings PVD coating equipment ISO9001:2008 ISO9001:2008 TS16949 Miba Coatings Trading (Suzhou) Ltd. Suzhou, China Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 Closed Field UnBalanced Magnetron Sputter Ion Plating (CFUBMSIP) Closed Unbalanced field Magnetic Field Field lines “closed” with Line another magnetron Plasma confined around S substrates N Electrons and ion loss to S chamber walls minimised Dense, adherent coatings N TransFAIR 2013 – IMF, Gaydon N Ar S N S Sample Holder N Dr K E Cooke S S N Magnetron © Teer Coatings Ltd, 2013 Electron/Plasma Confinement using Magnets (Magnetrons) B N N Electron “Race Track” (electron confinement in front of target) S B E Target Position of Magnets (behind target) N N Dr K E Cooke N S S N N S Cross Section Magnet Polarities Front Elevation TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 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… Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 Coatings for PEMFC Bipolar Plates Importance of the BPPs http://en.wikipedia.org/wiki/File:Pem.fuelcell2.gif Dr K E Cooke TransFAIR 2013 – IMF, Gaydon http://en.wikipedia.org/wiki/File:Fc _diagram_pem.gif © Teer Coatings Ltd, 2013 Coatings for PEMFC Bipolar Plates Why it has to be “nano”! • 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 Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 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 TEM cross section at substrate interface Ar Cr Good oxidation resistance Good performance in partially lubricated contacts One axis Applications F1 and high performance motorsport Cr N S N N2 Two axis S S N N S S Cr Good adhesive wear properties vs nonferrous alloys N S N Three axis Cr Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 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 One axis Applications F1 and high performance motorsport Fuel injection systems Ar C Cr N S N Two axis S S N N S S C Mechanical seals Injection moulding tools Dr K E Cooke TransFAIR 2013 – IMF, Gaydon N S N Three axis C © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications Graphit-iC™: Non-hydrogenated amorphous carbon coating Wear testing, e.g.: 5mm Ø WC-8%Co pin, 80N load, 200mms-1, 30mins ~10-17m3N-1m-1 1 to 3-nm sized graphite clusters in the amorphous carbon Yang et al, Surface and Coatings Technology, 142-144 (2001) 85-93 Unlike a traditional “diamond like carbon”, Graphit-iC™ is electrically conductive Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications Thin film coatings – benefits to interfacial contact resistance 16cm2 in area, total resistance under a particular pressure; usually 140Ncm-2 • • • • 0.5µm FC2 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] Dr K E Cooke TransFAIR 2013 – IMF, Gaydon 111 © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications Enhanced corrosion resistance • Thin (sub-micron) duplex coatings, such as Graphit-iC™ FC2, provide enhanced corrosion resistance. 0.5 µm FC2 • Potentiostatic polarization behaviour of coated samples at 1 V/SHE for 2 h in 0.5 M H2SO4 at 70 °C. (H. Sun et al, Thin Solid Films, 528 (2013) 199–204) Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications Duplex nitride + carbon coatings for PEMFC BPPs • 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. Carbon Nitride Stainless Steel (H. Sun et al, Thin Solid Films, 528 (2013) 199–204) Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 Hydrogen via Electrolysis - Transport On board alkaline electrolysis • • • • • 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) http://www.itmpower.com/wpcontent/uploads/2012/04/ CaseStudy5ImproveVehicleEmissions .pdf Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 Hydrogen via Electrolysis - Transport Fuel generation via electrolysis • 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 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! Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications Electrolysers – High Surface Area (HSA) coatings for increased activity 0 .0 (a) j / A cm -2 -0 .2 -0 .4 Ni HSA Ni N iA l N iS N iM o -0 .6 -0 .8 -1 .0 -1 .6 -1 .4 -1 .2 -1 .0 -0 .8 -0 .6 E v s . H g /H g O / V 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. Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 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 Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications In line, load-locked, semi-continuous processing concept Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications Summary & Conclusions • 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. Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications Acknowledgements 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 Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 PVD Coatings for Hydrogen Economy Applications Acknowledgements Contact: [email protected] +44(0)1905 827550 Dr K E Cooke TransFAIR 2013 – IMF, Gaydon © Teer Coatings Ltd, 2013 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
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