Transfair Presentation 4 (pdf file 8MB)

Transcription

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
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
How far can Evolution go…
• Surprisingly…providing the original concept
and values are clearly reflected in the product,
company or service we embrace changes
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
Sustaining Values …
• How many here are truly Design Classics….
Why Bright Chromium is Iconic…
• Iconic Designs
–
–
–
–
–
–
–
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
Bright Chromium…Fashion
• A true Design Classic is always in demand
despite changes in fashion and trend…
Bright Chromium…Innovation
• A true Design Classic is always in demand
even at the leading edge of innovation…
Bright Chromium…Technology
• A true Design Classic always delivers…even
when designs and technologies change
Bright Chromium…Enduring Value
• A true Design Classic can continue to enhance
value through many design generations
Bright Chromium Technology
Bright Chromium Advances…
Hexavalent
Deposition Modes
Trivalent
Bright Chromium Advances…
• Latest generation trivalent chrome systems
deliver the same unique metallic style but with
added benefits:
–
–
–
–
–
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
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
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
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)
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
Bright Chromium and Performance…
• Trivalent Chromium is
solving the problem of
Russian Mud !!! A BIG
issue in some countries
during severe winters…
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”
Bright Chromium…Automotive
100% of cars use Bright Chromium for plastic trim
2012
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 !!!
Thank You…
For more information about our world of
“Fashion Finishes”
see our web site
www.macdermid.com/industrial
www.macdermid.com/autotype
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
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
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
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
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
______________________________________
20 Sites Worldwide
Miba’s Global Network
Sinter Group
Bearing Group
Friction Group
New Technologies Group
Coating Group
Dr K E Cooke
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
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
N
Ar
S
N
S
Sample Holder
N
Dr K E Cooke
S
S
N
Magnetron
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
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
Importance of the BPPs
http://en.wikipedia.org/wiki/File:Pem.fuelcell2.gif
Dr K E Cooke
http://en.wikipedia.org/wiki/File:Fc
_diagram_pem.gif
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
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
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
N S N
Three axis
C
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
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
111
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
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
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
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
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
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
In line, load-locked, semi-continuous processing concept
Dr K E Cooke
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
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
Acknowledgements
Contact:
[email protected]
+44(0)1905 827550
Dr K E Cooke






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

Transfair Presentation 4 (pdf file 8MB)

Transcription

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