Keronite Surface Treatment for Light Alloys ASETS2009 Conference

Denver 2 Sep 2009 Steve Hutchins

What is Keronite?
An advanced surface treatment for aluminium, magnesium and other light alloys A patented process based on a technology known as Plasma Electrolytic Oxidation (PEO) Plasma process converts light alloy surface into a hard layer of protective ceramics A family of coatings Opens up new applications for light alloys A clean technology
WearResistant ExtremelyHard ChemicalResistance ElectricalResistance ThermalBarrier SuperbAdhesion CleanTechnology

The Keronite Process

Keronite uses a plasma discharge to convert the substrate surface into complex ceramics
The part is introduced into the tank and connected to the power supply

Power Supply
Recirculating Electrolyte Power Signal

A plasma discharge forms, creating very high energy conditions localised in a thin surface layer. Key process characteristics Oxidation of the substrate Elementary co-deposition from the electrolyte Fusing of the layer via plasma discharges
Pump Air

Heat Exchanger

Keronite Properties

SUPERB

X
ADHESION

Clean Technology

Hardness

Up to 2,000 HV on aluminium Up to 700 HV on magnesium

Comparative hardness (HV)

KERONITE on Aluminium Hard Chrome Hardened Tool Steel Hard Anodized Aluminium 304 Stainless Steel M ild Steel Aluminium 0 500 1000 1500 2000 2500

Hardness

Keronite coating on 7075

Hardcoat anodising on 7075

Wear rates ASTM G65

Volumetric wear rate (mm3 / km)

150 Steady State Over 1000 revs 100

50

0
Nitrided steel Uncoated 2xxx alloy Uncoated 5xxx alloy

Keronite coated 2xxx alloy

Keronite coated 5xxx alloy

Source: ABB, Cambridge University and Southampton University, poster presented at Materials Congress 2006.

Ford Cyclic Corrosion Testing on Mg

Diecast Mg AM60 test plates, 30 day cyclic testing Keronite

Cr6 + powder Keronite + ecoat

Keronite meets or exceeds the requirements of AMS 2466 Hard Anodic Coatings for Magnesium Alloys

Galvanic corrosion protection

Mg plate + stainless steel screw

Mg plate + anodised Al screw

Galvanic corrosion after just 7 hours in salt fog

Mg plate + zinc plated steel screw Mg plate + Keronite on Al screw

Confidential

Flexibility

100m detached Keronite

film showing ability to be bent or flattened elastically In more severe deformation, both plastic and elastic deformation occurs before failure

1cm
Courtesy of Cambridge University

Flexibility gives the coating resilience against small impacts or deformation of the substrate. Avoids cracking and delamination in-service

High Dielectric Strength Coatings

Power electronics cooling devices.

Breakdown voltage (max unsealed) Alloy 6xxx 5xxx LM24 99.9Al V 1500 2500 540 560

Thickness um 50 80 8-20 15

AA6xxx

Average voltage breakdown figures 3000V has been achieved when sealed. Thin layers give low thermal barrier

Composite coatings

500 nm

Nanometre-scale porosity facilitates impregnation

Polymers : Paints, lacquers, PTFE, E-coats, powder coats, organic-non organic polymers Metals : Ni, Cu (electroless), PVD, CVD Ceramics: PVD, CVD

Sharp edges and corners

Keronite on Ti-6-4

Courtesy: University of Bologna

Keronite on Ti - friction

Cylinder-onflat disc dry sliding wear 5-20N load 40mm steel cylinder plasma sprayed with Al2O3 + TiO2 of 1180 HV 0.6m/s Sliding distance 5000m

Courtesy: University of Bologna

Keronite on Ti - Wear

>10x more wear resistant than Ti Type 2 anodising according to AMS2488 Anti-fretting gimbal bearings on satellites

Courtesy: University of Bologna

Applications

Marinized aluminium components

Keronite

Trilobit 2 seismic node, at 4000m deep seabed operated by ROV

Courtesy: Carrack Measurement Technology and CGGVeritas

Aluminium sprockets

Harder than sand, Keronite enables the replacement of steel with aluminium and 66% weight savings, with superior performance Extract from distributor website: these ceramic coated alloy rear sprockets will outlast ordinary alloy Harderthan sand Weightsaving by 300%, AND sprockets RedesignedfromSteeltoAl increase the performance life of your Improvedinservice CleanTechnology chain too.

Aluminium print rollers

Hard chrome replacement Faithfully follows gravure pattern on surface Improved wear resistance and corrosion resistance No galvanic action Harderthansand between Weightsaving coating and RedesignedfromSteeltoAl roller
Improvedinserviceperformance CleanTechnology

Ball valves

Keronite gives the advantages of a ceramic finish for the cost of an aluminium component fuel line ball valves Provides excellent wear protection against PTFE seals, ingrained dirt etc

Black aluminium coating

Keronite Black Al coating demonstrates resistance to the extremes of temperature found in space Thermal emissivity approx 0.84 Absorption coefficient approx 0.90-0.95 over optical and near IR range. Corrosion resistance allows use of highstrength alloys Fully UV stable

Thank you

For more information please contact:

Bill Buchman Keronite Inc Greenwood IN bill.buchman@keronite.com Tel 586 677 2443