DURNI-COAT Industrial Coatings for Metals and Plastics

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1 DURNI-COAT Industrial Coatings for Metals and Plastics DURNI-COAT High wear resistance Good dimensional accuracy Outstanding hardness Excellent corrosion resistance Uniform layer formation Electrical conductivity Good chemical resistance Optimum anti-friction properties 1

2 Industrial Coatings for Metals and Plastics Electroless Nickel-Plating What is DURNI-COAT? DURNI-COAT, also known as DNC, is a surface treatment that is tuned to material and their processing and application. The main purpose of the DNC surface treatment is to provide machine components in all sectors of industry with protection against wear and corrosion, while at the same time fulfilling other application demands. How are DURNI-COAT layers built-up? The electroless deposition of DURNI-COAT layers is based on a reduction into metallic nickel of the nickel ions present in the aqueous process solution. The chemical reacting agents and formulators of the electrons required in this process are the hypophosphite ions in the solution. These agents transform themselves, by oxidation in the course of the reaction, into orthophosphite and are also responsible for the phosphorus content of the deposited DURNI-COAT layers. The electroless nickel-plating is carried out at our facilities according to DIN EN ISO (All technical values published in this brochure are subject to the test conditions specified. We therefore emphasise that the applications and operating conditions, along with the end user s practical experience, will ultimately determine the level of performance achieved by the coating and/or coating system) 2

3 Advantages of DURNI-COAT layers compared to electroplated layers: The surfaces of complex shaped components are treated true to their original contours; Sharp edges and impressions, accessible cavities and bores are coated uniformly. The uniform DURNI-COAT layer can be built up with close tolerances. Normal tolerances are ±10 % of the specified surface thickness, with a minimum of ±3 µm. Automatic plant for Electroless Nickel Plating, operating the DURNI-COAT process Control box with fully automatic control system and visualization This cross-section illustrates the uniform DURNI-COAT -deposit on an M4 thread like a snow layer on the mountains. 3

4 Industrial Coatings for Metals and Plastics Electroless Nickel-Plating Suitable materials for treatment with DURNI-COAT The range of base materials suitable for treatment with DURNI-COAT includes most of the metals destined for industrial use (and plastics): all types of low-alloy ferritic steel cast iron-based materials stainless steel non-ferrous metals such as copper, brass and bronze aluminium alloys die-cast zinc titanium materials magnesium alloys sintered metal materials LCP other metal and ceramic-based materials (depending on previously-supplied sample coatings) General coating characteristics DURNI-COAT finishes are highly suited to applications involving special uses: excellent corrosion resistance resistant to erosion and cavitation high wear resistance elongation at break up to 2% uniform layer formation good dimensional stability outstanding hardness Chemical composition and structure DURNI-COAT layers are nickelphosphorous alloy layers. The composition of the electrolyte and the processing conditions are used to control the phosphorus content of the DURNI-COAT layers. This content can be varied between 3 and 14 %. Phosphorus concentration is an important factor for many functional properties and Layer thickness recommendations magnetic properties suitable for contact functions and soldering surface conductivity optimum anti-friction properties good chemical resistance can be fine-tuned here to suit cases of special use. DURNI-COAT layers as-plated are normally X-ray amorphous. Heat treatment brings about re-crystallisation with the formation of nickel phosphides. Electrical and magnetic characteristics, and other mechanical and chemical properties, can be altered in this way. The following DIN EN ISO 4527 standard layer thicknesses can be used as a reference with respect to wear and corrosion loads: mild loads 5 to 10 µm (wear load) 2 to 10 µm (corrosion load) moderate loads: 10 to 25 µm severe loads: 25 to 50 µm very severe loads: > 50 µm When DURNI-COAT is applied to make surfaces suitable for soldering, a thickness of 2 to 5 µm is sufficient. When selecting a variant from the DURNI-COAT range and when deciding on the thickness of the finish the following factors should be taken into account: corrosion conditions, type and quality of the base material and its surface, the tribo-system and the required service life of the component. 4

5 Cover picture: Pump for the pumping of aggressive water. The valve housing, electroless nickel plated with the lead-free process DURNI-COAT 471 can be seen in the front left. Components with surface finishing using the DURNI-COAT process Components with surface finishing using the DURNI-COAT process This automatic switch-over valve for gas bottles (designed for medical use) has been electroless nickel-plated using the DURNI-COAT process DURNI-COAT surface-treated aluminium screw conveyors DURNI-COAT protected diode components for use in vehicle electronic systems DURNI-COAT treated tennis racket mould 5

6 Industrial Coatings for Metals and Plastics Electroless Nickel-Plating Fields of use DURNI-COAT surface finishing is an industrial coating for different components in many sectors of industry: aircraft manufacture chemical industry communications technology defence technology domestic appliances electronics/electrical engineering energy and reactor technology food processing industry hydraulic and pneumatic industry measurement and control technology mechanical engineering in general mining office and data technology pharmaceutical and medical device manufacturing printing machinery construction railway technology the automotive sector textile machinery construction valves and fittings Low tension lighting system with DNC-coated steel, aluminium and brass components Spindles for screwdriving systems with DNC-coated aluminium components 6

7 DURNI-COAT electroless nickel plated coax valve e.g. for the hydraulic and pneumatic component industry DNC-coated components of a concentric slave cylinder for a commercial vehicle clutch system Space craft seat for manned space travel, four of the 90MnV8 guide beads are nickel-plated using the DURNI-COAT process Clamping system made of aluminium for a 3D measuring machine, with 25 µm DURNI-COAT 7

8 Industrial Coatings for Metals and Plastics Process Variants DURNI-COAT DNC 450 and 471 (lead-free) DNC 450: especially ductile and corrosion resistant Layer characteristics (DNC 450): phosphorus content: % elongation at break: % (foils, dome method) abrasion: 35 mg, Taber-Abraser test with CS 10 wheel after 1,000 revolutions hardness: approx. 570 HV 0.05 more than 300 hours resistance according to DIN EN ISO 9227* (acetic acid salt-spray test) Kesternich test, resistance according to DIN *: > 3 cycles SFW 2.0 Typical applications (DNC 450): components used in sewage disposal technology drive units filter housings guide bushes hydraulic systems for mines printing press cylinders reactor construction structural parts subject to vibration valves DNC 471: lead-free, especially ductile and corrosion resistant Layer characteristics (DNC 471): phosphorus content: % elongation at break: % (foils, dome method) abrasion: 35 mg, Taber-Abraser test with CS 10 wheel after 1,000 revolutions hardness: approx. 570 HV 0.05 more than 500 hours resistance according to DIN EN ISO 9227** (acetic acid salt-spray test) Kesternich test, resistance according to DIN **: > 7 cycles SFW 2.0 Typical applications (DNC 471): metal fittings (stainless steel appearance) components with high corrosion and chemical loads * measured on 40 µm layer thickness, surface roughness R Z 1 µm, base material St. 52 ** measured on 50 µm layer thickness, surface roughness R Z 1 µm, base material St. 52 *** has to be tested for DNC 471/Ox in each individual case ****measured on 20 µm µm layer thickness, base material 42CrMo4 Distinguishing features (DNC 471): lead-free high solderability ultra-bright DNC 471 satisfies the regulations stated in the German Drinking Water Ordinance*** DNC 471 complies with the regulations of the U.S. Food and Drug Administration (FDA)*** DNC 471/Ox Post-treatment by deposition of chromium mixed oxide (free of micro cracks) Distinguishing features (DNC 471/Ox): more than 1,000 h resistance according to DIN EN ISO 9227 achievable**** (acetic acid salt-spray test) coefficient of friction: approx. 0.1 colour: black absorption coefficient for visible light α: 93% DNC 571 and DNC 571 (lead-free) Lead-free, especially corrosion and wear resistant Layer characteristics (DNC 520 and DNC 571): phosphorus content: 9 13% elongation at break: % (foils, dome method) abrasion: 35 mg, Taber-Abraser test with CS 10 wheel after 1,000 revolutions hardness: approx. 570 HV 0.05, after heat treatment up to 1,000 HV 0.05 more than 200 hours resistance according to DIN EN ISO 9227* (acetic acid salt-spray test) Kesternich test, resistance according to DIN *: > 3 cycles SFW 0.2 Distinguishing features (DNC 571): lead-free ultra-bright DNC 571 satisfies the regulations stated in the German Drinking Water Ordinance. DNC 571 complies with the regulations of the U.S. Food and Drug Administration (FDA) * measured on 40 µm layer thickness, surface roughness R Z 1 µm, base material St. 52 Typical applications (DNC 520 and DNC 571): pump housings and stopcocks for use with natural gas and crude oil food handling and processing equipment nozzles compressors screw threads the automotive industry transmission systems electrical engineering electronics 8

9 Brake caliper anchor plate (center), coated with DNC 471/Ox Washbasin mixer taps made of brass, coated with Crystal-Nickel plus DNC 471 (DURNI-COAT lead-free) Break-away coupling with pins and bushings, electroless nickel plated with the lead-free DURNI-COAT 571 process Corrosion and wear-resistant extruder mixing head for the dosage of colour, St 60 with 25 µm DNC 520 Jig platform (approx. 400 x 400 x 150 mm), DNC 520-coated, frame black anodised 9

10 Industrial Coatings for Metals and Plastics Process Variants DURNI-COAT DNC 700 Especially wear resistant Layer characteristics: phosphorus content: 3 7% abrasion: 10 mg by Taber-Abraser test with CS 10 wheel after DNC 771 Lead-free, especially wear resistant Layer characteristics: phosphorus content: 3 6% abrasion: < 20 mg by Taber- Abraser test with CS-10 wheel after 1,000 revolutions and DUPLEX-DNC For the most demanding specifications DNC-AL For aluminium and aluminium alloys Layer characteristics: Typical DNC characteristics, depending on processing variant (471, 520, 571 or 700), i.e. DNC-ZNGD For die-cast zinc DNC-LCP For plastics DNC-LCP is a process to provide adherent metal finishes to LCP (Liquid Crystalline Polymer). 1,000 revolutions and 9 mg after heat treatment 1h/400 C hardness: approx. 700 HV 0.05, after heat treatment up to 1,100 HV mg after heat treatment hardness: approx. 680 HV 0.05, after heat treatment up to approx. 1,000 HV 0.05 Distinguishing features: compressive residual stress ultra-bright DUPLEX-DNC, for example the double coating combining the advantages of a hard, wear-resistant DNC 700-finish with the ductile, corrosion-resistant properties of a especially ductile and corrosion resistant, or high corrosion and wear resistance, or extraordinarily wear-resistant and hard. Typical applications: structural parts for textile machines printing presses The DURNI-COAT variant DNC-ZNGD provides wear and corrosion protection for die-cast zinc components containing aluminium. Typical coating thicknesses are between 20 and 30 µm. The maximum layer thickness of a DNC-LCP finish is 20 µm ± 2 µm. The final finish can be added using different types of electroplating processes (e.g. Au, Sn, Ni). The metallisation of plastics can be used to fulfil a variety of different functional specifications. Typical applications: mining equipment and components metal fittings and hydraulic flaps high-spec non-ferrous alloys vehicle components Typical applications: mining equipment and components metal fittings and hydraulic flaps high-spec non ferrous alloys vehicle components DNC layer with a higher phosphorus content. For maximum mechanical, corrosive and chemical resistance specifications and use under extreme pressure fluctuations. packaging machines control system technology electronics, electrical engineering vehicle components An important example of use is on pistons for car diesel engines which have to be protected from cavitation erosion. Typical applications: the motor vehicle sector (e.g. carburettors, lock fittings, badges) electrical engineering/ domestic appliances light engineering and machine construction Typical applications: Full surface coating for EMC-components and as protection against wear for items such as those used in: domestic appliance electronics motor vehicle electronic systems systems and control technology telecommunications 10

11 Hub for clutch plate with idling-torsion damper (10 µm DNC 700) Ellipsoid mirror (AlMgSi0.5), coated with 20 µm DNC-AL Edge view of a nickel-phosphorus duplex layer subjected to a forced fracture (SEM photograph: magnification 1 : 2,000) Actuator housing made of die-cast zinc alloy, coated with DNC-ZNGD Microsection, 14 µm electroless copper on LCP 11

12 Industrial Coatings for Metals and Plastics PTFE-DURNI-DISP DURNI-COAT Electroless nickel-plating + PTFE Fluoroplastic Characteristics: = PTFE-DURNI-DISP tensile stress: N/mm² resistance to heat: short-term up to 300 C; long-term up to 250 C friction coefficient: depending on load, surface roughness and sliding speed Advantages: excellent hardness excellent abrasion resistance high corrosion resistance Advantages: good abrasion resistance excellent dry-lubricant characteristics high corrosion resistance excellent abrasion resistance good self-cleaning properties Especially wear resistant with anti-frictionproperties Characteristics: coefficient of friction: depending on tribosystem, PTFE dispersion rate: approx Vol.% hardness: approx. 230 HV 0.01 (mixed hardness) typical layer thickness: 7 15 µm Advantages: excellent adhesive wear resistance outstanding dry-running performance high temperature resistance outstanding anti-friction and anti-adhesive properties high corrosion resistance (with intermediate layer) Electroless nickel-plating with dispersed PTFE Typical applications PTFE-DURNI-DISP surface finish consists of an electroless (chemically) deposited nickel-phosphorus alloy layer applied according to the DURNI-COAT process in which PTFE dry lubricant is uniformly and homogeneously dispersed. The dispersion layer combines the properties of the DURNI-COAT layer with those of the PTFE. The corrosion resistance and hardness of pure DURNI-COAT layers are barely affected by the dispersed dry lubricant, and the tribological characteristics are actually considerably improved. bakery equipment bearing and mould making bearing seats control levers conveyor systems door lock fittings electrical switching components fan wheels filter gauzes gaskets gearbox components plastic moulding components printing machines rollers shafts structural pneumatic and hydraulic components textile machine parts tyre moulds valves 12

13 load (N) average friction number of revolutions wear (10-15 m²/n) coefficient (µ) with µ < 0.35 disc ball , , , , Optimum anti-friction properties Determined friction and wear values, measured by pin-on-disc tribometer, depending on load; v = 6 m/min; ball: 100Cr6; disc PTFE-DURNI-DISP; 15 µm, as-plated Outstanding dry-running performance Slide test with pin-disc-tribometer; F N = 5 N, v = 6 m/min; pin (ball) 100Cr6; orange curve: disc PTFE-DURNI-DISP; 15 µm, as-plated; blue curve: disc PTFE-DURNI-DISP; 15 µm, after heat treatment [2h, 350 C] Electro-magnetically actuated denture/overrunning clutch. The teeth are coated with PTFE- DURNI-DISP to reduce friction and provide wear resistance Valve gates and plugs of a multi-coupling coated with 15 µm PTFE-DURNI-DISP The injection moulding tool is made of St 2767 and used in the manufacture of polyamide 6-housings for hot-air welding machines, coated with 15 µm PTFE-DURNI-DISP SEM photograph: Edge view of a fracture in a PTFE-DURNI-DISP layer (magnification 1:1,000) 13

14 Industrial Coatings for Metals and Plastics SIC-DURNI-DISP DURNI-COAT + Electroless nickel-plating SIC The Hard Material = SIC-DURNI-DISP Characteristics: Mohs hardness: approx. 9.5 Vickers hardness: approx. 2,500 HV 0.05 melting point: approx. 2,480 C density: 3.2/cm³ average grain size: approx. 0.6 µm to 1.5 µm Advantages: excellent hardness excellent abrasion resistance high corrosion resistance Advantages: extreme hardness good chemical resistance excellent wear resistance Especially wear resistant Characteristics: abrasion: 5 8 mg with CS 17 abrasive wheel after 10,000 revolutions hardness: approx. 700 HV 0.05 (mixed hardness) dispersion rate: Vol.% Advantages: extreme hardness extreme abrasion resistance Electroless nickel-plating with dispersed SiC The SIC-DURNI-DISP finish consists of an electroless (chemically) deposited nickel-phosphorus alloy layer applied according to the DURNI-COAT process in which hard silicon carbide is uniformly and homogeneously dispersed. This dispersion layer combines the properties of the DURNI-COAT layer with those of the hard material. The corrosion resistance of pure DURNI-COAT layers is barely affected by the dispersed hard materials. The hardness of the compound and the abrasion resistance properties of the finish are actually considerably improved. Typical applications brake discs cylinder running surfaces feeding funnels pistons rollers structural pneumatic and hydraulic parts track rollers valve plates 14

15 Cross-section of a rotary transmission lead-through with a SIC-DURNI-DISP coated shaft High wear resistance Outstanding hardness SEM photograph: Edge view of a SIC-DURNI-DISP layer (magnification 1:3,000) Abrasion values, measured using the Taber wear-test CS 10, load 10 N, base material CK 45, dispersion rate SIC-DURNI-DISP: Vol. % SiC measured with CS 17 The cover, housing and impeller of this small capacity circulating pump are treated with a 30 µm coating of SIC-DURNI-DISP SIC-DURNI-DISP layer on an aluminium brake disc. The caliper support (also illustrated) is coated with HART-COAT PLUS 15

16 Industrial Coatings for Metals and Plastics SIC-DURNI-DISP Friction-increasing coating process SIC-9-DURNI-DISP The friction-increasing processing variant is an approx. 7 µm thick DURNI-COAT layer in which silicon carbide particles with a grain size of about 9 12 µm are uniformly and homogeneously incorporated. The layer is leadand cadmium-free. The silicon carbide particles protrude from the electroless nickel matrix. In the case of a friction-locked connection the sharp-edged hard particles mesh with the counter part and thus leave indentations. A re-assembly of join partners is easily possible. Typical applications SEM picture of a SIC-9-DURNI-DISP layer Connection elements that are treated with SIC-9-DURNI-DISP to increase the coefficient of friction can be applied wherever a load-bearing, delaying or accelerating effect must be achieved. Some examples of where this coating process may be used are engine technology, mechanical engineering and particularly the printing and textile machinery sectors. The component surface can be scanned using a 3D laser scanning microscope in order to determine the rate of surface depositing of silicon carbide particles in the electroless nickel layer. This ensures high-quality documentation and a high level of process reliability when coating customers' components. AHC/

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