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Necesidades de los Materiales y Recubrimientos Avanzados

en los Procesos de Manufactura

J. González-Hernández, V. Bringas-Rico, L.G. Trápaga-Martínez

D.G. Espinosa-Arbeláez, G.C. Mondragón-Rodríguez

E. Martínez-Franco, J.A. Villada-Villalobos,

I. Márquez-Jurado, D. Torres-Macías

Juan Manuel Alvarado-Orozco

International World Trade Overview

Word Trade Organization www.wto.org

Total Global Trade Distribution World Merchandise Trade Map

Developing Economies had a 41% Share of the World Merchandise Trade in 2014

What is manufacture?

• The making of articles on a large scale using machinery

http://manufacturing.gov/advanced_manufacturing.html

is a set of activities that (a) depend on

the use and cordination of information, automation, computation, software,

sensing, and networking, and/or (b) make use of

and emerging capabilities enabled by the physical and biological

sciences, for example , chemistry, and biology. This

involves both new ways to manufacture existing products, and specially the

manufacture of new products emerging from new

Global Manufacturing Industry Prespective

Word Trade Organization www.wto.org

0

500

1000

1500

2000

2500

1990

2000

2012

2013

2014

0

500

1000

1500

2000

1990

2000

2012

2013

2014

Export of Manufactures of Selected Economies

Import of Manufactures of Selected Economies

25

139

269 285 309

32

150

290 302

317

0

100

200

300

400

500

600

700

1990 2000 2012 2013 2014

Mexico Export/Import Ratio

Exports Imports

US

$ B

illio

n

US

$ B

illio

n

US

$ B

illio

n

0

50

100

150

200

250

300

350

400

450

500

1990

2000

2012

2013

2014

0

50

100

150

200

250

300

350

400

450

500

1990

2000

2012

2013

2014

Mexico in the World Mexico´s International Trade in Numbers

260 US $ Billions Between January and August 2014

5 0

65 92

3 5 11

46

64

43

6 4

0

20

40

60

80

100

120

140

Iron & Steel Chemical Office & TelecomEquipment

AutomotiveProducts

Textiles Clothing

Import

Export

Manufacturing Industry in Mexico by Sector U

S $

Bill

ion

M

illio

ns

of

Un

its

1.5

1.2

1.9 2.1

2.4 2.4

2.1

1.5

2.2

2.5

2.8 2.9

0

0.5

1

1.5

2

2.5

3

3.5

2008 2009 2010 2011 2012 2013

Export

Production

• ProMéxico has identified opportunities in fifteen metalworking processes and products in

demand by the supply chain of the automotive, auto parts, electric, consumer electronics and

domestic appliances sectors in Mexico.

• The top seven metalworking processes represent an opportunity of close to 57.3 billion dollars.

• The metalworking processes with greatest opportunities are (in billion dollars): stamping

($12.724), foundry ($11.225), forging ($10.291),machining ($8.969), plastic injection and

extrusion ($6.796), molds, dies and toolings ($4.131) and die casting ($3.196).

• Mexico offers 9.5% savings on the manufacturing costs of auto parts, as well as 12.5% savings

on the manufacturing costs of plastic inputs and 13.4% on metallic components used in the

industry, compared to costs in the United States. This makes Mexico the most competitive

country compared to eight other producer countries.

6.3

3.3 3.9 2.3

1 0.8 0.5 0.3

11.8

9.9 9.1

9.2

3.9

1.8 1.8 1.1

0

2

4

6

8

10

12

14

16

18

20

Troquelado y/oEstampado

Fundición Maquinado Forja Die Casting Ensable y/oMecanizado

TratamientosSuperficiales

TramientosTérmicos

Producido (Oportunidad de Mercado) Importado

Surface treatment

Thermal treatment

18.1

13.2 13

11.5

4.9

2.6 2.3 1.4

US

$ B

illio

n

National production and bussiness oportunities in automotive industry

Surface Treatments:

$1.80 MMD

Thermal Treatments:

$1.10 MDD

The market of the repair of parts and components is not considered

(Remanufacturing Process)

Market Opportunities in Automotive Industry

Forming / stamping

Casting Machining Forging Die casting

Assembly/ machining

Produced (market oportunity) Imported

Manufacturing Industry in Mexico by Sector U

S $

Bill

ion

3 2.5 3.2

4.3

5 5.4

193 199

238 249 270

287

0

50

100

150

200

250

300

350

0

1

2

3

4

5

6

2008 2009 2010 2011 2012 2013

Export

Companies

Evolution of the Manufacturing Technologies

Automobile Energy

Aerospace

Heavy Industry

Health

Rail Transportation

Home Appliances

Food

Advanced Manufacturing

Smart Manufacturing

Conventional Manufacturing

Biomedical

Oil & Gas

Infraestructure

Flexible Additive

Surface Engineering Thermal Treatments Advanced material

Reconfigurable High Reliability, etc.

MEMS Embedded Systems

Smart Materials High Performance

Collaborative SCADA

Dynamic control Robotics, etc

Casting

Forming

Welding

Conventional Machining (Turning,Drillng,Milling)

Electro-erosion, etc.

Why coatings are so important?

Coatings are the interface between the product (substrate) and the environment,

Coatings protect the substrate against environment conditions; light, humidity, corrosion, etc.,

i.e. tools in harsh conditions,

For small devices coatings become the product,

MEMS, NEMS, GMR thin film head, fuel cells

without with

Antireflective Coating

without with Anticorrosive coating After 500h service

Surface Engineering

Concept: surface structure, chemistry and properties modification to improve the substrate performance and durability.

o Surface engineering has impact in a wide range of industrial sectors,

o It’s a Multi-disciplinary Field

combines Physics, Chemistry, mechanical engineering with metallurgy and material science,

o Any surface can be coated or modified; metal, ceramic, polymer,

o One layer or multilayer are possible,

o Can be designed for a specific function or multifunctional.

Cutting

biomedical

Thermal isolation

corrosion

optics

• Longer service life

• Performance improvement (better

wear resistance, erosion, oxidation y

corrosion)

• Reduction of manufacturing cost,

machining and/or reparation

• Less emissions and polluting waste

• Better equipment performance (e. g.

motors)

• Better appearance

• Better weldability

Molds, dies and tooling Parts and components

Corrosion, wear, friction, reflectivity, emissivity, biocompatibility, etc.

Coatings Benefits :

Coatings Benefits and Uses

Some MetalWorking Coatings Applications

Certain desirable properties of a substrate (material) depends on its environmental operational conditions:

Cutting tools

Advanced Surface Technologies

Adapted from Oerlikon

Year 1980`s 1990´s 2000´s

Coating architecture

Single layer (1980´s)

Multilayers and Composites (1990´s)

Nano-structures, Superlattice, Gradients 2000

Smart Coatings (Self-Repairing) Today

200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²

Surface Engineering Scale, Deposition Methods and Substrate Temperature

Coating thickness or bounding surface (mm)

CVD: Chemical Vapor Deposition

LC: Laser Cladding+Powder

PACVD: Plasma Assisted CVD

PVD: Physical Vapor Deposition

PTA: Plasma Transferred Arc

TIG: Tungsten Inert Gas

Nitriding, Carburizing, Boriding

Diffusion (inside the surface)

Plasma Assisted Nitriding

Ionic Implant

Coating

CVD

PVD PA-CVD

Thermal Spray

DLC

Cold Spray

Electrodeposition

Welding TIG PTA LC

Diamond

Sub

stra

te T

em

pe

ratu

re(°

C)

Surface Engineering Process Classification

Adapted from Oerlikon

The proper coating technology is strongly dependent of the substrate and the final product application

200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


CVD: Chemical Vapor Deposition LC: Laser Cladding+Powder PACVD: Plasma Assisted CVD

PVD: Physical Vapor Deposition PTA: Plasma Transferred Arc TIG: Tungsten Inert Gas




Ionic implant

Coating

Sub

stra

te T

emp

erat

ure

(°C

)


Effective methods to increase the hardness and wear resistance of metals and alloys.

Applications: Automotive, forming industry, heavy machinery industry and drilling, etc.

Components: Molds and forming dies (metals, alloys, plastics, glass), gears, crankshafts, feed screws, camshafts, mandrels, milling, drilling tools, etc.

Boriding, Nitriding and Ionic Implant


200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²





Ionic implant

Coating

PVD

Su

bst

rate

Tem

per

atu

re(°

C)

Physical Vapor Deposition (PVD)

Deposition process wherein the material is vaporized in vacuum, carrying atom by atom and deposited on the substrate as the evaporated species or as a new compound.



PumpGas Inlet

Target Vacuum

Chamber

Tool

Arc Process



200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

PVD

Su

bst

rate

Tem

per

atu

re(°

C)

Physical Vapor Deposition (PVD)

PVD-Evaporation

Resistive

Inductive

Electron Beam

Electric Arc

Laser

PVD-Sputtering

Diode

Magnetron

Ion Beam

Triode

Deposition process wherein the material is vaporized in vacuum, carrying atom by atom and deposited on the substrate as the evaporated species or as a new compound.

Physical Vapor Deposition (PVD) Surface Engineering Scale, Deposition Methods and Substrate Temperature




200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

PVD

Sub

stra

te T

emp

erat

ure

(°C

)

Effective methods to increase the hardness, wear resistance, lubrication. Also used in semiconductors industry for design material devices: (Ti1-xAlx)N, (Al1-xCrx)N, ZrN, MoS2, nc-TiN/a-Si3N4

Components: hard and wear resistant coatings in general, optical coatings (anti-reflective), multifunctional coatings, semiconductors, etc.

Applications: Automotive, forming industry, hydraulic industry, etc.

Corte / Maquinado Moldes de Inyecciónde plásticos

Moldes de CD & DVDComponentes de precisión

Estampado / formación

Encapsulación de circuitos integrados

Physical Vapor Deposition (PVD) Surface Engineering Scale, Deposition Methods and Substrate Temperature




200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

PVD PA-CVD

DLC

Sub

stra

te T

emp

erat

ure

(°C

)

Effective method to increase the hardness and wear resistance, corrosion, self-lubricating metals and alloys.

Diamond Like Carbon (DLC)

Components: Components: Cutting tools for aluminum alloys, plastic molds, hydraulic components, crankshafts, camshafts, gears, bearings, piston rings, fuel injectors.

Applications: Automotive, forming industry, hydraulic industry, etc.





200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

CVD

PVD PA-CVD

DLC

Diamond

Sub

stra

te T

emp

erat

ure

(°C

)

Chemical Vapor Deposition (CVD)

Precursor + carrier gas

Heating elements

substrate

Residual gases

Reaction chamber

Electrodes Plasma

Precursores + carrier gas

Residual Gases

CVD Reactor

CVD Reactor Plasma Assisted (PA-CVD)

Process in which the gas species are transported and thermally actived or plasma assisted to react and form a solid coating on the substrate surface.





200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

CVD

PVD PA-CVD

DLC

Diamond

Sub

stra

te T

emp

erat

ure

(°C

)

CVD

Atmospherical Pressure

Low Pressure

Plasma Assisted

DC Plasma

Pulsed plasma

AC Plasma

Plasma asistido por RF

Assisted Microwave

Plasma

Atomic layer epiaxial

Assisted electron beam

Plasma Assisted

Hot Filament

Organo-Metalic Fase vapor- C.

Epitaxial

Chemical Vapor Infiltration

Chemical Vapor Deposition (CVD) Surface Engineering Scale, Deposition Methods and Substrate Temperature




200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

CVD

PVD PA-CVD

DLC

Diamond

Sub

stra

te T

emp

erat

ure

(°C

)

Effective methods to increase the hardness, wear resistance, lubrication in form of thin films, coatings or composites: (Ti1-xAlx)N, (Al1-xCrx)N, ZrN, MoS2, nc-TiN/a-Si3N4, DCL. Widely used in coatings for high temperature, resistant to corrosion and oxidation NiAl-X (X=Hf, Si, Y, Zr).

Chemical Vapor Deposition and Plasma Assisted CVD (CVD & PA-CVD)

Applications: Automotive, forming industry, hydraulic industry, power generation industry, gas industry and oil, etc.

Components: hard and wear resistant coatings in general, optical coatings (anti-reflective), multifunctional coatings, semiconductors, etc.





200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

CVD

PVD PA-CVD

DLC

Electrodeposition

Diamond

Sub

stra

te T

emp

erat

ure

(°C

)

http://www.daifuku.com/ir/news/2004/news040716.html

Process that used electrical current to reduce and dissolve species or cationic compounds (anode) to form a coherent coating on the sample (Cathode).

Electrodeposition Surface Engineering Scale, Deposition Methods and Substrate Temperature




Electrodeposition

Metallic

Coatings

Composites Coatings

Deposit alloys

Properties: uniformity, corrosion resistance, wear and abrasion resistance, weldability, toughness, high reflectivity, good magnetic properties.

Components: fuel injectors, heat sinks, differentials, transmission discs, shock absorbers gears, pumps, compressors, dice, mirrors, quirurgical equipment, etc


Electrodeposition

200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

CVD

PVD PA-CVD

DLC

Electrodeposition

Diamond

Sub

stra

te T

emp

erat

ure

(°C

)




200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

CVD

PVD PA-CVD

Thermal Spray

DLC

Cold Spray

Electrodeposition

Diamond

Sub

stra

te T

emp

erat

ure

(°C

)

Thermal Spray (TS) Cold Spray (CS)





105

Materia prima

Fundido de

las partículas

Interacción

partícula-sustrato

Stokes, 2003 Katika, 2012

Parcialm

ente

fundida

Hueco Oxido

Cooling

water

Spray stream

Com

pressed air

Fuel gas

Oxygen

Powder& carriergas

Oxygen

Fuel gas

Com

pressed air

Spray depositSubstrate

Multilayer Coatings Porosity

Gradient

Thermal Spray

Thermal spray where molten materials, semi-molten or heated are deposited on a surface.

200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

CVD

PVD PA-CVD

Thermal Spray

DLC

Cold Spray

Electrodeposition

Welding TIG PTA LC

Diamond

Sub

stra

te T

emp

erat

ure

(°C

)

Laser Cladding

Laser cladding is a method of depositing material by which a powdered or wire feedstock material is melted and consolidated by use of a laser in order to coat part of a substrate

PVD: Phisical Vapor Deposition PTA: Plasma Transferred Arc TIG: Tungsten Inert Gas




Laser cladding is also considered a weld build-up process and a complementing coating technology to thermal spray. It is increasingly used instead conventional welding methods like TIG for advanced weld repair applications.

This process enables new layers of metal with defined properties to be applied

200

400

600

800

1000

1200

-10 -1 -0.1 0 0.1 1 10 103 104 105 10²


Nitriding, Boriding



Ionic implant

Coating

CVD

PVD PA-CVD

Thermal Spray

DLC

Cold Spray

Electrodeposition

Welding TIG PTA LC

Diamond

Sub

stra

te T

emp

erat

ure

(°C

)

Laser Cladding

PVD: Phisical Vapor Deposition PTA: Plasma Transferred Arc TIG: Tungsten Inert Gas




Opportunities PVD

Machining process

I+D+i Opportunities

Surface engineering

Technological demand in the machining and

cutting tools industries

Reduction of manufacturing costs

PVD coatings allows a ~50% reduction of

tooling costs after 3 reconditioning cycles

with constant material removal

Same high level of

performance is provided after reconditioning

with PVD coatings

A 50% Increase of tool life cuts costs per piece by only 1%

A 30% reduction of tool costs reduces costs per piece by only 1%

An Increase of cutting parameters by 20% (cutting speed, depth of cut) reducing costs per piece by 15%

State of the art and trends in PVD and CVD techniques

Cutting tools

PVD

CD-Sputtering

Others Others

HIPIMS

Hybrid

PVD

Today Trends

Functional parts and components

Today Trends

Others Others

PA-CVD PA-CVD

CD-Sputtering

HiPIMS

CD-Sputtering

PVD PVD

Hybrid

Acero de baja aleación

Alta resistencia, tenacidad

Buena resistencia

al desgaste y corrosión

Alta resistencia a la fatiga y soporte de

carga

Composito: propiedades

tribo-, de fatiga &

corrosión

HiPIMS: High Power Impulse Magnetron Sputtering

37

Surface treatments for protection against wear and corrosion

SURFACE TREATMENT

WEAR OR CORROSION ATTACK

Adhesion Wear Fatigue Corrosion

Carburizing + + +++ -

Nitriding ++ + +++ +

Nitriding y Oxidation ++ + ++ +++

Boriding ++ +++ - -

PVD +++ ++ - +

PA-CVD +++ ++ - +

CVD +++ ++ - +

- = no improvement; +/++ = little improvement; +++ = significant improvement

Coating properties

Friction

coefficient

Oxidation

resistance

Crack

retardation

Hardness/

Ductility

Hot hardness Chemical

stability Thermophysical

properties

Abrasive wear

resistance

Compressive

residual stress

Compresive Load Strength

FA

FA

FR

FR

FA = FR

FA > FR

microcracks

delamination

The tool steel “breaks” underneath the coating leading to premature

surface wear on the die

Coating properties: in-situ hot hardness (vacuum environment)

AlCrN > TiAlN AlCrN < TiAlN

1620

1640

1660

1680

1700

1720

ALCRONA PRO FUTURA NANO

ha

rdn

ess [H

V]

20 25 30 35 600 800 1000

400

800

1200

1600

2000

2400

2800

3200

Hard

ness [

HV

]

Temperature [°C]

TiAlN (FUTURA NANO)

AlCrN (ALCRONA PRO)

in-situ hot hardness at 800°C

AlCrN (Monolayer)

TiAlN (Nano-

structured Monolayer)

Thermal Fatigue (H13)

Melt Pouring Solidification Demolding Spraying

Temp.

Stress

Strain

high

compressive

negative

Room temp.

tensile

positive

Source : METALNET KOREA

ΔT1(surface) > ΔT3(core)

tool surface

tool core

tool surface

tool core

Cycle in Aluminium die casting

Temperature mismatch

Nitriding reduces crack density

VC Layer

V

c c

VC Layer

V

c

VC Layer

V

Progressive De-carburization of the steel

Process Temperature 1000ºC

Load on the tool steel through repeated high temperature treatments (TD process)

D2

Carbon Atoms 1st TD Process 2nd TD Process 3rdTD Process

Possible 100,000 hits

Maybe 70,000 hits…

Maybe 40,000 hits….

Problems & Solutions

PVD Technology DUPLEX - Technology

Sticking & Soldering Erosion Thermal fatigue /

heat checking

• Reason

Melt depositon on tool due to mechanical locking and chemical reaction

• Effect

Increased ejection force: tool damage, adhesive wear, poor surface finish, frequent polishing, machine downtime

• Reason

Turbulent melt flow or particle impact

• Effect

Tool surface damage, difficult part ejection, poor surface

• Reason

Thermal cycles (300 – 720°C) and release agents cause alternating compressive and tensile stress

• Effect

Formation of cracks, melt penetrates into the crackes

Major Wear Factors in the Forming Industry

Adhesive Wear / Cold Welding /

Galling Material transfer from one surface to another caused by direct

contact and plastic deformation

Abrasive Wear Loss of material due to hard particles or hard protuberances that

are forced against and move along a solid surface.

Fretting Wear / Micro cracking Repeated cyclical rubbing between two surfaces, which over a

period of time will remove material from one or both surfaces in

contact

Wear on tools and PVD coatings

Applications of PVD coatings

TiCN multilayered, graded

CrN monolayer

TiAlN monolayer, nanostructured

AlCrN-based monolayer

Coating Strength

3000HV

400ºC

1750HV

700ºC

3300HV

900ºC

3200HV

1100ºC

Punching / piercing / trimming

Extrusion / Hot Stamping

metal sheet forming

TiCrN Deep Drawing 2100HV

700ºC

Stainless steel

600

900 900

1100 1100

7.5 17.3 51.5 74.5 118.1 0

20

40

60

80

100

120

140

0

200

400

600

800

1000

1200

HSS+TiN HSS+TiAlN Carbide+TiAlN Carbide+CrAlN CrAlN(nanostructure)

Mat

eri

al r

em

ova

l rat

e (

cm3/m

in)

Max

imu

m S

erv

ice

Te

mp

era

ture

(ºC

)

2300 HV 3300 HV 3300 HV 3200-3300 HV 3200-3300 HV

Evolution of advanced materials for tooling

1985 1996 1999 2006 2009

Duplex treatment

Nitriding + PVD coating

Nitrided M2 (1.3343) + PVD coating Schematic picture

PVD Coating > 3000Hv

1100 Hv 920 Hv

750 Hv 600 Hv

550 Hv

PVD coating

Nitriding

• High hardness • High thermal stability • High abrasive wear

resistance • Chemical inertness

• Increased surface hardness

• Improved hardness profile

• Compressive stress • Improved hot • hardness

DUPLEX:

PVD Coating

Step 3:

Polishing / Blasting

DUPLEX PVD-Coatings

N

HRC

72HRC 67HRC

60HRC

Step 1:

Nitriding 480°C-500°C

D2

Roughness /

Compound Layer PVD 3000+HV

Advanced/Duplex Technology

Surfaced overload

Plastic

deformation

of substrate

material

in High Tensile

applications

Improved

resistance

Standard

PVD

ADVANCED

technology

HV

HV

Improved

resistance DUPLEX

technology

HV

30 µm

Flash nitride

200 µm

Deep nitride

Higher substrate hardness improves resistance to high load

Advantages of PVD coating versus Nitriding

Low tool life

Tool breakage due to soldering

Injected part defects

Increased rework and tool

maintenance

No steel/Al reaction

Easier demoulding

No pin maintenance during

worklife

Maintenance of product

geometry

AlCrN coating FexSiyAlz intermetalics

Bilayer structure

Operations such as:

• Milling with:

• Shank tools

• Modular shank tools

• Indexable inserts

• Hard drilling

• Turning

Materials:

• Heat-treated and hardened steels

• HRC 45 – HRC 65

Bilayer structure is particularly suitable for:

WC/C (A-C:H:W) and DLC Coatings

WC/C (A-C:H:W) DLC 1 µm 1 µm

Structure of the WC/C (a-C:H:W)

Total coating structure WC/C-Section

WC/C- coating

Substrate material

Cr-interlayer

WC-coating

White lamella: WC-rich

Black lamella: C-rich

0.1 µm

Advantages of the nanolayer structure

Examples of use of PVD coatings for Plastics Processing

Tool

Wear

Disturbance

Corrosion

Adhesive

Abrasive

Deposit

Filling

Demolding

CrN monolayer

TiAlN

DLC (a-C:H)

WC/C (a-C:H:W)

TiN monolayer

TiCN multilayer, graded

TiAlN

TiN monolayer

CrN monolayer

TiN monolayer

TiN monolayer

WC/C (a-C:H:W)

DLC (a-C:H)

Substrate hardness

Copper alloys*

> 52 HRc necessary

Substrate hardness

>52 HRc necessary

Substrate hardness

< 52 HRc possible

Substrate hardness

< 52 HRc possible

Substrate hardness

< 52 HRc possible

Substrate hardness

< 52 HRc necessary

Coatings to solve injection aluminum problems

Erosion decreases in a significant way due to high hardness

Reduction of heat checking and mechanical fatigue

Protects tool agains thermal fatigue fissures

It’s possible to decrease demolding elements without wear risk

Markets and Coatings

Coating Market Segments

Cutting Tools Forming Tools Precision

Components Automotive Components

Forming tools for

metal & plastic

processing

(e.g. moulds &

dies)

Precision

components

(e.g. watch

components,

bearings, shaving

knifes)

High volume

automotive

components (e.g.

diesel injector

parts, piston pins)

Cutting tools for

metal machining

(e.g. end mills,

drills, hobs,

inserts)

Design Parts

Decorative

coatings as

substitute to

traditional chrome

plating solutions

(ePD™)

Tools Components

AUTOMOTIVE INDUSTRIAL APPLICATIONS

Coatings in the automotive industry

Adapted from Sulzer Metco - surface engineering market

- Howard Lang

Reasons for coating: o Improve wear resistance o Better corrosion resistance o Higher hardness o Decrease weight component o Increase fuel efficiency o Increase engine efficiency

Coating value: o lower oil use o Component cost reduction o Less emissions o Increase lifetime component

In México businnes partners are the heavy duty and automotive industry i.e. Cummins, Caterpillar, etc.

Examples: Coatings for Automobile components

Plastics Metal sheet

Examples: Wear protection coatings for forming tools

Plastics processing Die Casting Punching Forming

A - pillar

B – pillar

Side impact protection

Cross member

bumper

Roof rail

Application examples in press hardening

Applications of high strength steel sheets

Nitriding the surface will increase the hardness and compressive strength in the

tool steel.

Metal sheet forming of high strength steel sheets

Overview of area compressive cracking

Small compressive cracking Significant compressive cracking

1mm 100 µm 100 µm

Tool Wear & Failure Through Compressive Failure

Examples of Coating for Form and Flange Steels

AlCrN-based Monolayer +

Nitriding

TiCN multilayer graded

+nitriding

TiAlN monolayer

nanostructured +

nitriding

TiCrN + nitriding

Forming of Stainless

Hot Stamping Forming

Hot Stamping Tools

Forming Cold Rolled

Forming Hot Rolled

Forming HSLA

Forming Dual Phase

Forming Cold Rolled

Forming Hot Rolled

Forming HSLA

Forming Dual Phase

Examples of coatings for Trim Steels

AlCrN-based monolayer

TiCN multilayer, graded

WC/C (a-C:H:W) lamellar TiCN multilayer, graded

Trimming Stainless

Trimming Cold Rolled

Trimming Hot Rolled

Trimming HSLA

Trimming Dual Phase

Trimming Aluminum under 2mm

Trimming Steel Under 1.5mm

Trimming Steel Under 500KSI

Trimming Stainless Steel under 1mm thick

Saves in aluminum injections cores

Useful life Cleaning each… injections

Tool Core Material (X 2 NiCoMo 18 8 5) Application: For screw holes that cut thread Piece Burner box Alloy GD-AISI 9 Cu 3 690 to 720 ºC Source Bühler AG

Without coating 2,000 - 4,000 1000

Nitriding in salts 8,000 - 12,000 2,000

PVD Coating

25,000 8,000

17,362

5,437

1,979

0

5,000

10,000

15,000

To

ol co

st in

CH

F

Examples Automotive

Clutch

Electrical Engine

Clutch Water pump

Differential box Cover head engine

Hot Stamping Application

Release Date 7

1

Customer

Detailed App Description Automotive Hot Stamping

Type of produced part A & B Pillars, Side Rails, Door Beams, Roof Rails, Bumpers, etc

Original Application Problem Scale Formation, Galling, Sticking

Type of tool/part Upr & Lwr Form Details

Tool Dimensions 22 steels = LH/RH set

WORK PIECE MATERIAL Usibor Coated & Uncoated Material

Lubrication used NA

Additional Information

Type of Press NA

Tool condition (new/used) New

Tool steel H13

COATING TYPE AlCrN + nitriding

Coating thickness 10 microns

Pre-Post treatments Pre and Post Polish

FEEDBACK

Application result Over 1 millions hits to date and still running

Additonal Feedback Failure with no coating at 120-200k hits and the forms are typically replaced

Al-die casting main serves primarily the automotive and motorcycle

Automotive Transmission Engine

Motorcycle Transmission Engine

Electronics Hards Disk Drives

(HDD) housings

pins inserts cavities

Markets &

Applications

Coated tool types

Technology AlCrN-based Monolayer TiAlN nanostructured monolayer

Assisted by DUPLEX technology (nitriding + hard coating)

Wear problems in pressure die casting operations

5

1

4

3

2

1. Melt

2. Alloying of the melt

with the tool

3. Erosion

4. Heat checking

5. Material deposit caused

by the sticking of the melt

Main wear mechanisms

Crack formation by repetitive change in

temperature with temperature difference

between tool surface and core

Mechanical fatigue Thermal fatigue

Crack formation by cyclic loading when

certain treshold is reached

Main wear mechanisms

Hard particles abrade the softer workpiece

surface

Plastic deformation Abrasive wear

Yield strength is exceeded due to extreme

pressure and tremperature

Metal die casting

Extreme layer hardness

Protection against abrasive wear and erosion

Ceramic material low coefficient of friction

Prevents adhesive wear, e. G. Sticking melts

Improved de-moulding properties

Excellent thermal and mechanical stability

No oxidation

Reduced melt alloying on the tool

Homogeneous surface hardness profile

Protection against premature heat checking

Lower tool costs due to significantly prolonged tool

service life

Lower production costs due to reduced machine

dowtimes and improved part quality

Lower maintenance costs due to longer maintenance

intervals and reduced maintenance efforts

Increased productivity and

production reliability

Advantages of PVD coatings for Die Casting

Less maintenance

Higher productivity

Better part quality

Less scrap

Repair welding easily

done

Surface quality over

length of run improved -

heat checking delayed

Cleaner castings

Improved casting release

and in some cases

reduced consumption of

die lubes

Environmentally friendly

Plastics processing. Injection moulding

Extreme coating hardness.

Superb protection against abrassive wear.

Protection mould against discolouration when using agressive masterbatches.

Ceramic material-low coefficient of friction.

Prevents adhesion, e.g. Sticking of melt

Protection against seizure of moving mould parts (even when

operated dry)

Brilliant surface quality

Improved mould filling

Improved moulding

The coatings afford longer protection against surface

deposits

Reduction of tool costs due to longer tool life, less scrap, and

shorter cycle times

Reduction of production and unit costs due to less machine downtime and improved part

quality

Reduction of maintenance costs due to fewer servicing and

cleaning intervals

Coatings for injection moulding: boost productivity, cost-

effectiveness and process reliability

Example: grinded surface, parts for water box

Tool: • mold, BMW 3 series • 1.2738, 1100N/mm2 • grinded surface • 1590x750x206mm Molded part: • PBT 30% Long glassfiber • 3% Bariumsulfat • water box Problem • heavy wear after 220.000 shot • warranty tool life: 600.000 parts • high maintance cost Customer benefit / solution TiAlN nanostructured monolayer, reduce of wear (abrasive) after 200,000 shot

Source: Weidman Treuen, Germany Lengh: 1590mm

Example: polish surface-TiN

Case: Opel Corsa

Frame, PC Tool 1+1 cavity / left + right 1.2343 (ESU), 52 HRC Shot / year: 200,000 Surface: polished + chem.etching Wear of structure after 20.000 shot Cleaning of polished surface cases scratches

TiN coated; Lifetime: 280,000 shot without wear; No post polishing Wear resistance structure (>10-times lifetime)

Increased productivity: 12%

Comparison of coated and un-coated punches on 1400MSW

Graded TiCN

Nanostructured TiAlN

Cutting Edge

Coating worn

Some coating

wear but cutting

condition still

guaranteed

Material: 1400 MSW

Parts: 100,000

Trim Clearance: 10%

Test performed by Boehler Uddeholm

PVD coatings for tools in automobile industry

Automobile Industry

CrN monolayer- Brilliant, Plastic

Processing

Car side window, Smart

Brilliant - D- Process

Coating: 3 µm

3 years dry operation

PC - Makrolon

Mold weight: 1000kg / 2200 p

Mirror polish

Steel: H11, HRC 52

Advantages from PVD coating

Reduced deposit

Improved protection against

Hot gas corrosion (dies effect)

Protection against scratches

Operation without lubrication

Insert:

WC/C (a-C:H:W

Cavity:

CrN

AEROSPACE INDUSTRIAL APPLICATIONS

Benefits of PVD

coatings

Increased load bearing capacity

Longer service life

Lower cost of maintenance

Reduced energy consuption

Functional stability at elevated

temperatures

Coatings for Aerospace

85

Features of PVD

Coatings

Excellent wear resistance

Protection against fretting

Low coefficient of friction

Retention of tolerances &

surface quality

Actuation Systems Door locking

systems Thrust reversers Flap mechanisms

Engine Bearings Fuel pumps Compressor

blades Accessory gear

box

Landing gears Breaking

systems Bearings

High-end Deco Interior Parts

Structural parts Engine pylons

Coatings for Aerospace applications


Engine pylons

TiN or WC/C (a-C:H:W) reduce the danger of fretting corrosion (pins).

Shafts, pins and bearings WC/C (a-C:H:W) protects lightweight titanium alloys against seizure.

Bearings

Accessory gear box

Fuel injection nozzles

Compressor blades BALINIT® coatings protect compressor blades against erosion.

Engine mounts

Landing gear

Turbine


Flight control systems

Thrust reverser

Door locking mechanism

Landing Flaps TiN or WC/C (a-C:H:W) reduces the danger of seizure of landing flap connecting bolts.

Axial piston pump WC/C (a-C:H:W) reduces the friction and protects against wear for longer service life.

Cabin elements

Instruments Black and grey colored coatings like DLC coatings make instrument dials non reflective.

Actuation systems

Hydraulic systems & Fuel pumps

Interior decoration

~15µm

Erosion resistant multilayer system

Fracture cross-section (metallographical mount) was performed on a

Balzers THM sample (carbide insert)

Hard Layer

Abrasive wear resistance against hard SiO2 particles in air

Soft Layer

Avoiding of cracks propagation due to bombardment of solid particles

OTHERS INDUSTRIAL APPLICATIONS

Ship engines

The Nanostructured TiAlN coating prevents hydrocarbon buildup on

valves

The CrN coating significantly improves the wear resistance of the hard

chromium base layer. (40 µm thick coating)

PVD coatings offer: Higher wear resistance due to higher

hardness Enabling higher engine pressures

Less frictional losses

Due to higher engine temperatures and pressures in ship engines, there is an

increased stress and tribological demands on criticl components such as: valves, valve

plates, piston pins and piston tings

Air conditioning vane compressors

Air conditioning in household and moblie applications uses rotary vane compressors. The vane nose slides

against the rotating roller driven by an eccentric shaft. AC compressors operating with lubricant

increase tribological stress between the vane nose and rollers.

Lower loaded compressors work with nitrided vanes while the higher performance systems need hard and

low friction PVD coatings to enable sufficient operational lifetime and energy efficiency

Advantages of PVD Coated compressor vanes:

Excellent wear resistance in AC operation in combination with refrigerants and lubricants

Low friction which improves energy efficiency

Open-end and ring spinning machines.

The textile spinning machine operate at very high speeds. The fast running

fibres put extreme tribological stress on spinning components and bring nitride

and hard chrome plated surfaces to their limit

Opening cylinders are highly abrasive loaded by fibres that even Ni-Diamond

coatings can not provide sufficient wear resistance

CrC coatings offers:

High resistance against steel runner and therefore a higher speed is possible.

Reduced hairiness compared to hard chromium plating

CrN coated opening cylinders offers:

Higher wear resistance compared to Ni-diamond coatings for cotton and polyester for open end cylinders

The dents of opening cylinder shows nearly no wear after

3000 hours of polymer spinning if coated with CrN

The spining rinds coated with CrC achieve higher spindle speed and 20% less hairiness compared to

hard chromium plated rings

Advanced weaving machine components

The weaving reeds and air jet nozzles are touched by high speed fibres.

The abrasive particles in the fibers cause wear and reduce the lifetime of these components

DLC coatings can protect the parts against abrasive effects

Advantages:

• Higher wear resistance due to higher hardness

• Higher lifetime of components

Medical anti-microbial PVD coatings

Extremely low coefficient of

friction

Proven biocompatibility

Resistance to repeated

autoclave cycles

Corrosion resistance

Eliminates the need for lubrication

Protects patients against damages or impairments

High scratch resistance, stable colours and antiglare properties

Protection against cleaning liquids

Higher cost-efficiency


Orthopaedic instruments

Colour coded coating indicates that these instruments have hard metal inserts

Dental screws

Improved screw adjustability. Reduction of torque during the assembly of the screws. Cost saving due to easier and faster replacement of

abutment screws and implants

Bone drills

Wear-resistant ceramic coatings provide long-term cutting edge sharpness


Medical Instruments

Scratch and wear resistance, anti-

glare and antimicrobial

properties

Minimally invasive keyhole

operations

Widely use of Medical AlTiN to

indicate the depth of insertion

Bone saws

Coating provide oil-free lubrication

and high-speed operation at low

remaining temperatures

The gears of high speed dental drills

operate with no oil

Coatings for food processing and packaging

Food procesing machinery components have to work in corrosive and abrasive environment. In

many cases austenitic steels are used to prevent corrosion. Unfortunately austenitic stainless steels

are soft (300 HV) and suffer easily by wear in sliding motion. A PVD coating off CrN increases the surface hardness and protects components against seizure

and abrasion.

Higher surface hardness and therefore less abrasion by particles

Less danger of galling due to ceramic like surface

Damage-free cleaning due to higher surface hardness

FDA approved coating

Wear-resistent oil and gas drills and pumps

DLC coatings represent a solution for automotive

industry, mechanical engineering, oil and gas

industry because the coatings combine low

friction with high coating hardness.

Less friction against steel walls allowing less drilling torque

A unique combination of seizure resistance and abrasive wear due to high hardness and low

friction

Longer service life of pump components

Status of the Consortium Repair & Remanufacturing Technologies

101

As an example, we can develop a value chain mixing nanotechnology-mems-simulation-prototyping-virtual manufacturing in one single solution. Better sell with more impact.

To achieve this; we need to collaborate with high technology partners like CINVESTAV-CIMAV-BALZERS-etc. to provide high value added solutions to our clients, like CUMMINS, MAGNA, MABE, etc.

Coatings Department

Special Coatings Lab.

Material preparation and processing Lab.

Characterization Lab.

Performance Lab.

Simulation Lab.

Microelectronics Manufacture Molds, Stamping and Die

Welding Energy Automation

Automobile Coatings and MEMS encapsulation

Functional coatings, component remanufacturing, thermal barriers, wear resistance

Coatings, Hardening, wear resistance, rheology

Arc, plasma, laser coatings and welds deposition

Resistance strengthen, weight reduction

Robotization, speed increasing, additive manufacturing, hybrid process

Home Appliances Coatings and MEMS encapsulation

Functional coatings, thermal barriers, wear resistance, active surfaces

Coatings, Hardening, wear resistance, rheology, hybrid materials processing

Arc, plasma, laser coatings and welds deposition non compatible materials welding

Functional coatings, thermal barriers, active surfaces


Aerospace Coatings and MEMS encapsulation

Functional coatings, component remanufacturing, thermal barriers, wear resistance


Arc, plasma, laser coatings and welds deposition non compatible materials welding

Resistance strengthen, weight reduction


Health Micro sensors, micro actuators coatings

Surgical instruments coating


Non compatible materials welding

Functional coatings, thermal barriers, active surfaces


Coatings impact on CIDESI´s Knowledge areas and market

Thermal projection Thermal projection, CVD, PVD CVD, PVD

Opportunities AM & Thermal Spray

Nuevo León

Baja California

Querétaro

Campeche

Locations and Infrastructure Founds source: Own Projects, Government, Conacyt

Estado de México

Saltillo

Mérida

Manufacture

Markets: • Automotive • Aeronautical • Electronic • health • Oil & Gas • Energy • Foods • Textile • Infrastructure • Mining

• Dedicated • Flexible • High precision and complexity • Advanced Materials • High Reliability

Oil & Gas

(Cost)

Energy

(Cost & Efficiency)

Infrastructure

(Durability & Reliability)

Paper y textiles

(Cost)

Chemical Industry

(Cost)

Mining & Metals

(Durability & Reliability)

Biomedical

(Reliability)

Automotive Sector

(Cost & Efficiency)

Aeronautical Sector

(Cost & Efficiency)

Current CIDESI Research Lines (Business Cores)

Manufacture

Markets: • Automotive • Aeronautical • Electronic • health • Oil & Gas • Energy • Foods • Textile • Infrastructure • Mining

• Dedicated • Flexible • High precision and complexity • Advanced Materials • High Reliability

Agil

High Speed & Smart Control

Connectivity, mobility & data management

Reconfigurable

Adaptable

Energy Efficient

Additive

High Reliability

Continuous monitoring & Self-diagnosis

Simulation & Modeling

Man-Robot-Machine interfaces

High Performance

Smart Materials

Special Coatings Advanced Materials

Energy MEMS

Coat ing Archit ect ures

Monolayer (1980´s)

Mult ilayer & Composit es (1990´s)

Nanost ruct ures,

superlat t ice, gradient s

2000

Smart Coat ings

(self - healing )

HOY

Special Coatings Laboratory

Materials Synthesis & Processing Laboratory

Characterization Laboratory

Performance Laboratory

Simulation Laboratory

Coatings Innovation Division

• Hot-Stamping • Dry-Cutting Tooling • Abrasion - Wear • Corrosion – Oxidation • Powder Metallurgy • Alloy Processing

Opportunities for Value Creation

New vision CIDESI Research Lines

Research Topics of interest Coatings Innovation Division

0

Surface Treatment / Coating Thickness (µm)

Sub

stra

te T

em

pe

ratu

re (

x10

0)

(°C

)

- 10 - 1 - 0.1 0 0.1 1 10 102 103 104

2

4

6

8

10

12 Coat ings

Plasma assisted

Nit ruring

Thermal Spray

Cold Spray

Surface Engineering Scale,

Deposit techniques & Subst rate Temperat ure

Nit ruring

Carburizing

Borizing

Diffusion

CVD

PVD

PA- CVD

HiPI MS

P3e

HiPI MS = High Power I mpulse Sputtering

P3e = Pulse Enhance Elect ron Emission

Adapt ed f rom Sulzer- Met co

Consortium Coating Technologies

International Consortium in Coating Technologies

Manufacture

Design & Automatization

Surface Engineering

Characterization & Performance

Materials Synthesis & Processing

Structural & microstructural characterization

TEM

FIB

Mechanical Characterization

Nanoindenter

DFT Calculations

Simulation of Thermodynamics & Kinetics of Materials

Simulation of Contact Mechanics

TS Diagnostic plume & plasma

Characterization


Thermal Spray Coatings

CFD Simulation

APS, SPS

HVOF, HVAF, HVOLF

HP-CS

APS

HVOF

Thermal Plasma Propulsion

Spin-Offs incubator

Advanced and smart Manufacture



Consortium

Capabilities

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.marsilinox.pt/es/soldadura-robotizada.html&ei=ZlO5VNiUHpDKoAT5kYDoAw&bvm=bv.83829542,d.cWc&psig=AFQjCNEtIWPwQGCHqZVfNgmaeLUaPuOZRQ&ust=1421518040116907

0


Sub

stra

te T

em

pe

ratu

re (

x10

0)

(°C

)

- 10 - 1 - 0.1 0 0.1 1 10 102 103 104

2

4

6

8

10

12 Coat ings

Thermal Spray



Diffusion


Thermal Spray

Cold Spray

Scient if ic and Technological

Development s of specif ic I nterest

• Thermal Barrier Coat ings Systems

• Hot- Corrosion

• Oxidat ion/ Sulf idat ion

• Carburizat ion

• Wet- Corrosion & Erosion

• Catodic Protect ion

• Wear & Abrasion Systems

• Addit ive manufact uring & Remanufact uring

Hardwicke et al (2013)

0


Sub

stra

te T

em

pe

ratu

re (

x10

0)

(°C

)

- 10 - 1 - 0.1 0 0.1 1 10 102 103 104

2

4

6

8

10

12 Coat ings

Plasma assisted

Nit ruring

Thermal Spray

Cold Spray



Nit ruring

Carburizing

Borizing

Diffusion • Furt her explore t he degradat ion

mechanisms (oxidat ion and stabilit y) of t he

Ti1- xAlxN and Cr1- xAlxN systems at high

temperat ures.

• Determine effect s of dopant s and pre-

t reat ment condit ions on a- Al2O3

establishment and subsequent st ruct ure

stabilit y, t r ibological and mechanical

propert ies of single- layer coat ings.

• Opt imizat ion of t he deposit ion parameters

of commercial coat ings.

• Development of new hard- coat ings

architect ures (e.g. mult ilayer, superlat t ices,

composites and nanocomposites) for

improved HT protect ion.

• Development of new composit ions and

opt imal process condit ions of target s for

PVD coat ing applicat ions.

• Develop alternat ive novel coat ings systems

such as oxides (mullite, Al2O3, HfO2)



CVD

PVD

PA- CVD

HiPI MS

P3e





Consortium Locations and Infrastructure

Nuevo León

Baja California

Querétaro

Campeche Estado de México

Saltillo

Mérida

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.tecnalia.com/es/tecnalia/localizacion-sedes/index.htm&ei=EstLVaDpOImFsAWwloDYDA&bvm=bv.92765956,d.b2w&psig=AFQjCNGgKW2wcRzBXSvIQ1wgI09cecXFsQ&ust=1431116924588249

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://cee.cimav.edu.mx/2012/unidadcimavmonterrey&ei=7MZLVa7SFILJtQWiloCgBA&bvm=bv.92765956,d.b2w&psig=AFQjCNGsm08yuB3mUqf7srol1zZoWhG0oQ&ust=1431115855328303

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.immocalador.com/mallorca.informacion/?hl=es&ei=jclLVbzLMcXHsAXCv4A4&bvm=bv.92765956,d.b2w&psig=AFQjCNFXDuGOqA8XmBhcJfF_sTLA_dJ2Wg&ust=1431116411519412

High-Temperature Degradation of Alloys and Coatings Research Experience

Kinetic Study and Characterization of TGO on Commercial b-(Ni,Pt)Al

Bond Coats used in TBC systems for Gas Turbine Engine Applications

Funded by Project Title

Multiphase, Multifuctional Ceramic Coatings

Investigation of the Transitions between Desposit-Induced Degradation Regimes

and the Influence of Alloying Elements in Coatings and Structural Alloys

Oxide Evolution Dynamics and Stability in Harsh Enviroments

Ph.D Juan Muñoz Saldaña and Ph.D Juan Manuel Alvarado Orozco

Ph.D Gerardo Trapaga Martinez and Ph.D Juan Muñoz Saldaña

Ph.D Gerald Meier and Ph.D Juan Manuel Alvarado Orozco

Ph.D Brian Gleeson , Yihong Kang and Ph.D Juan Manuel Alvarado Orozco

0

3000

500

1000

1500

2000

2500

200 400 600 800 1000 1200

3500

Particle velocity (m/s)

Fla

me T

em

pera

ture

(°

C)

HVOLF

PLASMA

HVOF

HVAF

COLD SPRAY

HAp

YSZ

REZ

HP COLD SPRAY

Thermal-Kinetic Compromise Chart

Current Thermal Spray Technologies

CFM56 Turbine GE-Snecma Joint venture

Combustor

High-pressure Compresor

Low-pressure Compresor

Fan

Extracted from the GE Homepage

High pressure Turbine

Low pressure Turbine

Blade

Cross section

TC

BC

IDZ

SA

Thermal Barrier Coatings System

TGO

Al2O3

Role: Extend the limits and durability of

high performance alloys in gas turbines.

Surface Degradation of a Turbine Component Gas turbine blade, showing isotherms equivalent to full-power operation

At least two different regimes of degradation can be

defined for a Na2SO4-induced hot-corrosion attack.

Deposits: Na2SO4 +/- SiO2, CaO, MgO

Naval application

Aeronautical application

Type I Hot-Corrosion

Type II Hot-Corrosion

2

Adapted for Nicholls (2003)

119

TRATAMI ENTOS SUPERFI CI ALES para PROTECCIÓN a la

CORROSIÓN y al DESGASTE

TRATAMI ENTO

SUPERFI CI AL

DESGASTE o ATAQUE por CORROSIÓN

Adhesión Desgaste Fat iga Corrosión

Carburización + + +++ -

Nitruración ++ + +++ +

Nitruración y Oxidación ++ + ++ +++

Borizado ++ +++ - -

PVD +++ ++ - +

PA- CVD +++ ++ - +

CVD +++ ++ - +

- = sin mejora; +/++ = mejora poca/ media; +++ = mejora

signif icat iva

ESTADO del ARTE y TENDENCI Ade las TÉCNICAS PVD y CVD

Herramientas de Corte

PVD

CD-

Sput t ering

Ot ras Ot ras

HI PI MS

Hibrido

PVD

Hoy Tendencia

Partes funcionales y componentes

Hoy Tendencia

Ot ras Ot ras

PA- CVD PA- CVD

CD-

Sputtering

HI PI MS

CD-

Sputtering

PVD PVD

Hibrido

Acero de baja aleación

Alta resistencia, tenacidad

Buena resistencia

al desgaste y corrosión

Alta resistencia a la fatiga y soporte de

carga

Composito: propiedades

tribo-, de fatiga &

corrosión

igh Power Impulse Magnetron Sputtering

121

As an example, we can develop a value chain mixing nanotechnology-mems-simulation-prototyping-virtual manufacturing in one single solution. Better sell with more impact.

To achieve this; we need to collaborate with high technology partners like CINVESTAV-CIMAV-BALZERS-etc. to provide high value added solutions to our clients, like CUMMINS, MAGNA, MABE, etc.

Dirección de Recubrimientos

Áreas de Especialización de la


Recubrimientos especiales

Preparación y procesamiento de

materiales

CaracterizaciónDesempeño

Simulación

Dirección de Recubrimientos 1. Dr. Luis Gerardo Trápaga Martínez (Director)

(Simulación & Procesamiento de Materiales)

2. Dr. Juan Manuel Alvarado Orozco (Gerente)

(Recubrimientos, Simulación & Desempeño)

3. Dr. Diego German Espinosa Arbeláez (Investigador)

(Recubrimientos & Caracterización)

4. Dr. Enrique Martínez Franco (Investigador)

(Procesamiento de Materiales & Caracterización)

5. Dr. Guillermo Cesar Mondragón Rodríguez (Investigador)


Estudiantes Internos

1. Dr. John Alexander Villada Villalobos (Posdoc)

(Procesamiento de Materiales -Manufactura Aditiva)

2. MS. Idalia Márquez Jurado (Estudiante de Doctorado)

(Recubrimientos Duros Lubricantes)

3. MS. Erick Valladares (Estudiante de Doctorado)

(Recubrimientos Duros Lubricantes-Sumulación)

4. MS. Christian Félix Martínez (Estudiante de Doctorado)


5. MS. Diana Torres Macias (Estudiante de Doctorado)


6. Ing. Víctor Hugo Hernández Leyva (Estudiante de Maestria)

(Recubrimientos- Evaluación de Desempeño)

Capital Humano de la Dirección de

Recubrimientos:


Áreas de Especialización de la


Recubrimientos especiales

Preparación y procesamiento de

materiales

CaracterizaciónDesempeño

Simulación

Dirección de Recubrimientos 1. Dr. Luis Gerardo Trápaga Martínez (Director)

(Simulación & Procesamiento de Materiales)

2. Dr. Juan Manuel Alvarado Orozco (Gerente)

(Recubrimientos, Simulación & Desempeño)

3. Dr. Diego German Espinosa Arbeláez (Investigador)


4. Dr. Enrique Martínez Franco (Investigador)

(Procesamiento de Materiales & Caracterización)

5. Dr. Guillermo Cesar Mondragón Rodríguez (Investigador)


Estudiantes Externos

1. MS. John Edison Garcia Herrera (Estudiante de Doctorado)


2. MS. Lorena Ivonne Pérez Andrade (Estudiante de Doctorado)


Capital Humano de la Dirección de

Recubrimientos:

Recubrimientos


Links 2015

Technological Part ners

Trading part ners (Planned project s to 2016)

1. CENAPROT-2015 : $ 16,360,000

2. RTNA-2015 : $ 2,000,000

3. FOMIX-2015 : $ 20,000,000

4. CENAPROT-2016 : $ 8,000,000

5. Front. del Con- 2016(1) : $ 4,000,000

6. Problem. Nac.-2016 (3) : $ 4,500,000

7. Infra. CyT.-2016 (4) : $ 25,000,000

8. UC-Mexus-2016 (1) : $ 4,500,000

9. Proyecto de Posdoc (1) : $ 350,000

Total = $ 84,710,000.00

Project (5 years) 1. Hot Stamping : $ 3,000,000 / Year

Projects (5 years) 2. Aditive manufacturing : $ 3,000,000 / Year

Total = $ 6,500,000.00

Project (3 years) 3. Alphalt Coating : $ 500,000 / Year

• Additive manufacturing • Advanced Forming Technology • Micro and Nano Manufacturing • Advanced Thermal Treatments • Advanced coatings • Virtual manufacturing • 3D impresion • Conventional and Advanced Materials • Conventional and Advanced manufacturing methods

Advanced Manufacturing Technologies • Sensing, Performance, Monitoring, Measurement,

Inspection and Automation • Interface M2M m2m • Adaptive robotics, Collaborative, Cognitive • Intelligent Embedded Systems, Adaptive Control and

Cognitive • ICT, Software, SCADA and Big Data • Production management, logistics and supply chains • Mobile apps • Internet of Things

Smart Manufacturing

• Remote monitoring • Self-diagnosis and self repair Autotune • Intelligent and self-repairing materials • Intelligent inventory • ICT, Software, SCADA and Big Data

Smart Maintenance

• Economic Sustainability Manufacturing • Socially Sustainable Manufacturing • Environmental Sustainability Manufacturing • Conventional and Alternative Energies • New Materials

Sustainable Manufacturing

Advanced &Smart Manufacturing

CIDESI Thematic Lines (Business Cores 2015-2020)

Collaboration Network into CIDESI

Coatings

Joining Technologies

• Multifunctional coatings • Performance evaluation • Modelation and simulation • Procesing and synthesis of

materials

• Application • Automation

• Failure analysis, metallography, Scanning Electron Microscopy

• Mechanical Test • Chemical Analysis • Non Destructive Test

• Test • Application • Conventional and

advanced manufacturing

Manufacturing Qro.-EDOMEX - NL

Materials Technology

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjnvpv-r4LLAhXByyYKHXW1BmwQjRwIBw&url=http://www.thefabricator.com/article/automationrobotics/un-robot-para-soldaduraaen-continuo-movimiento&bvm=bv.114733917,d.cGc&psig=AFQjCNEoVGZKEtgGTP5e2BDXW6xiO-H-1g&ust=1455921379986206

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiD8vqzsILLAhWGJCYKHbi9A40QjRwIBw&url=http://www.mx.all.biz/limas-rotativas-herramientas-de-corte-de-carburo-g883&bvm=bv.114733917,d.cGc&psig=AFQjCNEvVrwe3wvo0z4FzxDOiAt4la77hw&ust=1455921502257862

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjt7YuisYLLAhUJ6iYKHcrDCN4QjRwIBw&url=http://www.enditec.com.ar/&psig=AFQjCNGKOd9mLDABpNusCgR-wCDTSPOB1w&ust=1455921723628347

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiJv_fYsoLLAhVIJCYKHQ_sAooQjRwIBw&url=http://tammesa.com.mx/servicios.html&psig=AFQjCNFr_IpDOu0fwzT-GjkJDrl7JC3vLw&ust=1455922000923724

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjlsOmis4LLAhWBKiYKHSOUDVQQjRwIBw&url=http://vaspview.sourceforge.net/&psig=AFQjCNGwmk0njcDktgBhlwLnb1bNO4VHxQ&ust=1455922247188253

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwi2_PKxtILLAhXBQyYKHQB7AswQjRwIBw&url=http://fejer.ucol.mx/cuicbas/?p%3D193&bvm=bv.114733917,d.cGc&psig=AFQjCNFTCqxikugnvfbbBUVRGhl2uIS_yQ&ust=1455922510558849

Market Coatings

Reliability

Durability

Performance

Cost

Energetic Efficiency

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiyzLnKpYLLAhXI7iYKHU1EA1gQjRwIBw&url=http://www.precision-plating.com/&bvm=bv.114733917,d.cGc&psig=AFQjCNFBgoZPX21P5Gb87Yo7pMR15N2nQA&ust=1455918591571572

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwi9xbWEpoLLAhUC6yYKHa99BtQQjRwIBw&url=http://www.boletinindustrial.com/producto.aspx?pid%3D124&bvm=bv.114733917,d.cGc&psig=AFQjCNGG5r4f9YbiJ1_bpfASFMqBaoZWHQ&ust=1455918524406933

e

Laser Cladding CVD

Gri

d B

last

ing

Ho

t p

ress

ing

HEB

Mill

ing

Glo

ve b

ox

CMT Welding

HTT PVD Nitriding

Planned dist ribut ion of t he facilit ies

Coat ings Division

SEM TEM

Microscopy Lobby

(CIDESI-Jeol Show Room)

FIB

First Floor


Coat ings Division

Coat ings Division


Principal

Manager

Meeting Room

Admisnistrative Offices (Director Assistant &

Lobby)

Trib

om

eter

A

bra

sio

n t

est

Sc

ratc

h t

est

C

alo

test

XRD GDOES

Raman IR

UV-VIS

Sim

ula

tio

n L

ab

DSC TGA

Nanoindenter C

orr

osi

on

Store Room

Second f loor

Research Topics of interest Coatings Innovation Division

International Consortium in Coating Technologies

Manufacture


Surface Engineering

Characterization & Performance


Structural & microstructural characterization

TEM

FIB

Mechanical Characterization

Nanoindenter

DFT Calculations

Simulation of Thermodynamics & Kinetics of Materials

Simulation of Contact Mechanics

TS Diagnostic plume & plasma

Characterization


Thermal Spray Coatings

CFD Simulation

APS, SPS

HVOF, HVAF, HVOLF

HP-CS

APS

HVOF

Thermal Plasma Propulsion

Spin-Offs incubator

Advanced and smart Manufacture



Consortium

Capabilities

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.marsilinox.pt/es/soldadura-robotizada.html&ei=ZlO5VNiUHpDKoAT5kYDoAw&bvm=bv.83829542,d.cWc&psig=AFQjCNEtIWPwQGCHqZVfNgmaeLUaPuOZRQ&ust=1421518040116907

High-Temperature Degradation of Alloys and Coatings Research Experience

Kinetic Study and Characterization of TGO on Commercial b-(Ni,Pt)Al

Bond Coats used in TBC systems for Gas Turbine Engine Applications

Funded by Project Title

Multiphase, Multifuctional Ceramic Coatings

Investigation of the Transitions between Desposit-Induced Degradation Regimes

and the Influence of Alloying Elements in Coatings and Structural Alloys

Oxide Evolution Dynamics and Stability in Harsh Enviroments

PhD Juan Muñoz Saldaña and PhD Juan Manuel Alvarado Orozco

PhD Gerardo Trapaga Martinez and PhD Juan Muñoz Saldaña

PhD Gerald Meier and PhD Juan Manuel Alvarado Orozco

PhD Brian Gleeson , Yihong Kang and PhD Juan Manuel Alvarado Orozco

0


Sub

stra

te T

em

pe

ratu

re (

x10

0)

(°C

)

- 10 - 1 - 0.1 0 0.1 1 10 102 103 104

2

4

6

8

10

12 Coat ings

Plasma assisted

Nit ruring

Thermal Spray

Cold Spray



Nit ruring

Carburizing

Borizing

Diffusion

CVD

PVD

PA- CVD

HiPI MS

P3e





0


Sub

stra

te T

em

pe

ratu

re (

x10

0)

(°C

)

- 10 - 1 - 0.1 0 0.1 1 10 102 103 104

2

4

6

8

10

12 Coat ings

Plasma assisted

Nit ruring

Thermal Spray

Cold Spray



Nit ruring

Carburizing

Borizing

Diffusion • Furt her explore t he degradat ion

mechanisms (oxidat ion and stabilit y) of t he

Ti1- xAlxN and Cr1- xAlxN systems at high

temperat ures.

• Determine effect s of dopant s and pre-

t reat ment condit ions on a- Al2O3

establishment and subsequent st ruct ure

stabilit y, t r ibological and mechanical

propert ies of single- layer coat ings.

• Opt imizat ion of t he deposit ion parameters

of commercial coat ings.

• Development of new hard- coat ings

architect ures (e.g. mult ilayer, superlat t ices,

composites and nanocomposites) for

improved HT protect ion.

• Development of new composit ions and

opt imal process condit ions of target s for

PVD coat ing applicat ions.

• Develop alternat ive novel coat ings systems

such as oxides (mullite, Al2O3, HfO2)



CVD

PVD

PA- CVD

HiPI MS

P3e





0


Sub

stra

te T

em

pe

ratu

re (

x10

0)

(°C

)

- 10 - 1 - 0.1 0 0.1 1 10 102 103 104

2

4

6

8

10

12 Coat ings

Thermal Spray



Diffusion


Thermal Spray

Cold Spray



• Thermal Barrier Coat ings Systems

• Hot- Corrosion

• Oxidat ion/ Sulf idat ion

• Carburizat ion

• Wet- Corrosion & Erosion

• Catodic Protect ion

• Wear & Abrasion Systems

• Addit ive manufact uring & Remanufact uring

Hardwicke et al (2013)

0

3000

500

1000

1500

2000

2500

200 400 600 800 1000 1200

3500

Particle velocity (m/s)

Fla

me T

em

pera

ture

(°

C)

HVOLF

PLASMA

HVOF

HVAF

COLD SPRAY

HAp

YSZ

REZ

HP COLD SPRAY

Thermal-Kinetic Compromise Chart

Current Thermal Spray Technologies

CFM56 Turbine GE-Snecma Joint venture

Combustor

High-pressure Compresor

Low-pressure Compresor

Fan

Extracted from the GE Homepage

High pressure Turbine

Low pressure Turbine

Blade

Cross section

TC

BC

IDZ

SA

Thermal Barrier Coatings System

TGO

Al2O3

Role: Extend the limits and durability of

high performance alloys in gas turbines.

Surface Degradation of a Turbine Component Gas turbine blade, showing isotherms equivalent to full-power operation

At least two different regimes of degradation can be

defined for a Na2SO4-induced hot-corrosion attack.

Deposits: Na2SO4 +/- SiO2, CaO, MgO

Naval application

Aeronautical application

Type I Hot-Corrosion

Type II Hot-Corrosion

2

Adapted for Nicholls (2003)

Additive Manufacturing (AM)

3D objects Layer-by-layer

Computer Aided Design (CAD)

DIFFERENT TECHNIQUES

LEN

S

DM

LM

Co

ld S

pra

y

ADVANTAGES

Differen

t M

aterials N

ot

Mach

inin

g

Co

mp

lex G

eo

metries

Laser and material interaction

W. M. Steen, Laser Mater. Proc., Springer-Verlag (2003)

Honeycombs structures

Zinc Bath Rolls

Automotive

Pumping of Sea water

Turbine blades AM

Applications

Turbochargers

Additive Manufacturing: Applications in México

Re-manufacturing • Centrifugal compressors

and blowers • Industrial Gas Turbines • Load engines

Manufacturing and Re-manufacturing • landing gear • Advanced bearings and seals Design and manufacturing • Turbomachinary seals

Re-manufacturing • Cutting tools • Storage Tanks • Pumping machinary • Valves Manufacturing (new disigns) • Imprube parts for pumping

machinary • Drilling • Valves

Design, manufacturing and Re-manufacturing • Aircraft parts (Nozzles

blades, etc)

Oil & Gas opportunities

Laser Cladding

Method of depositing material by which a powdered or wire feedstock material is melted and consolidated by use of a laser in order to coat part of a substrate

Laser Engineered Net Shaping (LENS)

• fabricating metal parts directly from a computer-aided design (CAD) solid model by using a metal powder injected into a molten pool created by a focused, high-powered laser beam.

• Objects created with this technology can be substantially larger in relation of LC, even up to several feet long

Thermal Spray

• Melted (or heated) materials are sprayed onto a surface. • Thick coatings (from 20 µm to several mm) • Materials: metals, alloys, ceramics, plastics and composites. • They are fed in powder or wire form • The "feedstock" is heated by plasma or arc means

Definition

ARC HEATED

PLASMA HEATED

The "feedstock" is heated by plasma or arc means

Thermal Spray

ARC HEATED

PLASMA HEATED

Heating Means

LASER MANUFACTURING- Opportunities

Laser power

Deposition direction Microstructure

Laser Cladding Applications Automotive industry

Coating: Cobalt Alloy (Stellite) Increased lifetime over Original components

Provide greater resistance to wear

Laser Cladding Applications Industrial Gas Turbines

To apply a thermal barrier coating

Restoration of turbine blades

Knut Partes et al. Surface & Coatings Technology 202 (2008) 2208 –2213

* K.M. Jasim et al. - Journal Of Materials Science 25 (1990) 4943-4948

* R. Vilar et al. Acta Materialia 57 (2009) 5292–5302

Laser Cladding Applications Aerospace industry

• Adaptive Restoration

E. Bagci / Advances in Engineering Software 40 (2009) 407–418 J. Gao et al. / Advances in Engineering Software 37 (2006) 592–600

INPUT (Damaged part)

DATA CAPTURE (Hardwares and methods)

• CMM • Laser scanner • Optic scanner • MRI • Stereo • Scanning

REVERSE ENGINEERING (Softwares and steps)

• PC-DMIS • CopyCAD • Pro/Engineer

Generation of Point Clouds

Generation of Boundary curves

of parts

Generation of Surface and solid

models

CAD

CAM

CAE

Laser Cladding Problems

• Influence of different factors on the coating deposition rate and laser energy efficiency

– Laser type,

– Laser power,

– Laser scan speed

– Preheating temperature

– Thermal cycles


Influence of the substrate temperature and the laser power on the coating properties

D. Wang et al. / Optics & Laser Technology 77 (2016) 16-22

• Substrate: 10 mm in diameter. AISI 1045 carbon steel

• Coating: Ni-Cr-Si

4.0 4.5 4.0 4.5 Laser Power (KW)

25 750 Substrate temperature (ºC)


• Typical microstructures of the laser coatings applied at 4 mm/s (Left) and 30 mm/s (Right)

• Substrate: High Carbon Steel, Coating: Fe alloy (Cr, C, Ti, Nb, Fe)

Qing-tang LI et al. Journal of iron and steel research, international. 23 (2016) 124-129

Influence of the scan speed on the coating

(a) (b)


• Cross section of Satellite 6 Alloy powder clad on a DIN 2393 steel plate (Left). HAZ simulate en COMSOL MULTIPHYSICS (right),

W. Ya et al. Journal of Materials Processing Technology 230 (2016) 217–232

• Study of the heat affected zone (HAZ)

LENS Problems

• Specimens fabricated with different laser power: (a) 326W; (b) 255W; (c) 410W; (d) 230W; (e) 510W

F. Niu et al. / Journal of the European Ceramic Society 34 (2014) 3811–3817

Laser power influence

LENS Problems

• Solidification microstructure when laser moving speed is (a) 2 mm s-1, (b) 10 mm s-1 and (c) 20 mm s-1.

H. Yin, S.D. Felicelli / Acta Materialia 58 (2010) 1455–1465

LENS Problems

• Substrate temperature as a function of the time S.M. Thompson et al. / Additive Manufacturing 8 (2015) 36–62

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