Surface coating for metal and plastic
Based on our already developed systems, we can offer you a wide range of different surface coatings for ceramics. Since each system – from the choice of the precursor to the finished sol – was developed and synthesized in-house, a functional optimization of our sols to your special requirements is possible. In the past we have often succeeded in adapting laboratory processes for the synthesis and coating of brines to industrial applications. Within the scope of feasibility studies we offer to carry out first coating screenings on your sample samples.
In addition, we also take on new challenges to make ceramic coatings possible. Ceramic coatings based on ceramic slurries or geopolymers can lead to completely new coating properties. We work daily to make our CerCoat® range more versatile.
When are ceramic coatings used?
Ceramic coatings are always used when other materials reach their material limits. For example, the conditions and requirements at the interfaces of metallic constructions are often different from those in the volume of the material itself. These can be thermal stress, excessive wear, electrical conductivity or contact with melts. In these cases, a ceramic coating can achieve an improved and/or additional functionalization of the surface, extend the service life of components and save costs. The application of ceramic coatings thus leads to a functional separation of the surface and the actual material, with the aim of optimally adapting the surface properties of the component to the environmental influences.
What properties do ceramic coatings offer?
The possible properties of ceramic coatings are as versatile as the material-specific properties of ceramic materials themselves:
- Wear resistance
- high hardness
- Resistance to heat and cold
- Corrosion Resistance
- electrical insulation
- low thermal conductivity
- high thermal insulation
- Resistance to acidic and basic environments
- Resistance to organic solvents
- piezoelectric properties
No ceramic material can cover all the above properties at the same time. The final property of the ceramic coating, however, depends largely on the starting raw materials used. Therefore, the choice of raw materials must be carefully matched to the respective application.
Which processes are used to produce ceramic layers?
In the meantime, a whole range of processes for the production of ceramic coatings has become established. A distinction is usually made between thick and thin-film techniques. For the production of thick layers (>30 µm), thermal spraying processes such as flame and plasma spraying are preferably used, in which the material to be coated is first melted or fused on and applied to the substrate surface with the aid of a spraying device. For the production of thin layers (<30 µm), on the other hand, processes such as PVD, CVD, galvanic processes and, more recently, increasingly the sol-gel process are used. In the PVD process (Physical Vapour Deposition), the coating material is generally put into a vaporous state in order to then be deposited as a thin layer on the component surface. In the CVD (Chemical Vapour Deposition) process, a gas with the coating elements reacts with the substrate surface in a reaction chamber under the influence of heat, resulting in the desired coating.
What is the principle of sol-gel coating?
Glass and ceramic materials are usually produced by high-temperature processes. The sol-gel process offers the alternative to produce these materials by chemical synthesis, whereby only a thermal post-treatment is necessary to form the final material. The term “sol-gel” describes the reaction process itself, in which a solid gel is formed from a liquid sol.
A sol is a stable suspension in which very fine non-metallic particles (nano range) have been dispersed. Due to its liquid properties, the sol can be applied to the surface of a component via a coating process and wet it homogeneously. Through hydrolysis and condensation, the dispersed fine particles then begin to form aggregates. Through further formation, enlargement and merging of aggregates, a comprehensive network is finally formed. The sol is now completely gelled, resulting in a solid layer (coating) on the component. Before the coated component can be annealed, it must pass through a drying step to completely remove any remaining liquid from the network that has formed.
What are the advantages of sol-gel coating over PVD, CVD and thermal spray processes?
The advantage of the sol-gel process over all known coating processes is primarily the significantly reduced production costs of the ceramic layers. The process does not require complex equipment or closed chambers, nor does it require a high energy input. Therefore, the sol-gel process is the most sustainable and environmentally friendly method of applying ceramic coatings. In addition, unlike others, the process does not pose a safety risk for its user. Since several processes (dip, spin or spray coating) can be used for sol-gel coating, it is possible to produce both relatively thick (up to 50 µm) and very thin layers (approx. 500 nm), thus covering a very wide range of layer thicknesses.
What advantages do thin films offer over thick ones?
A ceramic coating on a metallic substrate not only offers advantages, but also harbors dangers. Due to the brittle material behavior, ceramic coatings can easily flake off when bending stresses occur. Differences in thermal expansion can also lead to failure. Basically, it can be said that the danger of flaking increases with the thickness of the layer. Therefore, a major advantage of thin coatings is their better resistance to spalling.
Welche Coating-Verfahren bieten wir an?
We apply sol-gel layers using two different methods:
In the dip-coating process, the component is automatically immersed in the sol. Pulling it out then causes a layer to be applied to the component. It is important in this process to work at a continuous speed both during dipping and pulling out, and to avoid irritation of the sol during coating in order to avoid inhomogeneities and defects in the resulting layer. The thickness of the coating can be controlled by the speed of the pull-out. If it is adjusted slowly, the result is a thinner layer. If it is set faster, a thicker layer is obtained. Dip-coating allows layers of approx. 500 nm to a maximum of 2 µm to be applied, although the process itself can be used for simpler geometries.
In contrast, the spray coating process can be used to coat much more complex geometries. Here, the sol is applied to the component in finely atomized form with the aid of a spray gun and air pressure. The process allows multiple applications, allowing the desired layer thickness to be set very precisely. In this way, layer thicknesses of approx. 1-50 µm can be achieved.
In the case of both processes, the components with the applied layers are first dried after coating and must then be cured in the oven at moderate temperatures, whereby the final properties of the coating are created.
Which ceramic coatings do we offer?
CerCoat® - H forms a wafer-thin, glass-like, transparent coating that is characterized by outstanding hardness. Additionally, coated metal surfaces are optically enhanced. The characteristics of CerCoat® - H are increased scratch resistance (hardness can be adjusted according to requirements) very low film thickness (< 1µm) Dishwasher resistant Solvent resistant Facilitates the cleaning process Baking temperature > 180°C CerCoat® - H is applied by us as standard using the dip coating process.
By coating with CerCoat® - Y, hydrophobic properties can be achieved on a component surface. The system dispenses with the usual fluorine modification, making it significantly more environmentally friendly. CerCoat® - Y has the following properties: Transparent layer Hydrophobic properties, Contact angle from 90° to 110° against water Reduction of the adhesion of Plastic melting in the injection molding process Facilitates the cleaning process Resistant to chemicals and solvents Baking temperature >200°C Both dip coating and spray coating are suitable as coating processes. Spray coating is often preferred because it also allows complex geometries to be coated.
CerCoat® - P is a system in which ceramic particles are added to the sol. Thus a structuring of the surface is achieved. The layer thickness can be varied by the filling degree and/or the number of layers applied. The wear resistance is significantly increased compared to unfilled sols. Additionally, the electrical insulation and dielectric strength are increased. CerCoat® - P has the following properties: Transparent to colored coating, depending on the type and filling level of the particles Hydrophobic properties Contact angle from 90° to 110° against water By adding ceramic particles a layer thickness up to ≥ 80 µm is achieved Wear resistance, depends on the degree of filling with particles Electrical insulation ≥ 1,5kV Baking temperature > 200°C to 300°C CerCoat® - P is applied by spray coating.