Peru 1 PDF

Univ.-Prof. Dr.-Ing. habil. B. Wielage Prof. Dr.-Ing. habil. S.
Steinhuser
S. Steinhuser
Lehrstuhl fr Verbundwerkstoffe
Technische Universitt Chemnitz
TENDENCIES IN THE DEVELOPMENT

OF COATINGS AND THEIR
MANUFACTURING
S. Steinhuser
TU Chemnitz, Lehrstuhl fr Verbundwerkstoffe, Chemnitz, Deutschland
Lima (Peru), 23. 06. 2006
1
Leiter: B. Wielage
Univ.-Prof. Dr.-Ing. habil. B. Wielage Prof. Dr.-Ing. habil. S. Steinhuser
S. Steinhuser

Introduction (Remarks about our institute and
Chemnitz in Saxoni, Germany)
Coatings - general survey

Coatings - Examples
Coatings of paint
Electrochemical coatings
Ceramic coatings
Plasma coatings (PVD)
Thermal sprayed coatings
Some aspects of nano-technology
2 Conclusions
Acknowledgement
S. Steinhuser
Introduction
3
S. Steinhuser
Coatings
general survey
4
S. Steinhuser
Manifold technically useable coating systems and surface technologies are

integral part of our present-day life. High quality standards and service values
have been achieved in many domains.
We have become accustomed to coatings and we often only take notice of
them if their functionality has become constricted as a result of a problem.
Without surface techniques modern technologies such as traffic engineering,
information technology, medical engineering or micro and nanotechnology are
not practicable. Light-weight construction is very often connected with surface
enlargement and therefore requires comprehensive protection. Not only the
coating technologies but also the processing and testing methods as well as
the modelling and simulation theories have to be developed further or anew.
Innovative surface technology contributes to the development of new and to
the optimisation of products already in use. For this reason surface technology
will be considered a development impulse ranking amongst the strengths of the
economy.
On the one hand coatings comply with decorative, aesthetic-improving
requirements and therewith improve the market success of products, on the
other hand they meet multifunctional requirements (friction decrease or
increase; wear and corrosion protection; improvement of optical, thermal,
5 electrical, mechanical, physiological or medical properties) or serve as
information storage and improve operational reliability and life cycle.
S. Steinhuser
Basically, there is demand for high-quality, environmentally sound, process-

integrated and cost-minimised surface technologies.
The scientists and engineers are required to choose optimal conditions with
regard to the technical-technological and economic-ecological aspects and to
develop and apply them respectively.
Starting from the demands on surfaces and materials, it is essential to

recognise technological trends or emerging restrictions (e.g. restrictive or
prohibitive provisions on the part of the EU) at a very early stage. The
constructing engineers and developers have to understand the surface of a
component part as a constructional element and to include it into their
calculations. The optimal coating thickness has to be determined and the
stress maximum during load must not be located in the interface range.
Economical and eco-technical developments have to be incorporated.
6
S. Steinhuser
Increasingly more complex demands are made on the uncoated or

coated surface. The increase in power density of machines and the
rise of efficiency with the reduction of the total energy consumption
leads to ever-increasing operational demands on components (e.g.
motor, gear, bearing, brakes; compare Figure 4).
Additionally, surfaces are subject to strong tribological loads because
of the sparing application of precursors (e.g. lubricants).
Plasma technologies have become an important technology factor.
Modern coating systems for dry chipping are based almost without
exception on a TiAlN basis. Glass, foils and transparent plastics (e.g.
polycarbonate) are stabilised (scratch resistance) with thin coatings in
which ceramic nanoscaled particles are incorporated.
Hightech can also be found in metal-armouring refinement, for
example, in the additional upgrading of galvanised surfaces by means
of coatings with high-rate electron beam vaporisation or high-rate
sputtering.
7
S. Steinhuser
The mixed-architecture construction which necessitates pre-treating and

coating of different materials in one technological sequence makes high
demands on the coating experts.
More and more functions are being integrated into the surface
(multifunctionality; release of smells from microcapsules after a certain
wear in composite coatings; sensory surfaces, e.g. the indication of product
changes through colour changes of the package, for example, milk cartons;
self-cleaning and self-healing of the applied coatings).
Technical effects regarding the materials are increasingly tried to be
combined with processing technologies (e.g. surface modification through
aimed grinding). In-situ property requirements have to be met (e.g. coatings
in accordance with the wear pattern).
8
S. Steinhuser
In many cases the surface area of materials or

component parts is exposed to mechanical, tribological,
corrosive or thermal load - frequently in a combined form.
In order to avoid damages or destructions, very often
coatings are applied. Technological progress is not
conceivable without the application of coatings or coating
processes.
The surface and also the coatings are important for
decorative appearance, for functional properties and
nowadays for good feeling.
It was a long way to the modern technology.
9
S. Steinhuser
Surfaces as boundary regions between two media such as technical

objects (component parts, equipment, ...) and their adjoining space
(vacuum, atmosphere, fluid, bottom, ...) show very specific properties
on the one hand and they are always subjected to the influences of
their environment on the other. They either have to fulfil a certain
function (e. g. cylinder running in an engine) or a subordinate task (e. g.
the outer surface of an engine block). Surfaces can either develop
through an individual process (e. g. casting/solidification or machining)
or through a series of processes (e. g. milling, deep drawing, pre-
treatment, varnishing).
10
S. Steinhuser
In the course of this, processes such as material removal (e. g.

chip forming, pickling), material application (e. g. electroplating,

varnishing) or processes that change the properties of the
materials (e. g. milling, surface layer hardening, chemical
transformation) are used which finally lead to surfaces with very
different properties. Further functional requirements are made on
the surface region (corrosion and wear protection, decorative
effects, electrical or thermal conductivity and insulating capacity,
diffusion barriers, radiation absorption or reflection, physiological
harmlessness, low contamination, catalytic behaviour etc.),
whereas the basic material above all has to provide the expected
11 strength behaviour and support effects.
S. Steinhuser
Anwendung Korrosions- Verschlei- dekorative funktionelle

schutz schutz Gestaltung Zwecke
Schichtstoff 1)
Anstrichstoffe + + (+)
Metalle + + + +
Metallverbindungen + + + +
Silikate 2) + + + (+)
Kunststoffe + (+) + (+)
le, Fette + +
Wachse, Paraffine +
Gummi, Kautschuk + +
Teer, Bitumen +
1) Schichten mit spezifischen Eigenschaften wie spezielle thermische und/oder elektrische

12 Leitfhigkeit oder Isolationswirkung, elektromagnetische Eigenschaften, optische
Wirkungen u. a.
2) Email, Glas, Keramik, Zement
S. Steinhuser
Possibilities of coating
Inserting of elements
Application of Converting of
coating (paints,...) surfaces
13
S. Steinhuser
14
S. Steinhuser
Golf V
Decorative surfaces
Corrosion and wear resistance
Reliability
Functionality
15
Long-life cycle Quelle: H-J. Koeppen , G.

Laudien,Volkswagen AG,Zentrallabor
S. Steinhuser
Vollverzinkte Karosse des Golf IV

12 years guarantee against rust

elektrolytrisch- und
feuerverzinkte Bleche
Heiwachsflutung (hot
wax)
Mehrschichtlackaufbau
2K-
Basecoat Clearcoat
Fller
KTL
Zinkphosphatierung
Verzinktes
Stahlblech
16
Quelle: H-J. Koeppen , G. Laudien,Volkswagen AG,Zentrallabor

S. Steinhuser
Trends in the industry
Miniaturisation
Lightweight construction
Advancement of surfaces
Saving of energy
Environment protection
17
Quelle: VDI Technologiezentrum Dsseldorf Sept.2004

S. Steinhuser
18
Quelle: Alex Dommann, SGO GV 20 May 2005

S. Steinhuser

Market Forecast Nanotechnology ($ bn)
Matthias Werner, et. al. , Deutsche Bank Nanoreport 2004

19
S. Steinhuser
20
S. Steinhuser
21
S. Steinhuser

Ca. 20 Chips von Infineon in a care !
AIR CONDITION AIRBAG
POWER STEERING INTELLIGENT SEATS
CAR PC DOOR MODULE

BLUETOOTH
TELEMATICS
NAVIGATION TIRE PRESSURE
GSM GPS MONITORING SYSTEM
LIGHT MODULE ABS

ENGINE MANAGEMENT VEHICLE STABILITY CONTROL
TRANSMISSION CONTROL
22
Quelle: DESIGN&VERIFICATION 2/2004

S. Steinhuser
head / hard disc
23
S. Steinhuser
24
S. Steinhuser
25
S. Steinhuser
Joining of electronical and
biological systems
26
S. Steinhuser
Prospect of totality
27
Quelle: S. Steinhuser
Complete process
(example)
Legislation of Legislation of
environment Cost pressure
safety at work
Energy
supplies coatings
Units, Pre After

materials treatment coating
28 treatment
S. Steinhuser
Exchange regarding data relevant for coatings and component parts

Fundamental knowledge
Industry-academy-collaboration
Coating
Coating properties
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Construction
R&D engineer
Coating Component
load Consumer
engineer requirement
Coating characteristics
29 Practical know how

S. Steinhuser
Trends and ways of thinking
Optimating traditional Developing new materials

materials and technologies and technologies
30
S. Steinhuser
Using Synergien.
Thinking in networks.
Single fighters are undesirable.
Prospect of totality.
Researching world wide.
31
Using cooperations.
S. Steinhuser
All industrially manufactured units have a functional surface...
Constructors must
understand the
surface of a unit as a
construction element.
32
S. Steinhuser
Trends of development
scientifical
technical economical
environment
legislation
(national - international)
33
S. Steinhuser
Those who want to participate in technological progress must not allow

themselves any gaps of knowledge
Development of materials
Mischbauweisen
Process technology
(quality)
Multi functional, intelligent

Environmental friendliness coatings
Product development Adaptation of coating thickness
34 Ability for recycling
S. Steinhuser
Material load
and
35
coatings
S. Steinhuser
36
S. Steinhuser
Material load requirement and its consequences
Reduction of Use Properties Damage
covered external
defects influences
Overloading Destruction Fatigue
mechanical mechanical chemical

electrochemical
thermal physical
Frequent interaction between
the individual load requirements
e.g. tribocorrosion, stress
Corrosion corrosion!
Cavitation
37
S. Steinhuser
Properties generated or changed by surface treatment or coating

Surface Low or high

Properties
interaction with
Reproducibility environment
Applicability
Economy / marketing High interaction

with substrate
Environmental compatibility
Recycling Substrate
Influence on substrate
and material compound
(layer - substrate)
38
S. Steinhuser
Methods used in surface technology

Used surface processes Surface processes in the future
electroplating 70 PVD 32
varnishing 56 26
electroplating
heat treatment (diffusion process) 54 thermal spraying 19
thermal spraying 43 17
CVD
PVD 39
varnishing 17
heat treatment (hardening) 38
heat treatment (hardening) 14
currentless deposition 38
currentless deposition 12
CVD 30
anodising
anodising 21
Ion plating 3
pre-treatment and cleaning 17
nanotechnology 3
hot dip coating 16
heat treatment (diffusion process) 3
deposit welding 12
deposit welding 2
printed circuit technology 7
enamelling 2
ion beam process 5
printed circuit technology 2
enamelling 4
hot dip coating 2
sol-gel-process 3
sol-gel-process 2
laser beam process 2
other processes 5
other processes 4
39 0 10 20 30 40 50 60 70 80 0 5 10 15 20 25 30 35
S. Steinhuser
Environment
40
S. Steinhuser
Human beings are surrounded and

integrated in lots of systems.
As a first approximation it is the same in the
technology.
In the following parts Id like to talk about
some important systems.
41
S. Steinhuser
Environment
Environment-friendly process-technolgy
Environment-friendly materials
Application recyclable materials
Reduction materials variety
42
S. Steinhuser
Pre-Treatment
Pre-Cleaning
Mechanical Treatment
(Cutting, Grinding, Blasting)
Post-Cleaning
(Removing of Residues)
Masking, Covering of
Areas not to be Caoted
Coating
Post-Treatment (if necessary)
OR
Intermediate-Treatment
AND
Further Coating
As can be seen from the technological sequence (work cycle), in every

43
process step there are like in any other surface coating technology points
of contact with the environment.
S. Steinhuser
44
S. Steinhuser
Different materials
in one product
45
S. Steinhuser
Metallische Leichtbauwerkstoffe
Neue (ultrahochfeste) Leichtmetalle Leichtmetallbasierte

Sthle fr den neue Werkstoffe
Automobilbau
Einteilung z.B. in
DP-, CP-, TRIP/TWIP-, TMS- Aluminium u. MMC
Sthle Aluminiumlegierungen Einteilung z:B. in faserverstrkte
und partikelverstrkte MMC
Magnesium u.
Magnesiumlegierungen
Titanaluminide
Einteilung z.B. in 2-Ti3Al-, -TiAl,
Titan u. Ti2AlNb-Titanaluminide
Titanlegierungen
Einteilung z.B. in -, -, +-
Legierungen Metallschume
Einteilung z.B. in
46
geschlossenporige und offenporige
Beryllium Metallschume
nach Alisch, TUC
S. Steinhuser
VW Lupo Light weight construction
Lenkrad Heckklappe: Al /
Mg Hybrid Design
Tren
Motorhaube
Kotflgel
Bremstrommel:
Faserverstrktes Al
Fahrwerk: Al-
Komponenten
Bremssattel
47
Quelle: H-J. Koeppen , G. Laudien,Volkswagen AG,Zentrallabor

S. Steinhuser
Process integrated manufacturing

of functional surfaces
Today: Still predominantly produced in

separate process steps
In the future: Economizing of process

steps
48
S. Steinhuser
A wide field for further development

will be the improvement of the
process stability and process
control, to achieve an enhancement
of the process quality control. The
development and the application of
new feedstock materials under
economic and ecological aspects will
be of high interest for the future.
49
S. Steinhuser
Demands of economy
Pressure of price
Substitution or reduction of expensive materials
Reduction of process steps, variable production
Diversity of variants and technologies
Short times for developing and redesign
Highest demands on quality

Value creating
50
High productivity low costs
S. Steinhuser
Wear behavior
and
wear tests
51
S. Steinhuser
Circumstances of motion
Load
Operating variables State of friction
Temperature
Conditions of contact
Microgeometry
Counter body
Structure
of the
Surround medium
tribosystem
Material
Body
Interfacial medium
Wear process
Loss of material (wear quantity, wear products, wear debris) [DIN 50320]
52
Wear characteristics Wear phenomena (surface change)
Change of properties
S. Steinhuser
General possibilities of improving

tribotechnical properties
- interfacial material
- constructive and technological measures
- material composition and structure
53
S. Steinhuser
Characterization of tribology materials behaviour
Testing methods for Tests by integral Investigation of tribolo-

simulation of basic wear test methods Simulation of technical gical relevant material
wear systems properties
- abrasive wear - sliding wear test - stretching rolls - chemical composition

- adhesive wear - oscillation wear test - drawing - texture
- long time fatigue wear - fretting wear test - driving gear - hardness
- erosive wear test - state of stress
- Tabor-Abraser test - adherence of coatings
- grain size
10
4
test in practice
2
54
S. Steinhuser
Corrosion
behavior
and
55
Corrosion tests
S. Steinhuser
56
S. Steinhuser
Corrosion protection -
construction and material/coatings
Designabdeckung
Designabdeckung
57 New
New Beetle
Beetle
Quelle: H-J. Koeppen , G. Laudien,Volkswagen AG, Zentrallabor
S. Steinhuser
58

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Univ.-Prof. Dr.-Ing. habil. B. Wielage Prof. Dr.-Ing. habil. S.

Technische Universitt Chemnitz

TENDENCIES IN THE DEVELOPMENT

Lima (Peru), 23. 06. 2006

Technische Universitt Chemnitz

Coatings - general survey

Technische Universitt Chemnitz

Technische Universitt Chemnitz

Manifold technically useable coating systems and surface technologies are

Technische Universitt Chemnitz

Basically, there is demand for high-quality, environmentally sound, process-

Starting from the demands on surfaces and materials, it is essential to

Technische Universitt Chemnitz

Increasingly more complex demands are made on the uncoated or

Technische Universitt Chemnitz

The mixed-architecture construction which necessitates pre-treating and

Technische Universitt Chemnitz

In many cases the surface area of materials or

Technische Universitt Chemnitz

Surfaces as boundary regions between two media such as technical

In the course of this, processes such as material removal (e. g.

chip forming, pickling), material application (e. g. electroplating,

Technische Universitt Chemnitz

Anwendung Korrosions- Verschlei- dekorative funktionelle

1) Schichten mit spezifischen Eigenschaften wie spezielle thermische und/oder elektrische

Technische Universitt Chemnitz

Long-life cycle Quelle: H-J. Koeppen , G.

Vollverzinkte Karosse des Golf IV

12 years guarantee against rust

Quelle: H-J. Koeppen , G. Laudien,Volkswagen AG,Zentrallabor

Technische Universitt Chemnitz

Trends in the industry

Quelle: VDI Technologiezentrum Dsseldorf Sept.2004

Technische Universitt Chemnitz

Quelle: Alex Dommann, SGO GV 20 May 2005

Technische Universitt Chemnitz

Matthias Werner, et. al. , Deutsche Bank Nanoreport 2004

Technische Universitt Chemnitz

Technische Universitt Chemnitz

Technische Universitt Chemnitz

CAR PC DOOR MODULE

LIGHT MODULE ABS

Quelle: DESIGN&VERIFICATION 2/2004

Technische Universitt Chemnitz

head / hard disc

Technische Universitt Chemnitz

Technische Universitt Chemnitz

Technische Universitt Chemnitz

Units, Pre After

Exchange regarding data relevant for coatings and component parts

29 Practical know how

Technische Universitt Chemnitz

Trends and ways of thinking

Optimating traditional Developing new materials

Technische Universitt Chemnitz

Technische Universitt Chemnitz

All industrially manufactured units have a functional surface...

Technische Universitt Chemnitz

Those who want to participate in technological progress must not allow

themselves any gaps of knowledge

Multi functional, intelligent

Technische Universitt Chemnitz

Technische Universitt Chemnitz