Inert corrosion protection is a key to parts which are subjected to forces in a very aggressive and extreme chemical conditions,
including hydrogen sulfide and acids.

    The applications would include oil and gas industry and subsea pipeline valve applications, where maintenance is difficult.

Diamond Like Carbon Coatings Sulzer Metco Division DLC Proprietary Coating Family DLC: aC:H Hard amorphous carbon thin film very hard electrically insulating wear resistant Comprises C, H Primarily sp3 bonding => "Diamondlike" properties There are a few variants of DLC coatings Engineered interface layers for optimized film stress DYLYN®–doped: a C:H, a Si:O, a? Hard amorphous carbon thin film very hard electrically insulating wear resistant Comprises C, H, Si, O aC:H => "Diamondlike" properties aSi:O => enhances high temperature stability, leads to lower friction, lowers film stress Dylyn® is a family of coatings Low intrinsic stress Several US patents issued DYLYN®: a C:H, a Si:O Atoms* can be introduced into the carbon matrix to alter the coating properties These atoms can be metal; we most commonly use Titanium Others possible metal dopants include W, Hf, Zr, Al, Cu, Cr, Ni. Nonmetal ions may also be used Introduction of metal allows significant electrical tailorability Multilayer and gradient coatings are possible DLC vs Other Surface Treatment ABRASION:: The high hardness of DiamondLike Coatings reduce the likelihood of hard particle penetration into the tool or part. Coatings Reduce Abrasive Wear TOOL PART Hardness Comparison Hard Particle Soft DLC Hard 8000DLCDylyn®TiNCrN521004000500060007000Vickers ( HV)20000Metal Carbon1000Hard ChromeNickel TeflonDiamondCavidur® N3000 Coatings Reduce Friction // Material Pickup (Galling)(Galling) RESISTANCE TO ADHESION: The chemically inert characteristics of diamondlike coatings dramatically reduce possibility of cold welding and material pickup on the surface of the tool TOOL PART τ1 τ2 F=τ x A τ1 > τ2 0.8PTFEDLCTiN52100Dylyn®CrN0Cavidur® NDiamondMetal CarbonHard Chrome0.1Nickel TeflonCoefficient of Friction0.70.60.50.40.30.2 0.00E+002.00E064.00E066.00E068.00E061.00E051.20E051.40E05Wear ( mm3/Nm)TiNCrDylyn®/DLCCoating WearWear on Steel Ball (52100) Comparison of Wear Wear Factor(x 108 mm3/Nm)DLC1 5Dylyn®5 10WC/C41TiCN60TiN250TiAlN790 1000Coating F v Force (F): 20 N Velocity (V): 200 RPM Sliding Distance: 10,000 Revolutions Wear Rate Comparison of Coated and Uncoated Aluminum Coupons DLC Coated Uncoated Force (F): 1.7 N Velocity (V): 200 RPM Sliding Distance: 10,000 Revolutions Counter surface: ¼” 52100 Steel Ball Deep Wear Scar With Aluminum Particles Light Wear Scar With No Debris F v NewNew After 10 hoursAfter hours After 120 hoursAfter hours After 192 hours DLC TOOL PART Corrosice attach Corrosion Test Dylyn ® Coated ASTM B 11797 Salt Spray Test The high density and amorphous structure of DiamondLike Coatings inhibit the corrosive by products from penetrating into the tool. TiN Coated Amorphous coating structure without change in surface finish surface finish 2.5 μm Dylyn®/DLC (PACVD) TiAlN (PVD) SEM SEMComparison 5,000 X 1,000 X Surface Energy && Wetting Behaviour of Different Coatings Coatings lubricant fluid drop with constant volume, here water wetting angle of contact  fluid spreads over the surface TiAlN  TiN  Metal Carbide DLC Dylyn®  Better Wetting Behavior Better Release Behavior Closeup of a series of liquid droplets on a Dylyn® sample Surface energy is a measure of the affinity of a substance to stick to the material. The lower the value, the less likely a material will weld or stick to a surface. PFTE has a surface energy of 18 mN/m 20 40 40 42 42 46 46 53 Surface Energy (mN/mmN/m) Coatable Substrate Materials Metals Stainless Steel Carbon Steel Tool Steel Inconel Superalloys Aluminum Beryllium Copper Diecast Magnesium Carbides Tungsten Carbide Titanium Carbide Plastics Polyester (Mylar) Polyamide (Kapton) Ceramics Glass Alumina ceramics Aluminum nitride WCCo SiC Silica Semiconductors Silicon Germanium GaAs InP SiC 3μm SEM Cross Crosssection of Dylyn ®® on a metal substrate UUnnccooaattaabbllee MMaterials and/or Surfaces Uncoatable Materials Bronze Brass (Some exceptions depends on the alloys used) Lead (Pb) Manganese Tin (Sb) Low Temperature Braze (< 1000°F) Plastics Uncoatable Surfaces DLC Coated * Dylyn Coated * Chrome Plated Anodized Aluminum Note: We prefer to always coat virgin surfaces * We can sometimes coat over DLC or Dylyn by use of a Titanium layer. Characterization lab Thickness Tencor P10 and 16 Taylor Hobson Talysurf Hardness Nanoindenter Wear Sliding wear: pinondisk Adhesion Scratch Tester Rockwell C Indent Thermal Shock Testing Electrical Testing Microscopy Optical: inhouse SEM & TEM at BTC Other methods: FTIR UVVis Raman Spectroscopy Use of the Lab can show that all modifications in coating recipes can be quantified and measured to assure the new characteristic was achieved and show how all the related coating properties have been affected, as well as demonstrate current recipe coating properties. Sulzer is active in these focused application areas: Semiconductor components and tools ESC’s, vacuum chucks, cooling pedestals Docking components and screws for precision alignment Precision Valve components Air bearings Wafer/material handling components Wafer processing equipment Thermal Print Heads Molds for plastic molding Form giving molds / moving mold parts CD & DVD molds Medical Instruments… Racing/Automotive engine components Industrial Components Metal forming Dynamic Seals Applications In a nutshell: Why Sulzer Diamond Like Coatings? ®/DLC is able to offer a wide variety of properties with only ONE coating: lowest available coefficient of friction… (0.05 0.1) …which is maintained by the high hardness ( avg 85Rc) no surface roughness changes … that could influence galling and release properties Side benefits _ corrosion protection (amorphous coating) Coating temperature below 215°C Removable!! _ without changing the base surface Biocompatible Thank you….