Latest achievements in the field of modern surface treatment Thomas - - PowerPoint PPT Presentation

Latest achievements in the field of modern surface treatment

Thomas STIMPFLING, Florent DELIANE, Konstantin SIPOS

MMP 2015

Metallic Materials and Processes : Industrial Challenges

Deauville (France)

November 26th 2015

RESCOLL, Société de Recherche – 8 allée Geoffroy Saint-Hilaire - CS 30021 F-33615 Pessac CEDEX, FRANCE Phone : + 33 547 74 69 00 Fax : + 33 547 74 80 13 e-mail : Thomas.stimpfling@rescoll.fr www.rescoll.fr

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Rescoll in few words…

R&D

Polymers and Composites

Surface Treatment

Bonding and Bonded assemblies

Fire Engineering Analysis Testing Audits and Expertises Synthesis of Chemicals Regulatory affaires Machining Processes Production

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Rescoll in few words… 4 business units

B to B Collaborative Projects Internal Research Punctual basis Year contracts Analysis Vouchers Experts for the court Experts for the EC REACH and GHS Experts EWF bonding University Customised trainings

2 affiliates units

Machining Scale-up Production RMG Manufacturing STILZ Chimie

Rescoll – Surface division activities

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• Related topics :

 Surface preparation of materials.  Adhesion.  Processing :

• Functional primers.
• Functional coatings.
• Paints.
• Comprehensive approach comprising different aspects:

 Multi-skills (Formulation, Implementation, Characterization, …)  Multi-topics.  Multi-materials.  Interdisciplinary.

• Idea
• Faisability

R&D

• Scaling
• Qualification

Prototyping

• Production

Product

Research Innovation Knowledge

Testing

Surface treatments: advantages vs. inconveniences

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Metal Degreasing Chemical etching Conversion Coatings

• Solvents
• Acidic etching
• Anodisation
• Chemical conversion
• VOC
• Fillers

Advantages Inconveniences

• Homogeneity
• Surface texturation and

activation

• Improvement surface properties

(bonding, corrosion)

• Surface functionalization

(coating)

• Toxicity of components (CrVI…)
• Control of components
• Effluents reprocessing
• VOC

CrVI

Dead-line REACH = 2017 Alternatives are needed !!!

• Simplifications of process
• Lighten the structure
• Reduction of maintenance steps

Coating systems: News challenges…

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Coatings Challenges

Economic Aspect Environmental Aspect News Processes Multi- Functionality

• Legislations compliancy
• VOC reduction
• Effluents reprocessing
• Anticorrosion
• Intumescent
• Lubricant
• Biocide
• Dye
• And so…
• Implementation processes

Aircraft applications

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Wear resistance Corrosion resistance biocide Corrosion resistance Adhesion promoter Corrosion resistance & adhesion promoter Thermochromic Fire resistance

Thermochromic coating

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• There is a need to know that in case of backfiring :

 What temperature has been shown by the OMCs  If the CMO’s can be repared or replaced

• Concept: Thermochromic sensitive coating
• Next generations of Aircraft extand the use of Organic Matrix Composites
• But OMCs:

 Sensitive to temperature change  High temperature environments are critical

• The use of OMCs are critical in reactor zone due to backfiring

T

2 Partners: Rescoll Mapaéro

Fourmi

Fire resistant coating

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• Fire resistant evaluation (ISO 2685 - flame 1200°C )
• Substrate: AA 5xxx + Top-Coat RESCOLL.
• Compatible with aeronautic applications (T° >200°C / fluids compatibility)
• Performance : Evolution of temperature on non exposed surface

100 200 300 400 500 600 700 800 900 1000 50 100 150 200 250 300 350 Température (°C) Temps (s)

drilling ≈ 50s Drilling ≈ 280s

2 Partners: Rescoll Mapaéro

High temperature resistant coating

10 3 Partners: Rescoll Mäder Airbus helicopter

Clochette

Thermal stress area Paint degradation Loss of aesthetic

• Development of thermal resistant coating
• Up to 200 – 300°C
• Low VOC (< 420 g/L)
• Regulatory compliant
• Implementation by spraying with low thermal curing

Wear-resistant coating

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• Enhancement of fatigue resistance and durability under high loads for bearings
• Hybrid lubricant coating

 No modification of roughness  Scratch and abrasion resistance

Sol-Gel chemistry

Properties Target Results

Lubricant COF < 0.54 0.22



Roughness 0.15 µm 0.05  Temperature processing < 180°C 100°C 

• Weak deterioration of coating

after 104 cycles at 2 N

4 partners: Rescoll PIMM Fersa TTC group

Adhesion promoter coating

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• Coating for improvement of bonding properties on composite
• Clean one-stage process, free VOCs and small particle emissions
• Coating properties

 Adhesion promoter (covalent bonding)  Degreasing ability of the primer

« Dirty » substrate Coating of primer Primer curing Adhesive

« Clean » substrate

Sol-Gel chemistry

Reference Rescoll A Degreasing with Rescoll A Rescoll B

AF CF Adhesive 50%CF/ 50% AF Adhesive CF Composite 90%CF Adhesive

Degreasing with Rescoll B

12 Parteners:

Rescoll Aimplas Muegge Fraunhofer Composite aragon Synthesites Polymec RTU Resoltech Ecoinnova Acciona Alkè

Adhesion promoter & anticorrosive coating

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• Adhesion promoter and anticorrosive coating for bonding assemblies
• Substrate: AA 2xxx, 5xxx and 7xxx

Commercial Rescoll Corrosion resistance

(336 h NSS (ISO 9227))

OK OK

Adhesion property

KO OK Rescoll

336h NSS

(ISO 9227) AA 7xxx Primer Adhésive

5 10 15 20 25 30

Substrate Commercial Rescoll

Stress @ break (MPa)

Adhésive failure Cohesive failure Adhésive failure

Anticorrosive & biocide coating

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• Multifunctional coating dedicated to gas tank.
• Concept:

FFC after 1056h No pitting after 3500 h NSS

• Passive protection

Organic part: polyaddition Epoxy/amine Inorganic part: Sol-Gel chemistry

• Active protection

Corrosion inhibitor Biocide agent

8 Partners: Rescoll Mapaero L’electrolyse Airbus Dassault aviation EADS Cirimat LCPO

SMILE

Anticorrosive coating

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• Anticorrosive coating dedicated to structural elements (fuselage)
• Concept

Résistance à la corrosion

B R Q S

1 10 100 1000 10000 100000 1000000 10000000 2 6 9 14 23 |Z| (Ω.cm²) Temps d'immersion (jours)

Effet barrière

B R Q S

B Q R S

NSS (ISO 9227) 336h EIS 0.5 M NaCl

• Hybrid material = Significant improvement of corrosion properties
• Importance of matrix precursors

Barrier effect Corrosion resistance

Anticorrosive coating

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• ACET = Accelerated Cyclic Electrochemical Test

NSS

(ISO 9227)

ACET Avantages

• Standard
• Rapid (24h)
• Quantitative

Inconveniences

• Slow (few months)
• Qualitative
• Exposed surface

ACET (24h) equivalent to 1000 h of NSS

• Similar trends
• Differences due to:
• Thickness
• Localized matrice defects
• Cathodic polarization

Anticorrosive coating

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NSS (ISO 9227) 1500 h

1rst pit > 1000 h

NSS (ISO 9227) 1000 h

Self-healing effect

FFC (EN 3665) 1000 h

• Corrosion resistance
• Passive protection

Barrier property

• Active protection

Self-healing effect

• Excellent filiform corrosion resistance
• Transversal: Lmax < 1 mm
• Longitudinal: Lmax = 0,5 mm

CrVI Lmax ≤ 2 mm

Conclusion

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• News coating systems have to consider:
• Simple process
• Compliance to regulatory
• Environmental friendly
• Low cost
• Multi-functional coatings = attractive solutions
• Versatility of composition

 Chemistry routes  Fillers

• Easy to handle

 Spray deposition  According to usual system

• Reduction of number of layers with increasing functionalities

Chemistry route Fillers « Green » Multi-functional Coating

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Acknowledgements

• Dr. Thomas Stimpfling

R&D Research Engineer

thomas.stimpfling@rescoll.fr

• For financial supports,
• And you for your attention…