 |
 |
|
Unique PolyCermic Composite Coating for Light Alloys
Apticote 3200 is a unique electro-PolyCeramic composite that transforms the surface of light-weight alloys to provide a surface coating with the unique properties of low friction, low wear and superb corrosion protection.
The process is based on a duplex coating to provide surface properties that are un-matched by any conventional conversion or coating approach, the polymer being an integral part of the ceramic coating structure.
|
 |
|
|
Primary Features
- Superb corrosion protection; (> 5,000hrs salt spray)
- Extremely hard (up to 1,500Hv)
- Thick coatings, up to 100µ, with predictable coverage and dimensional control
- High wear resistance in sliding situations
- Very low friction (µ = 0.12)
- Tough, attractive finish
- Excellent bonding to the substrate
- Electrical insulation
| |
|
Some Key Benefits
- Reduced weight, with no wear, for automotive clutch baskets and piston skirts
- Light weight magnesium leisure wear, spectacles and watches, with no corrosion
- Eliminates galvanic corrosion cells with titanium components. Perfect for marine applications
- Replace expensive solid ceramics with a cost-effective coating, e.g. in ball-valves
- Prolonged corrosion protection for caps, housings and casings
- Corrosion protection, non-stick and low friction for components on packaging machines
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Automotive Pistons
Lowering the friction between the piston skirt and the cylinder bore pays real dividends in increased engine power.
In experiments on the Poeton engine test dynamometer, a 1.5% increase in engine power was resolved when operating A3200 coated pistons against an Apticote Ceramic 2000 coated bore.
There is also an end to scuffing and smearing of the aluminium to the bore surface!
Dyno in action |
For this application, the best performance is obtained with our ‘M’ type polymer, so that you should specify that variation of A3200. |
Clutch Baskets and Callipers
For lightweight aluminium alloy clutch baskets, A3200 provides superb protection from wear and damage, as well as reducing the friction.
In engine tests, the coated parts survived five times as long as uncoated baskets. And on the aluminium brake callipers shown below, A3200 provided unmatched corrosion
and wear protection, with the life extended 10-fold compared to that given by hard anodising. |
|
Bearing Surfaces
For dry running, where lightweight alloy shafts, journals, linear slide-ways are required to operate with low friction, anti-galling and minimal wear, Apticote 3200 coatings are unsurpassed.
For instance, A3200 is highly resistant to adhesive wear in sliding situations. The graph shows the relative wear rates in a ball-on-disc sliding test. It demonstrates that Apticote 3200 is almost as good as hard chrome plate, a coating that sets the standard for many applications.
On magnesium or titanium, Apticote 3200 will dramatically reduce both friction and wear compared to values obtained with the parent metal.
For instance, using a pin-on-disc sliding tester, Apticote 3200 gives much lower friction than conventional light coatings for light alloys.
| Surface |
Friction |
| Aluminium |
0.60 |
| Titanium |
0.90 |
| Magnesium |
0.60 |
| Hard Anodising |
0.55 |
| Electroless Nickel |
0.50 |
| Apticote 3200 |
0.12 |
 |
|
 |
Linear bearings coated with Apticote 3200, reducing rolling friction. Aluminium ball valve coated with Apticote 3200, ensuring ease of operation. |
|
Aluminium ball valve coated with Apticote 3200, ensuring ease of operation. |
|
|
|
|
|
Packaging and sorting machines – non-stick and low friction
Apticote 3200 coatings can give non-stick, non-wetting and low friction, bringing the advantage that these valuable properties can be produced on weight-saving and cheap-to-machine alloys of aluminium or magnesium. By creating the ceramic/polymer on the surface, the performance of sorting and packaging machines can be greatly enhanced.
In one application, machine downtime to remove sticky deposits was reduced 10-fold, with huge production savings.
Also, in a machine
sorting banknotes,
A3200 increased
the wear life of the
aluminium separator
disc, eliminating the
damaging build-up of gummy deposits that otherwise stopped production.
Galvanic corrosion protection
In offshore and chemical applications, where titanium is used for its weight savings and corrosion performance, it is often other parts that suffer. When in contact with titanium, parts made in ferrous alloys, copper alloys and aluminium can all suffer greatly accelerated galvanic corrosion. By providing superb electrical insulation, coupled with the anti-fretting action of the polymer/ceramic composite, Apticote 3200 completely eliminates the problem.
As an example, large titanium undersea structures were coated all over with an insulating layer, providing enduring corrosion protection to dissimilar metal mating parts.
|
|
Leisurewear
On moulded magnesium alloy watches and spectacles, Apticote 3200 has set the trend in aesthetics, combined with unmatched resistance to salt corrosion, sweat, sun-oil and all those concoctions that the wearer takes to the beach!
Whatever the colour, the Apticote 3200 system can handle it!
The polymer system within the coating can be tailored to meet any of your aesthetic requirements.
So, Apticote 3200 is unique in its ability to enable exciting new magnesium-based leisure products into the market place.
Insulation
Apticote 3200 provides both electrical and thermal insulation. Coatings on aluminium and magnesium can withstand DC voltages up to 1KV, ideal for applications like RF sealing bars. The coatings can stand temperatures up to 250DegC, allowing non-stick performance with the most aggressive products.
A3200 coatings
can provide the insulating base for a whole range of electronic parts, ensuring, where the conducting layer is laid over the coating.
|
|
|
|
Sport
Apticote 3200 brings wide benefits to the lightweight racing and mountain bikes, protecting Mg frames against corrosion and providing wear resistance for sprockets, brake hubs and discs.
Weight is everything! Let Apticote 3200 help you squeeze out those extra Kgms from your bike and make yourself the ultimate competitor.
Or you can improve your distance! Apticote 3200 adds scratch resistance, grip and spring to your lightweight titanium clubs.
Even the youngsters can get into the act with these lightweight clubs!
Vacuum applications
Apticote 3200 is suitable for operation in Space and terrestrial vacuum applications. For instance, in Mass Spec test, only water is emitted at 100°C.
The application here is on a titanium coil winder for an important space mission, with Apticote 3200 providing total electrical insulation and wear protection for the coil former.
Processing Characteristics |
|
Corrosion Protection
Apticote 3200 provides unparalleled corrosion protection for critical lightweight housings, casings and bodies. For instance, on 6082 aluminium alloy, for instance, the coating will provide 7,000 hours with no corrosion spots in a standard salt mist exposure test.
A3200 gives over 1,000 hrs protection to Mg alloys, where conventional chromating and painting rarely exceeds 300 hours.
 |
|
 |
Apticote 3200, provided 300 hours protection for these Mg housings in the most aggressive salt mist exposure tests! |
|
There was no corrosion on this bike saddlebag support after 1,700 hours! |
A3200 gives superb protection on all types of component.
|
|
|
|
Effect on Fatigue
Rotating bar tests show a reduction in fatigue strength of 7075 Al Alloy of only 14%, much less than is caused by plating or hard anodising.
Finishing
Apticote 3200 needs to be applied to a finished component, with due allowance being made for the coating thickness. It is not possible to post-finish the coating after application.
Masking
Apticote 3200 can be masked if it is necessary to leave any area uncoated, but like many coating processes this adds to cost and an ‘all over’ coating should be specified wherever possible. |
|
Thickness and Coverage
Coating thickness is typically 30 to 40µ. The outward surface growth is 60% of the total thickness. Penetration down holes is to one diameter deep.
Unlike anodising,
Apticote 3200 can coat a
sharp corner
without cracking.
Geometric features
Apticote 3200 can coat through bores with greater than 2 cm diameter, but small bores and blind holes will not be well covered.
Colour
The colour depends on the type of polymer composite, and reliable matching is very difficult. |
Health and Safety
The coating system is benign, with no hazards or disposal problems. There are no harmful emissions, so the process is completely environmentally friendly. Additionally, very little pre-treatment is required, so the potentially harmful effects of acid etching are absent.
|
| |
|
|
|  |
Top | Index | Home Page