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Corrosion, Erosion and Wear Resistant Tungsten Carbide CVD Coating

Technology Overview

This technology presents nano-structured tungsten carbide particles, dispersed in a tungsten metal matrix, to make a coating that can be applied via low-temperature Chemical Vapour Deposition (CVD) technology. This coating can do what most traditional coatings cannot: coat both internal and external surfaces, non-line-of-site areas, combing exceptional wear and corrosion resistance with toughness and ductility. Used on critical parts of oil and gas tools, pumps, valves, and aircraft components, this coating would typically triple their service life, especially in abrasive, erosive, or corrosive conditions.

The technology owner seeks technical and/or R&D technical cooperation to develop applications for tungsten carbide CVD coatings.

Technology Features & Specifications

This advanced coating is crystallised from gas media, atom-by-atom, enabling the coating of both internal and external surfaces and complex shape parts which are difficult or impossible to coat by most traditional coatings.

The following are properties that this technology carries:

  • Can be applied onto a wide range of engineering materials, such as stainless steel, inconel, tool steels, nickel, copper, and cobalt-based alloys
  • Free from inter-granular inclusions, impurities, porosity and other defects which can weaken the material's mechanical properties and make it brittle
  • Helps to achieve a combination of high hardness of 1100 – 1600 Hv (70 – 77 HRC) with enhanced toughness, crack and impact resistance
  • Imparts resistance to abrasive wear and solid particle erosion, outperforming other hard-facing materials
  • 50 microns thick coating
  • Pore-free and has high resistance to corrosion and chemically-aggressive media, including hydrogen sulphide (H2S) acid present in sour oil and sour gas

Potential Applications

The nanostructured tungsten carbide coating has been proven on critical parts of oil drilling tools, pumps, valves, aircraft components and other precision components, protecting them against mechanical and chemical degradation, and typically triples the parts’ service life.

Other potential applications of the coating are (but not limited to):

  • Plastics compounding, extrusion, pelletising and injection moulding equipment
  • Metal filters
  • Hydraulic pistons and cylinders
  • Rotating shaft seal tracks
  • Tilting pad bearings
  • Replacing ceramic parts and solid cemented carbide parts with coated steel parts which have better wear resistance

Market Trends and Opportunities

Advanced coatings are increasingly used across high-value manufacturing sectors, and help in making industrial equipment more competitive.

This coating enables producers of industrial equipment to make it more durable, reduce maintenance requirements and cut expensive downtime. The coating is able to replace hard chrome plating which is restricted by REACH regulations.

Customer Benefits

This coating technology has the following advantages:

  • Coating protects critical components against wear, erosion, corrosion
  • Resistance to wear outperforms Inconel by 500x
  • Resistance to erosion outperforms steel by 125x
  • Pore-free coating protects against corrosion, e.g. from acids
  • Reduces down-time and maintenance, enhancing the industrial equipment performance, as the critical parts stay within the optimal dimensions for longer periods, even in the highly abrasive/corrosive environment
  • Better-performing and environmental-friendly replacement for hard chrome plating, restricted by REACH regulations

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