Development of a thin film vitreous bond based composite ceramic coating for corrosion and abrasion services

摘要

To develop a thin film, abrasion resistant, corrosion resistant coating. Background information: Composite Ceramic Fluoropolymer Coating Technology IPC has been involved with the Alberta Research Council in developing a vitreous bond (VB) based composite ceramic fluoropolymer coating technology. Compared to the present state of the art which is based on a hard discontinuous phase (ceramic particles) suspended in a soft continuous matrix (fluoropolymer mix) the novelty of our approach consists of designing a composite system in which both the ceramic and the fluoropolymer phases are continuous. The ceramic matrix will provide the strength and the erosion resistance for the fluoropolymer matrix even at high temperatures. The ceramic formulation employed is not affected by temperatures up to 500 deg F while the fluoropolymer matrix provides a corrosion protection seal for the ceramic matrix. The inherent flexibility of the polymer matrix will protect against brittle fractures that may develop by handling or impact. Therefore the composite coating is able to withstand the deformation of the substrate without chipping or disbonding. The fluoropolymer matrix also provides dry lubrication properties further enhancing the erosion resistance of the ceramic phase. The thickness of the coating is very thin, in the 25 to 100 micron range. In summary, the coating technology is able to provide the following features: Corrosion protection levels similar to those of fluoropolymer coatings Erosion resistance similar to that of ceramic coatings Price comparable to that of polymer coatings Exceptional wear resistance properties Capability for coating complicated shapes internally or externally or both This paper will discuss the theory and development of this new technology and the resultant coating and potential properties.