Better environmental sustainability and reduced whole life cycle costs are important drivers in industry today. Surface engineering is a valuable tool in achieving both of these by facilitating optimal materials selection and innovative product design.
Surface engineering spans a wide range of processes. At one end of the scale ion implantation, nitriding, and aluminising affect the chemistry and properties of only a thin surface layer of the substrate, by modifying the existing surface to a depth of 0.001 - 1.0 mm. At the other end of the scale are weld hardfacings and other cladding processes. Typically 1-20 mm thick, these are usually used for wear or corrosion resistance and repairing damaged parts.
Between these two extremes we find deposition processes such as physical vapour deposition (PVD), chemical vapour deposition (CVD), anodising, laser processing, thermal spraying, cold spraying, and liquid deposition methods.
The coating application and performance characteristics are heavily dependent on the composition and processing parameters. Coatings ranging from purely ceramic to purely organic in character have very different properties, but can provide critical benefits to the component.
Selection of the most appropriate coating type and deposition method requires an understanding of the operational requirements, together with the candidate application methods and supply chain considerations. Testing and validation of the surface is essential to ensure that the necessary fitness-for-purpose characteristics have been achieved, and comparison between candidate systems against established or developing standards has been undertaken.
TWI possesses considerable capability, experience and facilities to allow the most appropriate coating methods and materials to be selected and validated from the wide range of options available.
TWI has been actively involved in fundamental research and applications development to help industry meet the dual challenges of improving the performance characteristics and durability of components and address sustainability challenges, such as finding alternative coatings to those being phased out due to environmental or health concerns. We have also assisted in the development of restoration/repair techniques for high-value parts in many industry sectors.
Examples of areas where we are working confidentially to address our members' requirements include:
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Coatings for corrosion mitigation in biomass and waste to energy plants
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Repair techniques for lightweight alloys
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Coatings for thermally sensitive substrates, e.g. CFRP, polymers
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Novel anti-fouling and anti-soiling coatings
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New surface treatments for wood, reducing the use of biocides
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New anti-microbial coatings for the healthcare sector
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Printable transparent conducting coatings
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New low cost anti-reflective coatings
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Selection of environmentally responsible coatings for high value consumer goods
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High performance hardcoats for glazing applications
In addition to fundamental and applied research, TWI also provides consultancy, materials selection and failure analysis services. We offer impartial specialist expertise and are uniquely situated to develop new coating compositions, formulations, or pre-treatments for coatings that span the full range of compositions and deposition methods.
Selection of appropriate coatings can drive down costs and lead to improvements in application and operational performance.
There is a wide range of options available for immediate use and as the basis for new products. Identification of the coating system that is fit-for-purpose is essential to achieve the desired result.
TWI has researched coatings for applications in the following sectors:
For more information, please contact us.
