Presentation on theme: "SilcoTek Corporation Gary Barone"— Presentation transcript:
1 SilcoTek Corporation Gary Barone Using Chemical Vapor Deposition Processes to Enhance the Corrosion Performance of Steel SubstratesSilcoTek CorporationGary Barone
2 Topics About Us Products and Applications Product Performance Conclusion/Future Product Development
3 Semiconductor/Research MARKET AREASAPPLICATION AREASSilcoNert™: InertnessSilcolloy™:Anti-CorrosionSilcoKlean™: Anti-CokingSilcoGuard™: Ultra-High VacuumAnalyticalPharmaceuticalEnvironmentalPetrochemicalChemicalProcessSemiconductor/ResearchSilcoNert 1000 (original inert coating)SilcoNert 2000 (most advanced inert coating) available through Swagelok. SilcoNert 2000 is used in sampling, instrumentation, gas chromatography consumables, process monitoring, emissions monitoring, oil and gas production/distribution and refining.Silcolloy (corrosion resistant coating) used in acidic corrosion environments. Recommended for chloride corrosion applications such at marine/salt corrosion, HCl exposure.SilcoGuard (low out gassing, ultra high vacuum coating) developed for high vacuum environments where high pumping speed is needed for improved productivity. UHV coating will allow up to 14x faster pump down.SilcoKlean (anti coking coating) developed to prevent catalytic coking in high temperature fuels and lubrication environments. SilcoKlean will reduce carbon build-up by 8x.Automotive
4 Basic Manufacturing Process Receive itemsDocument – digital, customer contactCleanStandard: caustic ultrasonic bath, 2 systemsCustom: solvation via other meansChemical Vapor Deposition (CVD) ProcessVacuum400ºCsilicon-based depositionPack, shipParts are received and inspected. Customer is notified of part receipt. Parts are cleaned in an ultrasonic bath and queued for treatment. Batch CVD process ovens heat parts under vacuum. Semiconductor gas fills the oven chamber coating the parts. All surfaces exposed to the process gas will be coated. SilcoTek cannot mask select areas of a part due to the high process temperatures.After coating, parts are cleaned, inspected, packaged and shipped. The customer is contacted regarding order status and shipping.
5 Product Characterization Amorphous silicon CVD coatingDensity: g/cm3Melting point: 1410oCMax operating temp.600oC to 1000oC: Silcolloy; SilcoNert 1000; SilcoGuard450oC SilcoNert 20001200A to 5um thickness, minimal smoothing of surface
6 Coating Cross Section 316 SS Cross section of substrate/coating shows minor variations in coating thickness. Coating at this magnification appears to show a surface coating. But Auger depth profile shows layer diffuses into the substrate.
7 Auger Depth ProfileAuger shows a 1200A silicon layer depth (red). Iron (green) shows the start of the substrate layer at 35min. Subsequent Auger and GD-OES data show iron/silicon interface can be up to several hundred angstroms thick. Providing a layer which is diffused (or meshed) into the surface, similar to Velcro. This diffusion creates a durable, flexible layer that will not delaminate.
8 Coating Capabilities: Substrates Tubing:0.004” to 0.5” ID2000+ ft. continuous lengthsComplex geometry parts (inside and out)Fittings, valves, fritsBlock manifolds, sample vesselscustom partsRestek is able to coat continuous lengths of tubing of feet. Custom components of complex geometry can be coated.Fittings, valves, frits can also be coated.
9 Sizes of reaction chambers “Standard” vessels:12” diameter cylinder w/ 56” height6” diameter cylinder w/ 72” height10” diameter cylinder w/ 18” height21” diameter cylinder w/ 42” heightLarge processing oven:27” diameter x 26” deepWalk-in Oven:4 feet by 4 feet by 5 feet6 feet by 4 feet by 5 feetSilcoTek processes orders in a variety of reactors depending on part geometry and volume.
10 Substrates Which Coat Well 300 and 400 grade stainless steelHigh carbon steelTitaniumCeramicsBorosilicate glassInconel®Hastelloy®SilcoTek coats most common steel alloys, along with borosilicate glass.
11 Substrates with Issues Nickel / Nickel platingAluminum*Monel®CopperBrassGold and Silver plated componentsChrome Plated componentsMagnesiumElastomers*heat-dependentPure nickel and copper cannot be coated. Copper alloys cannot be coated but Nickel alloys can be coated. Most aluminum alloys will soften when exposed to our process temperatures and are not recommended. Some applications using 6061 aluminum may be coated. Elastomers cannot be coated due to high process temperatures.
13 Silcolloy™ Corrosion Resistance: Stainless steel surfaces susceptible to attack from in chlorinated environments and acidic exhaust environments.Corrosion resistant deposition is insoluble in hydrochloric acid and unaffected in salt water environments.Silcolloy 1000 is a multi layer amorphous silicon coating designed to improve the corrosion resistance of steel or steel alloys. Silcolloy protects steel and stainless steel from chloride attack & is used in process, analytical and marine environments. Silcolloy is capable of withstanding temperatures up to 1000C making the coating an attractive option for customers looking for corrosion protection in high temperature environments.Silcolloy is a cost effective way to extend the life of steel, stainless steel or exotic alloys; but is not intended to be an alloy substitute.Because base metal attack can occur if the Silcolloy layer is compromised
14 Corrosion Resist studies External EvaluationCertified corrosionengineers (Matco)SpectroscopicanalysisMechanical testingElectrochemicalCyclic Polarization in neutral, acidic, alkalineAtmospheric corrosionASTM moisture condensationSalt spray ASTM B117Stress corrosion cracking (MgCl2; ASTM G36)SilcoTek partners with independent test laboratories to evaluate coating performance. Certified corrosion engineers, Matco Associates studied the corrosion performance of Silcolloy
15 ASTM G48 B Data: Pitting and Crevice Corrosion ASTM G48 method B; Pitting and Crevice Corrosion6% Ferric Chloride solution72hrs, 20ºC316L Stainless samples w/Gasket wrapSampleInitialWeight (g)FinalWeightLoss (g)Weight Loss(g/m2)Silcolloy™ Sample 170.039519Silcolloy™ Sample 280.051325Silcolloy™ Sample 470.0521Bare Sample 279.56550.4789231Bare Sample 349.69230.4342209Bare Sample 379.62760.4731228Pitting and Crevice Corrosion tests show an order of magnitude reduction in corrosion weight loss when comparing 316L coated stainless steel coupons with uncoated coupons.
16 ASTM G48 B (cont.)Bare 316L Stainless Steel coupon showing severe crevice corrosionUncoated coupon shows significant corrosion at gasket. Note deep pitting as well.
17 ASTM G48 B (cont.)Corrosion resistant treated sample showing no crevice corrosion and slight pitting corrosionCoated coupon shows only slight pitting and no gasket area damage.
18 ASTM G61 Data: Cyclic Polarization ASTM G-61; Cyclic Polarization Electrochemical Corrosion TestingAcid, neutral, basic aqueous solutions with varying Cl- ion concentrations (100, 3000, 5000ppm)EG&G VersaStat System, 23ºC316L vs. Silcolloy™ on 316L & 304L-CR vs 316L Raw: 50x improvementEc = corrosion potentialIc = current density at EcEb = pitting potentialCR = corrosion rateNeutral solution;3000ppm Cl-SampleEc, mVIc, uA/cm^2Eb, mVCR, mpy316 L-4180.0963700.04Silcolloy™ 316 L -5330.00214600.0009304 L-4350.1453610.06Electrochemical corrosion tests show a 50x improvement over 304 and 316ss coupons.
19 ASTM B117 Data: Salt SprayASTM B 117 – “Practice for Operating Salt Spray (Fog) Apparatus.”4000 hour exposure100 degree Fahrenheit3.5% by weight sodium chlorideReproduces exposure to marine environments.4000 salt spray tests show some corrosion in uncoated coupon and no corrosion in coated coupon
20 ASTM B117 Data (cont.)Silcolloy™ treated samples showed no signs of bleeding, rusting, or pitting corrosion
21 ASTM B117 Data (cont.)The non-treated samples showed some light surface rusting, but no signs of pitting corrosion.Some corrosion found at perforation in uncoated coupon
22 ASTM D4585 Data: Condensing Humidity ASTM D 4585, “Practice for Testing the Water Resistance of Coatings Using Controlled Condensation.”1000 hour study100 degrees FahrenheitDistilled waterReproduces exposure to atmospheric conditions1000 hour humidity testing shows no adverse affects.
23 ASTM D4585 (cont.)Silcolloy™ treated samples showed no signs of bleeding, rusting, or pitting corrosion
24 Silcolloy™ Advantages Longer Life:Extend lifetimes of equipment exposed to corrosive environments and/or process streamsProtection:Protection of high value equipment in corrosive environmentsInert:Provide enhanced corrosion resistance to analytical equipment while maintaining inert sample pathwayHigh Temperature:High temperature stability up to 1000cSilcolloy saves money by extending the life of process components. Customers may choose to Silcolloy coat stainless steel components and replace corroded components as needed over the life of the system rather than pay premium pricing for Hastelloy or other exotic alloys. Over the life of the system, a Silcolloy coated system will reduce costs by 60% when compared to a comparable Hastelloy system.
25 Silcolloy™ Applications Manufacturing/ChemicalProcess streams containing HClEnvironmentalContinuous Emissions Monitoring exposed to stack gases from coal fired plants and incineratorsAutomotiveEquipment used in Automotive Exhaust testing and catalytic converter studiesDiesel EGR & Turbo systemsMarineSome preliminary evaluation of coating in marine environments (offshore platforms)The principal market application for Silcolloy is for hydrochloric acid or other chloride corrosives in manufacturing, chemical and petrochemical environments. High temperature, corrosive environments, such as stack monitoring systems, are also key application markets.
26 Conclusions/FutureContinual process improvement and new product development for coatings:Improving the hardness of coatingsImproved corrosion resistant coatingsHydrophobic surfaces for moisture sensitive applicationsProtection of high nickel alloys such as Hastelloy® and Inconel®Hydrogen embrittlement resistance.