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Using Chemical Vapor Deposition Processes to Enhance the Corrosion Performance of Steel Substrates SilcoTek Corporation Gary Barone.

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Presentation on theme: "Using Chemical Vapor Deposition Processes to Enhance the Corrosion Performance of Steel Substrates SilcoTek Corporation Gary Barone."— Presentation transcript:

1 Using Chemical Vapor Deposition Processes to Enhance the Corrosion Performance of Steel Substrates SilcoTek Corporation Gary Barone

2 Topics About Us Products and Applications Product Performance Conclusion/Future Product Development

3 APPLICATION AREAS SilcoNert: Inertness Silcolloy: Anti-Corrosion SilcoKlean: Anti-Coking SilcoGuard: Ultra-High Vacuum MARKET AREAS Analytical Pharmaceutical Environmental Petrochemical Chemical Process Automotive Semiconductor/Research

4 Basic Manufacturing Process Receive items Document – digital, customer contact Clean –Standard: caustic ultrasonic bath, 2 systems –Custom: solvation via other means Chemical Vapor Deposition (CVD) Process –Vacuum –400ºC –silicon-based deposition Clean Document – digital, customer contact Pack, ship

5 Product Characterization Amorphous silicon CVD coating Density: 2.33 g/cm3 Melting point: 1410 o C Max operating temp. 600 o C to 1000 o C: Silcolloy; SilcoNert 1000; SilcoGuard 450 o C SilcoNert A to 5um thickness, minimal smoothing of surface

6 Coating Cross Section 316 SS

7 Auger Depth Profile

8 Coating Capabilities: Substrates Tubing: –0.004 to 0.5 ID –2000+ ft. continuous lengths Complex geometry parts (inside and out) –Fittings, valves, frits –Block manifolds, sample vessels –custom parts

9 Sizes of reaction chambers Standard vessels: –12 diameter cylinder w/ 56 height –6 diameter cylinder w/ 72 height –10 diameter cylinder w/ 18 height –21 diameter cylinder w/ 42 height Large processing oven: –27 diameter x 26 deep Walk-in Oven: –4 feet by 4 feet by 5 feet –6 feet by 4 feet by 5 feet

10 Substrates Which Coat Well 300 and 400 grade stainless steel High carbon steel Titanium Ceramics Borosilicate glass Inconel® Hastelloy®

11 Substrates with Issues Nickel / Nickel plating Aluminum* Monel® Copper Brass Gold and Silver plated components Chrome Plated components Magnesium Elastomers *heat-dependent

12 Corrosion Resistance of Coatings

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.

14 Corrosion Resist studies External Evaluation –Certified corrosion engineers (Matco) –Spectroscopic analysis –Mechanical testing –Electrochemical Cyclic Polarization in neutral, acidic, alkaline –Atmospheric corrosion ASTM moisture condensation Salt spray ASTM B117 –Stress corrosion cracking (MgCl 2 ; ASTM G36)

15 ASTM G48 B Data: Pitting and Crevice Corrosion ASTM G48 method B; Pitting and Crevice Corrosion –6% Ferric Chloride solution –72hrs, 20ºC –316L Stainless samples w/Gasket wrap SampleInitial Weight (g) Final Weight (g) Weight Loss (g) Weight Loss (g/m 2 ) Silcolloy Sample Silcolloy Sample Silcolloy Sample Bare Sample Bare Sample Bare Sample

16 ASTM G48 B (cont.) Bare 316L Stainless Steel coupon showing severe crevice corrosion

17 ASTM G48 B (cont.) Corrosion resistant treated sample showing no crevice corrosion and slight pitting corrosion

18 ASTM G61 Data: Cyclic Polarization ASTM G-61; Cyclic Polarization Electrochemical Corrosion Testing –Acid, neutral, basic aqueous solutions with varying Cl - ion concentrations (100, 3000, 5000ppm) –EG&G VersaStat System, 23ºC –316L vs. Silcolloy on 316L & 304L Neutral solution; 3000ppm Cl - SampleEc, mVIc, uA/cm^2Eb, mVCR, mpy 316 L Silcolloy 316 L L Ec = corrosion potential Ic = current density at Ec Eb = pitting potential CR = corrosion rate -CR vs 316L Raw: 50x improvement

19 ASTM B117 Data: Salt Spray ASTM B 117 – Practice for Operating Salt Spray (Fog) Apparatus. –4000 hour exposure –100 degree Fahrenheit –3.5% by weight sodium chloride Reproduces exposure to marine environments.

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.

22 ASTM D4585 Data: Condensing Humidity ASTM D 4585, Practice for Testing the Water Resistance of Coatings Using Controlled Condensation. –1000 hour study –100 degrees Fahrenheit –Distilled water Reproduces exposure to atmospheric conditions

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 streams Protection: –Protection of high value equipment in corrosive environments Inert: –Provide enhanced corrosion resistance to analytical equipment while maintaining inert sample pathway High Temperature: –High temperature stability up to 1000c

25 Silcolloy Applications Manufacturing/Chemical –Process streams containing HCl Environmental –Continuous Emissions Monitoring exposed to stack gases from coal fired plants and incinerators Automotive –Equipment used in Automotive Exhaust testing and catalytic converter studies –Diesel EGR & Turbo systems Marine –Some preliminary evaluation of coating in marine environments (offshore platforms)

26 Conclusions/Future Continual process improvement and new product development for coatings: –Improving the hardness of coatings –Improved corrosion resistant coatings –Hydrophobic surfaces for moisture sensitive applications –Protection of high nickel alloys such as Hastelloy® and Inconel® –Hydrogen embrittlement resistance.

27 QUESTIONS ?


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