Tuesday, December 15, 2015

Facts One Should Know About Diffusion Coatings

By Marci Nielsen


the use and/or operation of metal components occurs in many different environments. The environments differ a lot and some of them cause significant effect on the metal. Effect may be caused by high temperatures or corrosive elements. Functionality, aesthetic value, and durability among other aspects get affected diversely by such adverse conditions. These effects led to research that led to the invention of diffusion coatings. These kinds of coatings are meant to offer protection to substrates against damage that results from environmental effects. This article will discuss the process and how protection is offered.

Diffusion coating is the process through which metal substrates are coated with diffusion coating. The process requires a special piece of equipment called a chamber and optimal temperatures are usually very high. Thorough cleaning of substrate must be done first before the process is started. Abrasive blasting is the most commonly used method although other methods can be used. Unwanted materials must be removed because they prevent complete bonding between the metal and substrate.

Once the substrate has been cleaned properly, it is placed into a contained together with the metal used for coating. The container is then placed inside a furnace or a chamber. The furnace is turned on and the temperature set to the range of 380-425 degrees centigrade.

When certain temperatures are attained within the aforementioned range, diffusion occurs to the metal. This makes it to make an alloy with the substrate. The nature of the substrate and the kind of metal used dictate how much time this process can last. However, most processes last from two hours to four hours. The substrate must be continuously turned throughout the process to achieve equal thickness.

The resultant coating is smooth and its thickness is very uniform. Depending on the function of a component, the thickness can be varied. However, the normal range of thicknesses is between 15-80 micrometers. The color of the metal used for coating forms the color of the component after coating. Chromium, iron, aluminium, and silicon are among the most commonly used metals. Coating can also be done to various metals too, including iron, steels, cobalt, and nickel.

The resultant coating provides significant resistance against oxidation, erosion, oxidation, and reaction with various substances such as water and air among others. This process has made metal components meant for critical functions more reliable, stronger, and more durable. Some of the metal components that are passed through this process include gate valves, power generation components, pump impellers, and gas turbines engine components such as cases, blades, and vanes.

The use of this process is mostly confined in industrial settings. Very few household devices incorporate this process in their production. The invention of the process happened several years ago and it has been undergoing modification over time to achieve perfection. Currently, better methods and technology exist.

Modern day furnaces are very efficient and have improved functionality because they incorporate several features. The coatings achieved today are thin yet very durable, strong, and efficient at avoiding corrosion. This technology is highly employed in the automotive industry.




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