Low temperature chemical vapour deposition coating of duplex and super duplex alloys

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"The proposed Industrial Research project will develop a process for manufacturing hard Chemical Vapour Deposition (CVD) coating at a lower temperature than currently possible, and also optimising the coating process to make it more efficient and economical to enable coating a wider range of materials and applications. The patented CVD Hardide Tungsten Carbide coatings are currently used on some valve, pump, oil tool and aircraft components and are proven to protect them from wear, erosion and corrosion, typically tripling live of critical parts in demanding environments. Meanwhile the current CVD process temperature of 500°C may affect some grades of steel, limiting the range of the coating applications.The project will start with the lower temperature coating process development. This will involve a significant materials manufacturing technology innovation as reducing temperature has a strong exponential effect on the rate of chemical reactions. This stage will involve a series of experimental coating cycles designed using the Taguchi technique.Once the process development is completed the low-temperature coating key properties will be tested by certified UK laboratories, to enable engineers design the coated parts and to predict their performance.Main areas of focus are developing coating process for the oil and gas, petrochemical and chemical engineering equipment. The new low-temperature coating can also be useful for some aerospace industry materials, tool and bearing steels. Conformal low temperature CVD coating can be best suitable for complex shape parts made by Additive Manufacturing (3D printing).Achieving the project objectives will create new business for Hardide, expand the range of our coatings and applications. It will also have a wider impact on the UK producers of pumps, valves, oil tools, enabling a step change in durability of their equipment, making them more competitive internationally.The project will take 12 months, will be performed by Hardide Plc, an SME as a sole applicant involving several leading UK laboratories as subcontractors to conduct testing."