Lectrofluor® is a polymer-based coating that protects metals from corrosion and chemical attack in all kinds of hostile environments. Compared to other corrosion-resistant coatings, Lectrofluor provides some compelling technical advantages. Watch our video to learn more about how Lectrofluor's superior properties will work for your application.

 

For reliable mold release under high load bearing pressures up to 100,000 psi, choose our Magnaplate HTR™ coating. HTR increases the release efficiency of steel, copper, brass, aluminum and other metals used in the fabrication of molds and dies for a wide range of industries.

This unique surface enhancement coating creates a permanent, non-stick surface that exhibits a low coefficient of friction. When used with one of our various families of coatings, HTR is fully customizable and can be modified to meet your application’s thermal and electrical conductivity. In addition, the coating is great for applications like injection and blow molds, gears and bearings, seal bars and dies, bag formers and tablet punches.

Technical advantages include:

  • Seal dies at 800°F
  • Roll dies at 650°F
  • Chrome replacements at 800°F
  • Spindle heads and slides at 600°F
  • Blow molds at 550°F
Mold Release

Excellent wear resistance. Worn or damaged molds are often the cause of poor release. HTR’s superior resistance to wear makes it ideal for use in plastic and other molding industry applications where mold design or definition is subject to abrasive damage by the molding of the material.

Because HTR maintains a uniform, consistent level of thermal conductivity, it also solves release problems that stem from variations in mold surface temperatures. The use of HTR is also recommended for instances where sprays, release additives or other forms of paint-on or sprayed-on dry lubricant coatings don’t perform correctly.

Application examples. HTR is used in a wide range of applications spanning many industries. Below are some examples:

  • An injection molding company makes a polypropylene part with a 0.750” diameter and a 5” long core with a zero degree draft angle. A mold release had to be sprayed on the core every 10 cycles to help the parts harden on the core. After treating the core with HTR, more than 20,000 cycles were completed before they had to reapply the release spray.
  • One aerospace company used HTR to coat a mold cavity set for release at high temperatures. They were molding Polyimid plastic with carbon fiber at 400°C. The finished part is used as an insulator for an aircraft braking system.
  •  A pool chemical manufacturer needed a coating for a tablet punch that operates at room temperature. The company tried other coatings that either didn’t offer enough release, or were too thick and hid the marking on the punch. This company now uses HTR for coating their tablet punches.

Get a Quote

Specialized coatings play a crucial role in protecting machine components and increasing uptime across a wide spectrum of industries, ranging from packaging and food processing to aerospace and rubber molding. If your application needs a coating for high temperatures up to 1000°F, consider our Magnaplate 10K™ series.

Magnaplate 10K™ For High Temperatures. Before the introduction of Magnaplate 10K™, coatings from major suppliers provided mold release for temperatures up to 450°F. However, end users were constantly requesting release coatings for handling temperatures up to 1,000°F. In response, we developed three formulations of the 10K™ series:

 

  • 10K1: A solvent-based formula that withstands temperatures to 1,000°F
  • 10K2: A water-based formula that withstands temperatures to 1,000°F
  • 10K3: A solvent-based formula that withstands temperatures to 850°F

These coatings also have a low coefficient of friction (COF), retain their properties at high temperatures and provide easy mold and die release at high temperatures. Other technical features include:

  • Low surface energy
  • High water repellency
  • Anti-stick, easy-to-clean surfaces
  • No fluoropolymers or PFOAs
  • No degrading at high temperatures
  • FDA-compliant to Title 21 CFR175.300
  • Corrosion protection

Applications. The 10K™ family can be used along with many of our coating families like Nedox®, Tufram® and Plasmadize®. Typical applications for 10K™ coatings are found across a variety of industries that require a quick-release coating or corrosion protection and chemical resistance, Including packaging, food processing, aerospace, oil and gas, power generation, plastics and rubber molding.

Download The White Paper

Communicating early with your coating vendor to discuss base metal choices can limit issues later in the design process—especially if your part has tight tolerances. Deformation can occur if application surface loads are high, and coating process or post-process temperatures can often exceed the substrate heat treatment’s recommended operating temperatures. In addition to deformation, some metals suffer from structural stability issues where the part moves or changes size.

Avoid hydrogen embrittlement. When considering high strength alloys or other materials such as titanium or tool steels, part designers should be aware of hydrogen embrittlement that can cause parts to crack and fail under loads. During the cleaning process—which often involves acidic materials—some alloys impart hydrogen to the surface of the metal, causing embrittlement. If the coating vendor knows this, they can perform specialized procedures to the part after coating, or use alternative cleaning processes to expel the hydrogen from the surface to avoid the issue.

Surface Treatment

Engineers sometimes design a part that incorporates more than one material. In this case, the part may not be conducive to plating surface treatments because the cleaning methods before coating differ with each type of metal. For example, one cleaning process can activate the surface of a given metal for coating, while passivating the surface of the second material.

Adhesion issues. If you can’t coat both surfaces at the same time, you’ll need special masking, which will drive up the cost up due to its labor intensive nature. Adhesion issues on the boundary areas between the two metals also occur, and there may be a galvanic reaction between the two materials when you expose them to electrolytes. This can create corrosion of one of the base materials.

In addition, if the base metal of the part is hard, it can cause surface tensions that prevent a strong adhesion between the base material and coating. A bad bond between the part and coating will lead to chipping of the coating. Keeping coatings thin and paying special attention to surface preparation can help avoid this problem.

Download the White Paper

An enhanced titanium nitride physical vapor deposition coating (PVD) for extreme wear and tight tolerances, Magnagold® resists wear and abrasion up to 20 times better than stainless steel. This coating—used for applications with extreme wear and tight tolerances—provides metals with a hard, smooth surface and a rich, gold color without causing distortion or loss of hardness.

Technical advantages. Magnagold exceeds the physical properties of common vacuum deposition coatings like titanium nitride, PVD and CVD. With a thicknesses between 0.00004” and 0.0003” (1 to 7.5 microns), this coating also has an operating temperature range from -360°F (-218°C) to 800°F °(427°C), hardness up to an equivalent of Rc 85 and a dimensional accuracy of ± 0.00004 inches.

Magnagold

Other properties include:

  • Meets AMS 2444
  • Resistant to most acids, alkalis, fluxes, solder and weld spatter
  • USDA and FDA compliance
  • Processing temperatures as low as 400°F (204°C)
  • Excellent chemical resistance

Magnagold for longer life. One manufacturer that develops custom bearing solutions for delivering maintenance-free, high-performance products used Magnagold to triple the life of one of its crimping tools. This tool is used to crimp a retainer onto the bearings that hold the assembly together, a process that’s central to the company’s self-clinching products. On average, the machine tooling would fail every 200,000 pieces.

The company has several machines in its facility, and these failures would cost the company thousands of dollars for each failure. To deal with these failures on hardened tool steel, we suggested they coat a sample part with Magnagold. The first part coated with Magnagold crimped more than 500,000 assemblies without having to service—or even polish—the tool once. Because of the positive results of coating this tool, the company decided to coat all crimping tools with Magnagold.

Applications. Magnagold is used in a wide range of applications, including:

  • Forming tools
  • Drills
  • Extrusion dies
  • Punches
  • Wear rings
  • Hobs
  • Bushings
  • Sleeves
  • Bits
  • HSS tools
  • Critical tolerance components requiring extended wear life

Download our white paper that shows the benefits of Magnagold.

Download The White Paper

Titanium is often susceptible to hydrogen pickup or embrittlement. For applications that experience this issue, we’ve created a coating that focuses on preventing hydrogen absorption.

Better Than Titanium Anodizing. Our Canadize® coating lowers the coefficient of friction of titanium substrates and prevents hydrogen embrittlement. When compared to other common industry processes like titanium anodizing, this coating has better technical features, including:

  • An operating temperature range from -200 to 1200°F
  • Coating thicknesses from 0.0001 to 0.0006 inches
  • A hardness of Rc 45
  • AMS 2488 requirements
  • Excellent heat transfer
  • High fatigue strength
  • Chemical and corrosion protection

Surfaces coated with Canadize® can successfully solve wear, friction, galling, seizing, moisture and corrosion problems in a broad spectrum of applications involving titanium and its alloys. Through predetermined time and current control, a hard ceramic surface is formed.

Application Examples. Canadize® has been successfully applied to applications in aerospace, manufacturing and packaging equipment, construction, power tool applications. Here are two examples of times when this coating solved engineering problems:

  • A variety of metal parts used in the manufacture of sealed reagent kits for chemical testing were coated with Canadize® to provide chemical resistance and increase the service life of the manufacturing equipment.
  • Galling and seizing compromised valves in pressure vessels and piping systems controlling the flow of LP gas and anhydrous ammonia. With its anti-galling and anti- seizing properties, our Canadize® coatings solved the problem and eliminated a potentially dangerous situation.

Get a Quote Now

Too often, design engineers look at coating parts as an afterthought. Rather than being part of the discussion in the early stages of design, engineers sometimes try to solve problems with coatings during—or even after—manufacturing. While surface treatments such as anodizing, electroplating and thermal spray provide their own unique set of properties and benefits, these processes also have limitations that demand attention early in the design process to ensure optimal performance.

Engineers often look to extend the life of equipment by protecting parts from wear and abrasion. Protective coatings not only guard these parts against these issues, but also provide lubrication and increase structural integrity. Using the right surface treatment can increase a part’s lifespan, cut downtime and reduce overhead.

Key factors affecting surface treatment worth noting at the outset of the design process are:

  • Process limitations
  • Choice of base metal
  • Part configuration and design
  • Surface finish

Engineers risk lengthening product cycle times by not making surface treatment discussions a primary consideration early in the design process. By doing this, they risk specifying a treatment that cannot be completed due to the design properties of the part in question. Download our white paper to learn more.

Download the White Paper

By offering superior protection against wear, friction and corrosion, Nedox® can help less durable metals achieve the longevity and performance of chrome and stainless steel. Watch our new video to learn more.

 

 

Tufram® coatings for aluminum far outperform conventional hard anodizing and similar processes when it comes to corrosion resistance, friction reduction and hardness. Watch our new video to learn more.

 

 

Antimicrobial materials based on metal complexes have become an effective weapon in the war against the deadly microbes that cause foodborne illnesses, hospital infections and contaminated drugs. Yet these materials have shown a limited ability to deliver microbe resistance as part of a comprehensive surface enhancement treatment–until now.

Our MAGnanoSHIELD® proprietary antimicrobial coating technology minimizes this limitation by offering microbe resistance in conjunction with other beneficial surface properties. This coating technology, which can be incorporated into many of our proven surface-enhancement coatings, allows you to specify a single coating that not only resists microbe growth, but also provides protection against friction, wear, moisture and more.

Other technical advantages include:

  • FDA compliance
  • Potentially fewer chemical cleaning materials
  • Antimicrobial protection that prevents 99.9999% of bacteria and fungus growth
  • Potentially reduced maintenance and water usage
  • Increased production run times

Nanotechnology fights germs. While most antimicrobial materials today are based on generic formulations of a metal complex, MAGnanoSHIELD employs a proprietary metallic antimicrobial agent. Incorporated as a nanoscale dispersion within a polymer base, MAGnanoSHIELD inhibits the growth of microbes by interfering with DNA replication, damaging cell walls, altering cell membrane permeability or combining with bacterial proteins in ways that disrupt normal cell functions. These biological disruption mechanisms are well known and not unique to MAGnanoSHIELD’s active ingredient.

What does make our new antimicrobial technology unique is that it can be implemented as part of a more broadly useful coating. For example, MAGnanoSHIELD has been successfully combined with our Nedox® coating for use on any non-ferrous and ferrous alloys. It has also been combined with our Tufram® coating for use on aluminum. It is also compatible with our other coating technologies. This ability to combine MAGnanoSHIELD with other coating technologies adds microbe resistance to the long list of surface-enhancing properties we offer.

Applications. MAGnanoSHIELD has successfully been incorporated into coatings that offer low coefficient of friction, hydrophobicity and wear and abrasion resistance. Since it works as an integral part of a broader surface-enhancement coating, MAGnanoSHIELD opens up new application possibilities wherever microorganisms are just part of the problem. These applications are prominent in the following industries:

Medical. The benefits of imparting antimicrobial properties to medical devices, healthcare equipment and imaging machines are obvious. What’s less obvious is that many of these medical applications can additionally benefit from treatments that make them hydrophobic, and thus easier to clean.

Pharmaceutical. Microbe resistance and cleanliness are of paramount importance wherever pharmaceuticals are involved. Pharmaceutical manufacturing and packaging machines, which have their share of rotating and sliding components, can also benefit from the increased wear resistance and low friction provided by surface-enhancement coatings.

Food and beverage. MAGnanoSHIELD offers many opportunities to increase food safety while improving the surface characteristics of harvesting, handling, processing and packaging equipment. Food preparation surfaces, including cookware, are another good fit for MAGnanoSHIELD.

Get A Quote on MAGnanoSHIELD

Hard, slick surfaces minimize friction and heat buildup in metal-to-metal applications, improving the wear characteristics of the coated part. One option is applying an engineered coating.

Most polymeric or dry lubricant coating systems have a temperature limitation, since they can only function between 500°C (260°F) and 600°F (316°C). Also, polymers and dry lubricants are not always conducive to environments where particulate generation is undesirable.

For these applications, consider our Nedox PF™ coating. The composite ceramic, nickel alloy composition of Nedox PF lets it operate at temperatures up to 1500°F (816°C) and still maintain low friction and release properties. Some technical features include:

  • Excellent wear
  • Good corrosion resistance
  • Low coefficient of friction without polymers or dry lubricants
  • Good release properties without polymers or dry lubricants
  • Uniform coating deposition
  • Non-shedding and non-outgassing
  • Hardness up to 68 Rc

Nedox PF-F Applications. Under the Nedox PF umbrella of coatings, Nedox PF-F is an FDA-compliant coating that provides surfaces with high wear resistance and a low coefficient of friction without using traditional polymers. Nedox PF-F has been successfully used in a wide range of applications. Here are some examples:

  • In the nuclear power plant industry, a next generation valve manufacturer experienced binding and excessive torque demand on a ball valve stem operating at 800°F (427°C) and 2,000 psi. They used Nedox PF-F to prevent seizing at elevated temperatures without a forbidden fluorocarbon coating.
  • A major defense prime needed to protect a pawl hook for lifting mini-subs from wear in a marine environment. Applying Nedox PF-F provided the hard, slick surface required to prevent premature wear on the device.
  • A well-known guitar manufacturer was wearing out a band-bending tool too fast. Nedox PF-F was applied to the tool for extended life and less drag in the bending operation.
  • One ceramics manufacturing company needed a long-lasting, wear-resistant coating for their bottom punch. Nedox PF-F reduced drag enough to give a smoother, cleaner punch, while increasing the required tool’s longevity.

Get A Quote on Nedox PF-F

For better corrosion resistance, friction reduction and hardness than standard hard anodizing, our Tufram® family of synergistic coatings are a good choice for aluminum manufacturing, processing and packaging equipment.

Adherence and impact resistance. With a wide operating temperature range from -360 to 800°F depending on the alloy and process, Tufram adheres to most alloys, especially those containing magnesium. Impact resistance is limited by the structural strength of the base metal.

In addition, Tufram’s hardness varies from Rc 40 to 65, depending on the alloy and process chosen. This improves the surface hardness of aluminum to levels comparable to case-hardened steel, and allows aluminum to replace more expensive substrates such as steel or stainless in many applications.

Thanks to proprietary polymers, Tufram’s permanent self-lubricating surfaces reduces surface tension and provides longer wear life, less maintenance and less downtime. Very few solid substances—including adhesives—will permanently adhere to the proprietary polymer-impregnated surface of a Tufram-coated part. Some tacky materials may exhibit mild temporary adhesion.

Other technical advantages include:

  • Excellent thermal conductivity
  • Low coefficient of friction
  • High dielectric strength
  • Self-lubricating and non-wetting surface characteristics
  • No outgassing

 Reduces friction and corrosion. Tufram coatings are highly resistant to corrosion, as well as acids and alkaline chemicals. Their low coefficient of friction also protects against a variety of abrasive wear mechanisms and galling.

Recently, a manufacturer of book trimming equipment encountered friction and corrosion, as well as ink and glue clean-up problems on the skid plates, infeed and mailer table surfaces of its trimmers. Tufram reduced friction and prevented corrosion, allowing for the quick and easy cleaning of ink and glue.

FDA and USDA compliance. Tufram also meets FDA and USDA standards, making it ideal for food and pharmaceutical processing and packaging, and some medical industry applications. One example involves a creamery that experienced corrosive attack on an ice cream packaging machine’s turntable holding plates. Caustic cleaners caused the aluminum parts to pit and corrode. Applying Tufram to the hold plates helped prevent these issues.use.

Get A Quote

As the food processing industry keeps expanding, food and beverage producers must rely on sophisticated automated equipment to meet consumer demands. Companies that manufacture everything from bakery items and frozen food to meat and poultry products are continuing to specify new equipment and upgrade older machinery.

Meeting the diverse needs of food and beverage manufacturers requires equipment in excellent operating condition that will handle the demands of 24/7 plant schedules and rigorous cleaning routines. Among the many factors that plant engineers, equipment purchasers and those in the MRO (maintenance, repair and operations) community must consider are maximizing sanitation and performance of machine surfaces that interface directly with food products.

Minimize downtime. Engineered smart coatings that enhance and protect metal parts such as cutting blades and cookie molds are essential tools for solving hygiene and performance problems in the food processing industry. These coatings reduce downtime by solving issues such as:

  • Pitting and corrosion
  • Sticky build-up from sugars
  • Batter hang-up
  • Messy slitter blades
  • Residue on press plates
  • Abrasion of forming molds

Food processing regulations. Coatings that come into direct contact with food must meet strict criteria for use. First and foremost, coating formulas need to comply with FDA and USDA codes, or equivalent government standards in countries outside of the United States. Surface hardness levels should extend equipment service life by protecting against corrosion, wear, friction and galling, and when equipment is idle, coating surfaces must remain non-oxidizing even in harsh environments. Another key factor is that sanitation routines must be easy-to-follow, thorough and as environmentally friendly as possible.

To help enable ease of cleaning, surfaces must be dense and non-porous to inhibit bacterial growth. In addition, coated parts should feature non-stick surfaces to prevent product hang-up and ensure fast and efficient mold release. Above all, coatings must not contaminate the foods they have direct contact with, and cutting surfaces such as blades and slicers must remain sharp despite constant use.

Download the White Paper

General Magnaplate Converting White Paper

Whenever you drive fabrics, films or paper good at high speeds, tearing and sticking can create all kinds of engineering and productivity headaches. And one way to get rid of them is by applying the right type of engineered coatings to key machine components.

When selecting an engineered coating for converting applications, it usually pays to focus first and foremost on the release properties. Release is usually the fundamental surface requirement, since converting by definition requires the close contact between machine components and fast-moving, often-sticky products.

However, release is just the starting point. Beyond release, you should also look at high-temperature performance, abrasion resistance and product integrity. Our latest white paper will tell you how coatings can help improve the performance of your machines.


Download the White Paper

When deciding between coatings, evaluating performance characteristics is a good place to start. Our Tufram® and Tufram Basic Hard Anodizing coatings have similar processes but differing levels of hardness, friction reduction and corrosion resistance.

So which is right for your application? To help you decide whether or not to upgrade your coating, let’s take a look at each.

What’s the difference? While Tufram and Tufram Basic Hard Anodizing do share some similarities, it’s their differences that set them apart. Tufram’s surface hardness falls between 40 and 65 Rc, while the surface hardness of Tufram Basic Hard Anodizing ranges from 60 to 70 HRC in unsealed conditions.

Tufram

Tufram also comes with a range of proprietary polymers that give the coating a lower coefficient of friction for protection against a wide variety of abrasive wear mechanisms and galling. The coating also reduces stick-slip behavior and vibrations in sliding motion applications. Tufram Basic Hard Anodizing, on the other hand, doesn’t include a polymer, dry lubricant or other materials.

Another advantage of our Tufram coating is its resistance to corrosion, as well as acids and alkaline chemicals. In salt spray testing, for example, Tufram on high strength aluminum exceeds the AMS 2482 requirement of 336 hours, and typically achieves 1000 hours of salt spray resistance. Submersion tests in certain strong acids at 248°F show no effect after more than 170 hours. Tufram Basic Hard Anodizing achieves maximum corrosion resistance of 500 hours in salt spray testing.

In terms of coating thickness, Tufram ranges from 0.0004 to 0.003 inches, while the average thickness of Tufram Basic Hard Anodizing is 0.002 inches.

Which is best? For applications like close tolerance components, vacuum systems requiring non-outgassing components, guide rails and wafer chucks, you want Tufram. For automotive, aerospace and semiconductors, either Tufram or Tufram Basic Hard Anodizing can be used based on application needs and metal performance problems.

In addition, Tufram Basic Hard Anodizing and certain types of Tufram are FDA and USDA compliant, and either is good for food and beverage applications.

Click here to learn more about Tufram.

Learn More About Tufram

Acrison Case Study

Over the past forty years, Acrison has established itself as an industry leader in dry bulk solids handling—specifically, the precision metering of dry solid ingredients by volume or weight and the proportioning, blending, storage and hoppering of these materials.

Due to the variety of applications this equipment serves, Magnaplate coatings play an important part in the performance of its products. Applying a coating reduces friction, prevents material buildup, increases lifespan and more. Check out the case study about dry bulk solids handling to learn more.

Download the Case Study

When designing parts for coatings, there are some things you’ll want to take into account. Even the most impeccably designed parts sometimes face problems during the coating process. By following a few basic design tips, you can avoid potential issues down the road. Here are some things to consider.

Eliminate Sharp Edges. If possible, you should radius any of your part’s sharp edges to help the coating adhere to more surface area. Should your part require sharp corners, consult with your coating supplier early in the design process to select a more durable coating.

Consider Dimensions And Tolerances. Applying a coating to your part changes its dimensions and tolerances. If these factors are critical to your design, you should keep in mind that your part becomes thicker after the coating is applied, especially if you want threaded holes coated (up to 4x thicker), depending on pitch.

Design Tips

Some parts are subject to line-of-sight process restrictions or require special equipment for processing.

Pay Attention To Racking. It’s important to know how your part will be oriented and supported during racking. If your part is too big and can’t be supported by a small hole, you’ll need to find another solution during design to assure that no areas are left uncoated.

Know Your Geometry. Picking the wrong coating process without considering line-of-sight coating can leave key portions of your part uncoated. To avoid this issue, pay as much attention to your part’s geometry as its mechanical and physical properties.

Avoid Brittle Surfaces.Hydrogen embrittlement sometimes occurs during the cleaning processes of high strength alloys or materials like titanium or tool steels. If your parts are made from hardened materials, inform your coating vendor ahead of time so they can recommend changes to your base material or find alternative cleaning options.

FDA-Compliant Coatings. “Smart coatings” may require baking in an oven. Make sure there is an evacuation hole for heating and chilling rolls.

Download our White Paper for More Design Tips

Precision liquid dispensing nozzles may seem straightforward, but they come with some hidden design challenges. Chief among these challenges is the ability to maintain high flow rates at low pressures. While it may not be visible to the untrained eye, small improvements to the geometry of the nozzle and its surface characteristics can have a big impact on flow rates.

Subrex, a leading supplier of these nozzles, has mastered the art of refining nozzle geometry to reduce flow restrictions. The company’s standard-gauge and micro-precision nozzles feature thin walls, smooth transitions and a precise exit aperture—all of which contribute to optimize flow.

And now, the company has taken its nozzle performance a step further by applying General Magnaplate’s engineered coatings to improve the lubricity, hardness, release and corrosion resistance of the nozzle surfaces. These coatings include Nedox SLK and NH1, as well as Nedox Basic electroless nickel.

Subrex Case Study

Check out our latest case study to find out how Subrex uses Magnaplate coatings to enhance its liquid dispensing components.

In pharmaceutical packaging applications, our engineered coatings serve many purposes. Not only do they protect machine components, improve sanitation and provide antimicrobial properties, but they can also solve problems relating to release, friction, corrosion, speed and sticking. Here’s how:

  • Release. One contract packaging company that produces thermoformed plastic sheets with multiple cavities improved mold release with our Nedox coating. During production, these films sometimes stick to aluminum tooling after being thermoformed. If one of the many cavities on these sheets is ruined, the entire sheet must be discarded. The customer applied Nedox, adding dry lubrication and creating a dense, non-porous surface that also eliminates the potential growth of mold and bacteria.
Packaging White Paper
  • Friction. A pharmaceutical packaging supplier uses Magnaplate coatings for reducing friction and providing inert surfaces where chemically-active material could contact equipment components. The company makes fillers for handling irregularly shaped containers. One filler has a reciprocating head that’s timed to move with the conveyor belt so the filling nozzle can enter, fill and leave the container without touching it. For these filler heads, Tufram was applied, allowing the aluminum heads to withstand friction from its moving parts.
  • Corrosion. When engineers at another pharmaceutical equipment manufacturer began reassessing their manufacturing facilities, they focused on an 8-foot-diameter center slung centrifuge featuring a perforated basket that holds in-process pharmaceuticals. The customer anticipated corrosive attack from acids, bases, and solvents. To prevent these attacks, they applied our corrosion-resistant Lectrofluor coating.
  • Speed. A packaging equipment manufacturer supplies a variety of pharmaceutical companies with vertical and horizontal form-fill-seal machines for pouch packaging of viscous and aqueous liquid products, tablets, pre-moistened applicators and sterilizable hospital disposables in sealed and peel-open pouches. The company used several of our coatings on sealing head components and other key parts susceptible to corrosion, wear and product release issues.
  • Sticking. One pharmaceutical manufacturer needed to protect a three-piece mold that thermoforms blisters from PVC/PVDC laminates in form-fill-seal machines. This mold faced difficult product release and exposure to chemical fumes. Magnaplate HCR provides the desired non-stick properties and resistance to hydrogen chloride fumes given off by the laminate in the pre-heat station.

You can see many more examples of engineered coatings in pharmaceutical packaging applications in our latest white paper.

Download the White Paper

To provide aluminum parts with previously unattainable levels of hardness, wear and corrosion resistance and permanent lubricity, we’ve developed Tufram Omega®. This new, electronic-friendly coating combines our well-known Tufram® coating with a proprietary nanoparticle for optimal electrical resistance.

Let’s take a look at what makes Tufram Omega ideal for electronics applications, and some testing results that verify its properties.  

Engineered Coating for Electronics. Tufram Omega features a powerful combination of properties — harder-than steel abrasion resistance and a precise range of electrical resistance — for use in the electronics industry and many other applications. This new formula strikes a perfect balance between electrical resistivity and conductivity, and is useful in electronics applications that require a precise level of electrical surface resistance for aluminum parts. Examples include:

Tufram Omega
  • Semiconductor manufacturing
  • LED manufacturing
  • Solar cell manufacturing
  • Electronic component and device manufacturing
  • Aluminum rollers and slide carriers
  • Pick and place equipment
  • Medical electronic instruments
  • Telephone exchange equipment
  • Automated handling equipment
  • Exterior surfaces of spacecraft
  • Commercial satellites

Tests Favorably. When engineered coatings are created, a vital step in the development process involves testing and verification by an independent laboratory. To confirm the wear resistance properties of Tufram Omega, Taber abrasion testing was performed in accordance with ASTM D4060 using a 1,000g load and CS-17 wheels. Weight loss was recorded after every 1,000, 5,000 and 10,000 cycles.

An electron microscope was then used to check if conductive nano particles were still present in the pores of the abraded area. After 20,000 cycles, the conductive coating material remained in the pores, meaning that the Tufram Omega coating experienced very little wear and is a truly synergistic coating that becomes an integral part of the aluminum substrate.

To verify surface resistance, testing was done in accordance with ANSI/ESD STM 11.11-2006, which measures surface resistance in ohms. Measurements were made using a Prostat PRS-801 Resistance System. Based on surface resistance results, the testing lab confirms that Tufram Omega is a dissipative material with surface resistance between 106 and 109 ohms/cm, providing a surface that prevents open circuits and static buildup.

The new coating is now available as an off-the-shelf formula and is being used in several different applications and industries.

For more information, download our white paper on Tufram Omega

Download the White Paper

Packaging White Paper

Packaging machines often have to run sticky materials at high line speeds, which can pose friction, wear and release problems. Here’s a look at how our ‘smart’ engineered coatings can address all three problems.

Reduces Friction. When packaging machine components come in close contact with each other or the packaging materials themselves, the resulting friction can lead to slow line speeds and premature equipment wear. Our Tufram® and Plasmadize® coatings can combat friction and static buildup on a wide variety of packaging machine components.

For example, in one pharmaceutical application, a packaging equipment supplier makes extensive use of FDA-compliant Magnaplate coatings to reduce friction while also providing inert surfaces wherever chemically active material comes in contact with machine components.

This application involves a filling machine that handles irregular containers with a reciprocating head. The head moves with a conveyor belt so the filling nozzle can enter, fill and leave the container without any contact. Because of friction and wear issues, the packaging OEM couldn’t use aluminum for the filler heads until he applied Tufram. The coating helped the aluminum withstand friction between the assembly’s moving parts.

Eliminates Wear. Abrasive materials and dusty environments can lead to premature wear of machine components. Our engineered ‘smart’ coatings such as Nedox®, Tufram, Magnaplate HCR®, Plasmadize, Magnaplate HMF® and our anti-bacterial MAGnanoSHIELD® address these abrasive wear problems.

One packaging company confronted a problem with hot melt adhesive sticking to guides on a binding machine, causing excessive machine wear and bottlenecks. Another customer had sealing bars stick during the heat sealing of polyethylene bags.

Both problems were solved by applying our Plasmadize smart synergistic coating to the guides and sealing bars. Plasmadize prevented adhesive residue build up on the guides and eliminated sticking on the heat sealing bars. This surface enhancement coating provides reliable wear and corrosion resistance, as well as permanent non-stick dry lubricity for all base metals.

Provides Release and FDA Compliance. For sealing applications, melted plastic packaging materials sometimes stick to heated metal surfaces. Smart coatings like Tufram, Nedox, Magnaplate HCR, Magnaplate TNS® and MAGnanoSHIELD make packaging machine components non-stick to prevent product hang-up and ensure efficient substance release.

A contract packaging company in the pharmaceutical industry produces thermoformed plastic sheets with multiple cavities for individual tablets, capsules and caplets. After the cavities are filled and sealed with foil, sheets are cut into strips and packaged for sale or use as drug samples, hospital doses and clinical study packages.

Films tend to stick to aluminum tooling after thermoforming. Because each sheet of thermoformed film contains numerous cavities, if just one cavity is ruined because tooling sticks to it and tears it, the entire sheet must be discarded. Nedox provides a dry lubricating property that solves the problem by creating a dense, non-porous surface, which also eliminates the potential growth of mold and bacteria.

 

Download Our Packaging White Paper

Nedox Basic

You’re probably familiar with our advanced engineered coatings. What you may not know, however, is that we also provide high quality generic coatings. For example, let’s consider two coatings with some overlapping uses: our Nedox basic electroless nickel and much more advanced Nedox.

Nedox Basic electroless nickel will do the trick in many applications, but sometimes you will need all the enhanced surface properties that Nedox brings to the table. In this post, we’ll look at key performance differences between these two coatings and the best applications for each.

What’s the difference? Our Nedox Basic electroless nickel coating is a thin-film coating made from nickel and phosphorous. Nedox, on the other hand, is a nickel-based coating with the addition of a synergistic polymer and/or dry lubricants. Although they’re both based on nickel, these two coatings have very different performance characteristics.

A more robust coating than Nedox Basic electroless nickel, Nedox synergistic coatings have a surface hardness of up to Rc 68, compared to Nedox Basic’s electroless nickel’s maximum hardness of Rc 63. During salt fog testing, our Nedox CR lasts for 1200 hours, while Nedox Basic electroless nickel lasts for 1000 hours.

Nedox also performs better than Nedox Basic electroless nickel in chemically corrosive environments such as washdown and uranium-enrichment applications with UF6 exposure.

Even though these two coatings have many differences, they also have some similarities in their physical properties. Nedox and Nedox Basic electroless nickel both have a thermal conductivity of 0.0105 to 0.0135 Cal-cm/sec/°C and applied thicknesses between 0.0002 and 0.002 inches. These coatings both exhibit a coefficient of thermal expansion of 7.22 x 106 in/in/1°F (13 x 106 in/in/1°C).

Which is best? So which coating is better? For most applications, the answer is Nedox. Since it meets all FDA and USDA requirements, Nedox is a good choice for food and beverage and pharmaceutical applications. Nedox is also your best bet if you’re looking for a harder coating. However, if you’re looking for a coating that withstands high temperatures and costs less, Nedox Basic electroless nickel is the way to go.

Common Nedox Basic electroless nickel non-FDA applications include chemical processing, aerospace, transportation, instrumentation and manufacturing. More demanding applications such as nuclear equipment, food processing and molds are better suited for Nedox.

 

Learn more about our Nedox coatings and Nedox Basic electroless nickel

For increasingly corrosive conditions in oil and gas applications, standard coating technologies can marginally protect drilling tools against harmful galling, corrosion, pitting and other wear mechanisms that trouble drill strings. Engineered coatings, however, do an even better job protecting these tools from the tough conditions in deep wells.

In this post, we’ll examine some traditional coating problems in oil and gas applications, and tell you how our engineered do a better job solving them than generic coatings.

Traditional Coating Problems. Many types of coatings work adequately when used in the proper application. Standard or traditional coatings such as hard chrome, QPQ, fluoropolymers and tungsten carbides have long been used in oil and gas applications with some success.

 

Oil and Gas

Delivering an extremely low coefficient of friction, MAGNAPLATE HMF® eliminates galling that could result in premature wear, leaking and, ultimately, the total failure of valves and other metal parts.

The problem is that these traditional coatings don’t stand up to the levels of sour gas, pressure and rotating contact found in today’s oil and gas wells. Some designers still employ a nitride process or quench polish quench (QPQ) to reduce coefficient of friction and increase tool life, but these treatments case harden the part. QPQ penetrates six to ten thousandths into the part, changing its metallurgy. Tools used to spin, grab or lift QPQ treated components have shown limited ability to grip the case hardened components as they essentially are too hard for the tool to bite into.

Engineered Coatings. New engineered coatings are a much better choice for oil and gas applications than these traditional technologies. Take hardness, for example. A Nedox® synergistic coating with a coefficient of friction comparable to a 2H-hardness fluoropolymer coating ‘ups the ante’ on hardness to 68 Rc.

The major advantage of engineered coatings versus other types, such as paint-on varieties, is that the particles in synergistic coatings become an integral part of the substrate. Engineered coatings are mechanically bonded to the metal and the resulting new surface layer resists chipping, flaking, peeling or rubbing off. Because these coatings create metal surfaces that offer superior performance to both the original base metal and conventional coatings, these surface enhancements are said to be synergistic.

Further, because the engineered surfaces either duplicate or surpass the performance characteristics traditionally provided by metals such as chromium, cobalt, cadmium, and manganese, use of these expensive materials can be reduced.

System Design Advantages. Engineered coatings can improve drill string components as well as gate valves, impellers, rotors and mud pump components. They reduce friction and wear, and provide protection against corrosion and chemicals. Synergistic coatings such as Plasmadize®, Nedox and Magnaplate HMF® allow tool designers to make the drilling operation and extraction more efficient by downsizing casings and making components smaller. Initial tool costs can be lowered by employing reduced amounts of tooling material and less expensive metals.

Longer term, the improved COF and chemical resistance of surface enhanced parts increases the working life of tool and minimizes down time. System design advantages, such as power reduction, can also be realized with decreased COF and smaller, lighter tools available with engineered surface enhancements.

For more details, download our white paper.

 

Download The White Paper

Newsletter Signup

feedback