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Painel Ambientes Agressivos – Out/09Ricardo Ehlke – 11 3048-4140
VICTREX® PEEK™COMPONENTS AND
COATINGS FOR HIGH DEMANDING APPLICATIONS
Agenda
• Victrex Overview• Technical information on VICTREX®• Market and Application Review• VicoteTMCoatings• Coating Applications• Discussions
Global Organization
Victrex Europa GmbHHofheim, Germany
Victrex USA Inc.Philadelphia
Victrex plc.Hillhouse, UK
Victrex Manufacturing. Ltd.Victrex Sales Ltd.
Victrex Japan IncTokyo
Shanghai• Asia HQ• Asia Innovation and
Tech Center
Serving customers globally
Victrex PLC plants
Rotherham Seal Sands
Hillhouse
• Oil & Gas
• Automotive
• Aerospace
• Medical
• Industrial
• Electronics
• Semiconductor
• Alternative Energy
VICTREX® PEEK™ Markets
T Series
Per
form
ance
MAX- Series
VICTREX®PEEK™polymer
$40/lbs $120/lbs
VICTREXPEEK-HT®
Value to Performance for Victrex Products
PEEK-ST®
Polymer Hierarchy Continuous Use Temperature UL 746B
Amorphous Crystalline
Tem
pera
ture
Per
form
ance
Nylon
PPS (Polyphenylene sulfide)
PEI (Polyetherimide)
200°F
400°F
600°F
PPA (polyphthalamide)
PES (polyether sulfone)
PAI (Polyamide imide)
Victrex PEEK™ polymer
PI (Polyimide)
PBI(polybenzimidazole)
Victrex PEEK™ Tseries
VICTREX PEEK Polymer
▲ High Temperature Resistance• Continuous operating temperature of 500°F (260°C), maintains short term
properties at 644°F (340°C)
▲ Chemical Resistance• Outstanding chemical resistance to a wide range of chemicals up to 392°F (200°C)
▲ Resistant to Rapid Gas Decompression• Highly resistant to the damaging effects of rapid gas decompression
▲ Hydrolysis Resistance• Retains high level of mechanical properties when operating continuously in water,
brine or steam at elevated temperatures and pressures
▲ Excellent Permeation Resistance• Provides improved barrier properties than other commonly used polymers.Confidential
▲ Wear/Abrasion/Erosion Resistance• High abrasion and cut through resistance combined with low friction even in
aggressive environments
▲ Mechanical Properties• Excellent strength, stiffness and long term properties (creep/fatigue) retained over
wide range of temperature and environments
▲ Thermally Insulative Properties• Excellent thermal properties limit the thermal conductivity 1.73 Btu in h-1 ft2 °F-1
▲ Electrical Properties• Excellent dielectric strength maintained regardless of temperature and environment
▲ Proven Capability• Through more than 20 years of applications in demanding oil and gas environments
VICTREX PEEK Polymer
Confidential
Tensile Strength vs Temperature
Relative Thermal Index (RTI)
0
50
100
150
200
250
300
PA6/6 PPA PPS PES PEI PAI PEEK
RTI
, °C
, UL7
46B
0
50
100
150
200
250
300
350
PA6/6 PPA PPS PES PEI PAI PEEK
HD
T, °C
, 1.8
2MPa
HDT – Unfilled & 30% Glass Filled
VICTREX PEEK Comparative Properties for High Performance High Temperature Engineering Polymers
Process Update
Injection Molding• High production
volumes• Tight tolerances• Easy processing• Many different grades• No secondary operation• Parts consolidation
VICTREX PEEK Extrusion
• Usually for small volumes of production
• Good solution for machining parts
• Many standard dimensions in rods, tubes and plaques
• Different grades available• No investments in
prototype tooling in concept phase
VICTREX PEEK Compression Molding
• Near net shapes produced by unit
• Good solution for machining parts
• Many standard dimensions in rods, tubes and plaques
• Different grades available• No investments in prototype
tooling in concept phase• Low cost tooling if necessary
Application Case Studies
Parts and Components
Industrial and Oil & Gas – compressor components, bearings, seals connectors, …..
• Chemical resistance• Corrosion resistance• Resistance to hydrolysis• High operating temperatures• Electrical properties• Fatigue properties• Non-galling
Key features :
Typical Mill
Paper Mill downtime can cost $10,000 per hour
Details
System: Paper Mill Application: Drum bearing Material: Wear grade
Requirements
temperature max. 300°F
high load capability
self-lubricating
VICTREX PEEK Benefits
Reduced lubrication / contamination
Reduced unscheduled shutdowns
Shorter scheduled down time
Longer life
20% plant productivity
Pulp & Paper
PV Test Results
Single Screw Air Compressor
Reciprocal Compressor Focus
3) Main bearing 5) Crosshead 6) Crosshead shoes7) Piston rod 14) Valves 16) Piston Rings18) Cylinder 23) Crosshead guide Spring pockets
26) Suction vessel 27) Discharge vessel Cylinder Sleeve
Potential Opportunities
5.1% Unscheduled Shut Downs from Cylinder Lube Failure
Details
System: Centrifugal compressorApplication: Labyrinth seal Material: Wear grade of PEEK™
Requirementstemperature max 250°Fchemical resistance
ammonia, wet gas, alkaline
high mechanical strength
PEEK™ Benefits
non-galling
low moisture absorption
longer service life
Key Benefit: Carbon filled PEEK benefits enable the user to increase efficiency by running tighter clearances with out fear of rotor damage.
Victrex Carbon PEEK Labyrinth Seal
•50% Tighter clearance vs. Metal seals
•Greater efficiencies Maintained
•Teeth deflection prevents shaft wear
Valve Plates• When compared to metal plates,
VICTREX® PEEK™ valve plates are much lighter in weight.
•They don't impact the valve's seat as hard as a heavier metal plate. •The result is extended life for the seat, bumper, and springs.
• PEEK™ also has the chemical resistance, strength, durability, and high temperature capability required by compressors used for the collection, pressurization, and transportation of gases in a variety of chemical, petroleum, and industrial process applications.
Vane Types Typical Uses Current Applications Potential PEEK Fit
Fixed Vane Home Refrig. Vanes Bearings& Room A/C Discharge Valves
Rotary Vane Transport Refrig. Vanes S&D CheckMultiple vanes sliding & A/C Valves, Bearingsin and out of a slots in aeccentrically mounted rotor. 2 to 40kW (.6 to 11 tons)
Vane CompressorsRotary Vane Compressors uses a vane (or vanes) and a eccentrically mounted rotating shaft within a non-rotating cylindrical housing to capture a quantity of gas in a chamber. As the shaft rotates the chamber becomes increasingly smaller, compressing the gas until it is exhausted into a discharge port.
Single vane sliding in &out of slot in housing. Eccentrically moving shaft compresses gas in chamber.Up to 2 kW ( .6 tons)
Types of Valves
• BALL VALVES: Ball Valves (popular in HVAC systems) are designed to be operated fully open or fully closed with any liquid containing particles that could scratch the ball. Many applications use them successfully for throttling clear water. Ball valves have low pressure drops, open and close quickly. Ball valves can be opened and closed quickly, in a ¼ turn. The hazard of this ability is that opening or closing the valve too quick will result in “water hammer”. These valves are self cleaning and require minimum maintenance.
Typical HVAC Control Applications: air-handler heating & cooling coils, fan coil unit heating & cooling coils and unit ventilators and variable air volume reheat coils.
Industrial: Pump
• KERs:• -API 610, 9th Edition compliance• Temperature resistance: 180 –
200oC• -Limiting pressure differential up
to 140 bar• -Speeds to 8000 rpm.• -Wear resistance• -Chemical resistance• -Dimensional stability • -Low coefficient of thermal
expansion.• Remarks:
– Sourcing for stock shape supplier. (Greene Tweed, Ensinger).
– Bronze and brass replacement
EXTREMETUBE™made with VICTREX® PEEK™
Subsea Production Umbilicals
VICTREX PEEK Liners
Improved permeation and chemical resistance when compared to other commonly used polymer linersReduce the detrimental effects of methanol and biocide permeation, which in turn could be expected
to increase product lifetime and impact Health and Safety Environmental (HSE) concernsImproved collapse resistance
Extending the application of thermoplastic umbilicals to deeper water projects. (2000 m)Higher temperature rated thermoplastic material
VICTREX PEEK liner and sheath system can substantially reduce the detrimental effects of power cable induced heating to other umbilical components including super Duplex.
Victrex PEEK a stronger thermoplastic linerBetter bending radius vs. super DuplexWeight and diameter reduction vs. HCR or super Duplex Available at long, continuous lengths that reduce the umbilical costs and long lead times associated
with super Duplex umbilicals which require welding at regular intervals
Application OverviewUmbilicals are used for transportation of service fluids from the surface to the seabed, and normally incorporate electrical control cables and hydraulic hoses. VICTREX PEEK provides a solution for deepwater subsea applications at elevated operatingtemperatures and more aggressive chemical environments.
Confidential
The Next Generation of Coatings for Durability and Long Life
VICOTE™ COATINGSPowder and Liquid Dispersion Coatings
Based on VICTREX® PEEK™ Polymer
Market Trends For High Performance Coatings• Push towards longer life and lower total systems costs
– The performance demands in many products and industries are growing. Longer life and enhanced durability are mantras.
– Elimination of processing steps when making products is a key way to collapse total system costs: Vicote Coatings do not require a primer.
– Thinner and lighter coatings (compared with Fluoropolymer coatings) which offer enhanced performance are a key driver in the weight conscious aerospace industry
• Higher temperatures– Lead-free solder process temperatures moving from 220°C to 280°C – Higher end-use operating temperatures as electronics run faster, hotter and become smaller and more
functional.• Environmental concerns
– Global legislation like RoHS & WEEE restrict use of hazardous substances like halogens and bromines. – Demand for low VOC systems to reduce environmental impact
• Demand for improved reliability and more production up time– In many consumer products, longer warranties and the avoidance of costly product recalls are key OEM
needs. The performance of Vicote Coatings offers enhanced reliability and life of the coated part facilitating meeting these OEM needs.
– In many processes, production asset uptime is a key improvement objective: Vicote Coatings offer enhanced durability and longer life facilitating an improvement in production asset up times to help drive down the cost of maintenance and manufacture.
Definitions
• Electrostatic (powder) Coating: – Powders are sprayed directly onto a substrate and then heated.
Powders melt to form the coating with a typical dry film thickness (DFT) of 100 – 1000 microns.
– Typical applications – Pans, rice cookers, dampers, bushings, cylinder head gaskets, bearings, parts for corrosion resistance
• Dispersion Coating– The formulated aqueous based dispersion is sprayed onto the
substrate which is subsequently heated to form a thin film on the substrate with a DFT of 25-100 microns.
– Typical applications – cookware, irons, engine piston rings, bearings, large parts in chemical plants for corrosion resistance, coating glass and Kevlar™ fabrics.
• Thermal Spray– Powder is passed through flame to melt the polymer which adheres
and solidifies on the cool surface of the substrate.– Potential Applications – to coat objects that are too large to fit in an
oven.
VICOTE 700 and 800 Series Products
• A range of VICOTE (700 SERIES) powders can be used for electrostatic coating depending on the film thickness required.
• A range of dispersions (800 SERIES) are available where thinner coatings are required or where difficult geometries must be coated or where enhanced lubricity and wear properties are required.
VICOTE 700 Series Powder Grades
Used electrostatically with higher temperature performance requirements
50 micronVICOTE 709
Used where higher temperature performance is required in formulation of liquid dispersions
10 micronVICOTE 708
Used where high flow is required in formulation of liquid dispersions
10 micronVICOTE 707
Can be used electrostatically where higher flow and thinnest coatings are required
23 micronVICOTE 706
Used electrostatically where higher flow is required. First choice for thinnest electrostatic coatings with highest melt flow.
50 micronVICOTE 705
Used in formulation of liquid dispersions10 micronVICOTE 704
Can be used electrostatically and/or in formulation of liquid dispersions
23 micronVICOTE 703
Used electrostatically where increased flow and thinner coatingsare desired. First choice for thin electrostatic coatings with good melt flow.
50 micronVICOTE 702
Used electrostatically where heavy coating thicknesses are desired and where machining to tolerance may be required
50 micronVICOTE 701
DescriptionD50 Particle SizeNomenclature
VICOTE 800 Series Liquid Dispersions
These grades have been specifically formulated to provide a resilient coating with high wear and abrasion resistance combined with very good release properties throughout the profile of the coating. Available in natural and black
VICOTE F815 & F816Blk
A pure Victrex PEEK-HT dispersion with typical properties being very high continuous use temperature of 280°C (550°F), excellent wear, abrasion and cut through resistance at these high temperatures combined with very good chemical and excellent radiation resistance. Available in natural
VICOTE F814
This grade has been specifically formulated with Victrex PEEK-HT and lubricant additive to provide an even higher temperature, tough, resilient, high wear resistant coating with good release properties. Available in black only
VICOTE F813Blk
The 812 grade has been specifically formulated to provide a tough coating with good wear and abrasion resistance.
VICOTE 812
The 811 grade has been specifically formulated to provide a tough, resilient coating with high wear and abrasion resistance combined with dry lubrication properties.
VICOTE 811
These grades have been specifically formulated to provide a resilient coating with varying levels of lubricant to give high wear and abrasion resistance combined with very good release properties. Available in natural and black
VICOTE 808 & F808, 809 & F809 and 810Blk & F810Blk
These grades have been specifically formulated to provide a tough, resilient, high wear resistant coating with varying levels of lubricants to give good release properties. Available in natural and black
VICOTE 805 & F805, 806 & F806, and 807Blk & F807Blk
A range of pure Victrex PEEK dispersions with typical properties being high continuous use temperature of 260°C (500°F), excellent wear, abrasion and cut through resistance at these high temperatures combined with very good chemical and excellent radiation resistance. Available in natural and black
VICOTE 804 & F804 & 804Blk & F804Blk
DescriptionNomenclature
Thickness RangeThickness range from 100 - 1000 microns for electrostatic coating and 20 – 100 microns for liquid dispersion coating. (In some cases, coating thicknesses as high as 2mm have been achieved by multiple passes using the electrostatic process).
TolerancesTypical tolerances of +/- 5 microns on thinner coatings and +/- 25 microns on thicker coatings. Coatings made from Vicote 701 can be machined to tolerance – all other VICOTE Coatings can be lapped to tolerance.
VICOTE Coatings ProfileApplied to metal substrates as a protective coating. Typically used to improve scratch, corrosion, abrasion and wear resistance at hightemperatures.
SubstrateIdeal substrate is steel – stainless or carbon, aluminum or ferrous metals. Must be able to withstand 400°C (752°F) processing temperatures.Use on cast metals with caution due to out-gassing issues
Part Design / GeometryDesign with a uniform substrate thickness. Avoid sharp edges, deep draws and 90° joints where possible. Design with a generous radius. Encapsulate if exposed to liquids.
Substrate PreparationSubstrate should be cleaned and degreased. It should also be grit blasted to provide a mechanical keyed surface.
VICOTE COATINGS – General
Performance and Property Comparisons of
VICOTE COATINGS
VICOTE COATINGS – Performance
• VICOTE COATINGS complement the existing high performance coatings materials on the market today.
• VICOTE COATINGS overcome the deficiencies that exist with current coatings in abrasion resistance and poor performance at elevated temperatures.
• VICOTE COATINGS have outstanding wear performance and scratch resistance.
• Very Low Permeation of fluids and gases (e.g. H2S permeation is ~ 100 times better than next nearest competitor)
• VICOTE COATINGS adhere well to properly treated and coated substrates without the need for a primer.
FDA & PEEK-HT• Key grades of VICOTE coatings now comply with the
compositional requirements of regulation 21 CFR 175.300 for resinous and polymeric coatings of the Food and Drug Administration (FDA) of the United States of America.
• Vicote grades based on VICTREX PEEK-HT developed to address the needs of higher temperature applications; PEEK-HT has been the material of choice in demanding industrial applications for a number of years. VICOTE 708 & 709 are based on VICTREX PEEK-HT for higher temperature performance.
• The new VICOTE grades based on VICTREX PEEK and VICTREX PEEK-HT FDA food contact compliant grades offer a number of advantages over competitive materials for example providing more cost-efficient design of intricate parts, longer life and increased durability at high temperatures which will result in a reduction of process downtime for customers.
Electro–Static Dissipative (ESD) Vicote Grades
• Coatings made with VICOTE grades 807Blk and 810Blk can be classed as ESD. All other grades would be classed as insulative coatings.
• VICOTE grades have been recently tested for surface and area electrical resistance when applied to an aluminium substrate at approximately 30µm dry film thicknesses (DFT) using an ETS model 803B electrical resistance/resistivity probe and have been shown to exhibit impressive electro-static dissipative properties. The new Electro-Statically Dissipative (ESD) VICOTE grades, (see above), help to effectively control the rate of electrostatic charge build up. This is particularly important for coating applications where static build up is a concern, for example in processes that handle flammable materials and potentially explosive powders and dusts (in flour mills for example) or in the manufacture of sensitive electrical and semi-conductor equipment. Test results available on request.
• High performance, specialty coatings are dominated by the Fluoropolymers. i.e., PTFE, PFA, ECTFE
• Fluoropolymers are known for chemical resistance, low coefficient of friction and excellent release properties.
• Limitations include drop in mechanical performance at elevated temperatures resulting in poor wear, abrasion and cut-through.
• Release properties of Fluoropolymers can have an adverse effect on the adhesion of the coating to the substrate. Primer systems may be necessary to achieve satisfactory adhesion. N.B. No primer required for VICOTE products.
VICOTE COATINGS – PropertyComparison vs. Fluoropolymer Coatings
VICOTE COATINGS provides excellent corrosion resistance versus exposed metals especially against:
•Salts•Water / Steam•Alkalis•Acids•Aromatic Hydrocarbons•Halogenated Hydrocarbons
VICOTE COATINGS – Chemical Susceptibility of Exposed Metals
Specific data available on request
Taber Abrasion Comparing VICOTE Coatings against high end Industrial competitive coating systems at room temperature
Comparison of VICOTE Coatings with high end industrial competitive coating systems. Time to wear through 25 microns DFT coating with 250N load at room temperature
Comparison of VICOTE Coatings with high end industrial competitive coating systems. Time to wear through 25 microns DFT coating with 250N load at 250°C (482°F)
Tallysurf Scratch Resistance of VICOTE Coatings compared with various other coating materials with an applied load of 6kg at room temperature
Coefficient of Friction of VICOTE Coatings Compared with Other Polymers
Contact Angle After 8000 Taber Cycles at 1kg Load for F815 and F816 Blk Grades
Taber Wear Testing comparing various VICOTE Coatings grades with a load of 1kg for 1000 cycles at room temperature
Application Case Studies
Coatings
Markets & ApplicationsIndustrial & Automotive• Chemical processing and transport
components
• Vessels, pipes, valves, and ball seats
• Industrial mixers and agitators
• High Performance washers
• Compressor components
• Rollers and bearings
• Molds
• Textile manufacturing
Food Processing• Industrial bakeware
• Processing belts
• Cutting equipment
Semiconductor & Electronics• Equipment components
• Ultra-pure water systems
• Circuit substrates
• Mobile phone sliders
Pharmaceutical• Process tanks
Consumer• Cookware
• Appliances
• Exercise equipment
VICOTE® Production Tubing
Value PropositionHigher mechanical strength and temperature rating than current coating systemsExpanding the use of coated production tubulars for CO2 and H2S high temperature environmentsImproved coefficient of friction compared to uncoated metallic surfacesIncreased adhesion improving resistance to undercut Increased permeation resistance compared to most coating systemsSuperior chemical resistance compared to current coatingsImproved impact resistance compared to thermoset coating systemsImproved flexibility compared to thermoset systems
Application OverviewA high-performance coating exhibiting all the properties of VICTREX PEEK for:
Chemical flow lines HP/HT wellsCorrosive wells Subsea flowlinesDrill pipe
Production & Injection tubingWelded and flanged piping systems
Confidential
Type of Part: Open Face Impeller
Material: Cast Iron
Coating / Thickness:Vicote 701 – 600 to 700 microns
Service Condition.:Pumping abrasive and chemical solutions which are compatible with Peek Powder Coating.
VICTREX PEEK Coating Before & After
Type of Part: Pump housing
Material: Cast Iron
Coating / Thickness:Vicote 701 – 250 to 300 microns
Service Condition.:Pumping abrasive and chemical solutions which are compatible with Peek Powder Coating.
VICTREX PEEK Coating
Vicote Coatings case studyIndustrial Mold CoatingsChallenge: To withstand the high
temperatures and aggressive chemical and abrasive conditions in the molding of shoes and tyres, and provide release properties to ensure clean ejection of the part from the mould
Solution: VICOTE Coating successfully used to coat shoe mold
Benefits: Excellent high temperature performance (continuous use at temperatures up to 260°C) and retention of mechanical properties at elevated temperatures, exceptional wear and abrasion resistance, excellent durability, and extreme chemical resistance and great release properties. Shoe Mold coated with VICOTE lasted
30 times longer than same mould coated with PTFE
VICOTE Coatings for Industrial Textiles ProductionChallenge: To withstand the high
temperatures and aggressive chemical and abrasive conditions in the roller coating of glass fibres with PVC
Solution: VICOTE Coating successfully used to coat roller for use in industrial textiles production
Benefits: Excellent high temperature performance (continuous use at temperatures up to 260°C) and retention of mechanical properties at elevated temperatures, exceptional wear and abrasion resistance, excellent durability, and extreme chemical resistance.
Roller coated with VICOTE lasted 4 times longer than same roller coated with PTFE
Glass Fiber Belts coated with VICOTE Coatings increase wear and abrasion resistance, improve cut-through resistance, increase puncture and impact resistance when compared with PTFE coated belts. Case studies show an INCREASE IN THE BELT’S LIFE BY UP TO 40% reducing both downtime and maintenance cost for the belt manufacturer’s customers.
VICOTE Coatings a fit for Glass Fiber coating and fabric suppliers
VICOTE Coatings for Needle Roller BearingsChallenge: Roller bearings are widely used in crankshaft
and connecting rod mechanisms in engines especially in motorcycles, lawn mowers and outboard motors. Their purpose is to reduce the friction between 2 rotating surfaces –as a result they are subject to extreme wear especially of the outer surface. Current solutions are expensive and do not provide adequate wear relative to the demands of the application.
Solution: VICOTE 804Blk used in testing (at 9000 rpm for 100 hours) outperforms current solutions (traditional silver/copper coating), which wears away under the same test conditions causing damage to the cage and premature failure of the bearing. All this performance was achieved with a VICOTE coating thickness 50% lower than the traditional Copper/Silver coating.
Benefits: The excellent wear resistance and durability of VICOTE Coating can withstand the extreme conditions of this application.
F- grades are well suited for Needle Roller Bearings and applications that are made from low carbon mild steel pressed sheet or machined steel
NRB PR available
Conclusion
• Victrex has over 25 years accumulated experience in the application and processing of Poly(Aryl Ether Ketones)
• Comprehensive material qualifications and over 20 years in service in different Industries have proven VICTREX PEEK performance
• History of working closely with endusers and channel partners to ensure design process is successful and the product is manufactured to the highest standards
Thank you!