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Engineered Coatings & Coatings for Engineering

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Engineered Coatings & Coatings for Engineering

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  1. Engineered Coatings for Composites & Polymers Used in Defence & Aerospace: Now & the FutureHamburg: 10-11 February 2010Graham Armstrong FIMFTechnical Sales Manager

  2. Engineered Coatings & Coatings for Engineering

  3. IndestructibleThe Company and Our Products

  4. Birmingham Based SME; In Existence Since 1978 • Suppliers of Coatings to Aero Engine, Airframe, Aero Ancillaries and Other “High Tech” Industries • Approvals to: AS9100; ISO9001; ISO 14001 • Stocking Facilities in:- UK; US; France; India; Singapore; Saudi-Arabia • Representation Additionally in:- Germany; Belgium; Holland; Scandinavia; Switzerland; Romania & Eastern Europe; Italy; Russia; Israel; • Export to Over 40 Countries From UK Main Warehouse

  5. Facilities at UK Base • Full Development & Quality Control Laboratories • Innovative Development Team to Design New Coatings to Meet Ever Increasing Technical Requirements • Full Product Manufacturing • Total Commercial & Technical Back Up Teams to Support Distributors and Clients • Full Product Stocking • Full Export Packing & Despatch Team

  6. Rolls Royce Turbomeca ITP GE Sikorsky Meggitt ABS HAL India Messier Dowty Honeywell Airbus McDonnell Douglas Boeing OEM & Overhaul: In House & Pratt & Whitney (PWA/CPW) MTU Germany IAE Allied Signal Eurocopter BAe Snecma Goodrich Hamilton Sundstrand Agusta-Westland HAESL/SAESL/TAESL their Suppliers/Contractors Major Customers/Approvals

  7. Product Types • Organic Paints and Coatings Including ; Epoxy ; Polyurethane; Acrylic ; Silicon ; Silicate ; Polyimides ; blends and others. • Inorganic and Sacrificial Coatings ; Diffusion and Ceramic Products • Dry Film Lubricants • Intumescents / ”Thermal Barriers “ • Primer-filler Coatings for Composites

  8. Typically, Coatings Must Resist: • High Heat: >500-600oC • High Chemical Attack: Skydrol ; de icers etc • Erosion: Rain & Particle • Corrosion • Heat & Thermal Conductivity • Fuel and Lubricants

  9. Coatings for compositesthe current status

  10. Initial Work • Intumescent System for Helicopter Doors & Hatches • Coatings for Automotive Use (Motor Cycle Fairings; Small Car Components)

  11. Recent Development Projects

  12. Composite Airframed VehiclesElastomeric coatingsINTUMESCEnt & thermal barrier coatings

  13. Composite Airframed Vehicles HAL DHRUV Advanced Light Helicopter Low VOC 2K Epoxy Primer-Surfacer Low VOC 2K Epoxy Lightweight Spray Primer-Filler 2K Epoxy “Putty” (Localised Use) Low VOC 2K PU Finishes • Fully Composite Airframe • Composite Rotor Blades • Resin Rich/Weak Surfaces Specifications

  14. Composite Airframed Vehicles HAL DHRUV Advanced Light Helicopter MPC 50015-R3 Primer- Surfacer on Majority of Airframe MPC 50019-R3 Lightweight Filler on Engine Firewall & on Engine Exhausts IP6 PU Finish (Matt IRR Camouflage Colours)

  15. Composite Airframed Vehicles HAL DHRUV Advanced Light Helicopter

  16. Elastomeric PU Coatings Benefits • Erosion Resistance • Flexibility • Exterior Durability Issues • Application • System Adhesion Areas of Use • Engine Nose Spinners • Propeller Blades • Radome Coatings

  17. Elastomerics-Recent Projects Engine Nose Spinners Investigative Work Clear or Pigmented Base Coat Supply of “User Friendly” 2 Component System Integration of UV Absorbers • Adhesion Failures in Use • Causes felt to be: Base Coat Application UV Resistance

  18. Elastomerics-Recent Projects Engine Nose Spinners TEST CONCLUSIONS • Use of a 2K Epoxy Base Coat Solves Adhesion Issues • Clear Base Coat Better than Black/Aluminium • Use of UV Absorber Improves Both Adhesion & Clarity • System of Clear low VOC 2K Epoxy Basecoat, Plus UV Stabilised 2 Component Elastomeric Now Adopted and Written into Specification

  19. Elastomerics-Recent Projects Propeller Coatings • Similar Issue: Variable adhesion of System-Epoxy Base Coat + Elastomeric PU Topcoat However before our involvement, client was sourcing various components from differing suppliers. All products met individual specs, but combination gave varying results

  20. Elastomerics-Recent Projects Propeller Coatings • System Developed: • Low VOC 2K Epoxy Basecoat • Low VOC 2K Elastomeric PU • Single Source Supply • Products Balanced so 100% Adhesion • Additional Benefit: • Use of low VOC products gave >1/2 tonne reduction in VOC Emissions

  21. Elastomerics-Recent Projects Radome coatings Developed System: Low VOC 2K Epoxy Seal Coat (Green Tinted) Specially Pigmented 2K Elastomeric PU Meets Erosion Resistance to SAE-AMS C-83231 & Client Electrical Transparency • Specific Requirements: Erosion Resistance (Rain & Particle) Electrical Transparency • Client Issues Current Product Exhibits “Reversion”

  22. Intumescent Coatings • Increasing Use of Composites Present New Challenges for Fire Protection • Requirements for Both “External” & “Cabin Interior” Systems • Each Require Differing Approaches

  23. Intumescent Coatings Cabin Interior Systems Both Decorative & Functional Requirements Main Requirements: Technical: Non Burn Coatings Low/No Smoke Release (FAR 25853 Specification) Hardness/Durability Decorative: Colour & Finish Continuity Textured Finish

  24. Intumescent Coatings Cabin Interior Systems Developed System: Low VOC 2K Epoxy Primer-Filler (Low Weight; Thermal Barrier Effect) Low VOC 2K PU; Non-Burn, low Smoke Emission Nano Modified for Surface Hardness

  25. Intumescent Coatings Control Boxes-recorders Traditionally Metal Construction Moving to Carbon Fibre Epoxy Composite (Weight etc) Within Airframe But Usually Outside Passenger Environment Requirement to Protect From Fire for Minimum 5 minutes Requirement to Keep Interior Components Below 350oC (662oF)

  26. Intumescent Coatings Control Boxes-recorders Project with Prime Airframe Manufacturer Three Alternative Systems Evaluated: Substrate: Cycom 5215 T650 6K-135 5HS Prepreg Seal Coat: Low VOC 2K Epoxy Sealer (Green Tinted) Intumescent: 1.) IP 1265 Thermal Intumescent 2.) Combination IP1265/IP9189 3.) IP 9189 Full Intumescent Top Coat: Low VOC 2K Epoxy Low Flame Spread Finish

  27. Intumescent Coatings Control Boxes-recorders Coating Systems Clean Composite with Isopropanol Apply Green Tinted Seal Coat to Nominal 20 microns Apply Multi Coat Intumescent to Nominal 350 microns Apply Finish Coat to Nominal 30 microns All Coats Cured at 80oC (176oF) All Panels Allowed 7 days Stabilisation Before Burn Test

  28. Intumescent Coatings Control Boxes-recorders Test Procedure (to follow set up in BSX 37) Heat Source: Rothenburger Superfire 2 Torch Flame Temperature: 1060oC (1940oF) Flame Applied Directly to Coated Side of Test Panel for 2/5 Minutes Thermocouples Mounted at Flame/Panel Interface and on Reverse of Panel behind Burner

  29. Intumescent Coatings CONTROL BOXES/RECORDERS

  30. Intumescent Coatings Control Boxes-recorders Intumescence Values

  31. Intumescent Coatings Control Boxes-recorders Report/Comments All Three Systems Met Original Requirements IP 1265 Thermal Intumescent Gave Off Slightly More Smoke IP 9189 Selected For Use

  32. In mould primer application

  33. In Mould Primers • Originally Researched in Conjunction with Major Automotive Manufacturer • Being Investigated With Primes in Aerospace • Has been found to be Successful with both Injection Systems and Pre-Preg Layup.

  34. In Mould Primers • Product: Fast Set Up Low VOC 2K Epoxy Surfacer • Process Apply Epoxy Compatible Mould Release Spray Apply Primer to Mould Surface Cure Primer; Either Force Cure or Air Dry Lay Up Pre-Preg or Fibre Blankets/Inject Cure as per Normal Process (Autoclave) Break Mould

  35. In Mould Primers • Benefits Very Even Pre-Primed Surface (Primer Surface Mirrors the Surface of the Mould) No Resin Weak Surface Areas No/Minimal Additional Hand Filling Faster/Simpler Finishing Process

  36. Exciting new developments

  37. Electrical Conductive Coatings • UK KTN (Institute of Materials) • Possible FP 7 project • Use of Piezo Electric Cells for Aircraft De-Icing • Possible Use of Nano Materials

  38. Bruisable Coatings • Damage to Composite not always visible (different to metal) • Danger of structural weakening not being apparent • Investigation into “Bruisable” Coatings • Possible Use of Nano to Act as “Indicator” • Very Early Stage of Development - Watch this space!

  39. Increased Hardness & Resistance Properties • Requirement for Improvements in: Surface Hardness/ Erosion Resistance Heat Resistance/ Intumescence/Thermal Barrier Chemical Resistance

  40. Increased Hardness & Resistance Properties • Alternative Solutions: Alternative Cure Methods on Heat Sensitive Substrates Formulation of Cold/ Low Temp Cure Products With Increased Performance

  41. Environmental/Legislative Issues • REACH SVHC’s Ongoing Restrictions • Solvents Directive • HAPS • CLP • GHS • CrVI Elimination • CRIII Elimination • VOC Reduction/ Elimination • Example: Propeller Manufacturer Discussed Earlier: VOC Reduction of >1/2 Tonne

  42. For more information please contact our technical department +44 (0)121 702 2485 Outside UK office hours please use the form at: - www.indestructible.co.uk/form