SECTION TITLE
COATING TECHNOLOGY
the negative shape of a car. Used to make millions of cars, the forming tools will degrade over time and require reworking. To ensure optimal performance and long life, they require polishing and a PVD coating application. In addition to saving energy by keeping the forming tool in optimal condition, additional energy is saved by less frequently moving equipment of this size and weight to a separate location to be repaired. In the energy sector, applying a DLC coating to roller bearings in wind turbines extends their life and lowers maintenance expenses. Consider that changing one main shaft bearing costs between US$200- 300,000 in addition to the disruption caused by taking the turbine off of the grid.
ENABLING GREEN TECHNOLOGY DEVELOPMENT Beyond improving the efficiency and carbon emissions of existing systems, PVD coatings can be an enabler of new green technologies in categories such as fuel cells and high-power energy density batteries. “Within the fuel cell sector,
we are working with a client who manufactures bipolar plates, a key component in fuel cells,” says Zedda. “Here, the role for a PVD coating will be to promote conductivity while at the same time resisting corrosion. Together these attributes will promote the longevity of the fuel cells, extending their environmental benefits.”
Oerlikon coatings extend the life of component parts that require frequent replacement, the raw materials, metals and energy
Zedda adds, “We are also working with clients to apply PVD coatings on some exciting and highly innovative projects in high power energy density batteries. As industry continues to develop environmentally friendly innovations, there will be more opportunities for coatings to be engineered to support their performance and overall life span.”
LEFT: Coatings have become an enabler of more efficient, higher performance, cleaner and smoother running machinery
Specialised coatings play a pivotal role by reducing friction and adding hardness to reduce wear
EFFICIENCIES IN APPLICATION Further up the specialised coatings supply chain, coatings manufacturers themselves have examined their processes for applying coatings since it consumes both materials and energy.
When the energy consumed to produce coatings is compared to the energy savings they generated in their application, either through the improved efficiency and longevity of an engine or a cutting tool, an ‘energy payback’ or return on investment is generated. “We are constantly striving to reduce the energy consumption of our coating equipment,” says Zedda “Our new coaters consume 40% less energy by using new more efficient plasma sources. Multiply this saving on every batch at all our coating centres around the world and the environmental benefit is huge.” He adds, “Although the impetus to explore a new source was environmentally driven, it is also in our customers’ economic best interests because it reduces their coating cost and shortens our manufacturing cycle.” Specialised coatings have an
important role to play in reducing our environmental impact. Energy consumption and carbon emissions of manufacturing and operations processes can be reduced significantly. So, although industry continues to use specialised coatings for their ability to enhance operating performance, the environmental impact is an important value-add that should not to be overlooked.
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