High Performance Coating Technology

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High Performance Coating Technology
Fort Wayne Rubber Plastics Group, Inc.
February 12, 2009
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Outline

• Background and product family
• Adhesion and fatigue testing
• Oil and fuel resistance
• Ozone resistance
• Examples of exposed parts
• Heat Reflective Coating (HRC)
• Summary
• Questions

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Goal To Develop a Protective Coating for Rubber

• Heat resistant
• Ozone resistant
• Oil and fuel resistant
• Room temperature curable
• Adhesion to both rubber and metal
• Flexibility to withstand dynamic motion
• Aesthetically appealing

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HPC Product Family (High Performance Coating)

• HPC-3B and HPC-3C
• HPC-5B and HPC-5C
• HPC- 6C
• HRC

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HPC-3B and 3CBased on Fluorocarbon Rubber (FKM)

• HPC-3B black HPC-3C clear
• Maximum protection from exposure to oils and
  fuels

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HPC-3B and 3C (FKM)

• Two part system, mix 1002.5 with HPC-3 Curative
• Mixed pot life up to 2 days depending on humidity
• Cures at room temperature
• Full cure achieved in around 24 to 72 hours.
• May require a primer for best adhesion
• A short bake speeds cure and enhances adhesion

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HPC-5B and 5C Based on Hydrogenated Nitrile
Butadiene Rubber (HNBR)

• HPC-5B black HPC-5C clear
• Maximum protection from ozone

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HPC-5B and 5C (HNBR)

• One pack- keeps more than one year
• Cures at room temperature
• Full cure achieved in around 24 hours
• Excellent adhesion to many substrates
• Good for intermittent and periodic exposure to
  oils
• A short bake speeds cure and enhances adhesion

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HPC - 6C Based on Ethylene Acrylic Rubber (AEM)

• HPC-6C clear
• Offers protection from ozone
• Offers limited protection from oils
• Colorable
• Less than 3 HAP
• Uses VOC exempt solvent

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HPC - 6C (AEM)

• One part system
• Keeps more than one year in unopened container
• Cures at room temperature, but dries more slowly
  than HPC-5
• Full cure achieved in around 24 hours
• May require a primer for best adhesion
• Short bake speeds cure and enhances adhesion
• HPC-6C is recommended for cosmetic coatings

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A Wide Color Palette is Possible
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High Performance Elastomeric Coatings

• A Family of Coatings with Different Features and
  Benefits,
• but Sharing Core Strengths of
• High elongation
• Adhesion many substrates
• Fluid resistance
• Room temperature cure
• Colorable
• Good cosmetics
• Can be used in combination to solve
  difficult problems

HPC is Enabling and/or Disruptive Technology
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Adhesion and Fatigue TestingASTM D430 method B
not pierced
Runs at 5 hertz
DeMattia specimen as installed
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Adhesion and Fatigue Testing
DeMattia specimens in full flex position
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Uncoated control shows cracks initiating at
80,000 cycles
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HPC-5B shows only one flaw in the coating at
80,000 cycles
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Uncoated control shows severe cracking at 150,000
cycles
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HPC-5B coating shows minimal cracking at 150,000
cycles
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HPC-3B coating after 80,000 cycles
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What is the Tensile and Elongation of the
Coating?
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Fluid Resistance Testing on Natural Rubber
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Fluid Resistance Testing on Natural Rubber
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Physical Property Retention of NR After Fluid
Exposure
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Effect of Thickness on Fluid Resistance
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Coating Effectiveness over Different
SubstratesAfter 168 hours in IRM 903 Reference
Oil at 70ºC

• 35 Durometer Natural Rubber NR
• 55 Durometer Natural Rubber NR
• Butyl Rubber IIR
• Polybutadiene BR
• EPDM
• Polychloroprene CR
• Swell testing per ASTM D-471Tensile and
  Elongation tested per ASTM D-412

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Hydrogenated Nitrile Rubber Resistance to
Unleaded Gasoline at 21C
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Dynamic Testing in the Presence of Oil

• 70C IRM-903 oil dripping on double lap shear
  mount.
• Cycled at 10 Hz, /-10 shear strain in
  servo-hydraulic test machine.

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After exposure
After 10 million cycles, rubber in the uncoated
part is noticeably bulged and swollen.
After 16 million cycles, there is no obvious
swelling of the coated part.
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Dynamic testing of NR/BR blend with hot IRM-903
oil (70C) dripping on double lap shear mount
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Compounds and Coating Application

• Used 33 ACN 55 durometer nitrile compound as a
  reference compound.
• Coated and uncoated 55 durometer NR/BR blend used
  as a standard for a mount compound
• HPC-3C was applied over a primer coat of HPC-5C
  as part of the application process.
• HPC-5C primer coating thickness measured a mean
  of 8.1 µm with a standard deviation of 0.6 µm.
• HPC-3C coating thickness measured a mean of 5.1
  µm with a standard deviation of 0.9 µm when
  applied without the primer.

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ExampleLarge oil-field mount exposed to IRM-903
oil
27.8 weight gain 3.5 weight gain
Mount, (left) Uncoated and (right)Coated with
HPC-3B Before Oil Exposure
Mount, (left) Uncoated and (right) Coated with
HPC-3B after 2 Weeks at 100C in IRM 903 Oil
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Large oil field mount exposed to IRM-903 oil
50.8 weight gain 9.3 weight gain
Mount, (left) Uncoated and (right) Coated with
HPC-3B after 1024 hours at 100C in IRM 903 oil
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Comparison of HPC-5C with HPC-3C in oil at
elevated temperature on a laminated bearing
Part Coated with HPC-3C After 90 Days at 100C in
IRM 903 Oil
Part Coated with HPC-5C After 90 Days at 100C in
IRM 903 Oil
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Ozone Resistance Testing
Uncoated control after 52 hours ozone exposure
Uncoated control after 5 hours ozone exposure
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Ozone Resistance Testing
HPC-5C (two coats) after 275 hours ozone exposure
HPC-5C (one coat) after 275 hours ozone exposure
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Ozone Resistance Testing
HPC-5C (three coats) after 275 hours ozone
exposure
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Ozone chamber equipped for dynamic testing
ASTM D 3395 40C, 50 pphm of ozone
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Specimens in Dynamic Fixture
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Effect of Coating Thickness on Ozone Resistance
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Effect of Coating Thickness on Ozone Resistance
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Heat Reflective Coatings for Rubber
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Heat Reflective Coating - HRC

• Key Benefits
• Heat is the enemy of rubber
• Provides heat reflective properties along with
  fluid resistance to substrate material.
• Part operates cooler longer life, higher
  reliability.
• Reduced variation in spring rate more stable
  mechanical performance.

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Heat Reflective Coating - HRC

• Value Proposition Use of lower cost, simpler
  substrate with high performance coating
• Save cost of heat shield or heat reflective wrap
  
• Increases service life/reliability of component
• Cost Savings. Simplified installation and
  packaging. Better performance.
• Note Heat source/problem must be radiant heat
  does not work in an oven

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Typical Radiant Heat Problem
Maximum Temperatures (Part Req. The Heat Transfer from Conduction and Convection
are not enough to raise the part temp to137C
Heat Transfer from Radiation raises the part
temp up to 137C
107C
137C
115C

• Types of Heat Transfer
• Radiation
• Conduction
• Convection

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Test Setup
Thermocouples in the center of 7.5 x 7.5 x 1.2
cm natural rubber blocks positioned 16 cm from a
250 watt infra-red bulb.
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Infrared Light on Specimens
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Dual probe thermocouple measures the temperatures
of each specimen
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The uncoated specimen began smoking within the
first 10 minutes of the experiment
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Temperature Rise Data
Uncoated Rubber Block Coated Rubber Block Time
(minutes) Temperature (F) Temperature (F) Initial
0 73.8 73.6 10 162.1 97.3 20 214.9
118.7 30 238.5 130.5
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Heat Build-Up
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Repeat of experiment with a 16 inch 3 speed fan
running at low speed, blowing across specimens
from 9.5 feet away and infra-red light positioned
4 inches from specimens.
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Temperature Rise DataWith Fan
Uncoated Rubber Block Coated Rubber Block Time
(minutes) Temperature (F) Temperature (F) Initial
0 73 73 4 95 78 10 131 84 20
172 92 35 181 96 50 189 99 120
189 99
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Heat Build-Up With Fan
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Parts with Black and Heat Reflective Coatings
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HPC5C/HPC3C Coating on a Laminated Rod End
Bearing
Example
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HRC Part Mechanical Performance Unchanged
Just Appear Silver
HRC Coated vs Uncoated Muffler Hanger

• Uncoated Control vs HRC Coated
• NR strips on DeMattia
• _at_ 103,000 cycles

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Tech Performance Comparison with Heat Shield
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Cost Savings with Heat Reflective Coating
Not counting handling and installation labor of
heat shield Exhaust hanger in 5/lb Silicone or
1/lb EPDM with Coating
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Impact of HRC on cool-down rate
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Summary

• Coating Provides Excellent Fluid and Ozone
  Resistance Less expensive materials
  can be substituted for the bulk of the part.
• Coated Parts Last Longer More Fatigue Resistant
  than Un-Coated
• Heat Reflective Allows Parts Subject to Radiant
  Heating to Run Cooler
• Less expensive materials can be substituted for
  the bulk of the part.
• Heat shields may NOT be required for future
  applications.
• Coating Can Provide Cosmetic/Colorization/Customiz
  ation Capabilities

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Thank you Fort Wayne Rubber Plastics
Group, Inc.Acknowledgements

• Troy Chaffee
• Terry Krebs
• LORD Corporation
• James Halladay
• Bobby Kohli