Wear protection

Protection from wear is designed to keep components and products fully functional for as long as possible. The friction between different materials is reduced as far as possible, while also increasing the surface hardness. The strength of components is increased by combining fluoroplastics with metal or ceramic materials.

Impreglon products for optimal wear protection

  • CeC

    CeraCoat®

    Functional surfaces to protect from wear

    With CeraCoat®, high-quality metal and ceramic coatings are created in a thermal spraying process. Extreme surface hardness optimizes the wear resistance and traction properties and extends the service life of components subjected to high levels of mechanical strain.

  • CoC

    CompCote®

    Performance in surfaces

    With its low density (2.8 g/cm3), aluminum, in conjunction with CompCote®, opens up new approaches in technical and decorative applications with increased requirements on quality. CompCote® is a polymer-aluminum oxide composite coating with revolutionary properties.

  • FuC

    FuseCoat®

    FuseCoat is used anywhere that there is a need for outstanding cathodic corrosion protection and other functional and decorative properties combined in a duplex coating, e.g. in the automotive and construction industries, traffic engineering, wind power, the oil and gas industry or offshore.

  • NCA

    Nucocer® AL

    Electrochemical plasma ceramic coating of aluminum

    Nucocer® AL coatings are produced in plasma-chemical oxidation processes. They have a finely crystallized ?-AL2O3 structure and an amorphous zone in the upper part.

  • NTE

    Nucotec® EL

    The anodic oxidation of aluminum

    Nucotec® EL layers are made from hard, wear resistant aluminum oxide. They are formed through the chemical reaction that turns aluminum into aluminum oxide.

  • NTH

    Nucotec® HE

    The hard anodization (hard coat) of aluminum

    Nucotec® HE layers are made from extremely hard, wear resistant aluminum oxide. They are formed through the chemical reaction of the aluminum material in special cooled acid electrolytes.

  • PC

    PlasmaCoat®

    Wear-resistant combination coatings

    The PlasmaCoat® coating procedure combines the outstanding surface hardness and wear resistance of thermally sprayed metal or ceramic coatings with the nonstick and sliding properties of polymers and fluoropolymers.

  • StC

    StarCoat®

    Extraordinary wear protection

    StarCoat® metal and carbide coating systems are applied with high-speed thermal spraying techniques to achieve exceptional wear resistance.

CeraCoat® – Functional surfaces to protect from wear

With CeraCoat®, high-quality metal and ceramic coatings are created in a thermal spraying process. Extreme surface hardness optimizes the wear resistance and traction properties and extends the service life of components subjected to high levels of mechanical strain. Modifications in the surface roughness and profile enable the coating to be adapted to the relevant application. Sealed with a top coat, excellent nonstick properties can be achieved.

CeraCoat® coatings can be applied to nearly all metallic materials and carbon fiber materials to provide a wear-resistant surface. Mechanically finished CeraCoat® antiwear protective coatings can even replace hard chrome coatings for wear resistance.

Coating thicknesses: 80 µm to 200 µm
Temperature range: -40 °C to +270 °C
Surface roughnesses (Ra): approx. 0.2 µm (mech. finished) up to 30 µm
Surface hardness: 28 to 70 HRc
FDA-approved: yes, with certain coating types
Polymer layer
Metallic/ceramic reinforcement layer
Substrate

CompCote® – Performance in surfaces

With its low density (2.8 g/cm3), aluminum, in conjunction with CompCote®, opens up new approaches in technical and decorative applications with increased requirements on quality. CompCote® is a polymer-aluminum oxide composite coating with revolutionary properties. In addition to the CompCote® process, there is also "CompCote®-H". CompCote®-H offers better hardness characteristics and better wear and corrosion properties.

CompCote® is free of heavy metals, fluoropolymers and PVC. The procedure is patented in Europe, the USA and other countries and is classed as food-safe by the American Food & Drug Administration (FDA).

 

Layer structure, layer thicknesses and tolerances

CompCote® is formed by transforming the substrate and therefore guarantees optimal bonding. CompCote® grows in the substrate and out of it too. CompCote® layers are formed through anodic oxidation of the base material and simultaneous molecular bonding of the aluminum oxide layer with polymers. In contrast to the conventional anodization procedure, anodization with the CompCote® process creates a surface with a cellular structure.

Due to the molecular polymer content, CompCote® forms chemical bond bridges when a coordinated top coat is selected. This achieves a better adhesive strength.

 

The optimal solution for your specific application

Examples of applications where CompCote is successfully used:
Architecture, the automotive industry, electrical engineering, photo and video technology, household appliances, hydraulics, information technology, hunting weapons, the food industry, aviation, mechanical engineering, medical technology, pneumatics, sports articles, packaging machines, defense technology

 

Properties

  • High level of corrosion protection
  • High level of wear protection
  • Very good tribological properties
  • Low impact on the surface roughness
  • Protection against cold welding
  • Optimized microstructure
  • Improved surface hardness 300–600 HV depending on the alloy and process
  • High level of fracture strength
  • Good adhesion properties (chemical bonding with top coats)
  • High UV resistance
  • Food safe according to the FDA
  • More lightfast than colored standard anodized layers

 

Hardness & wear protection

CompCote® forms an extremely hard aluminum oxide (1200 HV). However, as with all anodic oxidation layers, only the "apparent hardness" is measured as the layer hardness. This value is between 300–600 HV depending on the alloy and the procedure.

CompCote® is over 3x and around 1.5x more wear resistant than anodic and hard-anodic (hard coat) oxide layers (Taber Abraser Test /MIL A 8625F). Results from the Taber Abraser Test show a significant reduction in the abrasion rate with the CompCote® procedure.

CompCote® replaces chromic acid layers: Thin chromic acid layers (2.0 ?m) are known for their good properties under alternating bending stress, which is why they are used in the aviation industry. CompCote® performs even better in this field, as it has no impact on the alternating bending stress resistance of the base material. It also outperforms chromic acid layers in corrosion resistance tests.

CompCote® is considerably tougher and break-proof: CompCote® shows a fibrous fracture pattern in notch impact tests. Conventional oxidation layers, on the other hand, have a brittle fracture pattern like glass.

In various pairings and friction tests, CompCote® shows very good anti-scuffing properties. In some cases, the friction values even reduce in repeat tests (self-smoothing effect). Stick-slip effects are reduced.

 

Corrosion protection

CompCote® is corrosion-resistant and outperforms conventional anodizing layers in corrosion tests (salt spray test / ASTM B117).

FuseCoat® –

FuseCoat is used anywhere that there is a need for outstanding cathodic corrosion protection and other functional and decorative properties combined in a duplex coating, e.g. in the automotive and construction industries, traffic engineering, wind power, the oil and gas industry or offshore.

Performance features

  • Cathodic protection against corrosion
  • No hydrogen-induced corrosion
  • Functional properties
  • Decorative properties
  • Zinc thermal diffusion + passivation + functional or decorative coating
    • Functional and decorative coatings:
      • Corrosion protection
      • Decorative coating
      • Non-stick coating
      • Slide coating
      • Traction coating
      • Resistance to abrasion
    • Coating pursuant to DIN EN ISO 17668 or DIN EN 13811 and DIN EN 15773:2010
    • Coating thicknesses: 10 to 200 µm
  • The following base substrates are suitable for zinc thermal diffusion:
    • Unalloyed carbon steel
    • Low alloy steel
    • Heat-treated steel
    • High-performance steel
    • Cast iron and gray cast iron
    • Sintered metal

Nucocer® AL – Electrochemical plasma ceramic coating of aluminum

Nucocer® AL coatings are produced in plasma-chemical oxidation processes. They have a finely crystallized ?-AL2O3 structure and an amorphous zone in the upper part.

Main features:

  • High level of hardness
  • Extremely high wear resistance
  • Excellent adhesion to the base material
  • Vibration resistance
  • Good corrosion resistance
  • High temperature resistance
  • Vacuum resistance
  • High absorption of radiation

Application areas

  • General engineering
  • Textile machinery parts
  • Vacuum technology
  • Chemical equipment
  • Lifting technology
  • Drive technology
  • Electrical engineering
  • Aerospace industry
Maximum layer thickness: 300 µm
Standard layer thickness: 70-120 µm
Coating thickness (depending on the alloy): 1200-2000 HV 0.01

Nucotec® EL – The anodic oxidation of aluminum

Nucotec® EL layers are made from hard, wear resistant aluminum oxide. They are formed through the chemical reaction that turns aluminum into aluminum oxide. This results in excellent adhesion to the base material. Nucotec® EL layers "grow" out of the base material by around 1/3 of the layer thickness.

Main features:

  • High quality, decorative surfaces
  • Silky shine to matt etched finish
  • Wide range of colors
  • Good wear resistance
  • Corrosion protection
  • Good dimensional accuracy
  • Food safe

Application areas:

  • Automotive industry
  • Mechanical engineering
  • Photo and video technology
  • Office and data processing technology
  • Pharmaceuticals industry
  • Medical technology
  • Telecommunication
  • Pneumatics
  • Household appliance industry
  • Food industry

 

Nucotec® HE – The hard anodization (hard coat) of aluminum

Nucotec® HE layers are made from extremely hard, wear resistant aluminum oxide. They are formed through the chemical reaction of the aluminum material in special cooled acid electrolytes. The transformation results in excellent adhesion between the base material and the hard oxide protective layer.

Nucotec® HE layers are much more compact than conventionally produced anodic oxidation layers (anodized layers) and are therefore significantly more resistant to wear and corrosion.

Due to the micro-porous properties, only the "apparent hardness" is measured. This value is between 300 – 600 HV0.025 depending on the alloy. The thermal conductivity is around 10% of the base material, the electrical dielectric strength is max. 20 V/µm (Nucotec® HE-Cu and Nucotec® HE-GD) or max. 30 V/µm (Nucotec® HE).

Application areas:

  • Automotive industry
  • Mechanical engineering
  • Aviation industry
  • Electrical engineering
  • Medical technology
  • Food industry
  • Communication technology
  • Measurement and control technology
  • Defense technology

Main features:

  • High, homogeneous hardness
  • Extremely good antiwear protection
  • Good corrosion protection
  • Good sliding properties
  • Excellent adhesion to the base material
  • Good dimensional accuracy
  • High electrical insulation
  • High thermal protection
  • Food safe

The optimal solution for your application

Process type Material (selection) Product example
Nucotec® HE AL AL wrought and cast alloys, e.g. AlMg3, AlMgSi1;, AlMGSiPb, AlZnMgCu, G-AlMg5;, G-AlSi10Mg Precision turned parts, cylinder liners, pump impellers, air bearings, control pistons, pneumatic valves, heating plates, injection molding tools, machine parts
Nucotec® HE-Cu Al wrought and cast alloys with a high copper content, e.g. AlCuMg1, AlCuMgPb, AlCuBiPb, G-AlSi9Cu3, G-AlSi6Cu4, AlCu4Ti Precision turned parts, motor parts, machine parts, rolls, coils, bearing parts, valves
Nucotec® HE-GD Al die-casting alloys, e.g. GD-AlSi9Cu3, GDAlSi10Mg, GD-AlSi12, GD-AlMg9Si Hydraulic cylinders, pump housings, motor pistons, machine parts, coupling parts

PlasmaCoat® – Wear-resistant combination coatings

The PlasmaCoat® coating procedure combines the outstanding surface hardness and wear resistance of thermally sprayed metal or ceramic coatings with the nonstick and sliding properties of polymers and fluoropolymers.

PlasmaCoat® combination coatings also offer very good traction properties with various surface roughnesses and profiles. An embedded metal or ceramic coating can be used as a substrate for the antiwear protective coating.

Coating thicknesses: 80 µm to 295 µm
Temperature range: -40 °C to +270 °C
Surface roughnesses (Ra): 1.5 µm to 17.5 µm
Surface hardness: 28 to 70 HRc
FDA-approved: yes, with certain coating types
Polymer layer
Metallic/ceramic reinforcement layer
Substrate

StarCoat® – Extraordinary wear protection

StarCoat® metal and carbide coating systems are applied with high-speed thermal spraying techniques to achieve exceptional wear resistance. The low proportion of pores creates an extremely high surface hardness of up to 70 HRc.

SuperChrome® belongs to the StarCoat® family. It is a cost-efficient alternative to conventional hard chromes, with high resistance to wear and corrosion. This coating is a favorite for rolls in wet applications like in the paper industry.

ArmorClad® is another member of the StarCoat® range. It provides an even harder carbide surface that is virtually pore-free and can withstand even the sharpest knives. When mechanically finished, this coating is particularly well suited for counter cutting cylinders used to cut paper, cardboard and films.

Coating thickness: 100 µm to 800 µm
Surface roughnesses (Ra): approx. 0.2 µm (mech. finished) up to 30 µm
Temperature range: -40 °C to +950 °C
Surface hardness: 53 to 70 HRc
Polymer layer
Metallic/ceramic reinforcement layer
Substrate

Locations for Coating: Wear protection

Landsberg

Impreglon Beschichtungen GmbH
Albert-Einstein-Straße 16
86899 Landsberg
Germany
1 +49 8191 911 86-10
+49 8191 911 86-12
landsberg@impreglon.de
Local Site

Lübeck

Impreglon Material Technology GmbH
Seelandstr. 7
23569 Lübeck
Germany
1 +49 451 39 006-0
+49 451 39 006-31
luebeck@impreglon.de
Local Site

Lüneburg

Impreglon Oberflächentechnik GmbH
Hohenhorststraße 1
21337 Lüneburg
Germany
1 +49 4131 882-10
+49 4131 882-250
lueneburg@impreglon.de
Local Site

Moers

Impreglon Moers GmbH
Altenbruchstraße 10
47447 Moers
Germany
1 +49 2841 3829
+49 2841 34424
moers@impreglon.de
Local Site

Pulversheim

Impreglon France SAS
Air de la Thur
68840 Pulversheim
France
2 +33 3 89 28 32 80
+33 3 89 28 32 89
info@impreglon.fr
Local Site

Löddeköpinge

Impreglon Sverige AB
Mobilvägen 1
246 43 Löddeköpinge
Sweden
3 +46 46 706 500
+46 46 706 900
info@impreglon.se
Local Site

Tamworth

Impreglon UK Ltd.
Kingsbury Link, Trinity Road
Tamworth B78 2EX
United Kingdom
5 +44 1827 871400
+44 1827 871401
info@impreglon.co.uk
Local Site

Baltimore

Impreglon, Inc.
2915 Wilmarco Avenue
Baltimore, MD 21223
U.S.A.
7 +1 410 644 4500
+1 410 644 1766
info@impreglon-baltimore.us
Local Site

Fairburn

Impreglon Inc.
220 Fairburn Ind. Blvd.
30213 Fairburn, GA
U.S.A.
7 +1 770 969 9191
+1 770 969 9192
info@impreglon.us
Local Site

Houston

Impreglon Surface Technologies, Inc.
6421 Lozano Drive
Houston, Texas 77041
U.S.A.
7 +1 713 466 9655
+1 713 466 1762
info@impreglonsurfacetechnologies.us
Local Site

Michigan

Impreglon Inc.
225 North Roeske Avenue
Michigan City, Indiana 46360
U.S.A.
7 +1 800 640 0090
+1 888 890 0077
michianaimp@ameritech.net

Milwaukee

Impreglon Cellramic
8399 N. 87 th St.
PO Box 241370
Milwaukee, WI 53224
U.S.A.
7 +1 414 357 0260
+1 414 357 0267
info@impreglon-cellramic.us
Local Site