High-performance coatings reduce environmental friction

Special physical vapor deposition (PVD) coatings are recognized for their key role in improving operating performance and extending the life of parts in countless manufacturing and industrial sectors. Little is understood about the value these coatings offer in reducing the environmental impact of the industrial processes that use them.
of the main reasons for using PVD coatings first is to reduce friction between butt parts to improve performance

. This directly saves energy and, in turn, reduces carbon dioxide emissions. Because these coatings extend the life of components that need to be replaced frequently, they also save the raw materials, metals and energy needed to make replacement parts.
, some professional paint manufacturers have proven that coatings are an important factor in improving the environment. Not only did they point to these environmental benefits, but they also pointed out the improvements they made in their coating equipment to run more efficiently. In addition, the continuous development of professional PVD coatings also plays an important role in the design of emerging green technology components.
reduce friction through a dedicated coating
reduces friction when paired parts come into contact with each other, especially in harsh environments with high loads and wear. Bearings, gears, rollers and other precision components can experience excessive wear, surface fatigue, pitting, wear and corrosion, which can also cause problems, especially in high-load applications.
In order to prevent these problems from occurring, special PVD coatings are usually only a few microns thick to further harden the surface of these parts, and they can also reduce coefficients of friction through mechanisms such as changing the chemical properties of the surface. As a result, less energy is used and fewer emissions are produced.
coatings PVD physical vapor deposition of Oricon Balchas carbon-based coatings, such as diamond-like carbon coatings (DLC) from specialty coatings formulator such as Oerlikon Balzers, are even more durable. These well-adhesive coatings are mainly produced through plasma-assisted chemical vapor deposition (PACVD), providing a unique combination of high hardness and low coefficient of friction.
coating components can be used in a variety of applications, including wind turbine shaft bearings and planetary gears; Coatings are also an effective technology for upgrading key rotating components in hydraulic drives, pumps and valves.
advanced hydrogen-free DLC coating provides higher hardness and very low coefficient of friction. These coatings can be used in demanding environments for high friction, wear and contact areas such as hydraulic pump parts, mechanical seals and high-pressure valve components. Today, they are also playing an increasingly important role in e-traffic applications.
efficiency adds up
in large industrial environments, even a small percentage of energy savings can really add up. "Considering a one percentage point increase in the efficiency of a 200-megawatt gas turbine, that's equivalent to the power required for 1,500 homes," said Alessandro Zedda of Oerlikon Balzers. This
smaller factors, such as smoother surface finish, can improve fuel efficiency. For example, in aerospace and energy, PVD erosion coatings are applied to compressor blades to protect polished surfaces from deverage over time. This reduces fuel usage by up to 0.5% while increasing component life. These reduced fuels translate into comparable CO2 emissions.
, in the automotive sector, DLC-coated valves and powertrain components reduce the average effective pressure of friction (FMEP) by 10 percent. This means a 2% reduction in fuel. A 20% reduction in FMEP will reduce fuel consumption by 5%.
stricter environmental regulations and standards around the world have also prompted the industry to focus on reducing its carbon footprint and designing green products.
take large cargo ships as an example. Today, operators need to reduce the sulfur content of their fuels to meet current sulfur limits. In cases where cleaner fuels are required, marine engine manufacturers need a new fuel injection technology because clean fuels are often not lubricated as efficiently as sulphur-containing lubricants.
, the coating for diesel marine engines needs to be redesigned to ensure that the new clean fuel works properly. Coatings that meet this new requirement have become agents of machinery that achieve more efficient, high-performance, cleaner and smoother operation.
energy savings by extending part life with PVD physical vapor deposition of PVD coatings
the environmental benefits of high-performance coatings can also be achieved by how they extend the life of parts and tools. If parts last longer, they are replaced less frequently, reducing the raw materials, metals, and energy needed to make them.
in the automotive sector, forming tools are made of tons of negative steel. The forming tools used to make millions of cars degrade over time and need to be reprocessed. To ensure optimum performance and long life, they require polishing and PVD coating applications. In addition to saving energy by keeping the forming tool in optimal condition, additional energy can be saved by moving equipment of this size and weight to a separate location to be repaired from time to time.
in the energy sector, rolling bearings that apply DLC coatings to wind turbines extend their service life and reduce maintenance costs. Considering that replacing a spindle bearing costs between $200 and $300,000, it can also cause damage to turbines off the grid.
green technology
in addition to improving the efficiency and carbon footprint of existing systems, PVD coatings can also drive the development of new green technologies such as fuel cells and high-power energy-density batteries.
In the fuel cell field, we are working with customers who produce bipolar panels, which are key components of fuel cells," Alessandro said. "Here, the role of the PVD coating is to improve conductivity while resisting corrosion. Together, these properties will promote the life of fuel cells, thereby extending their environmental benefits. Alessandro
added: "We are also working with our customers to apply PVD coatings to some exciting and highly innovative projects in high-power energy density batteries. As industry continues to evolve environmental innovation, there will be more opportunities to design coatings to support their performance and life.
efficiency of coating applications produces an environmental return on investment
Deeper in the professional coatings supply chain, paint manufacturers themselves have checked their coating coating processes because they consume both materials and energy.
coating PVD physical vapor deposition Oricon Balchas when comparing the energy consumed by the production coating with the energy generated by the coating in the application, whether by increasing the efficiency and service life of the engine or cutting tool, or by generating an "energy return" or a return on investment.
"We've been trying to reduce the energy consumption of coating equipment," Alessandro said. "Our new coating machines reduce energy consumption by 40% by using new and efficient plasma sources. Multiplying the savings by each batch of our products in all coating centers around the world is of great benefit to the environment. He added: "While the motivation to explore new sources is environmentally driven, it is also in the economic interest of our customers as it reduces their coating costs and production cycles." Special
play an important role in reducing environmental impact. Energy consumption and carbon emissions from manufacturing and operations can be significantly reduced. While industry continues to use specialized coatings to enhance their operational performance, environmental impact is an important added value that should not be overlooked.
。