The Advanced Materials Show 2019 presentation

1. Application of functional ceramic
coatings created via Plasma
Electrolytic Oxidation
Dr Samuel Troughton, Keronite Ltd
Dr Robin Francis, Keronite Ltd
Advanced Materials Show, July 2019

2. About Keronite
Keronite is the world leader in the application of Plasma Electrolytic Oxidation
– we design develop and deploy advanced surface solutions that enhance the
performance of light alloys (Aluminium, Titanium and Magnesium)
Our coatings are deployed globally, in a diverse set of markets and in a range of
applications
We design, develop and deploy our coatings at our world-class technology and
manufacturing facilities in Cambridge, UK and Greenwood, Indiana

3. Plasma electrolytic oxidation (PEO) is an advanced surface
treatment that improves the performance of and enables the
use of light alloys such as Al, Mg, Ti
● High potentials (up to 800 V) applied to parts immersed in an
electrolyte bath
● Millions of very short-lived plasma discharges – like microscopic
bolts of lightning – transform the surface layers into hard oxide
phases (e.g. corundum on Al)
● Combines oxidation of the surface and co-deposition from the
electrolyte
PEO dramatically enhances the tribological and corrosion
performance of light alloys (amoungst other benefits)
PEO Technology

4. Plasma Discharges

5. Keronite: Uniform, conformal, hard, stable and
resistant coatings with exceptional adhesion
• Dense & uniform functional layer
• Porous top layer
• Uniform conformal coverage of complex shapes
• Extremely high hardness (2-4x harder than steel/hard
anodising)
• Strong adhesion
• Excellent corrosion resistance
• Chemically stable and highly insulating
• Thermal management capabilities
• Superior edge protection

6. Our industries
Aerospace
Aerospace has always been at the
cutting edge of materials
innovations. Keronite are working
with the industry to cut weight and
increase component life.
Automotive
Lighter materials make for quicker,
more economic vehicles. Keronite
are working closely with automakers
to meet emissions targets by
increasing life and reducing weight.
Industrial
We’re helping industry cut costs,
increase uptime and maximise their
efficiency through our bespoke
coating solutions.
Oil & Gas
Corrosion is an ongoing battle for the
oil & gas industry. Keronite’s duplex
coatings are extending oil & gas
component life.
Medical
Surfaces are integral for bone and
cell adhesion. PEOs irregular pore
structure accelerates and
strengthens adhesion.
Defence
Weight is a key concern for the
defence sector. Thanks to
developments in PEO technology,
lightweight alloys are replacing
heavier materials.
Sports Equipment
Every ounce counts in elite sport.
Keronite partner with leading sports
performance brands to help their
athletes break records and win
championships.
Electronic Consumer
Technology
Performance matters, but so does
aesthetics. Keronite delivers coatings
in a diverse range of colours whilst
offering exceptional performance.

7. Customers within our base business & pipeline include:

8. Keronite: Hard, yet compliant coatings for
wear protection
● The hardest Keronite coatings can reach
2000 HV - at 4 x harder than hard anodised
coatings, and more than 3 x harder than hard
steel
● Yet in spite of their hardness, the coatings
are far more compliant than typical ceramics
● These exceptional properties derive from the
unique structure of the coatings
0
500
1000
1500
2000
AZ91Mg
Al7075
Titanium
Hard
anodisin
g
Hard
steel
Keronite
Hardness(Hv)
Minimum hardness of
typical Keronite coatings
Maximum hardness of
Keronite coatings (on Al)
100µm detached Keronite film showing ability to be bent
or flattened elastically (Young’s Modulus 30±15 Gpa)
Benefits:
• Exceptional wear
performance
• High strain
tolerance
• Mechanical stability
(resistance to
cracking/delamination)
• Thermal stability

9. Application example: Wear protection coating
on Boeing 737 bearing carriers
● Titanium bearing carriers are used on many
commercial airliners
● Excessive wear found to be an issue
● Keronite coatings reduce wear by at least a factor
of 10 under typical loads
● Keronite coatings have been certified for this
application by Boeing Aircraft Corporation (spec
BAC5696) since 2011
● Keronite now routinely process these parts in
production
0
1
2
3
4
5
6
7
8
0 50 100
Wearvolume(mm3) Applied Load (N)
Bare Ti6Al4V
KTT coated
KTT+modifier

10. PEO coatings have exceptionally good
properties for thermal barrier applications
● Low thermal conductivity
○ k~0.1-1W/mK) compared to 18W/mK for alumina, and 2W/mK
for YSZ
● Stability and durability
○ Coatings stable to over 900°C
○ Ability to withstand repeated thermal shock/cycling
● Adhesion
○ Extreme adhesion due to conversion of the substrate results in
no interfacial attack/corrosion creep and coating delamination
● Porosity and microstructure
○ Uniformly distributed pore architecture in both microscale and
nano-scale sizes – good for low conductivity and heat capacity

11. Application example – Piston coatings for
reduced engine emissions
• Thermally insulating coatings on the surface of engine components such as pistons can increase the
fuel efficiency and reduce harmful emissions from internal combustion engines (CO2, particulates,
CO)
• Extensive materials testing has shown that Keronite thermal barrier coatings have ideal properties
for this application (previous slide)
Efficiency data on uncoated piston (black), Keronite
coated piston (red), and an anodised sample (green)
• Engine testing by OEM, Tier 1, and academic partners
has indicated that significant efficiency and
emissions benefits are possible in some situations
(~3-5% improvement)
• Potential accessible market volume of millions of
units
• Next step is full performance and durability testing by
Tier 1 and OEM partners

12. Keronite delivers superior corrosion
protection versus competing solutions
• Alloy AA7075-T6
• Thermal shock (between -196 and +100°C)
followed by 360 hours of salt fog test to ASTM
B117
• Cracked edges of HA lead to corrosion weak
spots, even after sealing
0
500
1000
1500
2000
2500
Exposuretime
withoutfailure(<9
rating)(h)
PEO (2219, unsealed)
PEO (2219, sealed)
PEO (7075, unsealed)
PEO (7075, sealed)
Hard chrome
Electroless nickel
Hard anodized (7075, sealed)
Uncoated
• ASTM B117 salt fog test
• Comparison of PEO (unsealed, sealed) on Al 2219
and 7075 vs. hard chrome, electroless nickel and
sealed anodizing on 7075
• Unsealed Keronite performance comparable or
better
• Sealed Keronite performance is clearly superior
Uncoated 7075 Anodised 7075 Keronite on 7075

13. Application example – Oil & Gas corrosion
control
• Oil field downhole conditions are extremely challenging from a
materials perspective – high salinity, high temperatures, acids and
alkalis, other chemicals
• However, also opportunities for process innovation to take
advantage of the conditions, e.g. dissolvable alloys (Al and Mg) to
avoid drill out operations
• Interest in Keronite from a number of directions:
• Improved corrosion protection – stopping critical areas/parts
from corroding too quickly
• Controlled corrosion - designing coatings to corrode at a
particular rate in a given environment
• Hard and high friction coatings for mating of parts to hardened
steel
Piston being coated with PEO
Example of frac slip on development tooling

14. ● Keronite are designing, developing and
deploying the world’s most advanced surface
coatings for light alloys.
● The unique microstructure and properties of the
Keronite coatings enable the use of light alloys in
demanding environments.
● Keronite coatings aren’t just designed to work in
the lab, we use a proven NPI procedure to create
scalable and cost-effective advanced coatings.
● Keronite welcomes proposals for joint
development projects.
Summary