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ArmorGalv - Wear & Corrosion Protection

Agritek Industries Inc. 1

Winner of EPA ‘S (NPPR) 2006 MVP2

Award (Most Valuable Pollution Prevention)

a licensed applicator for:

thermo diffusion galvanized coatings

• precision• heavy duty corrosion and wear protection• chrome and cadmium free• cost effective

ASTM - A1059 A/M

Arm rGalv®

What is ArmorGalv®

Thermal Diffusion Galvanizing?

ArmorGalv® is the trade name for a technology developed by the Distek Group in 1993. It is a method of creating a uniform, barrier and sacrificial, zinc- iron or zinc-aluminum alloy surface using a metallurgical vapor diffusion process for heavy duty corrosion and abrasion protection on ferrous metals.

ArmorGalv® can be applied to many surface types:

Powder Metal Steel Stainless Steel Castings& Forgings



Structure of ArmorGalv® coating

ArmorGalv® forms multiple layers of zinc-iron alloy on ferrous metals,with a super corrosion resistant inner gamma layer, compact delta layer,and outer zeta layer - like an onion. Each layer is successively harder andmore corrosion resistant.

Key characteristics of ArmorGalv® Coating

• ArmorGalv® zinc iron alloy coating is sacrificial, providing Galvanic protection to the steel parts, as well as a barrier coating.

• highly corrosion and abrasion resistant

• hard, non magnetic, weldable, and spark free

• chip proof and suitable for crimping, bending, and forming

• very good anti-galling properties and low co-efficient of friction

• excellent functional replacement for CADMIUM

• highly heat resistant - withstands working temperatures over 10000F (5400C)

• provides an excellent bonding surface for paint, e-coat and over-molding with rubber or plastic

• ArmorGalv® is totally non-toxic, and free of heavy metals.



ArmorGalv® Coating Process Advantages:

• The thermo diffusion process operates at significantly lower temperatures than hot dip galvanizing

(650 – 825 F) versus (840– 880 F)

• Maximum process temperature can be precisely adjusted for each batch, based on coating characteristics of the part to be coated.

• Special zinc powder formulations are available which will allow parts to be ArmorGalv coated at temperatures low as 570 F.

• Coating thickness can be adjusted from 0.5 to 6 mils (12 -150 microns) with a +/- 10% tolerance.

• The process evenly coats the inside of hollow and tubular parts.

• Parts do not need to be fixtured, and parts with similar coating characteristics can be mixed where small batches are needed.

• Current process equipment can handle parts up to 7 ft. long.

• It is a superior replacement for hot dip galvanizing and zinc plating.

• No hydrogen embrittlement!

ArmorGalv® -- real world applications at the Dead Sea!

Badly Corroded

2 mils of Hot-Dip Galvanized bolts after 3 years in the aggressive Dead Sea atmosphere. Fasteners are corroded to base metal.

Dead Sea 350 g/l salinityNorth Sea 35 g/l salinity

No Corrosion

1 mil of ArmorGalv® after 3 years in the aggressive Dead Sea atmosphere. Note white salt encrustation. Fasteners still have original gray color.



Laboratory Test Results

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Nut and Bolt, coated with 35 microns ofArmorGalv®, after 3000 hours in A2LA Certified Laboratory salt spray test. Picture was taken on Apr.29.2009 – parts are still in the Salt spray chamber with no signs of corrosion. Please note: white is salt encrustation – no red rust!

On going salt spraytest, started Dec 2, 2008, in the same A2LACertified laboratory.These tubes are coated with 50 microns of ArmorGalv®, including sealer. Results after 5,000 hours.Parts are still in the salt spray chamber with no signs of corrosion.

ArmorGalv® follows the contours of any part , creating a uniform coating thickness over the entire surface, including complex shapes and internal cavities.

This ability allows for ArmorGalv® to coat parts that areTraditionally impossible to coat.



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ArmorGalv® and Castings

ArmorGalv® on the new Stabiloc manhole cover lock. Ductile iron castings.Armorgalv on left after 1,176 hours in salt spray, original phosphated and e-coated finish at 912 hours. Red staining on Armorgalv is from diffused iron on thesurface, not a coating breach. Armorgalv outperforms!

ArmorGalv® adds new capabilities to powdered metal parts because it saturates the grain structure. It is not just a surface coating.

• improves wear resistance• replaces resin impregnation• increases density• improves powder coat and paint quality• can replace expensive stainless and non-ferrous powders

Before ArmorGalv® After ArmorGalv®

ArmorGalv® & Powdered MetalNo Pre-Impregnation Required



ArmorGalv® coating is particularly useful for fasteners and other complex parts with internal threads

• Below is a picture of a fastener with a captive washer and a Rivnut that were coated by ArmorGalv® .

• Notice that the Thermal Diffusion coating is extremely uniform, obviating the need to designate portions of a fastener as “insignificant”. The ENTIRE surface is significant – and coated! Salt spray results of greater than 1,000 hours are common.

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Top coating and overmolding ArmorGalv®

The smooth surface created by electro-plating requires various preparations, such achromates and primers, to provide basic adhesion of paint, or over-molding.ArmorGalv® grain structure provides a much better bonding surface thanelectroplated (or mechanically plated) zinc, as illustrated in the photos below.

ArmorGalv® surface electro plating Electro-plated Zinc surface

Likewise, hot dip galvanizing creates a surface which cannot be top-coated withoutaging, etching, or priming. The ArmorGalv® surface permits superior adhesion ofany top coat.



ArmorPlex®:Thermal Diffusion + hi-tech polymer coatings

For extremely rigorous conditions, many top coat options may be used to take advantage of the Armorgalv base and strong bonding surface. This is an ideal combination to reduce corrosion creep when the topcoat barrier is breached in continuous severe conditions.

ArmorGalv® out-performs other coating systems in every category, fromlifecycle to uniformity, coating thickness and functionality.

Get better performance withArmorGalv®

Coating ThicknessRange(inch)

Corrosion Resistance

ThicknessUniformity

HydrogenEmbrittle

ment

RecessFill

TopCoat

Adhesion

Weld-Able?

Anti-Galling

Heat Resis-tance

AbrasionResis-tance

Hard?

Hot Dip 0.002-0.004

Moderate Poor Yes Yes VeryPoor

No No Mod-erate

Fair No

Mechanical 0.0001-0.003

Moderate Poor No YesGlassBeads

Poor No No low Poor No

Dip/Spin 0.00075-0.001

Moderate Poor No Yes Good No No low VeryPoor

No

Electro-Plating

0.0001-0.0005

Moderateto Good

for Alloys

VeryPoor

Yes No Moderate

No No low Poor No

ArmorGalv®

Thermal Diffusion

0.0005-0.006

Excellent Excellent No No Excellent Yes Yes Yes to1200F

Excellent

Yes 38/42HRC

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Solid waste generated from zinc electroplating 33 million lbs of parts

Solid zinc losses from zinc electroplating 33 Million lbs of parts

Waste-water generated from zinc electroplating of 33 Million lbs of parts

ArmorGalv® isEnvironment friendly

The ArmorGalv® Thermal Diffusion process is the winner of the 2006 Most Valuable Pollution Prevention Award (MVP2).

The EPA, in 2006, conducted an extensive study of ArmorGalv®

technology. The EPA stated that the process “approaches zero discharge”.

ArmorGalv® history

The forerunner of ArmorGalv® is called Sherardizing, Invented by British metallurgist Sherard Cowper-Coles in 1901. Due to lengthy process times and difficulties controlling coating thickness, Sherardizing operations were greatly diminished by the 1950’s.

Inventor of “Sherardizing”Sherard Cowper- Coles

1916 Sherardizing Plant

In Europe, the best known applicator of Sherardizing has been Bodycote Int’l. For the past eight years Bodycote has been a licensee of DiSTeK’s ArmorGalv®

In the 1990’s Distek metallurgists discovered and patented modifications to the zinc powder formula and process controls, to reduce process time and improve consistency. DisTek continues to innovate with new formulations and process improvements today.



Springs

SomeSome ArmorGalv® ApplicationsApplications

Tempered and Hardened Parts

No Hydrogen Embrittlement No No loss of hardness or loss of hardness or tensile strengthtensile strength

Cylindrical, Threaded Parts, Shafts

1”- 8 bolt & nutClevis pins



Stampings & powdered metal parts

Powdered metal traveler nutsFence & latch parts

Castings and Forgings

Stabiloc™ Manhole Cover Lock casting assembly

Cast cable sheave

Tower support castingsConveyor chain



Fabricated, assembled items and welded parts

Container door hinges

Hasps, chain, &fence connectors

Tubes, pipes, pipe fittings –coated inside and out

Seawall Anchor Kit(7 ft. sections)

2” barb/NPT coupling



Some high profile projects, using ArmorGalv®

coated fasteners and hardware

Hong Kong - new underwater tunnel hardware

Kansai airport - JapanRoof pivot pins

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Mining roof support hinge pins –a standard application in Great Britain

Some other current applications:• North Sea oil rigs – Fasteners• German railway – rail fasteners and hardware• The England-to-France Chunnel – various components

Barcelona fish sculpture - 200 tons of ArmorGalv® coated fasteners hold it together.



ArmorGalv® applicationsArmorGalv® offers wear, abrasion, and corrosion protection properties making it suitable for applications in many industries, including:

• Chain and fittings exposed to marine or road salt environments• Communication, power transmission, wind turbine tower, railway

components• Automotive and heavy truck underbody components• Manhole cover locks, hydrants, etc.• Oil field equipment and fittings• Construction, mining, and agricultural equipment components requiring

abrasion and corrosion protection• Shipping container hardware and hold-downs• Rebar and seawall reinforcements and other infrastructure components• Fasteners in all industries requiring heavy duty corrosion and wear

protection • Replacement for Cadmium and other toxic coatings, where they are

used for corrosion protection and/or anti-galling

Standards• ASTM A-1059 A/M

• ASTM A641-98

• ASTM A-123

• ASTM A-153

• European Community Standard - BS EN 13811:2003

• European Community Standard - BS EN ISO 14713-3:2009

• Israeli Standard-4271 - road barriers and infrastructure.

ArmorGalv® Specifications Met



ArmorGalv®

Contact:Moshe Moked.Tel: (617) 566 0058E-mail: [email protected]

U.S. Offices:DiSTeK N.A. LLC1800 Touhy Ave.Elk Grove Village, IL 60007

Licensed producer of DisTek/ArmorGalv:

4211 Hallacy DriveHolland, MI 49424

Contact:Bill MaddoxTel: (616) 786 9200 X 119E-mail: [email protected]

ArmorGalv®

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US Navy Field Trial ResultsCast Fittings – Mining Equipment

END

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thermo diffusion galvanized coatings - ArmorGalv | Mi · PDF fileThermal Diffusion Galvanizing? ... • Maximum process temperature can be precisely adjusted for each ... Some high