"Hard chrome plating is widespread through many industrial sectors due to its excellent combination of hardness and low friction combined with corrosion and wear resistance. The manufacturing process however requires the use of hazardous chromium salts which give rise to health and environmental concerns, leading to an uncertain long-term future due to legislative changes such as REACH. Electrodeposited metal matrix nanocomposites (MMNCs) have the potential to make a significant improvement to surface properties such as increased microhardness and inherent lubricity. The development of nanotechnology over the last 25 years means that there are now a multitude of nanoparticles, nanowires and nano-tubes in a wide range materials, hence the scope for new nanocomposite coatings is greater than ever. Recent work at Leicester University has resulted in demonstration of the process across a range of coating compositions. This enables the production of strengthened coatings, with the potential to develop a coating with functional performance equivalent to hard chrome. Working as a consortium, the present project is taking the work forward to validate the capability with partners JCB, PPUK, NMB Minebea and Weir Valves and Controls for a wide range of industrial applications. Additionally, the technology will be made more broadly available through Tewkesbury Diamond Chrome Plating which provides electroplating services to industry, and through TWI with its network of over 700 industrial members."

The objective of this project is to substitute selected scarce (Co and Cd) and health- and environment-threatening coatings in the electricity generation and aerospace industries. These objectives will be met through the development of a new, innovative suite of PVD coatings with properties that can be tailored to suit many different applications. The price and availability of cobalt is volatile, causing uncertainty for manufacturers of power plant. Co-based overlays are used to reduce supersonic water droplet erosion (SWDE) of turbine blades and sliding wear in valves. Cd is a heavy metal toxin posing serious health issues. It is banned from most applications except those for which there is no alternative. This project aims to develop effective alternatives. The suite of new coatings will provide tailored properties of barrier corrosion resistance and/or sacrificial protection with lubricity (i.e. Cd replacement). The same coating concept will be tailored to provide SWDE resistance by incorporating additional functional nanocomposite layers. Processes will also be developed for the stripping of these coatings to promote recycling/reuse. Metrology requirements will be addressed through development of the UK’s first test rig to evaluate SWDE. Many projects have previously been undertaken with the aim to replace electroplated Cd. This project will succeed where others have not because the design of the new coatings benefits from the novel combination of leading edge results, recently completed research not previously available.

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