advanced coatings technologies

Other Research Areas:

• Composite Materials
• Manufacturing Systems
• Gear Research Institute

Electron Beam-Physical Vapor Deposition (EB-PVD) is a materials coatings technology whereby coating materials including metal, alloy, or ceramic are melted within a vacuum and then deposited on a component or part requiring the surface properties inherent in the coating. A strong mechanical vapor bond, uniform microstructure, and relatively high deposition rates make it an attractive and versatile coating process. Since it is performed in a vacuum, it is an environmentally friendly technology, suitable as a replacement for other coating processes in many applications.

	Advanced Coatings include: Electron Beam-Physical Vapor Deposition Cold Spray Laser Processing Sputtering
EB-PVD is also a member of a family of coating technologies that can replace environmentally incompatible coating processes used today. EB-PVD has the advantage of working with a wide variety of materials and techniques to improve performance and increase the service life of coated components.		EB-PVD Research Facility at the Material Research Institute (MRI) Building.

Industry has independently estimated the domestic economic potential of EB-PVD technology over the next decade to be over $10 billion along with the creation of an additional 10,000 skilled jobs.

EB-PVD equipment includes:

• 270 kW, 6 gun, 45 kW/gun, 10^-6 torr vacuum, ion beam assisted, 3 continuous ingot feeders, general purpose EB-PVD machine
• 10 kW, 2 gun, 100 cc crucible, 10^-6 torr vacuum, EB-PVD system
• 8 kW, 1 gun, 25 cc crucible, 10^-6 torr vacuum, ion beam assisted, EB-PVD system

The Penn State/Applied Research Laboratory EB-PVD program was initially sponsored by the Department of the Navy Manufacturing Science and Technology (MS&T) office. Participation by EB-PVD equipment builders as well as equipment  users in both the EB-PVD and the Consortium Alliance is encouraged. Members have priority for teaming in R&D projects and for use of the EB-PVD facilities. ARL and Penn State also provide a data base of EB-PVD applicable materials for use by the Alliance and Consortium members.

There are three EB-PVD coating units. Two are laboratory units for thin film coatings, while the third is an industrial prototype which is unique to the United States. The unit size is one cubic meter with six electron beam guns (45kW powered), and three continuous ingot-feeding systems, along with a load-lock chamber. The unit is capable of evaporating any materials on the periodic table.

Other Facilties

• High Temperature Wear Tester (pin-on-disk) - up to 800° C
• Thermal Cyclic Furnaces - capable up to 1400° C
• Water Vapor Thermal Cyclic Furnaces - capable up to 1130° C
• Grit Blast
• Tumblings
• Material Characterization Facilities include X-Ray, SEM, TEM