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Drying rate during industrial coating application is important to understand because drying a coated paper requires energy. If an unnecessary high amount of energy is used to dry paper, a fast evaporation rate can be achieved which can result in defects of the coated surface.   In this bachelor’s thesis, temperature profile during industrial coating application was studied. An industrial pilot trial on a coating machine was implemented at UMV coatings at Säffle, Sweden. Two boards with grammages of 210 and 350 gsm were used, where cardboard 210 gsm was precoated on the backside with two different precoatings. Where the two precoating differed in latex content and type of Hydrocarb. Board 350 gsm was not precoated. Temperatures between 65 to 85 oC were achieved in the drying section, depending on which substrate that was used.  Laboratory tests were also performed to investigate the relationship between surface temperature and dry content of a substrate during drying. As the temperature and time increased, did also the surface temperature and dryness of the samples. It was assumed that the temperature readings from the pilot coater could be correlated to the dry content of coating color.    The results from the study showed that by decreasing the dry content in a coating, a higher surface temperature was obtained during industrial- and laboratory drying due to the increase in heat transfer rate. Results showed also that when fraction of clay in a coating was decreased, a higher evaporation rate and higher surface temperature was obtained during drying.

<p>At solid oxide fuel cell (SOFC) operating temperatures (650^oC--800^oC), the chromia scale growth on the interconnect surface and chromium poisoning of cathode can lead to performance degradation of the whole cell. A spinel coating can be effective for blocking chromium outward diffusion to overcome this issue. In this thesis, two spinel-forming systems, Zn-Mn-O and Co-Cu-Mn-O were studied to identify a suitable coating.</p> <p>In-situ high temperature XRD was used to identify the phases in the Zn-Mn-O system between 600^oC and 1300^oC. The results showed that cubic spinel phase was stable only at high temperatures (above 1200^oC) and when the temperature decreases, the cubic phase tends to deform to tetragonal structure. In addition, the conductivity results showed low conductivities (below 3 S/cm) at SOFC operating temperature. Thus, the Zn-Mn-O system is not suitable for SOFC interconnect coatings.</p> <p>Another potential coating material analyzed was the Co-Cu-Mn-O system. This system exhibited promising conductivity values. Electrodeposition was used to apply Co-Cu-Mn-O coatings on both ferritic stainless steel and chromium-based alloy (Cr-5Fe) followed by oxidation in air at 800^oC. The spinel coating formed nicely on the stainless steel substrate. However, on the chromium plate, nitride formation, blistering and metal isolation were the common problems that occurred during the oxidation process. In order to improve the quality of coating on the chromium alloy, different heat treatments were explored, such as annealing in reducing atmosphere, oxidation in pure oxygen / mixed gas and decreasing the oxidation temperature. The objective of modifying the heat treatment was to produce adherent, dense coatings.</p> / Master of Applied Science (MASc)

Friction in machining is a complex phenomenon that can directly affect cutting productivity and product quality. Currently, different coatings are developed for machining applications which can increase tool life in the machining processes. Since performing a real machining test to quantify the friction is expensive and time-consuming, developing a bench scale testing method to simulate the friction in machining can reduce the cost and help researchers and industries select a suitable coating for their specific applications. The goal of this work was to study the adhesion between the tool and workpiece material under machining conditions by simulating them using a heavy-load high-temperature tribometer. A high normal load was applied to plastically deform the workpiece material. The contact zone was then heated up using a resistance heating method. The normal load should be in the range that can generate a plastic flow on the surface of the workpiece material prior to seizure. Three groups of in-house coatings were tested to study the effects of coating deposition parameters on the coefficient of friction. The results of these tests showed that the coating with the lowest bias voltage and highest Nitrogen pressure had the best tribological performance. As a next step, three different commercial coatings were selected. Super duplex stainless steel was chosen as the workpiece material and the tribometer tests were performed. To validate the tribometer results real machining tests and tool wear analysis were performed. AlTiNOS+ WC/C was observed to be a lubricious coating which reduced the cutting force and coefficient of friction during the running-in stage. However, the low hardness of the coating provided little abrasion resistance and was removed after the first pass. AlTiNOS+ TiB2 demonstrated a good combination of hardness and lubricity associated with improved coating tribological performance as well as wear resistance. / Thesis / Master of Applied Science (MASc)

Recently, Zn-XAl-YMg coatings have emerged as lighter-weight substitutes for traditional Zn-based coatings for the corrosion protection of steels; however, little is currently known concerning the interactions between the oxides present on advanced high strength steel (AHSS) surfaces and the Zn-Al-Mg bath. In the current contri- bution, the selective oxidation and reactive wetting of a series of C-Mn AHSS were determined with the objective of providing a quantitative description of this pro- cess. The process atmosphere pO2 was varied using dew points of −50◦C, −30◦C and −5◦C. The surface oxide chemistry and morphology were analysed by means of SEM and XPS techniques. Reactive wetting of the selectively oxidized surfaces using a Zn-1.6 wt.% Al-1.6 wt.% Mg bath was monitored as a function of annealing time at 60 s, 100 s and 140 s at 800◦C. The resulting bare spot defects in the Zn-1.6 wt.% Al-1.6 wt.% Mg coating were assessed by means of SAM-AES and FIB, while coating adhesion was analysed by 180◦ bend tests. Annealing the steel substrates resulted in the formation of surface MnO, which varied based on pO2 and Mn alloy content, and that this MnO greatly reduced the wettability of the steel by the Zn-1.6 wt.% Al- 1.6 wt.% Mg bath, resulting in bare spot defects. It was determined that the reactive wetting of the steel substrate was dependant on the oxide morphology and oxidation mode, which was a function of both alloying content of Mn in the steel and annealing pO2 process atmosphere (dew point). Finally, it was concluded that the bare spot area percentage on the coated panels was statistically invariant for annealing times of between 60 s and 140 s at 800◦C. / Thesis / Master of Applied Science (MASc) / Metallic coatings are applied to steels that are not naturally corrosion resistant. The aim of this research was to determine how well a coating containing zinc, aluminum and magnesium adhered to high strength automotive steel. It was deter- mined that manganese oxides formed on the steel during heating prior to applying the metallic coating. The manganese oxides prevented good adhesion between the steel and the coating, resulting in bare spot defects in the coating. The bare spot defects are undesirable as they leave the steel exposed and therefore susceptible to corrosion and are unsightly when painted.

Yes

Yes / Dynamic wetting failure was observed in the simple dip coating flow with a series of substrates, which had a rough side and a comparatively smoother side. When we compared the air entrainment speeds on both sides, we found a switch in behaviour at a critical viscosity. At viscosity lower than a critical value, the rough side entrained air at lower speeds than the smooth side. Above the critical viscosity the reverse was observed, the smooth side entraining air at lower speed than the rough side. Only substrates with significant roughness showed this behaviour. Below a critical roughness, the rough side always entrained air at lower speeds than the smooth side. These results have both fundamental and practical merits. They support the hydrodynamic theory of dynamic wetting failure and imply that one can coat viscous fluids at higher speeds than normal by roughening substrates. A mechanism and a model are presented to explain dynamic wetting failure on rough surfaces.

Yes / This experimental study of forward gravure coating considers the effects of operating variables on air entrainment, ribbing instabilities and the thickness of the film formed. The data show that this coating method can yield very thin films of thickness of order of 15 - 20% at most of the equivalent cell depth of a gravure roller. Air free and non ribbed stable uniform films can however only be obtained in a narrow window of operating conditions at very low substrate capillary number (CaS ~ 0.02) equivalent to substrate speeds typically less than 20m/min. The paper draws a similarity with flow features observed with smooth forward roll coating and slide coating. It is shown that the onset of ribbing and the flux distribution between the gravure roller and the substrate at the exit of the nip obey approximately the same rules as in smooth forward roll coating, whereas the onset of air entrainment actually corresponds to a low-flow limit of coatability similar to that observed in slide coating.