Your partner in the field of
machines and systems.
Functional coatings for wear, scuffing and corrosion protection as well as friction reduction
The history of surface coating in mechanical and plant engineering goes back centuries. Even in the past, intensive searches were made for solutions to increase the wear resistance of machines and systems, extend their service life and prevent surface fatigue. With our extensive product portfolio, we offer customised solutions for all surface requirements in mechanical and plant engineering. Various processes such as chemical, galvanic, PVD/PACVD or hybrid processes are used. Nowadays, different surface processes are often required in order to achieve maximum results. We are ready to develop the perfect surface treatment for your machines and systems.
Insight into our customised solution for our customers in the field of machinery and systems.
Challenge: Wear and dry lubrication in gas compressors
Gas compressors are essential for numerous industrial applications applications, from petrochemicals to food production. The efficiency and longevity of these machines depend heavily on the performance and condition condition of their components. One of the biggest challenges with gas gas compressors is the wear caused by the high frictional forces between moving parts. moving parts. Especially under dry lubrication conditions, where no or only minimal lubricants can be used, the components are components are exposed to extreme mechanical loads. This not only leads to to increased wear and frequent failure of components, but also to a significant a significant increase in operating costs due to maintenance and replacement spare parts costs.
Solution: Coating with electroless nickel
One promising solution for reducing friction and wear in gas wear in gas compressors is to coat the parts with electroless nickel (EN). nickel (EN, electroless nickel). This coating is applied to the surface of the components applied to the surface of the components by a chemical reduction process, whereby a This achieves a uniform coating thickness across complex geometries. Electroless nickel offers excellent tribological properties, including high hardness and a very smooth surface structure, which reduces friction. In addition, the nickel layer protects the base base materials from corrosion and chemical attack, which is particularly beneficial in aggressive gas environments. gas environments.
Technical and economic benefits
The use of electroless nickel coatings in gas compressors has several technical and economic advantages. From a technical point of view, the reduced friction leads to a longer service life of the components, as wear is significantly reduced. This means less downtime and lower maintenance costs, as the intervals between maintenance cycles can be extended. In addition, the corrosion resistance of the coating improves the reliability of the gas compressors in various environments, allowing the machines to be used in a wider range of applications.
In economic terms, this results in a significant reduction in costs. The longer maintenance intervals and reduced need for spare parts lead to lower operating costs. In addition, the increased efficiency of the compressors can lead to energy savings, as less energy is required to achieve the same performance. This is particularly important in industries with high energy consumption, where any savings directly reduce operating costs and therefore improve the overall cost-effectiveness of the system.
Overall, electroless nickel plating is an effective solution for improving the performance and reliability of gas compressors by minimising friction and wear while reducing operating costs.