Transcript Teer Coatings Ltd Hydrogen Energy Teer Coatings Limited Coatings for Fuel Cells & Hydrogen Applications Kevin Cooke Teer Coatings Ltd, West Stone House, Berry Hill Industrial Estate, Droitwich,

Teer Coatings Ltd
Hydrogen Energy
Teer Coatings Limited
Coatings for Fuel Cells & Hydrogen Applications
Kevin Cooke
Teer Coatings Ltd,
West Stone House,
Berry Hill Industrial Estate,
Droitwich, Worcestershire,
WR9 9AS, UK
www.teercoatings.co.uk
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
Outline of Presentation
• Introduction to Teer Coatings Ltd:
 TCL’s proprietary technology: Closed Field Unbalanced
Magnetron Sputter Ion Plating (CFUBMSIP)
• Applications in Fuel Cells and Hydrogen
 Example: coatings for PEM cell electrodes
 TCL’s Low Carbon related Collaborative Research
• Summary & Conclusions
• Acknowledgements
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
Company History
ISO:9001
2008
US Patent
Key Facts:
25 yrs!
Dymon-iC
2007
• Turnover Approaching £4-5M/yr
2008
ISO:9001
New
• Equipment Sales Approaching £2-3M/yr +3rd
2003
Factory
• High Proportion of Export Sales
Building
2004
2001
ISO:9002
MoST
• Now ~57 Employees
2001
Patent
+2nd
1999
UK Pat
Building
CFUBMSIP
1999
1994
US Pat
CFUBMSIP
1996
Larger
Premises
Closed Field
1992
1st Prod
System
Equip
1987
Sale
Founded
1989
1982
Coating Services
(Hartlebury)
1985
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
Company Structure
PRODUCTION
COATINGS
• 15 Coating Systems
• Automated cleaning, etc.
• Single items to 10,000’s/wk
3 PRIMARY DIVISIONS:
• Design & Manufacture
• Coating & Test Equipment
• Inc. “bespoke” designs
EQUIPMENT
BUILDING
Kevin Cooke
• ~17 Coating Systems
• plus, range of Testing &
Analysis Equipment
RESEARCH &
DEVELOPMENT
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• July 2009: Miba AG took a
minority share (24.9%) of TCL
 full ownership is expected by the
end of 2010.
 until then TCL remains a SME!
• The Miba Group is a leading international company,
of ~2600 employees, headquartered in Austria.
• Miba is a leading strategic partner of the
international engine and automotive industry.
 Miba’s product portfolio includes sintered components,
engine bearings, friction and coated materials.
• TCL & HTC (Miba’s Coatings Competence Centre,
with ~40 employees) will collaborate closely.
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
Routine Production Coatings:
• Hard coatings, e.g. for cutting tools, etc.
– e.g. single nitrides TiN, CrN… & alloy nitrides TiAlN,
CrAlN, CrTiAlN…, oxides, multilayers, etc.
• Self lubricating, low friction coatings for wear resistance
– e.g. carbon based: TCL Graphit-iC™& Dymon-iC; and
MoS2 based: TCL MoST™
• Plus, coatings for corrosion resistance, electrical
conductivity, optical properties, etc.
• Coatings typically 1-3µm thick, but…
– nm to mm thickness possible for special applications
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
Coatings: a continually expanding range….
1
2
H
He
1.0079
4.0026
3
4
5
6
7
8
9
10
Li
Be
B
C
N
O
F
Ne
6.941
9.012
10.811
12.011
14.007
16.00
19.00
20.179
11
12
13
14
15
16
17
18
Na
Mg
Al
Si
P
S
Cl
Ar
22.99
24.30
26.98
28.09
30.974
32.06
35.453
39.948
19
20
31
32
33
34
35
36
21
22
23
24
25
26
27
28
29
30
K
Ca
Sc
Ti
V
Cr
Mn
Fe
Co
Ni
Cu
Zn
Ga
Ge
As
Se
Br
Kr
39.10
40.08
44.96
47.90
50.94
52.00
54.938
55.85
58.93
58.69
63.55
65.39
69.72
72.59
74.92
78.96
79.90
83.80
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
Rb
Sr
Y
Zr
Nb
Mo
Tc
Ru
Rh
Pd
Ag
Cd
In
Sn
Sb
Te
I
Xe
85.47
87.62
88.91
91.22
92.91
95.94
(98)
101.1
102.91
106.42
107.87
112.41
114.82
118.71
121.75
127.60
126.91
131.29
55
56
57
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
Cs
Ba
132.91
137.33
*
La
Hf
Ta
W
Re
Os
Ir
Pt
Au
Hg
Tl
Pb
Bi
Po
At
Rn
138.91
178.49
180.95
183.85
186.21
190.2
192.2
195.08
196.97
200.59
204.38
207.2
208.98
(209)
(210)
(222)
As a major constituent
As a minor component
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
….for many different applications….
Cutting Tools
Gears, Bearings
and other
Wear Components
Body Jewellery….!
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
….including Coating of Powders & Grits!
Coating
sources
project
into
barrel
Barrel Coater
(Load Locked)
Powder
exposed
to coating
flux
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
Closed Field Magnetron
Sputtering
• Unbalanced field.
• Field lines “closed” with another
magnetron.
• Plasma confined around
substrates.
• Electrons loss to chamber walls
minimised.
• Increased ionisation.
• Dense, adherent coatings
• Typical energies 20-30eV, ideal
for high quality film growth.
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• FC&H2 Example - coatings for bipolar plates:
– TCL’s magnetron sputtering technology is
• industrially qualified
• ideal for the deposition of thin, dense, well adhered,
high quality coatings on a wide range of substrates
(including metals and vacuum-stable polymers).
– Product-specific results of TCL’s previous work
in this field are obviously confidential to the
customers concerned!
[V Fox: presented at - Manufacturing of Bipolar Plates
event, Swerea IVF, Stockholm, 29th January 2008]
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• “Metallic” thin film coatings for bipolar plates:
– dense, homogeneous coatings of metals are deposited
at high rates
– multiple elemental targets (typically 4 or 6)
• alloys and/or graded compositions easily created
– compounds (nitrides, oxides, etc.) can be synthesised
by reactive deposition
• reactive gas (e.g. N2) introduced during the deposition process
• compound (e.g metal + nitrogen = MeN) formed in situ
• automatic feed back control (reactive gas flow slaved to metal
content of the plasma)
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• Transition metal nitrides (e.g. TiN, CrN etc.)
–
–
–
–
hard, dense and relatively inert
routine coating sources up to 1m (>2m demonstrated!)
metallic levels of electrical conductivity
excellent adhesion (Rockwell and scratch adhesion
results on M42 tool steel substrate shown below)
TiN (~3µm)
SEM cross section
Kevin Cooke
TiN
Rockwell C indentation
Friction force (N) 1st derivative
20
15
10
5
0
0 20 40 60 80 100
Load (N)
TiN, Critical load ~ 90N
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• New high rate magnetron deposition of TiN:
– 2 magnetrons (12.5kW each)
– 50 mins deposition: total thickness 3.36 μm
– deposition rate 4 μm/hr  4x higher than from
conventional magnetrons
– hardness: 33 GPa
– scratch adhesion – Lc>60N (i.e. very good)
• So, achieved 4x increase in rate with no
obvious deterioration in coating quality
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• Graphit-iC™ coatings
– originally developed for demanding, high load
bearing, tribological applications
•
•
•
•
•
•
contains ~5 at. % chromium
hardness H = 10 to 40 GPa (selectable);
Young’s modulus E* ~ 155 GPa
low coefficient of friction (<0.1)
very low specific wear rate (~ 10-17 m3N-1m-1)
electrically conducting (like graphite) – high sp2
content
– conventional process, ~2µm takes several hrs
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
• 3-steps:
Hydrogen Energy
Graphit-iC™ Coating Process
– in-situ ion cleaning
– deposition of thin metallic Cr interlayer
– deposition of C-Cr layer
1.8 m
0.2 m
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Two high power magnetrons
used in place of conventional
magnetrons for the carbon targets
Hydrogen Energy
Magnetron 3
(Conventional magnetron)
Chromium target
Towards high
rate Graphit-iC
deposition
Carbon target
Carbon target
Magnetron 1
(Conventional magnetron)
Chromium target
Kevin Cooke
Target size 380 x 175mm
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• Graphit-iC™ coatings for bipolar plates:
– power input can be increased by up to 3x cf TCL’s
“conventional” Graphit-iC coating process
– deposition rates improved by 2 to 2.7x, say
– here, 2-axis rotation improves coating uniformity. In-line
systems with magnetrons sputtering simultaneously
onto both sides of the plates could be used in a
production process.
– pure carbon or Graphit-iC coatings can be deposited at
thickness ranging from <100nm to a few microns
– coatings can be (have been) deposited with or without
Cr adhesion layers
– rates as high as ~5 µm/hour are already achievable for
a stationary substrate (equivalent to 85nm per min)
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
TCL’s Collaborative Projects related to “Low Carbon”
HydroGEN
TP (’08-’11)
NECLASS
TP (’08-’10)
PROSVACT
TP (’08-’11)
CLUSTERBEAM
MNT (’06-’09)
Kevin Cooke
TSB
Projects
Low Cost PVs
TP (’08-’11)
HYPNOMEM
TP (’06-’09)
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• Technology Programme projects include:
–
–
–
–
NECLASS: improving FC catalyst utilisation
HydroGEN: coatings for electrolysis
HYPNOMEM: thin film membranes for H2 purification
CLUSTERBEAM/PROSVACT: creating nano-clusters
for model catalysts, etc.
– Low cost Photovoltaics: cheap, PV materials by thin
film, with improved spectral response & long life
• TCL project leader
– except for HydroGEN &NECLASS
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
Summary & Conclusions
• PVD coatings have multiple potential applications
in Fuel Cells and the Hydrogen Economy
• Teer Coatings Limited offers relevant, industriallyqualified, thin film coatings
– e.g. environmentally resistant, electrically conductive
thin film coatings for electrode plates
• TCL can support partners’ process and
equipment needs, from R&D through to full
production
• TCL’s research portfolio includes relevant
collaborative projects
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
Acknowledgements
• The collaborative projects described above have
benefited from DTI/Technology Strategy Board
(MNT and Technology Programme) support.
• HYPNOMEM was a joint feasibility project by
Univ B’ham’s Metallurgy & Materials Department
(Rex Harris, John Speight, David Book, Vicky
Mann, Sean Fletcher, Jo Grant) and TCL (Joanne
Hampshire).
• Other project collaborators are too numerous to
mention, but are gratefully acknowledged!
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• For more information please contact:
Teer Coatings Limited,
West Stone House,
Berry Hill Industrial Estate,
Droitwich, Worcs, WR9 9AS, UK.
Tel: +44(0)870 220 3910; Fax: +44(0)870 220 3911
www.teercoatings.co.uk
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010
Teer Coatings Ltd
Hydrogen Energy
• Key Contacts:
Paul Teer – Managing Director
Dennis Teer – Chairman/Technical Director
Dr Kevin Cooke – Collaborative Research Coord
Dr Glynn Dyson – Sales & Marketing Manager
Wayne Southall – Production Coatings Manager
Dr Joanne Hampshire – Special Coatings Manager
Kevin Cooke
Universities of Birmingham & Warwick, Hydrogen Energy, 22nd January, 2010
© Teer Coatings, 2010