Semi Coating Blog | Surface Science For Semi & PV Manufacturing

How to Stop Heat Exchanger Fouling and Tube Fouling

Posted by Marty Higgins on Apr 20, 2018 12:39:54 PM

applications-image-350px.jpg

Can SilcoTek coatings prevent deposit formation and coking in analytical and process applications?  Read on and get some pretty impressive results!

Heat exchanger fouling and tube fouling can severely impact the performance of processes and instrumentation in just about every industry.  The effects of the accumulation of substances, be it binding of proteins in medical diagnostics or carbon particulates in aerospace, can have a range of impacts: 

  • Increase weight
  • Causes contamination
  • Reduces flow
  • Increases drag
  • Encourages corrosion
  • Increases emissions
  • Increases maintenance requirements
  • Creates false results
  • Costs money!
heat exchanger fouling.png

Learn How To Manage Surface  Energy, Fouling, and Moisture Resistance 

A High Price 

Dealing with the impacts of deposits and build-up of unwanted materials depend on the application and importance of the process.  Regardless, the cost can be high.  Here are some examples of the impact of material build-up on critical surfaces:

  • Medical / bio analytical
    • -Annual costs of false results in USA >$3 billion annually
  • Automotive
    • -10%+ increase in fuel consumption due to fouling
  • Refining
    • -$0.5 billion spent to overcome coking issues (2002)
  • Heat exchangers in semiconductor and other applications
    • -50% of maintenance costs are caused by deposits, causing billions of dollars to industry.

 

Read our presentation on preventing coking and fouling

 

Potential Solutions

There are many possible solutions to the problem.  Some expensive, some not realistic, most are costly and can result in redesign or added maintenance.  Here are a few examples:

Solution Result
Increase energy / power / fuel consumption (basically brute force idea) Expensive and does not solve the problem
Control the incoming media that’s causing deposit build-up Rarely an option in industrial applications
Material selection Several options, difficult to optimize performance & cost
“Surface engineering” through advanced anti-fouling coatings 

Flexible and cost effective

Modify the existing part’s surface to make it behave how you need it to

 

The Benefits of Coatings to Prevent surface interaction and stop heat exchanger fouling

 

Coated frit 3.png Coated fittings.png HPLC column 8.png

 

Inert Coatings can be an effective solution for multiple applications and industries because they enhance the performance of the surface while preventing interaction of the base material with the interacting substance.  The result?  A better surface without changing the part design or physical property of the base material.  There are, however, several factors to consider when selecting the right coating for the application.  Such as:

-Do I have to re-engineer to account for tolerance changes?  In most cases no change in tolerance needed.  But consider for super high tolerance applications.

-Is there an environmental impact?  The amorphous silicon surface has very little environmental impact both during processing and as a product.

-Can the anti-coking coating withstand temperature, abrasion, corrosion, etc. in the application?  In many cases, yes but consult with a SilcoTek representative to be sure.

-How long will it last?  Depends on the application, but the coating should provide superior performance for years.  Contact a SilcoTek representative to discuss your application.

Want to learn more about our coatings and how they improve the performance of your product?  Get our webinar on demand.

Solving coking and fouling problems

How SilcoTek Coatings Prevent build-up

SilcoTek coatings act as an inert barrier, preventing catalytic or chemical interaction with the underlying surface.  For example nickel containing substrates catalytically form carbon deposits (coke) from petrochemical media. Causing build-up on the surface.  Coatings like SilcoKlean® or Dursan® bond to the surface and change the surface energy and inertness, preventing chemical adhesion and adsorption of the substrate.  The coating's low energy surface prevents the attachment of flow path chemicals to the surface.  

Applications include:

 

SilcoTek Solutions & Applications    
     
Problem SilcoTek Coating Solution  
Carbon deposit, coke, formation from incomplete burning of fuel SilcoKlean barrier coating reduces catalytic coking and carbon deposit formation coking heat sink fuels.jpg
Bio-fouling in food applications.  Spores from sour milk suspensions stick to testing equipment Dursan prevents sticking by up to 76% Residue from sticking.png
Protein binding in medical diagnostics Dursan prevents surface interaction and sticking Protein_adsorption_graph-666998-edited.jpg
Carryover in GC & HPLC chromatography Dursan corrosion resistance prevents pitting & sticking to flow path surfaces Corrosion_Solutions_Dursan_Graph_10_16_13-118258-edited.jpg

 

SilcoTek offers many solutions to the problem of sticking, corrosion, deposits and carryover.  Go to our solutions page to learn more about our coatings.

 See How We Perform  In Your Application

 

Tags: Semiconductor

Where to Buy High Purity Silicon Coated Products For Semiconductor

Posted by Marty Higgins on Apr 13, 2018 8:47:00 AM

Dursan_flanges-resized-600-774957-edited

  

Did you know that you can buy SilcoTek CVD high purity silicon coated products directly from the manufacturer?  Do you care?  Well you should because it could save you time and money in the long run.

Our network of Approved Partners offer SilcoTek® coated products directly off the shelf to help simplify your supply chain.  We don't sell finished products (only coating services), so we work with leading OEMs and re-sellers to make the purchasing process easier for you.  Now you can get the benefits of high purity silicon barrier coatings without the hassle!

In this blog post you will learn how buying SilcoTek CVD coatings through OEM manufacturers can benefit your supply chain:

  • Save time - place one order with your supplier and let us handle the rest
  • Lower costs - save on shipping and product disassembly/assembly
  • Simplify logistics - eliminate the need to manage multiple POs and vendors

View OEM Partner Directory

Lots of customers send in parts for CVD coating application.  Our manufacturing lead time averages about 5 business days for most coatings.  We're fast and offer a great product but there is one drawback.  Parts need to be disassembled before sending them to SilcoTek for coating service. 

single-stage_regulator_cross_sectionWhy do I have to disassemble parts? 

In order to coat a part, the surface must be exposed to our coating gases.  We don't need much space (we can penetrate and coat a sintered metal frit for example) but we do need some space.  Areas that are not exposed, like seals or internals of assembled parts may not get a consistent exposure to our process gases.  Surfaces also can't be inspected or adequately prepared for coating so there's a risk of inadequate coating.  As we noted before lots of customers send in their disassembled parts but others really don't want the headache.  It's one thing to take a fitting apart but it's can get sketchy for a novice to take apart a valve or a regulator.  Then there's the time factor.  Some companies or individuals have the resources and knowledge to assemble and disassemble parts but others have to either become fast learners or must pay to have someone properly assemble the part.  That's where our OEM Partner program comes in handy.

 

Scott_regulator

 

 

 

 

No More Assembly

We've partnered with some of the best manufacturers in the industry to offer SilcoTek® coated products.  They recognize our coatings are the best in the industry and want to improve the performance of their products (here are just a few case studies for example).  Our coatings offer an additional dimension in performance, be it high purity, corrosion resistance, non-stick, or moisture resistance.  For the customer it means you don't have to take the time and effort to send in parts, just order them already coated from the manufacturer!  What can I buy?  Lots of things.  Here's list of components you can get directly from the OEM manufacturer. 

  • Fittings & Valves
  • Sample Cylinders
  • Process Sample Probes
  • Regulators & Flow Control
  • Filters & Separation
  • SST Tube, Tubing & Heat Trace
  • OEM & Instrumentation

 

The Cost

Just do a Google search on the cost of placing and processing a PO and you'll see a wide range of estimates.  PO costs can range from about $60 per order to over $700 depending on industry.  That's just the administrative cost associated with order processing.  Now add in the handling cost at shipping and receiving and you're talking a fair amount of money invested in sending in a part for coating.  That's why it's worth a look into specifying our coatings when purchasing parts from the component or equipment manufacturer.  Depending on the OEM stock situation, the lead time may or may not be longer but from a cost perspective it'll be worth it to add our coating when specifying and purchasing the part.  Are you an OEM?  Become a partner and improve your products.

Become a Partner

The logistics

From a logistics and SKU perspective it also makes sense to consider purchasing coated parts.  A typical purchasing cycle can entail the following:

  • Specify coating
  • Source uncoated part or component.
  • Disassemble part
  • Place coating PO
  • Ship part to SilcoTek
  • Status order
  • Receive coated part from SilcoTek
  • Reassemble part
  • Process invoice

With good planning, the entire purchasing cycle can be eliminated by specifying our coating when placing an order for the uncoated part at the OEM level.  That will go a long way toward getting home a little earlier from work or greatly reduce the complexity of the order process!

Click here to go to our OEM partner directory.  The directory will take you to specific products and vendor purchasing information.

Want something that's not on our list?  Contact us and we'll do our best to work with your vendor to get us added as an option.

 

 

Tags: Semiconductor

How Materials Impact Silicon Barrier Coatings

Posted by Marty Higgins on Apr 6, 2018 8:59:03 AM

Silicon CVD Coating Material Compatibility Coated Parts

 

Did you know the base material can have an impact on the performance of CVD coatings?  We tested the compatibility of most metals and other materials commonly used in analytical testing.  Here's what we found out.

About Silicon CVD Coating Material Compatibility 


Why is it that we can coat most metals but cannot coat some materials like nickel? Furthermore we say that we see excellent results with Hastelloy® (up to 74% nickel) and Inconel (over 70% nickel) but on the other hand Monel (2/3 Nickel & 1/3 copper) is not treatable.  Why is there variation in material compatibility for CVD coatings?  All great questions!  To understand why certain metals perform the way they do we'll need to jump into alloys and how they react with our coatings.

In this blog post you will learn:

  • How metal alloys can improve CVD coating adhesion.
  • How some base metal elements cannot be coated but can be coated in an alloy.
  • How material compatibility can impact surface quality and purity.
  • How to select the best coating and surface for the application.

 

About alloys and why they make a difference in coating results.

0210SampleCylinder700x350-110300-edited.jpgAn alloy is a mix of a base element metal with another element (or elements).  Metal alloys can often have quite different properties than their base metal.  In the case of alloys, two wrongs can often make a right.  For example aluminum and copper are pretty soft metals, but mix them and you get an aluminum alloy that's stronger. 

The same goes for iron mixed with a touch of carbon.  Carbon's not even a metal but mix a touch of it with iron and you get steel which can have all sorts of benefits like greater strength. Throw in a bit of chromium into the mix and the resulting stainless steel will vastly improve corrosion resistance.    

Alloys have benefits and drawbacks that impact coatability.  We'll use nickel as an example. 

Confused about what we can coat?  Get our latest quick reference Material Compatibility Guide.

Get Our Material Compatibility Quick Reference Guide

How Silicon Coating Material Compatibility Can Impact Performance

Our process is incompatible with pure nickel, because it induces a different growth mode and does not produce the typical nice amorphous (unstructured or non crystalline) coating we see on a stainless steel substrate.  You see silicon is happy to bond and diffuse into all sorts of metals, glass or ceramic surfaces but it preferentially does not bond particularly well with nickel.  In fact after the first few silicon atoms bond to the nickel surface, the remaining silicon atoms prefer to bond to themselves rather than to the nickel.  The result?  Under magnification you'll see lots of silicon columns with deep voids, almost like skyscrapers in a big city.  That's not a good coating because chemicals you're interested in testing can hide in the valleys or corrosive chemicals can attack the exposed surfaces. The SEM image below is a general example of what columnar growth looks like under magnification.  See?  Kind of like big buildings.

fig_3_silcoklean_B.jpg

Our amorphous coating when applied to stainless steel, glass, ceramics or many metal alloys will bond uniformly to the surface and build a coating layer-by-layer over the entire surface.  It will look something like this SEM image below (note silicon particulates on the surface).

fig_3_silcoklean_A-resized-600.jpg

The Auger plot below shows how our silicon barrier coatings bond to the surface.  Auger electron spectroscopy (AES) sputter depth profile analysis quantifies the material composition and diffusion zone characteristic of our silicon coatings (in this case our inert SilcoNert® coating).  The plot shows a layer of approximately 2000 angstroms (200 nm) of silicon.  Note the approximately 500 angstrom diffusion zone between the stainless steel surface and the silicon coating.  An Auger depth profile of a coated nickel part would show areas with little to no coating while other areas would have a much greater depth profile.

silconert auger 4 9 15 1.jpg

Back to alloys.

In cases where nickel is alloyed with other “stabilizing” elements, such as Cr (chromium), Si (silicon), P (Phosphorus) etc., even when nickel (Ni) is the major component base metal, our process coats beautifully over these alloys (e.g. Hastelloy®, Inconel, or typical nickel brazing filler alloys such as Ni-Cr-P or Ni-Cr-Si-P).  In these cases, the coating is able to bond to the "more beneficial' alloy despite the Ni base metal because the alloy characteristics will allow silicon to more easily or preferentially bond to the surface uniformly.  So that's why we can coat superalloys and Ni brazing material.

You can't win them all!

In cases where nickel is alloyed with another difficult to coat element, such as copper, there is no “stabilizing force” or synergy to allow our CVD coatings to bond to the surface.  A copper nickel alloy is usually incompatible with our process. Monel is such an example. Nickel and copper by itself are both incompatible with our process, so when you combine these two into Monel, it is incompatible as well.  

If you want to learn about our coatings and how they benefit your applications, get our webinar:

How To Choose The Right SilcoTek Coating

 

Have questions about silicon CVD coating material properties?  Go to our Material Property Page and get coating specifications, material data and much more.

Go To Our Coating Material Property & Specifications Page

Tags: Semiconductor

Wear Resistant CVD Coatings For High Purity Applications

Posted by Marty Higgins on Mar 30, 2018 10:57:19 AM

NASA Tensile Strength Test 3 7 31 17.jpg

We smashed stretched and burned our impact resistant coating.  What we found was alarming, for the other test coupons....

It looks like our R&D staff had some pent-up anger lately.  We set them lose on our Dursan® coating so they could let off some steam (and keep the rest of the the team safe)!  They compared the coating durability, strength and bend resistance of Dursan® in what looked more like a medieval torture chamber than a lab.  Did the coating survive?  Let's find out.*

In this blog post your will learn:

  • How Dursan withstands high stress and remains intact.
  • How Dursan holds up to wear.
  • How Dursan withstands high temperature exposure.

What about wear resistant CVD coatings?

High purity CVD coatings are thin but are they wear resistant?  We tested Dursan vs. uncoated stainless steel in a comparative pin-on-disk wear test. We found Dursan was more wear resistant than stainless steel and had higher surface lubricity, making the wear resistant coating ideal for valve components and wear prone surfaces.

Durability_Solutions_Wear_Graph_10_9_13-resized-600.jpg

Read the wear resistance report.

 

Want to see more material tests of our coatings?  Here's a great webinar that tests the mechanical properties and material limits of our coatings.  The webinar is focused on semiconductor applications but the data applies to all coating applications.

Improve Material Performance Watch Our Webinar

 

Mechanical properties of coating.

We tested the tensile strength of an uncoated 316 stainless steel 1in diameter rod and a Dursan coated 316 stainless steel rod.  We pulled the samples to ultimate tensile strength and Bang! Rod failure!  Wow that was cool!  Here's a video of a tensile test, it's not our test, but it does give you a good idea of how the test was performed. 

Results showed the Dursan coating performed at or above the uncoated coupon in ultimate tensile performance; failing at 96,000 psi at ambient temperature.

Dursan Tensile Strength 7 31 17.jpgWe tested again at 450ºC to see if the relative tensile test changed.  The ultimate tensile strength dropped as expected, but the Dursan coated rod fared a bit better, with a 20% drop compared to a 23% drop for the uncoated rod.

Comparative tensile strength    
     
Material Ambient Tensile Strength 450C Tensile Strength
316 stainless steel 93000 71500
Dursan® Coated Stainless Steel 96000 76500

Read the complete report to compare the yield data and test specifications.

 

Read The Complete 

Tensile Strength Test Report

 

The Crush Test...Ouch!

We crushed a coated foil sheet and a stainless steel ball to see if the coating would stay put.  Here's the video of our crush tests.  First we compared a coated stainless steel foil sheet and a painted foil sheet.  We balled them up to see if the coating would flake.  Nope!

Then we got out the press and crushed a coated stainless steel ball to see if we could get the coating to say uncle.  Again we were amazed at the durability of the coating.  Finally we coated a tube to see if the coating failed.  You guessed it, the coated tube bent without a problem.

 OK, Let's Turn UP The Heat!

Durability_page_2_Torch_Image10_10_13

You guessed it we torched the coating to see if it would burn, flake, oxidize or explode.  I was hoping for explode but no luck!  In fact the coating took the flame test in stride.  Here's the video.  Watch how the surface glows bright red yet after cool down the coating looks unscathed with no oxidation or damage.  The stainless steel coupon was severely oxidized after the heat exposure and the PTFE sample really took it on the chin. 

Want more data about SilcoTek® coatings and applications?  Go to our new E-book library and download our easy to read e-books.  You'll get lots of application and coating data and great tips on how to make your process or products better.

Read Our E-books!   Improve Your Products

 

* Photo Courtesy of NASA.

Tags: Semiconductor

How To Protect Stainless Steel From Corrosion in Gas Delivery Systems

Posted by Dr. Min Yuan on Mar 23, 2018 11:20:06 AM

Concoa_regulator.jpg

We tested our coatings in a wide range of corrosive environments to see just how effective they are in protecting stainless steel from corrosion and preventing rust on stainless steel gas delivery systems.  Here's what we learned.

 

In this blog post you will learn;

  • How traditional stainless steel passivation techniques are not effective in preventing corrosion.
  • Ways to protect stainless steel from rust and prevent gas supply system corrosion with a corrosion resistant barrier coating.
  • Review corrosion data for various corrosives including:
    • HF
    • Nitric Acid
    • Phosphoric Acid
    • Sulfuric Acid
    • Hydrochloric Acid
    • HBr
  • Get links to more in-depth corrosion data

 

Corrosion can not only compromise analytical system integrity and increase maintenance cost; it can also generate particulates that can result in obstruction and fouling of the system and cause adsorption of reactive compounds. Pitting can also create excellent hiding places for “sticky” molecules, resulting in carryover and false positive results. Passivation and polymeric coatings have been utilized to reduce corrosive attack, but there’s a higher performing alternative that improves both inertness and corrosion resistance of the surface.  But first let's talk about passivation and why it's not an ideal corrosion prevention technique in analytical flow paths.

About Passivation


corrosion_comparison_in_HCl_images_c22_dursan-151746-edited.jpgNitric acid passivation is commonly used in an effort to remove exogenous iron from surfaces and add an oxide layer in the
hope that the stainless steel flow path will become more corrosion resistant or inert.


Traditional passivation techniques involve the following steps:
• Thorough cleaning of surfaces
• Immersion in nitric or citric acid bath for 30 minutes. (acid concentration and additives are dependent on the grade of
  stainless steel)
• Rinse parts thoroughly in water
• Test part for passivation by placing in a humidity cabinet.

Unfortunately, when applications require the use of aggressive agents like bleach, sulfuric, or hydrochloric acid, no amount of
passivation or electropolishing will prevent corrosive attack.  That's because highly corrosive agents react with the stainless steel protective oxide layer, causing pitting and corrosion of the surface.

Read more on how to effectively prevent corrosive attack. 

Get Our Corrosion Webinar Summary Presentation

 

An Alternative to Passivation
There's an alternative to passivation that produces better results: change the surface properties of the material by bonding enhanced silicon compounds onto the steel surface via chemical vapor deposition (CVD).  A CVD coating like Dursan®, for example, will improve the corrosion resistance and inertness of the surface, offering a multitude of benefits. The chemical vapor deposition process used to coat stainless steel flow paths will prevent disruption of grain boundaries and act as an inert barrier to aggressive and sticky compounds. Dursan coated analytical flow paths will prevent HCl, sulfuric acid, bleach, and other corrosives from pitting and attacking stainless steel surfaces.  Here are some examples of how Dursan and Silcolloy® can improve corrosion resistance.

Corrosion data summary.jpg


Click here to learn more about improving the corrosion resistance and durability of analytical systems.

Dursan offers inertness, durability, fouling, and carryover contamination benefits for process analytical, gas supply, etch and semiconductor fab applications.  Want to learn how our coatings improve purity and yields?

Improve Semiconductor   Yield With High Purity Coatings

 

Dursan Corrosion Resistance Data.  How a CVD Coating Can Protect Stainless Steel From Corrosion in Gas Delivery Systems.
Dursan® can increase corrosion resistance by 10x or more through preventing interaction of the analyte or process fluid and the stainless steel surface. Dursan exceeds typical metal passivation capability. Immersion testing in 6M hydrochloric acid (HCl) shows that Dursan coated surfaces prevent surface attack and protect stainless steel from rust by orders of magnitude compared to passivated stainless steel, preventing gas supply system corrosion.

Dursan_HCl_corrosion_2_copy.jpg

Sulfuric acid can form in process analytical sampling systems and stack sampling systems that transport stack emissions or hydrocarbon flare samples. When exposed to water and heat, sulfur compounds commonly found in stack samples can form sulfuric acid and corrode and contaminate sample systems. Inert coatings like Dursan reduce the risk of corrosion, even when exposed to sulfuric acid.

Dursan_sulfuric_acid_corrosion.jpg

HBr corrosion resistance

Comparative HBr corrosion testing shows that Dursan and Silcolloy coated stainless steel surfaces improve flow path corrosion resistance by up to an order of magnitude over uncoated stainless steel.  Virtually all stainless steel surfaces can be coated including small and large bore tubing, regulators, stainless steel frits, fittings and valves.

hbr data graph.jpg

 

Get more corrosion application information and benefits for your process or products.  Get our corrosion presentation.

Get Our Latest Corrosion Solutions Presentation

Protecting analytical flow paths from rust can revolutionize the reliability of process and analytical sampling.  Contact our technical service team to discuss your application.  Need an inert hydrophobic surface?  How about an anti-fouling surface that's wear resistant?  Our team can help match the best coating for your application.

 

Tags: Semiconductor

Improve Detection of Airborne Molecular Contaminants in Cleanrooms

Posted by Marty Higgins on Mar 16, 2018 8:40:14 AM

Markes_TD_tube.jpg

Organic vapors and outgassing from sealants, clothes, paints, adhesives and other organic sources are having a greater impact on semiconductor manufacturing operations.  Airborne molecular contaminants (AMC) can cause major fab problems including:

  • Delamination
  • Moisture/hydrophobicity problems
  • Voltage breakdown 
  • Doping
  • Hazing

That's why target organic contaminant levels on wafers have been decreasing and will continue to decrease.

Organic Compound Detection in Semiconductor Cleanrooms

Detection of airborne molecular contaminants in semiconductor cleanrooms.

The need for improved analytical sensitivity to trace analysis of organics has increased with the need for detection and elimination of organic contamination in cleanrooms.  Unfortunately the materials and methods used when detecting higher level organic contamination may not always work for trace detection and speciation of organic compounds.  Adsorption by flow path materials such as stainless steel, glass, viton, and trace surface moisture can result in loss of trace organics.  

Dursan_adsorption_rate_2_18_16.jpg

Analysis of trace active organic compounds can result in almost total loss of the target analyte due to stainless steel or glass surface adsorption.  New CVD barrier coatings like Dursan® improve trace organic analytical results by preventing the interaction of reactive base materials like stainless steel with the analyte.  Barrier coatings like Dursan® and SilcoNert® can improve the test response and sensitivity of chromatographic and airborne monitoring systems.  Trace amine response for example can be improved significantly by lining the flow path with an inert silicon coating; improving the detection of contaminants in semiconductor fabs. 

 

Amine_Relative_Response.jpg

What Material is Fastest for Analytical Response?  The Winner is SilcoNert!

Comparing sample line materials for retention shows that for trace reactive compounds like ammonia, SilcoNert® improved response by about 2x over PTFE and stainless steel surfaces.

Sampling Line Material

Average Rise Time

(average of 5 replicates)

PTFE

16.2 seconds

SS316L

17.0 seconds

SilcoNert® 2000 coated 316L

8.4 seconds

 

Want to learn more about how SilcoTek coatings can improve the response of active compounds? 

Read our presentation.

 

See How Our Coatings Improve Analytical Response and Sensitivity

 

 

 

Tags: Semiconductor

Tips for CVD Coatings Research (SilcoTek Website)

Posted by Marty Higgins on Mar 9, 2018 10:06:53 AM

chemistry-banner.jpg

Confused about what SilcoTek coating to use?  Want find out if SilcoTek® CVD coatings are right for your application but don't have time to wade through our website?  Here are some tips on how to get relevant data for your application quickly and efficiently.  

Where to start?  Do I read through the Home page and just pick a coating?  Do I tab through the various solutions or applications to find out if a coating works for me?  How do I find relevant test data quickly?  Ugh, so complicated.  Well no worries, let's take a step-by-step approach to CVD coatings research and walk through our website.  We'll show you how to get the information you need within minutes!

If you're new to SilcoTek

Start with SilcoTek 101.  You'll find it prominently displayed on our home page.  SilcoTek 101 is exactly what it sounds like, it's an introduction to our coatings and a review of coating basics.  You can check it out here.

Get Our Free E-Book SilcoTek 101

Now that you've got a basic idea of what our coatings are and what they do, what now?  Go to the navigation bar at the top of the page and work your way from left to right.  That can take a few minutes but by the third tab you'll know what each of our coatings do and how they solve material problems. 

Web-Navigation-532509-edited-650377-edited.png

To short cut your way to selecting a coating just go to our coating selection guide.  That will give you an idea of which coating will work for your application. 

Or get our coating properties guide for the short and sweet results about what our coating do.

coating-properties-table-thumbnail.png 

Then jump on over to our Common Applications guide for a primmer on, you guessed it, applications!

Application Guide

Where can I find these on the SilcoTek website?  Just click on the Learning Center tab.  The coating basics are all listed on the left side of the page.  

Check out our Learning Center if you want to get the latest coating data.

Or you can take the ultimate shortcut and contact our Technical Service Team and discuss your application and desired results.  We'll pick a coating for you.  One email and you'll have a solution that day.

Have Questions? Contact Our Technical Service Team

Wait, that day?  You said minutes!  Liar!  OK, that was just one option.  You can have a coating solution in minutes by navigating to our our solutions tab to get a coating recommendation for many material problems such as corrosion resistance, inertness, anti sticking, fouling resistance, carbon coking and purity.  If you don't see your solution that doesn't mean you're out of luck.  It means you'll have to jump over to our learning center to get a more specific application or study. 

If you're data driven and need test results and whitepapers.

There's only one place you need to go for CVD coating data, the learning center tab.  There you'll get a deep dive into whitepapers and data from independent resources.  You can get everything from brochures and whitepapers to videos, webinars, and e-books under that tab.

Web navigation 2-255759-edited.png

If you want the source for fastest data, go to presentations and scan through the presentation of choice.  For example go to our corrosion presentation and you'll find all the latest corrosion data.  Need a coating specification?  Go to our Coating Properties & Specifications tab under learning center to get coating specs.

OK so let's take this navigation thing for a test drive and see how long it will take to get data on say hydrochloric acid corrosion.  Follow the example flowchart below:

Navigation flow chart 2.jpg

Success!  From clueless to expert in 11 minutes, not bad.  I wish my calculus class was that easy!  Full disclosure, it may take longer to take a super deep dive into whitepaper data and studies.  Reading through a corrosion whitepaper can take some time but it's worth the time to discover how other scientists and engineers have evaluated our coating in similar applications.  If you want lots of data about a particular subject, go to our new e-book tab under Learning Center.  There are literally volumes of data about our coatings there.  Pardon the pun!

Read Our E-books!   Improve Your Products

 

Tags: Semiconductor

How to Protect Stainless Steel Against HBr Corrosion

Posted by Marty Higgins on Mar 2, 2018 10:16:28 AM

showerhead_2_2_19_16.jpg

Hydrobromic acid or hydrogen bromide (HBr) is commonly used in polysilicon etch applications and plasma etching.  It's an excellent etch compound but unfortunately it will also cause stainless steel corrosion in delivery systems which can result in yield robbing ion contamination and increased maintenance cost. 

Preventing HBr corrosion can lead to the use of costly super alloys, but an alternative semiconductor approved material is available.  Silcolloy and Dursan silicon barrier coatings bonded to stainless steel flow paths offer the best of both worlds.  A durable and corrosion resistant surface and an inexpensive, workable stainless steel substrate.  In fact SilcoTek coatings, applied by CVD, can be bonded to existing components, no matter how intricate, and still maintain precision tolerances.

 

Get Our Latest Corrosion Solutions Presentation

Proven Results

ASTM G31 immersion testing demonstrates the superior corrosion resistance of Silcolloy and Dursan coated coupons.  After 264 hours of exposure in 48% (wt) HBr (hydrobromic acid) the SilcoTek coated coupons reduced the corrosion rate by up to 10X.  Uncoated stainless steel corroded at a significant rate while the Dursan coating corroded at a fractional 0.29 mills per year. 

hbr data graph.jpg

Visual inspection of the test coupons tell the story.  The uncoated stainless steel coupon shows moderate corrosion while the Dursan and Silcolloy coupons maintain their bright appearance, helping to prevent stainless steel corrosion.

hbr data.jpg           

Want to watch our coatings in action?  Watch our corrosion video.

 

An inert corrosion resistant barrier silicon coating improves yield by preventing corrosive attack in semiconductor etch systems.  Get more information about how our coatings improve semiconductor performance.

Watch Our Semicon  Coatings Webinar

 

Tags: Semiconductor

A Corrosion Resistant Metal Free Coating for Semiconductor Fabs

Posted by Marty Higgins on Feb 23, 2018 10:10:19 AM

Dursan_flanges-resized-600-774957-edited.jpgWe put our new Dursox™ metal free coating to the test.  Here's what happened.

There are lots of corrosion resistant coatings out there.  But what if you're concerned about metal contamination and metal leaching?  Or what if you need to protect a precision instrument or flow path that requires high tolerance or high heat resistance and a dry coating technology?  Then your options are limited.  Want a metal free high durability corrosion resistant coating?  Let's test our new Dursox coating and find out if it fits the bill.

In this blog post you will learn:

  • Elemental composition of Dursox CVD coating
  • How Dursox improves corrosion resistance by 80%
  • Discover how Dursox prevents metal ion contamination & improves product quality
  • Applications for a metal free coating & specifications

Get Our Latest Corrosion Solutions Presentation

Is Dursox™ metal free?

We measured the elemental composition of of Dursox to find out if it is in fact metal free.  We tested the surface by X-ray Photoelectron Spectroscopy (XPS).  Basically we blasted the surface with X-ray energy beams and analyzed the material that came off the surface.  As the X-ray beam penetrates the surface you get a pretty good idea of what's in the material.  The XPS plot below shows the coating consists of oxygen carbon and silicon, no metals.  The amorphous structure of the material allows the coating to flex with the base metal without cracking or failing.  That enables the coating to be used in high stress applications like high pressure cylinders or compression seal fittings.

Dursox_XPS_Data_4_cropped.jpg

No metal, check.  But is it corrosion resistant?

Let's look at the data.  ASTM G31 hydrochloric acid immersion testing demonstrates the high purity corrosion resistance of Dursox™.  After 72 hours the coated test sample showed roughly an 80% reduction in corrosion compared to uncoated 316L stainless steel.  

Dursox_corrosion_Comparison_2_18_15.jpg

Dramatically less corrosion, but what about ion contamination?  Let's do a visual check and find out.

HCl corrosion Dursan-324523-edited-106253-edited.pngHere's a photo of the uncoated coupon during the HCl immersion test.  Notice the green liquid?  HCl is clear so why is this beaker green?  That's the result of chloride corrosion of the stainless surface and metals being leached from the coupon.  A great example of metal ion contamination. 

 

 

 

Applications that require high purity, are sensitive to contamination (like semiconductor fabs), analytical testing, or processes where metals can impact yield, this sort of contamination can cost a company in high maintenance, poor product quality or low yields.  

Dursox_HCl_imersion_10_08_15_.jpgThe Dursox™ HCl beaker by comparison is clear.  There's no change in color so no leaching of nickel into the acid solution.  The result?  More accurate test results, improved flow path durability, lower maintenance and better product quality.

 

 

 

 

 

 

Benefits

Dursox™ makes critical surfaces non reactive and corrosion resistant, preventing process contamination and improving yield.  The highly inert CVD coating offers improved stability, delamination resistance and durability over ceramic coatings like yttria.  The coating is ideal for high purity gas transfer flow paths, high purity applications where corrosion is a concern, and whenever improved durability for precision instrumentation is needed.   

    showerhead_2_2_19_16.jpg   
Etch High purity coating eliminates ion contamination in corrosive etch gas streams.
Atomic Layer Deposition (ALD)        Enhance purity by coating of all chambers and equipment. Reduces carryover, burn-in, and corrosion.
Ozone Stabilize flow path to assure ozone purity.
Gas Transfer Prevent ion contamination, assure high purity gases.
Chemical-Mechanical Planarization (CMP) Increase lubricity, prevent sticking and cut downtime.
Epitaxy Significantly reduces contamination and maintenance caused by corrosion.

Dursox™ Specifications

Need a dry coating that will withstand exposure to extreme temperatures or challenging process environment?  Dursox specifications highlight the durability and heat resistance of the coating.  Our CVD coating technology is moisture free and deposits a thin high tolerance silicon coating onto the surface of metal, glass, and ceramics.    Contact our Technical Service Team to discuss your application or to arrange an evaluation with our R&D staff.

Dursox spec table 2 21 18.jpg

Not sure if Dursox™ fits your application?  We've got coatings for a variety of corrosion resistant applications.  Read our corrosion presentation and get relevant data to improve your process.

Get Our Latest Corrosion Solutions Presentation

 

Tags: Semiconductor

See Our New Biofouling & Super Hydrophobic Coating at Pittcon 2018

Posted by Marty Higgins on Feb 16, 2018 11:33:35 AM

Drusan flange 2.jpg

From our first coating, Silcosteel®, to SilcoNert®, Dursan® and Dursox®, our coatings have helped customers improve corrosion resistance and process analytical sensitivity and performance.  Here's what we're talking about this year at Pittcon 2018 in Orlando.  

Spoiler alert!  We're talking about the benefits of our new super hydrophobic fluoro based coating as well as how Dursan® can improve bioinert flow paths and prevent biofouling.  You should go to Pittcon to chat with our SilcoTek® staff to learn more about our coatings.  (Not to get a break from the cold weather, who me? Never!)

Pittcon-2018-pre-show-banner-1.jpg

 

About our new fluoro coating

We recently developed a new fluoro chemistry based coating that proved to be super hydrophobic coating with anti fouling or non stick properties. 

Learn How to Improve  Injection Mold Performance   

Hydrophobic coating demo 7 17 17-1-968266-edited.jpg

To demonstrate the super hydrophobic nature of the new fluoro coating, Dr. Smith (our R&D director) sprayed water on the coating to see if the water wetted the surface.  The water stream bounced off the coated part without getting the surface wet, showing excellent moisture resistance.  Watch our video to see how the new fluoro coating resists moisture.

The low energy of the fluoro surface makes for a super hydrophobic surface, making a 160 degree contact angle.  Because of that low surface energy, we found another application for the coating.

Surface energy comparison.jpg

Get more information about

hydrophobic and corrosion resistant coatings.

 

Hydrophobicity, check, but what else can the coating do?

Well we're not sure about all the potential uses, but we're finding great success in plastic mold release applications.  It turns out the coating promotes better release of product from plastic molds and can prevent fouling in some applications. 

Learn How to Improve  Injection Mold Performance

Here are some mold release benefits of Dursan and our new fluoro surface:

  • Better wear resistance for higher durability, and erosion prevention.
  • Higher lubricity to improve operation of moving cores and slides and improved resin flow for reduced energy cost and wear.
  • Prevents contamination by oxidation by products in medical and electronic applications.
  • Visual inspection of the surface signals coating loss without precision measurement. 
  • Mold complexity does not significantly impact coating price. 
  • Eliminate Diamond finish release problems by improving surface lubricity.  

If you want to learn more about fouling prevention and mold release read the latest article in AZOM: 

Improving and Protecting Industrial Applications With Anti-Fouling CVD Coatings

Contact our Technical Service Team and we'll be happy to discuss details about the coating. 

Have another material problem?  Get our applications guide to learn how SilcoTek can improve the performance of your products.

 Get our coating application and properties guide.

 

 

Metal Free Flow Path for Bioinertness

Now you can count bioinertness and biofouling coatings to our list of applications that benefit from our coatings.  This year at Pittcon we're talking metal free flow paths for bio technology benefits.  Did you know you can eliminate many of the problems caused by a metal flow path with inert coatings like Dursan?  In fact, you can improve the bioinertness, anti fouling, and sensitivity of instrumentation and filtration by coating metal flow paths with Dursan.

  • Stop biofouling
  • Prevent corrosion
  • Less maintenance

Learn More About  Bio-Inert Coatings

Dursan® is a very low surface energy, bioinert coating and anti fouling coating designed to reduce non-specific protein binding and carryover while improving corrosion resistance in biotechnology, filtration or wherever bio growth is a problem .

With the assistance of a non ionic surfactant-containing wash solution, Dursan® was found to facilitate 100% removal of adsorbed proteins (BSA, mouse IgG and NHP), the same proteins remain adsorbed on the bare stainless steel surface.

 

Protein_adsorption_image.jpg

 

Stop Protein Binding And Corrosion On Stainless Steel Surfaces

Dursan® benefits protein testing 3 ways:

1. Very low protein carryover

  • Dursan® significantly reduced protein binding compared to uncoated stainless steel and an amorphous fluoropolymer.

2. Beneficial to surfactants

  • Facilitated 100% removal of tested proteins.  The same wash solution had no effect on protein loading on bare stainless steel.     

3. Corrosion resistance means high purity

  • Comparison studies between Dursan® and stainless steel show the high purity Dursan surface prevented ion contamination and corrosive attack from bleach and other commonly used cleaning agents.

 

Click here to learn more or visit SilcoTek in booth #2113 to see how we're changing the game in flow path surface technology to create a new standard of performance.

 

 

Tags: Semiconductor