TUFRAM
Surface Enhancement Coatings Protect
Aluminum and Aluminum Alloys
Against Wear, Corrosion, Sticking and Galling
Dramatically increase surface hardness Permanently self-lubricating forextended wear
Resistcorrosion, chemicals, and acids Many meet FDA, USDA, and CFIA codes
Prevent abrasive wear and galling Speed cleanup and sanitation maintenance
Provide superior mold release No outgassing in the vacuum of space
Meet AMS 2469 and AMS 2482 Low COF eliminates sticking and product “hang up”
Offer high dielectric strength Won’t chip, peel, or 鸻ke offlike “paint-ons”
Meets the End of Life Vehicle (ELV) initiative ITAR registered and REACH compliant
forthe automotive industry Intermediary combinations and permutations of coating
characteristics can be formulated to speci鹀 order
Engineers worldwide recognize TUFRAM as the solu- Magnaplate proprietary polymers to give aluminum
tion to a host ofproblems encountered in commercial parts previously unattainable levels of hardness, wear
applications in alltypes of manufacturing, processing and corrosion resistance, aswell as permanent lubricity.
and packaging equipment. Since the surface issuperior in performance to both
Created in a proprietary, multi-step process that the aluminum or any of the individual components
makes aluminum surfaces harder than steel,TUFRAM used in the process, Magnaplate-applied TUFRAM
coatings combine the hardness of aluminum oxide coatings are identi鹐d as “synergistic.”
ceramic with the desirable properties of selected
Engineering Data and Performance Characteristics
Corrosion resistance Abrasion resistance
TUFRAM coatings exhibit much greater corrosion A smooth surface substrate produces the most abra-
resistance than conventional hard anodizing. sion-resistant TUFRAM 鹡ish.Taber abrasion measure-
Some types show extremely high resistance to most ments show that its wear resistance is farbetter than
common chemicals and salt spray. Tests show no either case-hardened steel or hard chrome plate. No
effect after 168 hours immersion in Aqua Regia at matter what other metal rubs against the TUFRAM
248癋 (120癈). A TUFRAM-coated surface showed coating, it too will show only slight wear.
almost no corrosive activity after prolonged, continu-
ous exposure to the atmosphere and salt water. In EQUILIBRIUM WEAR RATES*
addition, TUFRAM enhancements on high strength
mg 10 20 30 40 50 60
aluminum exceed the AMS 2482 requirement of a
minimum of 336 hours in saltspray.
42 mg
When maximum corrosion resistance on aluminum
HARDCOAT ANODIZED (SEALED)
is required, MAGNAPLATE HCR , which provides 40
times the required protection, isrecommended. 15 mg
HARDCOAT ANODIZED (UNSEALED)
PER AMS 2469
SALT SPRAY TEST 11mg
TUFRAM H-2
hrs. 200 400 600 800 1000 1200
7 mg
336 hrs.
TUFRAM L-4
STANDARD HARDCOAT PER AMS 2482(0.002")
*UsingTaberAbrasion,WEIGHTLOSS =mg. per10,000cycles
CS-17 wheel,1000gm.load
1000 hrs.
TUFRAM H+ (0.002")
Friction coated parts exhibit a longer wear-life, require less
In some cases, the static friction decreases with an maintenance, and provide greater operating ef鹀iencies
increase in load. TUFRAM eliminates “stick-slip”and with less downtime. Mating parts that operate with a
undesirable vibration of higher break-away friction. sliding or rotating motion experience a dramatic
For more information, see General Magnaplate’s reduction in friction.
Friction Data Guide on CD.
Thermal conductivity
Aluminum that has been coated with TUFRAM
TUFRAM FRICTION CHART exhibits rapid heat and cold transfer. By converting
the original single 鸻tcrystal into millions of surface
facets, the TUFRAM process permits heat distribution
COF
within the encapsulated outer surface far better than
Material Vs. Material Static Kinetic
Aluminum Aluminum 0.42 0.34 that of untreated aluminum. Some of the proprietary
Aluminum TUFRAM HO 0.25 0.22 polymers impregnated into the TUFRAM coating have
TUFRAM H2 TUFRAM H2 0.17 0.14 a heat conductivity of 1.7 .03 Btu/hr/sq ft/deg F/in.
TUFRAM L4 TUFRAM L4 0.18 0.17 Selective processing permits wide ranges of conduc-
tivity forheat sink applications.
Hardness Resistance to acid and alkaline solutions
Varies from equivalent hardness of Rc 40 to Rc 65, TUFRAM 600 Series coatings provide superior resis-
depending on the TUFRAM chosen and alloy used. tance to attack from acid or alkaline solutions and
atmosphere. In humidi鹀ation tests, panels with one
Adherence and impact resistance
edge exposed by a saw cut were immersed in acid
TUFRAM coatings adhere 鹯mly to most alloys, espe- with a pH range of 3.5– 4.0 and in an alkaline solution
cially those containing magnesium. Impact resistance with a pH range of 8.5 –9.0. Both panels protruded
is limited only by the structural strength of the base for half their lengths to provide immersion and vapor
metal to which they are applied. tests simultaneously. After 90 days, saw cut edges on
both panels were badly corroded. Heaviest damage
FDA/USDA/CFIA compliance
occurred at interfaces of the liquid and vapor states.
Compliance with FDA, USDA, and CFIA codes makes
However, TUFRAM-treated surface areas showed no
most TUFRAM coatings advantageous for food and
effect.
pharmaceutical processing and packaging, and some
medical industry applications. Non-wetting
Temperature The new, integral surfaces are oleophobic and hydro-
phobic, and resist wetting by most liquids.Cleanup is
Exhibits high strength, toughness, and self-lubricity
faster, easier, and more thorough. Parts become self-
down to –360癋 (–218癈), and intermittent operating
capability at temperatures as high as +800癋 cleaning. Maintenance time and labor are greatly
(+427癈), depending upon the process speci鹐d and reduced.
the alloy used.
Weather resistance
Non-stick release properties Tests of TUFRAM-coated samples, exposed foryears to
Very few solid substances, even adhesives, adhesive- severe climatic conditions, con鹯m itsresistance to all
backed products or glues, willpermanently adhere to types of weather. TUFRAM coatings also exhibit excel-
the proprietary-polymer-impregnated surface of a lent resistance to ultraviolet light and extreme heat.
TUFRAM-coated part. Most substances, such as plastics,
Performance in vacuums
rubber or slurries,release easily.Some extremely tacky
TUFRAM coatings have been applied to parts on every
materials may exhibit mild temporary adhesion.
space vehicle. They are required to perform in
Self-lubricating surface extreme environments, including vacuums to 10–6
Proprietary polymers impregnated into the aluminum torr and temperatures from –100癋 (–73癈) to +350癋
during the TUFRAM process leveloff surface asperities (+177癈), and under conditions of extreme vibration.
to provide a permanent self-lubricating surface, and Today, they are used in vacuum packaging and on
result in greatly reduced surface tension. TUFRAM- machinery that must operate under vacuum.
Dielectric properties
Ultra-Thin
The TUFRAM processconvertsthe aluminum surface
TUFRAM 2000"! to one withexcellentdielectriccharacteristics,without
affectingthe high conductivityofthe parentmetal.
The proprietary-polymerimpregnation impartsout-
Offers all these special features and
standing propertiesasan insulator.Thepolymers do
benefits in one ultra-thin coating!
not absorb water.Volume resistivityvaluesremain
Precisionwith.0003–.0007"thicknesses
unchanged, even afterprolonged soaking in water.
(.00015–.00035"buildup)
Surface resistivityvaluesweretakenat100% relative
Superiorresistancetowear(4.68/10,000cycles)
humidity.Dielectricconstantforthepolymer remains
No chrome— environmentallyfriendly
constant at 2.1 fora temperature range of –250癋
Excellentcorrosionresistance(2,500hrs.)
(–157癈)to+550癋 (+288癈)and afrequency rangeof
USDA/FDA-compliant
5Hz –10,000MHz. Dissipationfactorisalsoconstant
Sealedorunsealedversions
at 0.0003forthe same rangesof temperatureand fre-
Retainsexcellentthermalconductivityofaluminum
quency. Non-conductive TUFRAM actsas aninsulator
Createsaneffectivedielectricbarrier
that withstandsarange of500 –2,000volts,depend-
Forcomplexgeometricshapes
ing upon thickness.
Denseand uniformoxidelayerwithaccurate
controlviamicroprocessors
Meetsperformancerequirementsof TUFRAM FAMILY OF
AMS 2469 “SYNERGISTIC” COATINGS
Application to aluminum alloys
FC-12 Specialcombinationsofpolymersand
Aluminum and itsalloysthatcontain lessthan 5% drylubricantsallowlowCOF.
copper and 7% siliconandthatdo notcontain exces-
H-2 Maximum hardness(Rc60–65).
sivezinc orlead aremost suitablefortheapplication
HCD-31 High dielectricstrength.
of TUFRAM coatings.Most cast,forged,extruded or
wrought alloyscan be treated.The degree ofhard- H-O Hard (Rc40–50),wearresistant,dry
ness orpenetrationdoes varywith some alloys.Finish lubricatedsurface.Goodrelease.
USDA/FDA/CFIA-compliant.
color may vary depending on base alloy,coating
selectionand thickness. H+ High strengthaluminum(T-6)maintains
maximum hardness,corrosionresistance
Coating tolerances / thickness and lubricity.
With few exceptions,aconsistentlyuniformcoating L-4 Minimizes“stick/slip”.
can be appliedto partsof any con鹓urationor R-66F Permanentmold and sealingsurface
weight, and virtuallyanysizeor thickness.Precise release.USDA/FDA-compliant.
control ofthicknesspermits use on threaded mem- 604 Chemicalresistanceandmoldrelease.
bers and similarclose-toleranceapplications.By USDA/FDA-compliant.
undersizing outsidepitchdiameter by roughlytwice
608 Forrubberand foodapplications.
the coatingthicknesspriortocoating,originalthread Durable,abrasionresistant.Darkgreenin
sizesaremaintained. color,USDA/FDAcompliant.
Formachining allowances,note thatoverall鹡al 611 Tough.Easytoclean.Availableincolors.
thicknessofthe coatingisin鹵encedby two factors: USDA/FDA-compliant.
A. Penetration B. SurfaceGrowth 615 Maximum releaseproperties.Operating
temperaturesto550癋(288癈).Sparkling
The tablebelow shows typicalexamples:
blackorwhitecolor.USDA/FDA-compliant.
COATING SURFACE 641 Excellentreleaseforfoodanddrug
ThicknessinInches Growth inInches* packaging,moldingandmanufacturing
applications.Greyincolor,USDA/FDA
0.0008 0.0004
compliant.
0.0010 0.0005
0.0020 0.0010 2000 Excellentthermalconductivity.Effective
dielectricbarrier.Forcomplexshapes.
*Note:Growthisapproximately50%ofthethicknessvalue.
USDA/FDA compliant.
Thickness is customized for each application.
Formaximum saltsprayresistance,seeseparate
Maximum thicknessislimitedby alloycomposition.
MAGNAPLATE HCR brochure.
Minimum practicalthicknessis0.0005".
Examples of TUFRAM Coatings in Use
B
A
D
E
C F
G
A. TUFRAM on aluminumsectionsofJohnson Controls’bi-metallicPETbottlemoldspreventerosionandgalvaniccorrosioncausingpoorrelease,
highrejectratesandshortenedmold life.SteelsectionsaretreatedwithMagnaplate’sNEDOX .
B. TUFRAM providessuperiorprotectioninsevereabrasiveenvironments.Thisrollerguideisusedtomanufacturecardboardtubing.TUFRAM
coatingsrunon Taberabrasiontestingunitshaveproducedweightlossnumbers aslow as0.5mg per1000 cycles(FedStd.#141).
C. TUFRAM on thispneumaticshifterreducesfrictionastheaccompanyingpistonrunsagainstit.Theshifterisusedonaircrafttowingvehicles,
which operateundersubstantialloads.
D. TUFRAM coatingsareexcellentinvacuumenvironments.TheTUFRAM coatingonthiswaferchuck provideswearresistanceanddoesnot gener-
ateparticulateundervacuum,enablingcontamination-freewaferstobemanufactured.
E. TUFRAM coatingsprotectedaluminumfuelmixingcontrolvalvesontheLEM AscentEngine ofApollo13againstvibrationand“outgassing”
underoperatingconditionsof10–6torrvacuumand–100癋(-73癈)to+350癋(+177癈)temperaturevariations.
F. TUFRAM on an aircraftcentrifugecomponentreducesfrictionandincreaseswearresistance.
G. Aluminum aircompressorimpellerbladesexhibitlongerwearlife,reduceddrag,andimprovedair鹢wafterbeingcoatedwithTUFRAM
toprotectthemagainstcorrosiveanderosivechemicalprocessindustrygasstreams.
Corp.
Magnaplate
■ GeneralU.S.A.
800-852-3301Fax:908-862-6110
E-Mail:info@magnaplate.com
Web Site:http://www.magnaplate.com in
2005Printed
2006,
1-711-5M
2011,
Category:lubricant coating
