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The Bottom Line
Displacement piston pumps for delivering high-pressure abrasive paint to airless applicators had short life between failures. Piston scoring led to leakage and pressure loss.

The Numbers
With other coatings:
4 months avg life
With FortiPhy:
Still going strong since last July...

Metal Forming Success Stories with FortiPhy High Performance Surface Coating

Die Casting Success Stories about FortiPhy Corrosion Resistant Coating

Injection Molding Success Stories with FortiPhy PVD-based Tool and Die Coating.




Emerging Applications Success Story

Thin Film, Chromium Nitride (CrN) Coating Helps Paint Pistons Continue Pumping

One large Midwestern manufacturer of metal office furniture operates a traditional factory with raw materials entering at one end and finished products exiting at the other. The operation includes metal forming processes such as folding, stamping, welding, and drilling. Near the end of the production line, components go through a sophisticated painting process with high-pressure pumps feeding airless applicators.

The factory's paint delivery pumps turned out to be one of the biggest maintenance bottlenecks. These high-pressure displacement piston pumps keep hundreds of gallons of abrasive paint pressurized and flowing. The typical life for each of eight pump pistons, even with commercial coatings, is under four months. The failure mode usually is piston scoring, which leads to internal leakage and pressure loss. The pumps work harder and harder until they can no longer keep up with demand. The pistons, 13-inches long by 1-1/4-inches in diameter, are custom made, in house. When they fail, production stops until a replacement can be installed, lines bled, and the system pressurized.

According to the plant manager, the company found a solution that exceeded its expectations when a set of pistons was sent to Phygen for coating. The FortiPhySM coated pistons were installed last July. They are still going strong today with no sign of wear. The company's experience shows that FortiPhy thin film tool coating by Phygen prevents abrasive wear, and ensures that critical part dimensions are maintained under the toughest conditions.

The key to FortiPhy's exceptional toughness, low coefficient of friction, and corrosion resistance is its uniform, nanocrystalline structure. Phygen’s patented plasma acceleration process improves upon traditional PVD to produce the most uniform coating deposition layer possible, with exceptionally high adhesion. Having solved the uniformity problems inherent in the PVD processes of the past, Phygen can apply thinner coatings, which outperform thicker, less-uniform coatings. In addition, Phygen's coatings are applied at much lower temperatures. Low-temperature processing and thinner coatings help keep critical tool dimensions within tolerance, without the costly rework of other processes.

This factory's trial is still ongoing, but so far has proved that FortiPhy Chromium-Nitride (CrN) coatings can outperform other coatings in reducing abrasive wear. According to the plant manager, “The Phygen coating process appears to have a much finer quality and better surface finish than other coatings. We expect to double the life of these critical parts.”

Phygen Coatings, Inc.
1400 Marshall Street, NE / Minneapolis, MN 55413-1040
Toll Free 888.749.4361 / Fax 612.331.4230 /