PCSIR - Engineering Development Board-Official Website. Shahzad Ala… · · 2014-03-22PCSIR New...
Transcript of PCSIR - Engineering Development Board-Official Website. Shahzad Ala… · · 2014-03-22PCSIR New...
PCSIR
PVD Hi-tech Coatings for Surgical Instruments
Dr. Shehzad AlamDirector General,
Pakistan Council for Scientific and Industrial Research, PCSIR, Lahore
Workshop on “Challenges & Potentials of Surgical Instruments Industry”
April 14, 2011
PCSIR
Format of Talk
• INTRODUCTION TO PITMAEM
• AREAS OF RESEARCH AND INTEREST
• AREAS OF NEW AND EMERGING TECHNOLOGIES
• PHYSICAL VAPOR DEPOSITION (PVD)
• BENEFITS OF PVD COATINGS
• BIO-MEDICAL APPLICATIONS
• TYPES OF INDUSTRIAL COATINGS PRODUCED
• CHARACTERIZATION
• CONCLUSION
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Our Mission
• Conduct fundamental and applied research in the field of materials science and engineering.
• Develop new materials.
• Improve the performance of traditional engineering materials.
• Promote high quality scientific and engineering research, identifying the national need and help in its progress.
• Enhance interdisciplinary research and international collaboration.
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Areas of Research
• Materials Processing
• Materials Characterization
• Materials Modeling
• Materials Properties and Performance
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•Engineering composites
•Material characterization
•Mineral processing & mineral based chemicals
section
•Corrosion control studies section
•Electrometallurgy section
•Product development section
Areas of Interest
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•Nano technology
•Non destructive testing
•Centre of excellence in industrial coatings
•Jewelry hallmarking
•Foundry technology
•Heat treatment & rolling
•Industrial chemicals
Areas of Interest
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Targets of the country to strengthen the
economy
• Rapid industrialization,
• Export enhancement,
• Self-reliance and
• Minimizing the import could be the basic
targets.
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Current Status
However, the engineering industries
• Automobile
• Textile
• Chemical
• Surgical etc
have failed to achieve the targets set for
deletion of imported parts. The reason for this
state of affairs can be attributed to the:
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The reason for this state of affairs can be attributed to
the
• Inability of the local industry to
manufacture good quality products
due to use of out-dated techniques and
• lack of technical know how
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The situation can be rectified byrestoring, the production of thoseengineering based parts locally. Toachieve these targets, capacitybuilding in science and technology is
quite vital.
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Industrial based economic system
• What it means in actual terms is that the
agro- based-economic system should be
changed to industrial-based system. This
simple realization of the ground reality
requires action in certain areas.
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Industrial based economic system
• We as scientists/engineers in Pakistan
must be able to identify the usefulness
and relevance of the technologies that
should be adopted or materials to be
developed. This is most essential to avoid
wastage of time, resources and the
materials
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• The specific areas of the new and
emerging technology that need our
immediate attention pertain to the
following specific field.
AREAS OF NEW AND EMERGING
TECHNOLOGIES
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• Powder metallurgy
• Composite Materials and Engineering
Ceramics
• Shape memory alloy
• Single crystals
AREAS OF NEW AND EMERGING
TECHNOLOGIES
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• Special alloys for surgical and
biomedical applications
• High temperature alloys
• Plastics, composite plastics & ceramic
polymers
• Materials for sports industry
AREAS OF NEW AND EMERGING
TECHNOLOGIES
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New magnetic materials & ceramicmagnets
Surface modification by plasma, CVD and PVD techniques
Nano-technology with special emphasis on Nano-materials and their characterization for engineering industrial applications.
AREAS OF NEW AND EMERGING
TECHNOLOGIES
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Surface modification
• Surface modification is a valuabletechnique in order to producedesirable properties on surface ofthe material.
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Surface Engineering
Electro -plating
Electro less-plating
CVD
PVD
Plasma Coating
CladdingAnodization
Bluing
TBC
EBPVD
Pack Cementation
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Physical Vapor Deposition (PVD)
A vacuum deposition technique and is a
general term used to describe any of a variety
of methods to deposit thin films by the
condensation of a vaporized form of the
material onto various surfaces (e.g., onto steel
substrate).
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The coating method involves purely physical
processes such as high temperature vacuum
evaporation or plasma sputter bombardment
rather than an involving a chemical reaction
at the surface to be coated.
Physical Vapor Deposition (PVD)
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TiN
The general purpose coating for:
• Cutting
• Forming
• Injection molding
• Tribological applications
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TiCNConventional carbonitride coating for:
• For milling and tapping
• For stamping, punching and forming
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TiAlN
• Dry machining
• Universal high-performance coating for:Cutting
• Monolayer: for stable finishing and roughing
• Multilayer: for interrupted cuts
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AlTiN
• High-performance coating
• High aluminum content (>50%)
• High heat resistance
• For dry high speed machining
• Hard machining
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µAlTiNSpecial high-performance coating:
• Finest Coating surface
• Highest edge stability
• Especially for precision machining (like reaming and tapping)
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TiCN-MP
Standard gradient coating for
• Interrupted cutting
• Milling, Tapping, Hobbing
• Forming, Stamping and punching
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CrN
The standard coating for
non-cutting applications:
• For molds and dies
• For machining parts
• Low deposition temperature possible (above
220˚C)
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CBC CVIc
Double coating with nanogradient structure:
• For cutting sticky materials to avoid built up edges
• For forming application with optimum release
• For Tapping
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ZrN
• Ti-free monolayer coating
• Effectively reduces the built up
edges when machining aluminum
and titanium alloys
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nACo
• Nanocomposite coating
• nACo = (nc-AlTiN)/(a-Si3N4)
• Extremely High Nano Hardness
• High Heat Resistance
• Available with decorative blue top layer
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nACRo
• Nano Composite coating
• nACRo=(nc-AlCrN/a-Si3N4)
• Extremely High Scratch Resistance
• High Heat resistance
• High Coating Thickness
• Specially for hobbing and Forming Tools.
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Benefits of PVD Coatings on
Surgical Instruments
The value of PVD technology rests in its
ability to modify the surface properties of
a device without changing the underlying
material properties and biomechanical
functionality.
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Benefits of PVD Coatings on
Surgical Instruments
• PVD coatings provide a number of
benefits to surgical devices in
addition to hardness and adhesion.
• The most significant are listed below:
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Key Benefits of PVD Coatings
on Surgical Instruments• Improved wear resistance
• Reduced friction
• Biocompatibility
• Decorative colors & aesthetic
• Chemical barrier
• Nickel Sensitivity
• Saline Solutions
• Sterilization
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Benefits of PVD Coatings on
Surgical Instruments• PVD coatings on
surgical devices must
also be compatible
with the sterilization
process. Both TiN and
CrN resist corrosion
that can be caused by
steam and chemical
autoclaving.
Corrosion resistance of
PVD coatings after
medical sterilization
processes
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Benefits of PVD Coatings on
Surgical Tools
• A variety of PVD coatings including
TiN, TiAlN and AlTiN are being used
on surgical tools.
• Examples are shown in next slides.
PCSIRBiomedical applications> Scratch Resistance on contact lenses > Materials properties on teeth materials
> Controlled drug release valves
> Hardness of bone tissue > Adhesion on coating for hip prostheses
> Scratch resistance
of arterial implants (Stents)
> Scratch Test on Breast Implants
> Blood Pump System
Pakistan Institute of Technology for Minerals and Advanced Engineering Materials (PITMAEM)
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Benefits of PVD Coatings on
Orthopedic Implants• TiN has been in clinical use on orthopedic
implants for more than 9 years in North
America and Europe. The most common
applications involve total joint replacement
with Co-Cr-Mo or Ti-6-4 alloy implants.
• TiN is used for hip, knee, shoulder and
ankle implants.
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Benefits of PVD Coatings on
Dental Tools
• Dental instruments and orthodontic
devices are also coated with TiN in
order to provide resistance to germs
attack during surgery and routine
checkup etc.
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CHARACTERIZATION TECHNIQUES FOR COATINGS
Following are the techniques most commonly used for
the characterization of these coatings
• Atomic Force Microscopy (Topographic Analysis)
• Nano Indentation (Mechanical Properties)
• Micro Scratch Testing (Adhesion)
• Pin/Ball on disc Tribometer (Tribology)
• Calotest ( Thickness Measurement)
• Scanning Electron Microscope