For decades, Fluoropolymer cookware coatings found little use in the industrial realm because they were soft and wore away easily.
A new coating combines all the advantages of cookware coatings – extreme release and low friction – with toughness and abrasion resistance that is demanded in applications such as agitators, mixers, rollers, and compactors.
The coating, called Excalibur, is an externally reinforced coating and is known as the most wear-resistant of all low-friction and release Fluoropolymer (PTFE) coatings. It differs from conventional non-sticks by combining tough PTFE-rich coatings with stainless-steel alloy reinforcement. The stainless-steel’s hardness and the low-friction nonstick properties of PTFE help Excalibur make the crossover from cookware to heavy industry. The smooth surface of the substrate is blasted with an abrasive.
This roughens it so that other elements in the Excalibur process will adhere to it better. Then, the most important part: white hot particles of stainless steel are sprayed onto the surface. The particles cool and harden, welded to the surface, actually becoming part of the substrate. They form a permanent series of “peaks” and “valleys” that provide a tough base for the nonstick coatings. The first coat of tough nonstick is applied, settling down into the valleys. More tough nonstick is applied, filling the “valleys” and covering the “peaks.” This superior nonstick is held permanently in place by the stainless steel “peaks”.
Safety harnesses use Excalibur for consistently free movement over steel cables.
Now, if abrasive materials such as steel utensils are scraped harshly across the Excalibur coating, they simply skip along the stainless steel peaks, unable to gouge out the nonstick coating filling the valleys. So, Excalibur retains its nonstick qualities under even the harshest treatment. That’s why the Excalibur system outlasts all nonstick coatings.
Excalibur coatings are flexible through a 25ø range and elongate up to 25%. These properties are useful in applications such as chutes and tumblers, where process materials strike the coated surface with considerable impact. Wear-resistant properties of Excalibur resemble those of plated or anodized surfaces impregnated with PTFE. However, flame spraying is a much simpler process and requires no electrodeposition baths or secondary surface modifications. Since the flame-sprayed stainless-steel layer is porous, it need not be “opened up” like plated surfaces to give the PTFE a place to grip. Flat or convex surfaces such as roller guides and feed screws are good candidates for Excalibur. Concave profiles, on the other hand, pose problems for the process if they cannot be uniformly sprayed.
So Excalibur retains its durability, corrosion resistance, low friction and release qualities, even under the harshest conditions.