Thin Flim Coating

CERAMIC NANO

Kal-Gard has invested heavily in both the ceramic coatings and Nano derived coatings for use in the defence and aerospace industries. This technology is also now being used in the automotive and industrial fields. The number of different products that can be made is extensive and we have ongoing research in these fields.

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DEFENCE APPLICATIONS

The diverse field of Kal-Gard products includes a range of conductive coatings for plastic electronic equipment housings. These coatings are formulated to the required conductivity and characteristics demanded by the specifier. Based on silver, silver plated copper or nickel, combined with different resin systems, these coatings are easily applied, are air-drying, and give excellent adhesion, corrosion and humidity resistant characteristics, as well as the required electrical properties. Our many years experience in formulating RFI shielding coatings for Government and Defence specifiers has placed us in a good position to meet the requirements of the civil electronics industries as required by the E.M.C. directives.

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FASTENER COATINGS

Kal-Gard was founded some forty years ago, initially involved in specialised coatings for aerospace and military applications. The coatings were developed primarily for fasteners to stop corrosion whilst facilitating easy installation and removal.

Subsequently over the years in addition to the aerospace and military applications, an entire range of coatings for the building, automotive and petrochemical industries have been developed.

Not only are some of these coatings revolutionary but unique pre-treatments cater for the varied requirements and specific needs of the customer. "Kal-Gard is the answer"

Kal-Gard KG 650 Fluoropolymer Coating

This coating has been specially developed for the spray coating of fasteners to give a combination of corrosion protection and low friction properties. KG650 is particularly suitable for the coating of offshore, marine, outdoor and other extreme applications.

The combination of its corrosion barrier and reduced friction give a high order of maintainability and re-usability if the fastener. This results in reduced and more controllable make up torque and easy break-out after environmental exposure.

A wide range of colours are available for identification and variation (Red, Blue, Green & Black)

Coating thickness : 15 – 25 microns

 Application : Spray

Kal-Gard KG213/1 Composite Coating

This coating was specially developed for fasteners used in the construction of ocean containers and has a 20 year proven record. The requirement being excellent corrosion protection on the standard steel fastener without increased tolerances. This coating then soon found favour in the roof and building industries. Its dry lubricant properties allowing for easy installation on metal and wood with no galling on the screw threads. KG213/1 is particularly suitable for all types of fasteners from 2 to 18mm. All ingredients used in the makeup of this coating as well as the pre-treatment are free of all toxic substances (lead, chrome, etc...)

Coating Thickness : 8 – 12 Microns

 Colour : Silver

 Temperature Resistance: 350°C

Kal-Gard KG146 Fluoropolymer Coating

KG164 has been specially developed for fasteners, valves and all components requiring outstanding dry lubrication and corrosion protection. It is particularly suited to the petrochemical, mining and offshore oil/gas industries.

This coating differs from most other Fluoropolymer coatings in that it has been developed to offer excellent corrosion at a much thinner film thickness than any other products available. The coating can be applied by conventional spray application or via the dip spin process.

Coating Thickness : 8 – 12 Micron

Colours : Blue, Red, Green, Black & Yellow

Temperature Resistance : 260°C

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HI TEMPERATURE

Kal-Gard makes a number of high temperature coatings which offer both temperature resistance, corrosion resistance and in some cases thermal barrier properties. These coatings are based on silicone technology as well as the latest ceramic and nano technologies and find use in the following industries:

◾Defence industries

◾Automotive and Motorcycle (Exhausts)

◾Industrial Equipment

◾Domestic Heaters

◾Etc.

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KAL-GARD GUN-KOTE 16/2

Gun-Kote 16/2 is a range of coatings which are specially developed for the coating of steel ammunition boxes, mortars, cartridge cases and shells.

The coating offers exceptional corrosion protection at a dry film thickness of 8 – 12 um (1000 hrs of salt spray). As the coating is so thin it penetrates into all laminations on boxes greatly improving corrosion resistance over conventional methods. When used on mortars and shells the problems of too thick a paint film causing rejects, becomes a thing of the past.

Coatings are engineered to provide dry lubrication which overcomes with the extraction of large calibre cartridge cases. All these coatings have been operationally tested and exceed all performance requirements.

Included in this range are coatings for the replacement of electro galvanising and cadmium plating especially on nuts and bolts offering far better corrosion protection, resistance to galvanic couples and resistance to acids. Gun-Kote 16/2 can be made in most colours and does not require any primer. The coatings are also now used for automotive and industrial applications especially where fine tolerances are required.

Qualities of Coating

◾Very thin 8 – 12 Micron.

◾Resistant to solvents and acids.

◾Can withstand far higher and far lower temperatures than conventional coatings.

◾Excellent impact resistance.

◾Excellent corrosion resistance. 1100 hrs at salt spray.

◾Resistance to UV 1000 hrs.

◾Compatibility to explosives.

◾Can be applied electrostacilly.

◾Thin coating is very hard and scratch resistant.

◾Dry film lubrication.

Some Gun-Kote 16/2 Coatings

◾Gun-Kote 16/2 (Standard). All colours. For ammunition and cartridge cases.

◾Gun-Kote 16/2 DG. Usage on threaded fasteners, studs, brackets, pulleys and linkages. (Fluoropolymer coating)

◾Gun-Kote KG – 27-5 Fluorocarbon coating is formulated for application/usage on automotive and truck weld nuts, pierce nuts, weld studs and related hardware. It provides corrosion resistant, non conductive, non-stick finish, restricting adhesion of unprimed paint/primer systems to threaded fastener areas while providing lubrication necessary to meet installation torque and tension to assure joint integrity.

◾Gun-Kote 16/2 Box-Kote: specially developed as a dip coat for ammunition boxes, tail fins, etc to penetrate into all laminations and difficult areas.

These are just a few of the many coatings available, for more information contact us.

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NON STICK COATINGS

Kal-Gard makes an extensive Range of Non-Stick Coatings which consists of Fluoropolymer (Teflon), Silicon and the very latest Nano and Ceramic coatings which are used in the following industries:

◾Cookware

◾Rubber mould release

◾Injection moulding tools

◾Industrial bake ware

◾Rollers

◾Fasteners

◾Chemical resistance

◾Valves

◾Etc.

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R.F.I SHIELDING COATINGS

The diverse field of Kal-Gard products includes a range of conductive coatings for plastic electronic equipment housings. These coatings are formulated to the required conductivity and characteristics demanded by the specifier. Based on silver, silver plated copper or nickel, combined with different resin systems, these coatings are easily applied, are air-drying, and give excellent adhesion, corrosion and humidity resistant characteristics, as well as the required electrical properties. Our many years experience in formulating RFI shielding coatings for Government and Defence specifiers has placed us in a good position to meet the requirements of the civil electronics industries as required by the E.M.C. directives.

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S.C.K RANGE OF COATINGS

Formulated to meet or exceed appropriate MIL specifications, the Kal-Gard SCK range of ultra thin film coatings offers a unique treatment for firearms and other applications where there is a requirement for outstanding corrosion resistance, combined with self-lubrication, high temperature thermal shock capability, and whose working tolerances are very close.

Because Kal-Gard SCK coatings can be successfully applied as thin as 8 to 10 microns, they can be used to impart such properties to moving parts of a mechanism without having to allow extra clearance normally required when functional coatings are used.

Kal-Gard Gun-Kote SCK

What is Gun-Kote SCK?

Gun-Kote SCK is a coating which was developed in America and perfected in South Africa for local conditions, for use on military weapons used in extremely adverse conditions. The coating is made up of abrasion resistant, corrosion inhibiting and lubricating solids dispersed in a resin binder using a solvent carrier and is available in the following colours:-

SCK 1 Nutria Brown

SCK 4 Green

SCK 6 Black

What are the properties of Gun-Kote SCK?

Ability to meet automatic weapons dry firing requirements after 60 days sea water immersion.

Kal-Gard Gun-Kote SCK will give you:

◾ Corrosion resistance (1000 hrs at 5% salt spray)

◾ Extremely good wear and abrasion resistance.

◾ The coating is non reflective.

•Specular reflection at 60 degree units = 1

•Specular reflection at 85 degree units = 1

◾Excellent impact resistance. Minimum .375 inch deformation before loss of adhesion evidenced by crack and peeling of coating on upset area of panel when struck at .250 inch radius round impact rod.

◾Dielectric Strength. Minimum insulation with 50 VAP applied 1,100 MEG OHMS Insulation breakdown at 500 VAC min applied.

◾The coating is resistant to most acids and alkalines. •MIL-SS-3135 Standard test fluid Hydrocarbon 24 Hrs

•MIL-G-5572 Aviation Gasoline grade 115/145 24 Hrs

•MIL-H-5606 Hydraulic Fluid 24 hrs

•MIL-J-5624 Jet Fuel JP-4 24 Hrs

•MIL-L-6082 Lubricating Oil 24 Hrs

•MIL-H-8446 Hydraulic Fluid 24 hrs

•MIL-R-81294 Remover, Paint Epoxy System 24 Hrs

•Trichloroethylene 24 Hrs

•Dow Corning DC-500 24 Hrs

•Nitric Acid HCL 10% 24 Hrs

•Hydrochloric Acid HCL 10% 24 Hrs

•Hydrogen Peroxide H202 3% 24 Hrs

•Aluminium Hydroxide NH40H 10% 48 Hrs

•Sodium Hydroxide 1% 1 Hr

•Sulphuric Acid H2S04 30% 1 Hr

•Sulphuric Acid H2S04 3% 1 Hr

•Sodium cleaner highly Chelated 1 Hr

•Ann-Ro 101 at 212 degree F 1 Hr

◾ Coating thickness is extremely thin 8-12 microns which allows coating of close tolerance components.

◾ Can withstand temperature of up to 650°C.

◾ Has excellent emissivity (ability to conduct away).

◾ Can be applied to all ferrous and non ferrous surfaces.

◾ Stop galvanic couples.

What are the advantages of Gun-Kote SCK?

◾Gun-Koted weapons can be fired dry: in contact situation proper lubrication of weapons is not always possible. Secondly dirt and grit attracted by oil is a major cause of weapon stoppages. Gun-Kote SCK prevents these problems.

◾Gun-Kote SCK is a complete barrier to all forms of corrosion and can be applied to every part of the weapon – constant maintenance of weapons in the field to prevent corrosion by cleaning and oiling is extremely costly in man-hours and materials. The chemical blackening now used is at the outset. A form of rust and the alternative phosphating which is also currently used offers very minimal corrosion protection. Acid corrosion caused by detonation debris deposits are also a major problem. Corrosion caused by storage in damp, humid is a serious problem which is currently overcome by expensive oiling, greasing and packaging material. Gun-Kote SCK alleviates these problems.

◾Gun-Kote is extremely hard and abrasion resistant – the existing phosphate painted, chemically blackened or browned surface treatments quickly wear and burn off leaving a bare shiny surface which is reflective, thus very, very dangerous and corrodes fast.

◾Gun-Kote SCK is impervious to acids and cleaning agents – strong barrel and weapon cleaning agents currently used do not harm the coating.

◾Gun-Kote SCK is extremely thin and does not interfere with close tolerance parts – this allows each individual component of the weapon to be coated giving complete protection and lubrication.

◾Gun-Kote SCK can withstand extremely high temperatures e.g. 650°C and has a high rate of emissivity - Gun-Kote SCK does not peel off at high temperatures and conducts heat away from operating surfaces allowing weapons to operate at low temperatures at peak firing rates.

◾Gun-Kote SCK can be applied to ferrous and non ferrous metals. This allows a uniform finish, ease of maintenance and complete protection. This is not possible with existing finishes e.g.: protection of aluminium.

◾Gun-Kote SCK is available in camouflage colours – the uses of these colours at manufacturing level preclude the costly operation of re-painting the weapons after supply.

How is the Gun-Kote SCK applied?

The pre treatment for Gun-Kote SCK is either a mechanical or chemical etch but preferable both. It is also very important to have no oil or grease on components before coating.

Pre Treatments

◾Alloy Steels Sandblast and Phosphate (Zinc Class 2 or 3)

◾Stainless Steel sandblast and passivate of Ann-Ro 1013

◾Aluminium Alondine or Anodize non sealed.

◾Titanium vapour blast max grit size No. 325. •Max pressure 101 lbs Ann-Ro No. 1012

◾Nickel Plate Sandblast

◾Chrome plate sandblast

◾Cadmium plate Bonderrite or chromate treat

◾Magnesium Dichromate Treat

◾Copper sandblast

The weapons to be coated are first to be stripped completely and then degreased. It is very important to strip completely as the coating will not adhere to oil or dirty surfaces. Once this has been done proceed with correct pre treatment.

Application of the coating

Once the pre treatment has been done, no component is to be touched by naked hands as this imparts oil onto the surface. Use cotton or rubber gloves for handling.

Pre heat all components to be sprayed at approx 35°C and spray on in light fog passes. This is done to ensure that the parts are dry and as the coating is very thin, runs will develop unless the parts are pre heated.

Bake

Baking time only starts from the time the metal has reached baking temperature.

SCK 1 Nutria Brown  Bake at 200°C for 30 Minutes

SCK 4 Green Bake at 150°C for 60 Minutes

SCK 6 Black Bake at 150°C for 60 Minutes

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SPECIALISED COATINGS

At Kal-Gard we specialise in precision thin film coatings used in a wide variety of fields such as Military, Aerospace, and Industrial applications. These products include anti-corrosion coatings, Nano & Ceramic Coatings, Thermal barrier coatings as well as Conductive coatings. Although the product range is extensive and should satisfy most coating needs, we still believe in tailor making coatings to meet specific customer requirements. Contact us if you cannot find a suitable product here and we will work with you to come up with a solution…

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