The IPCote Range of Sacrificial Aluminium CoatingsThe Ipcote range of sacrificial aluminium basecoats and sealcoats has been developed and refined over a number of years.
The range was originally introduced at the request of Rolls-Royce Aero Engines for use as a high corrosion resistant, high temperature resistant coating for use on compressor blades and allied engine parts as a commercially available alternative to a proprietary range of imported US products.
Subsequently, the coating range has been adopted by a large number of additional manufacturers of aero engines and industrial gas turbines, as well as being introduced as a cadmium replacement on undercarriages and fasteners.
Initially the range was purely based on inorganic technology, which by their very nature contained both trivalent and hexavalent chrome.
The IPCOTE range of products has been developed over a number of years at the request of Rolls Royce aero engines for use on their jet engines. The range has now been adopted by several other jet engine manufacturers, and it is also being used on many industrial gas turbines, as well as being used as a cadmium replacement on under carriages and fasteners.
Recent introduction of environmental and safety legislation has highlighted the use of chrome containing products. Whilst the levels of hexavalent chrome in most of the products are minimal, in most cases below all current environmental limits, there are ongoing developments to remove all chrome compounds. We can now offer a single component chrome free coating, based on organic chemistry, and thus containing solvents, which has been tested to Rolls-Royce MSRR 9253. In addition we are testing with clients, a chrome free inorganic basecoat.
BasecoatsMSRR 9140; OMat 7/46B; PCS2550; LB598; ITP SMM-903
The original sacrificial basecoat. This coating, when applied at film thicknesses of 50 microns will give in excess of 3000 hours corrosion resistance to ASTM B-117.
Used as a replacement/alternative to Sermetal W/WFX.
Can be cured using a variety of processes, but typically for 1 hour @ 560°C to give a matt grey conductive film, or 1 hour at 350°C, followed by bead peening or polishing, to a bright silver conductive finish. Refer to our Ipcote Application Information Sheet for typical schedules. For application on temperature sensitive alloys, can be cured at temperatures as low as 260°C, but with longer dwell time.
IP9183-R1 contains only 37ppm hexavalent chrome.
LB598; CPW88
A smooth surface alternative to IP9183-R1, manufactured using smaller particle size aluminium powder. Gives a denser, more erosion resistant product, with similar corrosion protection to IP9183-R1.
Is easier to apply and produce smooth surface finishes of typically 20-25µ-inches. Smoothcote is cured in the same way as Ipcote, typically RPS 666/1.
Usedas an alternative to Sermetal 962/5380/5380DP. IP9442 contains only 14ppm hexavalent chrome.
MSRR 9356; ITP SMM-919
Thin film version of Ipcote, to allow easy application of film thickness of 12-25 microns. This is of use in areas where tolerances are critical, including interference fit joints, flanges, bolts, engine mounts, fasteners and dovetails.
Ipthin is processed as standard Ipcote, and is an alternative to Sermetal 709/762/962. Refer to RPS 666/2 for a typical system.
Organic Chrome Free
MSRR 9253
Originally produced to meet the requirements of Rolls-Royce MSRR9253, first production quantities contained chrome anti-corrosive compounds.
Recently reformulated to be totally chrome free. Approved to MSRR 9253, and now under evaluation at Rolls-Royce to MSRR 9140, and by other engine manufacturers as an alternative to chrome containing Ipcote and Sermetal basecoats.
To meet the requirements of MSRR 9253, process in accordance with RPS666/3. Can also be processed to RPS666/1 system A to give coatings that pass MSRR9140.
Normally used with chrome free organic sealcoats.
Inorganic Chrome Free Recently developed product to be supplied as a 2/3 component system for simple mixing before use. Applied and cured as per standard Ipcote IP9183-R1. Currently undergoing application and specification testing with clients throughout the world.
SealcoatsSealcoats provide an electrically non-conductive barrier coat to the aluminium surface. They have an added benefit of sealing any porosity that may be present in the conductive, sacrificial aluminium basecoat, without detracting from the sacrificial properties. This results in a smoother, harder coating which provides a barrier against carbon deposits, etc, extending the useful life of the coating system. Additionally, the smoother surface enhances airflow characteristics, and therefore engine efficiency.
MSRR 9140; OMat 7/168B; LB598; ITP SMM-903; PCS 2550
High temperature sealing compound used over Ipcote, Ipthin. For use at temperatures in excess of 600°C. Can also been used as a stand alone product, most recently as a one coat system on titanium to give protection against Skydrol at 250°C.
Available in green or khaki, the sealcoat gives a smooth, eggshell finish. Other colours can be manufactured; a black version has been produced for use on agricultural vehicle exhaust systems. Applied and processed typically as per RPS 666/3, to a typical film thickness of 6-8 microns.
Used as alternatives to Sermetal 570A. Ipseal contains less than 0.6% hexavalent chrome. Blue and black also available.
Smoothseal IP9444MSRR 3010
Very smooth, thin sealcoat, used over either Smoothcote or Ipcote as an alternative to Sermetal 5380/5380DP.
Gives a smooth, golden finish with excellent surface smoothness with resultant excellent airflow characteristics.
Applied and processed typically as per RPS 666/5. Note that Smoothseal is normally cured at 250°C to retain the golden finish. Normal film thickness 3-5 microns applied in 3-4 very thin coats.
Smoothseal contains less than 0.6% hexavalent chrome. Blue also available.
Newly developed totally chrome free khaki coloured sealcoat, for use over any basecoat in the Ipcote range, but usually in conjunction with Organic Ipcote IP9253-R3.
Used as a chrome free alternative to Ipseal IP9184 and Sermetal 570A.
Applied as a thin seal, typically 4-8 microns. Processed as per RPS 666/3. Blue also available.
PWA 595
Chrome free, heat and corrosion resistant sealcoat developed specifically for Standard Aero to give a very fine surface finish. Usually applied as a thin film and processed at 350°C (660°F) for 30 minutes.
Will also pass to CPW 563.
Recently developed high temperature (up to 600°C) clear sealcoat, organic but chrome free as an alternative to Smoothseal. Recently tested over IP9442 smoothcote (560°C processed) to give a surface profile < 15µin at 30 thou cut off. To be used in both organic and inorganic chrome free basecoats as a totally chrome free smooth coat system.
CPW 563
Developed for use as a chrome free alternative sealcoat for use on Pratt & Whitney Canada range as an alternative to the 5380 range; Smoothseal.
Applied as a thin coat at typically 4-8 microns, J900 is processed at 190°C for 1 hour.
Allied to the Ipcote range, by nature of their basic chemistry, but used in areas where higher temperature and corrosion resistance are required.
MSRR 1041
Aluminium Silicon Ceramic diffusion coating, formulated for higher temperature corrosion protection and excellent oxidation and sulphidation protection.
Used for example on turbine blades in aero engines and industrial gas turbines and nozzle guide vanes.
Approved alternative to Sermaloy J.
Applied and processed as per RPS 603, which includes diffusing under argon at 885°C, up to the solutioning temperature of the base metal.
(Alt to PL 219 -3863 -A 6000)
Aluminium diffusion coating, formulated to be chrome free, for use on steam and industrial gas turbines running up to 650°C. Can be diffused in air; does not need inert gas atmosphere.
Touch UpsAs with most industrial processes, it is sometimes necessary to touch up small areas of damage on parts treated with Ipcote or Ipseal.
It must be remembered that the touch up systems, whilst excellent coatings will not meet the high performance criteria of Ipcote/Ipseal, and consequently any areas to be touched up must be small, usually defined in the end user specification.
MSRR 9141; OMat 7/47; ITP SMM-914
Recently re-formulated to be chrome free and easy application, touch up for Ipcote; Smoothcote and Ipthin, where processing has been to type “A”, and the finish is matt grey.
MSRR 9040; OMat 7/22B; CoMat 07-038; MTU-MTS 1254
Air drying chemical & heat resistant coating in its own right, used as the touch up for process “B” Ipcote which has been bead peened to a bright silver finish.
Routinely tested to 100 hours@500°C; 100 hours in ester lubricant at 150°C, and skydrol for 3 hours at 70°C.
MSRR 9394; OMat 7/169A; ITP SMM-915
Recently re-formulated to be chrome free and easy application, air drying touch up for either Ipseal Green or Khaki. Will operate at temperatures up to 650°C. The khaki version can also be used as a touch up for Sermaseal 570A.
Full technical information is available for all the products discussed on this information sheet. Please contact our sales office for further information.
Approved to MSRR 9140 Apply in accordance with RPS 666/1
The first of a range of sacrificial aluminium coatings for high temperature and corrosion resistance. This coating when applied at film thickness of 50 microns (2 thou) give in excess of 3000 hours corrosion resistance in an ASTM.B117 salt spray cabinet. Alternative to Sermetal W & WFX IP9183
As Ipcote IP9183, but with reduced chrome content, less than 1% hexavalent chrome. All tests passed as IP9183. Alternative to Sermetal 1129. IP9182
Thin Film High Heat Resistant
Sacrificial Aluminium Coating
IP9356 to MSRR 9356 is similar to IP9183 Ipcote, but at film thickness of about half. This is of use in areas where tolerances are critical such as
Sprayed at thicknesses of 12-25 microns (1/2 to 1 thou, 1-2 coats) see Ipcote for further general information. Also used as a coating for part marking, it does not obliterate when thinly applied. Alternative to Sermetal 709, a product that appears to be used only by Rolls Royce, now being replaced by 762 & 962, and our LR168g
Approved to MSRR 9356. Apply for RPS 666/2 IP9356
New low temperature curing thin film coating with resistance to a 1000 hours salt spray with only 2 thou (12 microns) film thickness! Currently under review by several aero space manufacturers as an alternative to 962CR.LR168G
High Temperature Aluminium Silicon Ceramic Diffusion Coating
An exciting new product currently awaiting approval, formulated for higher temperature corrosion protection and excellent for oxidation and sulphidation protection in, for example, industrial gas turbines and nozzle guide veins. Also used for patch repairs (TSD 594). Alternative to Sermalloy J. IPAL IP1041
Also black and other colours please enquire for more details.
High Temperature Inorganic Sealing Compound IPSEAL is an inorganic protective coating used as a barrier over
All of the above are conductive, sacrificial coatings, and inherently porous. Ipseal seals this porosity without detracting from their sacrificial properties. It also creates an electrically non-conductive barrier coat. The use of Ipseal on top of these products results in a smoother, harder coating which provides a barrier against carbon deposits, etc extending the useful life of the base coat and a smoother finish which enhances airflow characteristics, and therefore engine efficiency. For use at temperatures up to 800ºC. Alternative to Sermaseal 570.
Approved to specification MSRR 9140, OMAT number 7/168B (under test to CPW 406)
Smooth eggshell finish in either Green or Khaki
Typical Film thickness 6 microns per coat (0.2 thou)
Operating temperature -40 to +800ºC, (14001F)
Less than 0.6% Hexavalent chrome
IP9184 - IPSEAL GREEN and KHAKI
Low chrome containing variant of IPSEAL IP9184. Approved to MSRR 9140 (also available in green or khaki) contains less than 1% chrome. IP9185
An exceedingly thin, clear, seal coat giving 3-4 microns thickness, and very smooth sealing to the range of Ipcote products. Dyed to show where it is being applied, the colour disappears at temperature leaving a very thin film barrier coating of very high finish. Less than 0.6% chrome.
Approved to MSRR 3010. Apply in accordance with RPS 666/5 IP9444 SMOOTHSEAL
To MSRR 9141, an air drying aluminium touch-up for Ipcote IP9183, Sermetal W, Ipthin IP9356 and other coatings to MSRR 9140 (OMAT 7/47). Matt in appearance, this material most closely matches Ipcote that is unpeened, and not burnished. For touching up Type A processed Ipote. PL177
High heat resistant aluminium coating, to MSRR 9040 and OMAT 7. A one part air drying, erosion resistant organic coating with resistance to heat, corrosion and aircraft fluids. For use on steel, aluminium and other metal parts, this product is routinely tested for 100 hours at 500ºC, 100 hours in ester lubricant at 150ºC and skydrol for 3 hours at 70ºC. For touching up Type B processed Ipcote.
Although often used as an air drying touch up for sacrificial products such as our IP9139, PL101, Sermetal W and our Ipcote, it is also used as an air drying high temperature product in its own right.
Being skydrol resistant, it is used for, amongst other things, undercarriage and wheel protection. IP9138
Olive air drying touch-up to 650°C for Ipseal - IP9184 (Khaki) to MSRR 9394 (OMAT 7/169A) also for sermaseal 570 PL270
Green air drying touch-up to 650°C for Ipseal Green To MSRR 9394 (OMT 7/169A) PL155
Olive 2 part epoxy airdrying touch up for IP9184 Khaki Ipseal up to 220°C for use at lower temperatures IP9064
Health & Safety |
Before use please request, our latest Health and Safety Data Sheet before using any of the above products. |
