Technology
At Genio, we take pride in our approach, which combines exceptional coating formulations with advanced application methods, ensuring that our customers receive optimal and customized results tailored to their specific applications. Our Genio coatings have earned widespread use for various purposes, including prolonging equipment lifespan, minimizing downtimes, reducing overall ownership costs, and lowering production expenses.
We firmly believe that it’s not just about what we apply, but how we apply it! Our accumulated expertise spans over 60 years, enabling us to tackle the most demanding challenges with confidence and efficiency.
About MoS2/WS2 Based Coatings
Genio presents a cutting-edge range of solid lubricant coatings, featuring inorganic nanostructured materials like tungsten disulfide MoS2/WS2 with a fullerene-like structure. Our commitment to utilizing the most advanced technologies and materials enables us to create coatings that are perfectly tailored to our customers’ needs.Thanks to their specific atomic structure, our MoS2/WS2 based coatings exhibit exceptional resilience against high loads and impacts. They also demonstrate a remarkable reduction in friction, outperforming traditional platelet analogues like 2H MoS2 and 2H WS2 by up to 10 times.
These coatings are ideal for various applications in robotics, automotive, aerospace, agricultural, and medical industries. With Genio coatings, you can experience enhanced performance and efficiency, making your components and equipment stand out in their respective fields.
About IF-WS2
What Material is IF- WS2
Inorganic fullerene-like tungsten disulfide (IF-WS2) nanoparticles were first synthesized in 1992 by Tenne and all. These IF-WS2 nanoparticles are multi-layered, onion-like spheres. The IF-WS2 nanoparticles 20–200 nm big are constructed of multiple layers, which can be represented as a sandwich within the plane. The layers, which covalently bonded S–W–S moieties, are weakly connected by van der Waals forces. This unique structure provides the IF-WS2 nanoparticles with properties of a solid lubricant, which allow remarkable improvement of friction and wear properties under wet and dry conditions at different load levels. As the load between the bodies increases, IF-WS2 nanoparticles penetrate into the interface between rubbed surfaces, they gradually deform and exfoliate, leaving nano-plates of the sandwiched material to coat the asperities at the interface.
What is advantage of WS2 based Lubricants?
At “GENIO” we suggest a new generation of solid lubricant coatings, based on (IF-WS2. IF-WS2 and its composites, due to their specific atomic structure can withstand considerably high loads and temperatures compare to their platelet analogues. The distinctive spherical and cylindrical morphology of IF-WS2 particles allow them to roll between the sliding surfaces of any contacting parts by lowering friction between them up to 10 times in some applications. While standard additives offer moderate tribological properties, the spherical and cylindrical IF-WS2 composite particles are designed to have dozens of concentric layers so they excel under extreme pressure, load and impact. Decreased friction leads to reduced operating temperatures, metal wear, and overall cost of ownership. In addition it provides non-failure service of many important mechanisms under extreme conditions of exploitation.
What are Basic Technical Characteristics of the suggested Coatings?
The performance of each type of coating depends on several factors. In order to suggest best candidate coating, all-important factors affecting on coating performance under the given conditions of exploration should be discussed with customers. Substrate material also plays an important role for coating performance and for many applications could defines how solid lubricant will work. Some basic characteristics of IF-WS2 based composite coatings deposited on Stainless Steel (SS), High Speed Steel (HSS), Carbone Steel (CS), Al and Ti alloys are described in Table I. Maximum working temperature of the coatings depend on several factors and could be reach up to 800 OC or more for some application. The hardness and corrosion resistance of the surface could be controlled by combining classical surface modification techniques and solid lubricant coating.
Table I. Some Basic Characteristics of IF-WS2 Composite Coatings
|
Materials |
Coating Composition |
Thickness (μm) |
COF |
| SS / HSS/ CS/ Al / Ti | IF- WS2 | 0.05 - 0.1 | 0.01 - 0.1 |
|
SS / HSS/ CS/ Al / Ti |
IF- WS2 /Various form of carbon |
1.5 - 3.0 |
0.1 - 0.2 |
|
SS / HSS/ CS/ Al / Ti |
IF- WS2/ MoS2 |
1.0 – 1.5 |
0.05 - 0.15 |
|
SS / HSS/ CS/ Al / Ti |
IF- WS2/ Teflon | 1.0 – 3.0 | 0.1 - 0.15 |
Benefits and Capabilities of Our IF-WS2 based Coatings
[1] Low Friction Coatings
Some examples below are demonstrating the applications of our IF-WS2 based composite coatings as a friction reducing layer. Titanium and steel bolts, moving aluminum slides, ball bearings and brass door locks, as well as many other moving and sliding metallic parts are good candidates where our coatings could perform as a good candidate for providing low friction between the contacting surfaces.
[2] Soil Resistant Coatings
Some of our IF-WS2 / carbon composite coatings could serve as soil resistant protective layers by preventing polymers, carbides, sulphides, dust and other materials from adhering to the metallic parts..
[3] Wear Resistant Coatings
Some of our composite coatings recommend itself as a very good protective coating against wear for the following applications: threads of CNC Machines, forming dies and punches, drill bits and end mills, as well as various types of gears. For many applications the life of performing tools could be extended up to 10 times and more.
Typical applications for Genio coatings
Although it is hard to describe every possible application, however IF-WS2 have been successfully implemented on: Mold releases, Cutting tools (drill bids, inserts, saws etc.), Bearings, bushings, rollers, Threads, Fasteners, Gears, Chains, Pistons (automotive and non-automotive), Plungers etc.
About BN Coatings
At Genio, we take pride in offering a diverse range of proprietary Boron Nitride (BN) based coatings, uniquely blended with inorganic nanostructured fullerene-like tungsten disulfide MoS2/WS2. The combination of BN coatings’ renowned high-temperature resistance and chemical inertness with MoS2/WS2’s exceptional lubricity allows us to create custom coatings that possess the best of both worlds.
Our composite coatings exhibit unparalleled thermal and chemical stability, making them ideal for applications that demand reliability at elevated temperatures, withstanding up to an impressive 700°C. These coatings prove to be excellent candidates across various industries, including robotics, automotive, aerospace, agricultural, and medical sectors. Moreover, they find extensive use in processes such as casting, cutting, rolling, extruding, pressing, forming, and more.
With Genio’s innovative coatings, your equipment and components can thrive in demanding environments, delivering enhanced performance and extended operational life. Trust us to provide you with tailor-made solutions that elevate the efficiency and reliability of your applications to new heights.
Boron Nitride Coatings
Most dry film lubricants have lamella type structure and provide low friction thanks to low shear forces between their crystalline lattices. Boron Nitride (BN), Tungsten Disulfide (WS2), and Graphite are typical representative of such lubricants. The coatings and lubricants based on those materials have very low coefficient of friction, remarkably durable and can withstand high loads in many applications. For many applications only 0.5-1 microns thick, those coatings can be applied to high-precision parts without tolerance problems.
Boron Nitride occupies a unique place among dry lubricants because of its unusual physical, thermal and dielectric properties. BN coatings are especially valuable for high temperature applications because it operates as very good lubricant up to 850 C in oxidizing atmospheres; up to 1372 C in reducing atmospheres and up 3000 C in a vacuum. Typical friction coefficients of HBN in air are 0.15 to 0.2 up to about 700-800°C. Some other important properties of BN coatings include:
[1] Resistance to high temperature corrosion/oxidation
[2] Non-wettable by most molten metals, salts, fluxes and slags
[3] Anti galling and soil resistant properties
[4] Anti-stick barriers during hot pressing operations
BN coating deposited at Genio can be used independently or in continuous matrix of binder to achieve the desired results such as high load bearing, chemical and corrosion resistance, abrasion resistance or high temperature applications. Boron Nitride coating can be applied to refractories, metals, glass, composites and other materials requiring non-wetting, lubricating or refractory protection.
At Genio BN based coatings can be custom formulated by mixing it with IF-WS2 lubricant or various types of polymers to improve it lubricity and maximize cost-efficiency and workability for casting, cutting, rolling, extruding, pressing, forming and other operations. BN has high thermal and chemical stability, while IF –WS2 provides excellent lubricity and this composite coating operates well up to 700°C for many applications.
Some basic technical characteristics of BN and BN/IF-WS2 composite coatings are described in table I.
Table I. Some Basic Characteristics of BN Coatings
Deposition temperature [0- 100oC], maximum working temperature 850oC, hardness could be varied in big range by using different ceramic sublayers.
| Materials | Coating Composition | Thickness (μm) | COF |
| SS / HSS/ CS/ Al / Ti | BN | 0.1 - 0.15 | 0.2 - 0.3 |
| SS / HSS/ CS/ Al / Ti | BN / IF- WS2 | 1.5 - 3.0 | 0.1 - 0.15 |
| SS / HSS/ CS/ Al / Ti | BN / Teflon | 1.5 – 3.0 | 0.15- 0.2 |
About Carbon Based Coatings
At Genio, we take great pride in offering a diverse array of custom-formulated carbon-based coatings. The growing interest in carbon coatings over the last few decades has been driven by their remarkable properties, making them highly sought-after in various industrial applications. Notably, Graphite, Graphene, Diamond-Like Carbon, and other forms of carbon coatings have been extensively developed, varying in carbon crystalline structure and sp3-to-sp2 bonding ratio.
Our team of skilled engineers at “Genio” has ingeniously combined the unique physical, mechanical, and tribological characteristics of carbon with those of MoS2/WS2 and other solid materials, giving rise to a new generation of coatings. These coatings have been meticulously designed to meet the most demanding specifications across a wide range of industries, including chemical, food and packaging, compressors and pumps, automotive (for components like piston rings, camshafts, gears), biomedical applications (such as surgical instruments), and aerospace, among others.
Through our innovative carbon-based coatings, we empower our customers with enhanced performance, increased reliability, and extended lifespan for their critical components. Rest assured that with Genio coatings, you can achieve excellence and efficiency in even the most challenging industrial applications.
About Graphite Coatings
Graphite is another example of lamellar solid lubricant that provides low friction and high wear resistance to sliding surfaces. Because of its good lubricity and low cost, it is used in many industrial applications. Graphite has a layered structure where strongly bonded carbon atoms lie in a plane and the planes are bonded weakly to each other. In moist air, the friction coefficient of graphite varies from 0.07 to 0.15, depending on test conditions. In dry air, inert atmospheres, or vacuum, graphite’s lubricity degrades rapidly, the friction coefficient increases to as high as 0.5, and it wears out quickly. It is well known that the lubricity of graphite is not due to its layered crystal structure alone but depends strongly on the presence of certain condensable vapors and even a small amount of condensable vapor considerably improves the lubricity of graphite.
Graphite can provide lubrication up to about 500°C in open air, although friction tends to increase as the temperature rises. At higher ambient temperatures, it begins to oxidize and lose its lubricity. In vacuum, the friction coefficient is initially high (i.e., 0.4), but decreases to about 0.2 at 1300°C. Graphite is inexpensive and readily available in various forms. It is resistant to both acids and bases.
At Genio we suggest several graphite based coatings that provides excellent lubricity to many metallic and non-metallic parts. It provides also excellent corrosion protection and wear resistance to the surfaces as well as improves thermal barrier, anti-sticking, anti-galling, mold release and more properties of the contacting surfaces. Some basic characteristics of Graphite based coating is shown in Table I
Table I. Some Basic Characteristics of Graphite Coatings
Deposition temperature [0- 100oC], maximum working temperature 500oC, hardness could be varied in big range by using different ceramic sublayers.
|
Materials |
Coating Composition |
Thickness (μm) |
COF |
|
SS / HSS/ CS/ Al / Ti |
Graphite |
1.5 - 2.0 |
0.0.7 - 0.15 |
|
SS / HSS/ CS/ Al / Ti |
Graphite / IF- WS2 |
0.5 -1.5 |
0.01 - 0.15 |
|
SS / HSS/ CS/ Al / Ti |
Graphite / Teflon |
1.5 – 3.0 |
0.1- 0.15 |
About Graphene Coating
Graphene has received significant attention due to its combination of remarkable mechanical, thermal, chemical and electrical properties. Furthermore, due to its superior strength, graphene has great potential for use as an ultra-thin protective coating for various precision components. It is shown that various graphene coatings can be successfully used to decrease friction and wear in nano-, micro- and macro-mechanical applications. However, the conditions under which graphene serve as an effective protective coating depends on several factors and our coating engineers are ready to assist customers to find best candidate coating for their applications.
Graphene can provide lubrication up to about 650°C in open air and it thermally stable in inert atmosphere up to 2000°C. In oxygen containing atmosphere graphene is ignite and burn starting at about 700°C. In opposite to graphite, the lubricity of graphene does not affected much by presence of moisture or condensable vapors and graphene still excellent lubricant under dry air or vacuum. Depending on test conditions the friction coefficient of graphene varies from 0.001 to 0.15. In addition to outstanding friction behavior graphene coatings demonstrate also excellent wear resistant properties. The key factors that were found to influence the friction and wear behaviors of graphene were number of layers, deposition method, and substrate material. Despite the ultra-thin nature of graphene sheets, they were effective in reducing the friction and wear not only under micro-scale contact loads but also in relatively high loads. It was shown that friction of graphene coatings are decreasing when the numbers of layers are increasing. Overall in recent studies, graphene was shown to be very effective for friction and wear reduction not only as a lubricant but also as an additive to oils, composite materials and solvents.
At Genio we suggest several graphene based coatings that provide excellent lubricity to many metallic and non-metallic surfaces. Those innovative coatings provide excellent lubricity along with corrosion and wear resistance. Some basic characteristics of Graphene based coatings is shown in Table II
Table II. Some Basic Characteristics of Graphene Based Coatings
Deposition temperature [0- 100oC], maximum working temperature 650oC in air and up to 2000 oC in inert atmosphere, hardness could be varied in big range by using different coating sublayers.
|
Materials |
Coating Composition |
Thickness (μm) |
COF |
|
SS / HSS/ CS/ Al / Ti |
Graphene |
0.01 - 0.05 |
0.01 - 0.05 |
|
SS / HSS/ CS/ Al / Ti |
Graphene / IF- WS2 |
0.01 - 0.5 |
0.01 - 0.05 |
|
SS / HSS/ CS/ Al / Ti |
Graphene / Teflon |
0.5 – 1.5 |
0.05- 0.1 |
What are Basic Technical Characteristics of the suggested Coatings?
The performance of each type of coating hinges on several critical factors. To select the optimal solution for a specific application, a comprehensive understanding of all variables and performance indices is essential. It is widely acknowledged that certain coatings excel in particular environments, operating within specific temperature and humidity ranges, while others may falter even with seemingly superior characteristics. Additionally, the substrate material significantly influences the coating’s performance and, in numerous applications, defines how effectively the solid lubricant will function.
In Table 1, we outline the fundamental characteristics of MoS2/WS2 based coatings deposited on various substrates, including Stainless Steel (SS), High-Speed Steel (HSS), Carbon Steel (CS), Aluminum, and Titanium alloys. The maximum working temperature of these coatings varies based on multiple factors and can reach up to an impressive 1472°F (800°C) for certain applications.
By carefully considering these factors and selecting the most suitable combination of coatings and substrates, we ensure that our customers receive the optimal performance and longevity from our solid lubricant solutions across a diverse range of applications.
Materials | Coating Composition | Thickness (μm) | COF |
|---|---|---|---|
SS / HSS/ CS/ Al / Ti | MoS2/WS2 | 0.05 – 0.1 | 0.01 – 0.1 |
SS / HSS/ CS/ Al / Ti | MoS2/WS2/Various form of carbon | 1.5 – 3.0 | 0.1 – 0.2 |
SS / HSS/ CS/ Al / Ti | MoS2/WS2 | 1.0 – 1.5 | 0.05 – 0.15 |
SS / HSS/ CS/ Al / Ti | MoS2/WS2/ Teflon | 1.0 – 3.0 | 0.1 – 0.15 |