Lab Services

Applications Development

To match coatings to the particular demands of specific applications. We develop new coatings and surface treatments from conception through to production. Collaborative R&D projects carried out working closely with customers to achieve their goals.

Coatings Development

Ensures Wallwork Cambridge remains at the leading edge of Surface Engineering with state of the art coatings to meet our customers’ needs.

New Process Development

New coatings often call for new processes, sometimes requiring equipment modifications or new equipment builds. Working closely with our Engineering/machine build department and Universities from around the world we have all the skills and experience we need to come up with the solution on an industrial scale.

R&D projects

• Short term R&D projects to deal with current issues, customer requests and enquiries.
• Future market opportunities requiring long term R&D projects.

Project Management

Good track record in leading the writing of successful project proposals winning grant funding and leading multi-partner collaborative R&D projects. For a list of research projects with industrial companies, research establishments/universities, please see the link below.

• Ambient Temperature Tensile Testing of metallic materials
  • Zwick/Roell Z250 tensile tester
    • UKAS 17025 accredited
    • Maximum load of 250kN
    • Fitted with noncontact laser extensometer
    • M8-M10 threaded specimen grips available
    • Various split collets specimen grips also available
    • Test standards included in accreditation – BS EN ISO 6892-1; EN 2002-1; ASTM E8/E8M
    • Limited to round samples only.
• Pendulum Impact Testing
  • Zwick/Roell HIT450P Impact testing machine
    • UKAS 17025 accredited
    • 250J machine
    • Round IZOD to BS 131:1961
    • Broaching of samples available
• Dimensional checks – Shadowgraph
  • Easson Profile projector (Shadowgraph)
  • UKAS Calibrated shadowgraph able to carry out length and radius measurements on samples.
  • Available magnifications x10 & x50

Carl Zeiss EVO MA25 scanning electron microscope

• Carl Zeiss EVO MA25 scanning electron microscope equipped with EDAX EDX system
• Analytical characterisation of materials/coatings (structure, thickness, defects, etc.);
• Acceleration voltage range: 0.2-30 kV;
• High brightness LaB₆source;
• Variable pressure (VP) mode (examination of non-conductive samples – no thin coating required to eliminate charging effects);
• Variable pressure range: 10-400 MPa;
• 3 detectors: SE (high vacuum mode), environmental SE (VP mode) and 5 segment backscattered BSD (high vacuum and VP modes) detectors;
• Spacious chamber to examine large and heavy samples (maximum specimen height: 210 mm, maximum specimen diameter: 300 mm, maximum specimen weight: 5 kg);
• Motorised 5 axes: X, Y, Z, rotation and tilt;
• Resolutions: 2 nm at 30 kV (SE); 4.5 nm at 30 kV (BSD in VP mode) and 15 nm at 1 kV (SE).
• Equipped with an EDAX X-ray dispersive energy (EDX) system for compositional analyses, elemental detection down to Beryllium.

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Mitutoyo 810-129E microhardness tester

• Measurement of Vickers or Knoop hardness (in both surface and cross-section to obtain hardness depth profiles);
• Wide load range: 0.5gf, 1gf, 2gf, 3gf, 4gf, 5gf, 10gf, 25gf, 50gf, 100gf, 200gf, 300gf, 500gf, 1Kgf and 2Kgf;
• 3 magnifications: 100X, 500X and 1000X;
• Minimum reading: 0.1 mm;
• Automatic load control.

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Fisherscope HM2000-XYP

• Instrumented indentation measurements (load-indentation depth method) and determination of various material intrinsic properties
• Ideal for measuring properties of metals, hard PVD and CVD coatings, electroplated coatings, paint or lacquer coatings, polymeric materials, anodic coatings.
• Vickers indenter, video microscope and programmable XY stage;
• Load range: 1-2000 mN;
• Maximum indentation depth: 150 mm;
• Maximum load or maximum penetration control.

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Anton Parr scratch tester

• Evaluation of coating/substrate adhesion (typical coating thickness of several microns);
• Evaluation of friction coefficient;
• Rockwell C diamond indenter (typically a 200mm radius indenter);
• Constant or progressive loads;
• Single or multipass options;
• Load range: 1-200 N;
• Acoustic emission detection;
• Detection of frictional force and penetration depth;
• Optical microscope with video camera.

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Zemetrics ZeScope 3D optical surface profilometer

• Surface profilometer using light interference;
• Non-contact, non-destructive surface measurements (nothing touches the surface when making surface measurements other than light);
• Three-dimensional surface measurements, including surface roughness, surface height and volumetric metrology;
• Ideal for applications such as tribology (wear of materials), corrosion (quantification of pits) evaluation of surface texture, ablation;
• Two objectives: 5X and 20X;
• Flexibility in sampled area due to motorised auxiliary magnification changer, which gives each objective 2x and 0.625x versatility;
• Large optical vertical travel (180 mm) for large samples;
• Large test volume for test materials, up to 500mm x 500mm x 180mm;
• RMS repeatability of surface accuracy : 0.01 nm;
• Stitching capability so high magnifications can be used to cover large test areas;
• Motorised X, Y, Z and tilt;
• Up to 1.3 million points of surface detail can be captured.

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CV Instruments TR-2000 Surface Roughness Tester

• Portable stylus surface roughness tester;
• Ideal for fast analysis and evaluation of component surfaces;
• Cut-off length: 0.25, 0.8 and 2.5 mm
• Range of R-values, including R_a, R_q, R_z, R_t, R_pand R_v.

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Oxford Instruments MAXXI 6 HDL X-ray fluorescence system

• X-rays are used to excite the specimen and generate X-ray fluorescence radiation that is characteristic for each element;
• Measurement of coating thickness and material analysis (chemical composition);
• Large adjustable measuring distance
• Flat, plane objects as well as larger specimens with complex shapes
• Programmable X-Y stage;
• Calibration standards required;
• Accurate thickness measurements when coating material is dissimilar to that of substrate.

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Ball Crater Equipment

• In-house ball crater equipment to measure coating thickness;
• A ball with known diameter is rotated against the specimen surface to produce a crater; measurements of crater geometry (inner and outer diameter) are used to determine the coating thickness;
• Destructive as a crater impression results from the test;
• Only flat, plane samples can be tested;
• Unlike XRF, coating material does not have to be dissimilar to that of the substrate (e.g. thickness of TiN coating on Ti alloy substrate can be accurately measured).

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High precision abrasive cut-off machine

Ensures successful initial sample preparation of coating cross-sections.

Wet abrasive sectioning;

Accurate, low deformation sectioning;

Minimal damage when sectioning thin coatings;

Range of thin cut-off abrasive wheels suitable for a particular material type;

Precision cutting of small parts and delicate materials such as thin, hard coatings;

Only small specimens can be sectioned;

1. A. Scerri, J. Buhagiar, S. Banfield, J.C. Avelar-Batista Wilson, J. Housden, A. Leyland, A. Matthews, G. Cassar. “Corrosion behaviour of triode plasma diffusion treated and PVD TiN-coated Ti–6Al–4V in acidified aqueous chloride environments”. Surface and Coatings Technology 280 (2015) 185-193. 2015Corrosion behaviour of triode plasma diffusion treated and PVD.pdf
2. J.C. Avelar-Batista Wilson, S. Wu, I. Gotman, J. Housden, E.Y. Gutmanas. “Duplex coatings with enhanced adhesion to Ti alloy substrate prepared by powder immersion nitriding and TiN/Ti multilayer deposition”. Materials Letters 157 (2015) 45-49. 2015Duplex coatings with enhanced adhesion to Ti alloy substrate prepared by powder immersion nitriding and TiN-Ti multilayer deposition.pdf
3. Danielle de Villiers, Alison Traynor, Simon N. Collins, Sarah Banfield, Jonathan Housden, Julia C. Shelton. “Chromium nitride coating for large diameter metal-on-polyethylene hip bearings under extreme adverse hip simulator conditions”. Wear 328-329 (2015) 363-368. 2015Chromium nitride coating for large diameter metal-on-polyethylene hip bearings under extreme adverse hip simulator conditions.pdf
   
4. T. Bonello, J.C. Avelar-Batista Wilson, J. Housden, E.Y. Gutmanas, I. Gotman, A. Matthews, A. Leyland, G. Cassar. “Evaluating the effects of PIRAC nitrogen-diffusion treatments on the mechanical performance of Ti–6Al–4V alloy”. Materials Science and Engineering A 619 (2014) 300-311. 2014Evaluating the effects of PIRAC nitrogen-diffusion treatments.pdf.
5. J.C. Avelar-Batista Wilson, S. Banfield, J. Housden, C. Olivero, P. Chapon. “On the response of Ti–6Al–4V and Ti–6Al–7Nb alloys to a Nitron-100 treatment”. Surface and Coatings Technology 260 (2014) 335-346. 2014On the response of Ti–6Al–4V and Ti–6Al–7Nb alloys to a Nitron-100 treatment.pdf.
6. Michelle C.S. Duarte, Cristina Godoy, J.C. Avelar-Batista Wilson. “Analysis of sliding wear tests of plasma processed AISI 316L steel”. Surface and Coatings Technology 260 (2014) 316-325 2014Analysis of sliding wear tests of plasma processed AISI 316L steel.pdf.
7. Ana P.A. Manfridini, Cristina Godoy, J.C. Avelar-Batista Wilson, Marcos V. Auad. “Surface hardening of IF steel by plasma nitriding: Effect of a shot peening pre-treatment”. Surface and Coatings Technology 260 (2014) 168-178. 2014Surface hardening of IF steel by plasma nitriding- Effect of a shot peening pre-treatment.pdf.
8. Y. Chen, X. Nie, A. Leyland, J. Housden, A. Matthews. “Substrate and bonding layer effects on performance of DLC and TiN biomedical coatings in Hank’s solution under cyclic impact-sliding loads”. Surface and Coatings Technology 237 (2013) 219-229. 2013Substrate and bonding layer effects on performance of DLC and TiN biomedical coatings in Hank’s solution under cyclic impact–sliding loads.pdf
9. A.Traynor, A Kinbrum, J. Housden, S. Collins. “Fretting and Corrosion of Tapered Head-Neck Junctions of Modular Hip Components”. Orthopaedic Proceedings, (2013) vol.95-B no. SUPP 34 270. Print ISSN: 135-992X, Online ISSN: 2049-4416. 
10. J.C. Avelar-Batista Wilson, S. Banfield, J. Eichler, A. Leyland, A. Matthews, J. Housden. “An investigation into the tribological performance of Physical Vapour Deposition (PVD) coatings on high thermal conductivity Cu-alloy substrates and the effect of an intermediate electroless Ni-P layer prior to PVD treatment”. Thin Solid Films 520 (2012) 2922-2931. 2012An investigation into the tribological performance of PVD coatings ….pdf
11. G. Cassar, J.C. Avelar-Batista Wilson, S. Banfield, J. Housden, A. Matthews, A. Leyland. “Surface modification of Ti-6Al-4V alloys using triode plasma oxidation treatments”. Surface and Coatings Technology 206 (2012) 4553-4561. 2012Surface modification of Ti-6Al-4V alloys using triode plasma oxidation treatments.pdf
12. G. Cassar, S. Banfield, J.C. Avelar-Batista Wilson, J. Housden, A. Matthews, A. Leyland. “Impact wear resistance of plasma diffusion treated and duplex treated/PVD-coated Ti-6Al-4V alloy. Surface and Coatings Technology 206 (2012) 2645-2654.2012Impact wear resistance of plasma diffusion treated and ….pdf
13. G. Cassar, S. Banfield, J.C. Avelar-Batista Wilson, J. Housden, A. Matthews, A. Leyland. “Micro-abrasion wear testing of triode plasma diffusion and duplex treated Ti-6Al-4V alloy”. Wear 274-275 (2012) 377-387. 2012Micro-abrasion wear testing of triode plasma diffusion ….pdf
14. F. Lu, M. Royle, F.V. Lali, A.J. Hart, S. Collins, J. Housden, J.C. Shelton, “Simple isolation method for the bulk isolation of wear particles from metal on metal bearing surfaces generated in a hip simulator test”. J Mater Sci: Mater Med. 23 (2012) 891-901.2012Lu et al 2012.pdf

PRIOR TO 2012

1. G. Cassar, J.C. Avelar-Batista Wilson, S. Banfield, J. Housden, M. Fenech, A. Matthews, A. Leyland. “Evaluating the effects of plasma diffusion processing and duplex diffusion/PVD-coating on the fatigue performance of Ti6Al4V alloy”. International Journal of Fatigue 33 (2011) 1313-1323.
2. G. Cassar, J.C. Avelar-Batista Wilson, S. Banfield, J. Housden, A. Matthews, A. Leyland. “A Study of the reciprocating-sliding wear performance of plasma surface treated titanium alloy”. Wear 269 (2010) 60-70.
3. L. Wang, D.O. Northwood, X. Nie, J. Housden, E. Spain, A. Leyland and A. Matthews. “Corrosion properties and contact resistance of TiN, TiAlN and CrN PVD coatings in simulated proton exchange membrane fuel cell environments”. Journal of Power Sources 195 (2010) 3814-3821.
4. A. de Frutos, M.A. Arenas, G.G. Fuentes, R.J. Rodrguez, R. Martnez, J.C. Avelar-Batista and J.J. de Damborenea. “Tribocorrosion behaviour of duplex surface treated AISI 304 stainless steel”. Surface and Coatings Technology 204 (2010) 1623-1630.
5. J.C. Avelar-Batista Wilson, S. Banfield, G. Cassar, A. Leyland, A. Matthews, P. Smith, B. Karadia, N. Vaghela, J. Housden. “Enabling lightweight, high load aero-bearings”. In: CEAS 2009 European Air and Space Conference, Manchester, United Kingdom, 26-29/10/2011. CD-ROM – Proceedings of CEAS 2009 European Air and Space Conference, 2009, pp.1-22.
6. C. Godoy, R.D. Mancosu, R.R. Machado, P.J. Modenesi, J.C. Avelar-Batista. “Which hardness (nano or macrohardness) should be evaluated in cavitation? Tribology International 42 (2009)1021-1028.
7. L. Wang, X. Nie, J. Housden, E. Spain, J.C. Jiang, E.I. Meletis, A. Leyland and A. Matthews.”Material transfer phenomena and failure mechanisms of a nanostructured CrAlN coating in laboratory wear tests and an industrial punch tool application”.Surface and Coatings Technology 203 (2008) 816-821.
8. J.C. Avelar-Batista, E. Spain, G.G. Fuentes, A. Sola, R. Rodriguez and J. Housden. “Triode plasma nitriding and PVD coating: A successful pre-treatment combination to improve the wear resistance of DLC coatings on Ti6Al4V alloy”. Surface and Coatings Technology 201 (2006) 4335-4340.
9. J.C. Avelar-Batista, E. Spain, M. Letch, J. Housden and R. Beechey. “Improvements on the wear resistance of high thermal conductivity Cu alloys using an electroless Ni-P coating prior to PVD deposition”. Surface and Coatings Technology 201 (2006) 4052-4057.
10. A. Conde, C. Navas, A.B. Cristbal, J. Housden and J. de Damborenea. “Characterisation of corrosion and wear behaviour of nanoscaled e-beam PVD CrN coatings”. Surface and Coatings Technology 201 (2006) 2690-2695.
11. G.G. Fuentes, M.J. Das de Cerio, R. Rodriguez, J.C. Avelar-Batista, E. Spain, J. Housden and Y. Qin. “Investigation on the sliding of aluminium thin foils against PVD-coated carbide forming-tools during micro-forming.” Journal of Materials Processing Technology 177 (2006) 644-648.
12. Godoy, R.D. Mancosu, M.M. Lima, D. Brando, J. Housden and J.C. Avelar-Batista. “Influence of plasma nitriding and PAPVD Cr_1-xN_xcoating on the cavitation erosion resistance of an AISI 1045 steel”. Surface and Coatings Technology 200 (2006) 5370-5378.
13. J.C. Avelar-Batista, E. Spain, J. Housden, A. Matthews and G.G. Fuentes. “Plasma nitriding of Ti6Al4V alloy and AISI M2 steel substrates using D.C. glow discharges under a triode configuration”. Surface and Coatings Technology 200 (2005) 1954-1961.
14. J.C. Avelar-Batista, E. Spain, J. Housden, G.G. Fuentes, R. Rodriguez, F. Montal, L.J. Carreras and T.J. Tate. “Effect of coating thickness and deposition methods on the stripping rate of Cr-N coatings”. Surface and Coatings Technology 200 (2005) 1842-1848.
15.  E. Spain, J.C. Avelar-Batista, M. Letch, J. Housden and B. Lerga. “Characterisation and applications of Cr-Al-N coatings”. Surface and Coatings Technology 200 (2005) 1507-1513.
16.   J.C. Avelar-Batista, E. Spain, J. Housden, G.G. Fuentes, R. Rebol, R. Rodriguez, F. Montal, L.J. Carreras and T.J. Tate. “Characterisation of pristine and recoated electron beam evaporation plasma-assisted physical vapour deposition Cr-N coatings on AISI M2 steel and WC-Co substrates”. Thin Solid Films 491 (2005) 177-183.
17. A.B. Cristbal, A. Conde, J. Housden, T.J. Tate, R. Rodrguez, F. Montala and J. de Damborenea. “Electrochemical stripping of hard ceramic chromium nitride coatings”. Thin Solid Films 484 (2005) 238-244.
18. G.G. Fuentes, R. Rodriguez, J.C. Avelar-Batista, J. Housden, F. Montal, L.J. Carreras, A.B. Cristbal, J.J. Damborenea and T.J Tate. “Recent advances in the chromium nitride PVD process for forming and machining surface protection”. Journal of Materials Processing Technology 167 (2005) 415-421.
19.   R. Rebol, A. Martinez, R. Rodriguez, G.G. Fuentes, E. Spain, N. Watson, J.C. Avelar-Batista, J. Housden, F. Montal, L.J. Carreras and T.J. Tate. “Microstructural and tribological investigations of CrN -coated, wet-stripped and recoated functional substrates used for cutting and forming tools”. Thin Solid Films 469-470 (2004) 466-471.
20. M. Bin-Sudin, A. Leyland, A.S. James, A. Matthews, J. Housden, B. Garside. “Substrate surface finish effects in duplex coatings of PAPVD TiN and CrN with electroless nickel-phosphorus interlayers”. Surface and Coatings Technology 81 (1996) 215-224.
21.  A. Wilson, A. Matthews, J. Housden, R. Turner and B. Garside. “A comparison of the wear and fatigue properties of plasma-assisted physical vapour deposition TiN, CrN and duplex coatings on Ti-6Al-4V”. Surface and Coatings Technology 62 (1993) 600-607.
22.  A. Leyland, M. Bin-Sudin, A.S. James, M.R. Kalantary, P.B. Wells, A. Matthews, J. Housden, B. Garside. “TiN and CrN PVD coatings on electroless nickel-coated steel substrates”. Surface and Coatings Technology 60 (1993) 474-479.

 PATENTS

Patent Schedule for Wallwork Cambridge Limited
Our Ref	Short Title	Country	Publication No	Status
330.00/T	TITANIUM NITRIDING PROCESS	United Kingdom		abandoned
809.05/T	PVD-Ag Biomedical Coatings	Australia		Pending
809.03/T	PVD-Ag Biomedical Coatings	Europe	2009/095705	Pending
809.00/T	PVD-Ag Biomedical Coatings	United Kingdom	2459081	Pending
809.04/T	PVD-Ag Biomedical Coatings	Japan	510725/2011	Pending
809.01/T	PVD-Ag Biomedical Coatings	USA	2009/0198343	Granted
809.02/T	PVD-Ag Biomedical Coatings	PCT	2009/095705	Pending Matured
810.03/T	Triode Plasma Oxidation	Europe	2262919	Pending
810.01/T	Triode Plasma Oxidation	USA	2009/0236014	Pending
810.02/T	Triode Plasma Oxidation	PCT	WO 2009/115830	Pending Matured

List of collaborative grant funded projects past and present

Collaborative projects

** Dr J. Housden project Leader.

1988-91: Brite RI.1B.0151C(H) (EU) Duplex coatings and plasma nitride on Titanium alloys.

1989-93: EuramMA1E 0079, (EU) Ion implantation of Ti alloys for surgical prostheses.

1988-91: BP + Hull University Development and characterisation of Multilayer coatings.

1989-92: IAC Harwell (DTI) – Ion assisted coatings including Diamond-Like-Carbon.

1994-96: CRAFT Project No. CR-1414-91 (EU) Coatings for Cold Forming.

1996-99: Innovation Project IN 10141D (EU) Trans-sectorial and Trans-Regional Implementation of Surface Engineering in European Industry.

1997: INFO2000 STM 5010 “SURFA” (EU) Multimedia Information service on Advanced Surface Engineering.

1996-99:** initiative “DEBCOAT” project. (DTI) Development of Electron Beam PVD coatings with improved composition control.

2000-01: CRAFT Project TOMAC BRST-CT98-5378 (EU) Cold Forming and Blanking Tools Manufacture for Optimal Coatings Performance.

2000-07: EUREKA E! 2307 “FUSECOAT” (DTI) A novel system for high-rate ultra hard coatings.

2001-04: GROWTH G1RD-CT-2000-00336 “COMING DRY” (EU) Organic matrix composites and Inconel alloys: Improvements in their machining under low coolant flows and dry conditions.

2003-08: EUREKA E! 2846 “AIMTECH” (DTI) Advanced Injection Moulding Technology.

2003-06:** EUREKA E! 2949 “CREST” (DTI) Coatings removal for environmental surface technology.

2005-09** EUREKA E! 3499 “DUBIOP (DTI) Duplex process for biocompatible prostheses.

2006-09:** Technology Programme, GCR&D “LIB-TEC” (DTI) Enabling lightweight high-load aero bearings.

2008-11** Technology Programme, GCR&D “SMART-HIP” (TSB) – Smart bioactive
nanocomposite coatings for enhanced hip prostheses.

2009-12** Technology Programme, GCR&D “SUSCOAT” – Coating Substitution for Reduced Environmental Impact.

2010-13 Matera+ “NEET” (EC/TSB) – Novel duplex processes to enhance compressor blade life and retain engine efficiency.

2011-2014 Technology Programme, CR&D “BERTI” – Biomedical implant with Exceptional Resistance to Tribo-bio-corrosion and with Inherent antimicrobial properties

2011-2014 EU Marie Curie Progamme, “ENTICE”