Funktionelle Oberflaechen

Poligrat: Creating Added Value.

Functional Surfaces

Functional Surfaces

Optimized surfaces improve the function and extend the useful life of products. The result is increased process reliability and reduced maintenance. This also improve the quality of the product as well as its profitability. POLIGRAT processes achieve in a single operation the combination of several functional qualities.

Unwanted scaling can impair both function and product quality. It increases energy consumption, reduces performance and encourages corrosion.

Added value through POLIGRAT processes

  • Prevention of scale formation thanks to the reduced levels of bacteria on the surface and low bonding force
  • Considerable improvement to the ease with which a residue-free suface can be achieved on crystalline, polymer and biological films and coatings

Typical applications

Heat exchangers, heating elements, equipment and machines for the pharmaceutical, chemical, food and drinks industries

The quality of functional or decorative coatings which have been applied galvanically, chemically (CVD) or physically (PVD) is largely determined by the characteristics of the substrate.

Added value through POLIGRAT processes

  • Surface texture micro-smooth and rounded
  • Undisturbed base structure
  • Metallic purity
  • Homogeneity
  • Firm adhesion of layers

Typical applications

Galvanized, hard chrome-plated or chemically nickel-plated machine parts, electrical contacts, cutting tools.

The compatibility and neutrality of metal surfaces with regard to tissue and cells are an essential requirement for the safe use of implants and biochemical processes.

Added value through POLIGRAT processes

  • Extremely pure, micro-smooth, passive surfaces
  • No emission of particles or heavy metals

Typical applications

Medical implants of all kinds, heart-lung machines, biochemical reactors and process plants

The fracture and failure of dynamically loaded parts is frequently a result of material fatigue. Over 90% of such fatigue fractures start on the surface. The most common causes are micro-cracks, internal stresses, structural failure and sharp-edged microstructures.

Added value through POLIGRAT processes

  • Maximum freedom from incipient cracks
  • Four to six times higher lifespan

Typical applications

Springs of all shapes and sizes, drive shafts and axles, turbine blades, surgical implants.

The undesirable emission of electrons under high tension or strong electromagnetic fields as well as the absorption and emission of electromagnetic radiation (thermal radiation) reduce quality and performance.

Added value through POLIGRAT processes

  • Micro-smooth profile
  • Avoidance of peak discharge
  • High reflectivity
  • Minimal absorption and emission of thermal radiation

Typical applications

High-tension components (X-ray tubes), high-performance electromagnets, thermal radiation shields (satellites), cryoengineering (low-temperature engineering).

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The conduction of high-frequency current takes place only over the thin surface layer of the conductor. Any defect within this layer such as micro-cracks, inclusions or structural failure will reduce the conductivity.

Added value through POLIGRAT processes

  • Freedom from micro-cracks and structural faults
  • Micro-smooth profile
  • Metallic purity
  • Optimal conductivity for high-frequency current

Typical applications

High-frequency technology, research and diagnostic installations.

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Corrosion occurs in a wide range of situations for a wide variety of reasons. It is usually an electrochemical process which requires moisture in the form of electrolytes and electric potential from local elements or external power. Passivated materials such as stainless steel, aluminium, titanium or zircon are protected by a resistant oxide layer (passive layer) on their surface against corrosion.

Added value through POLIGRAT processes

  • Ideal conditions for the formation of homogenous and durable passive layers
  • Optimal corrosion resistance
  • Largely free of local elements
  • Corrosion resistance of stainless steel is almost doubled

Typical applications

Processing plants for the chemical, pharmaceutical, food and drinks industries, processing plants for machinery and apparatus construction, medical instruments and implants, vehicle construction, architecture, mounting elements, sanitary engineering, domestic and kitchen appliances

Mechanical and thermal processing lead to contamination of the materials surface layer through tool friction, lubricants and coolants, oxides, buffing and polishing materials and the inclusion of gases.

Added value through POLIGRAT processes

  • Removal of contamination from the surface of the workpiece
  • No release of foreign substances, particles or heavy metals during operation

Typical applications

Medical technology, semiconductor technology, clean room creation, pharmaceutical industry, fine chemistry.

Passive surfaces are corrosion-resistant, do not have a catalytic effect and do not react with their environment. Chemical reactions take place homogenously and without interruption with optimal product quality; allergic reactions can be avoided.

Added value through POLIGRAT processes

  • Real size of the surface area reduced to a minimum
  • Low potential energy level
  • Few local impurities
  • Reactive inertness, homgeneity

Typical applications

Installations for plastics, food and drinks manufacture, surgical implants

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Reflections and emissions behaviour towards light and thermal radiation are determined by the degree of electrical conductivity and the metallic purity and smoothness of the surface.

Added value through POLIGRAT processes

  • Top values for reflection of light and thermal radiation
  • Metallic purity
  • Uninterrupted metalic structure
  • Optimal conductivity
  • Micro-smooth profile

Typical applications

Thermal solar panels, light reflectors, high and low temperature insulation.

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Friction and wear shorten the lifespan, increase energy consumption and cause breakdowns in manufacturing processes and during operation.

Added value through POLIGRAT processes

  • Micro-smooth profile
  • Energy-reduced potential energy
  • Reduced friction and wear

Typical applications

Friction bearings, textile machines, drawing tools, sealing gaskets.

Cleanability and sterilizability of surfaces are important requirements for applicability. They depend less on the roughness of the surface than on the enegetic and chemical state of the top layer of material.

Added value through POLIGRAT processes

  • Smooth, enclosed, rounded profile
  • Chemical and energetic reactive inertia and passivity
  • Accessibility of the entire surface for cleaning processes
  • Easy, residue-free cleaning

Typical applications

Plants for the pharmaceutical, chemical and food and drinks industry, façades, automobile parts, medical equipment, kitchen appliances, sanitary articles.

Pumping times required to reach a vacuum and to stabilize that vacuum are largely determined by the quality of the surface. The “degasing rate” is the determining factor as a key figure as to how much gas is emitted from a surface per unit of time. Over 90% of gases are bonded to the surface in a material layer which is approx. 30µm thick. The degasing is also dependent on the absolute size of the surface.

Added value through POLIGRAT processes

  • No gas-conducting surface layer
  • Minimized absolute expansion
  • Minimized absorption of gases
  • Minimizing of pumping times to reach a high ultra-high vacuum by 90%
  • Broad stability of the vacuum

Typical applications

Equipment for research institutes, electronic conduits.

Optimal soldering and welding joins require surfaces which are metallically pure and with homogenius edges.

Added value through POLIGRAT processes

  • Optimal conditions for diffusion and bridging of the gap in soldered joins as well as top-quality welded joins which are free from pores and cracks
  • High degree of firmness in soft-welded joins through the bridging of the gap

Typical applications

High-temperature, vacuum and hard soldering, electron beam and laser welding.


Decorative Surfaces

In design, the trend is moving towards real values.

BURR-FREE SURFACES

Depending on the process, burrs, flaking and particles on edges and surfaces can occur during production.