Overview of the Surface Treatment Sector During the Covid-19 Period

As the Covid-19 pandemic significantly affects both the manufacturing sector and our daily lives, this article examines surface treatment technologies with a view to understanding expectations, demands, the impact on manufacturing and surface technologies, what awaits us, and new surface technology developments.

The importance of surface treatment

Various surface technologies applied to metals and other material groups exist (surface preparation pre-treatments, surface treatments, surface hardening treatments, surface modification, surface coatings, post-coating treatments), and are generally referred to as surface treatments in industry. Surface treatments applied to metallic alloys are mainly used to protect metallic workpieces from the adverse effects of external environmental conditions, extend component service life, enhance working performance, impart new functional and aesthetic properties to surfaces, repair damaged, impacted and scratched surfaces and bring them into tolerance, improve properties for paints and other adhesive pre-treatment, and obtain new surface textures. Each method and application has different technological characteristics and advantages and disadvantages relative to one another, and material selection and testing capability are highly important issues. The surface treatment sector is a rapidly developing and expanding sector, and in our country there are numerous applications ranging from automotive to aerospace, from iron and steel industry to the aluminium sector, from textiles to the food sector, from energy to agricultural equipment, to the medical sector and household and hand tools. Worldwide and in our country, many researchers and research groups in our universities, public research institutions, and R&D centres are conducting R&D work and projects targeting surface technologies. Bringing together many companies, subcontractors, suppliers, applicators and distributors operating in surface treatment both domestically and internationally, and bringing them together on a common platform, an important step has been taken for the development of the sector, resulting in the establishment of the Association of All Surface Treatments (TÜYİDER).

Sectoral expectations

Developments in system equipment, advances in chemical solutions and coating materials, as well as increases in process control and testing capability, serve as driving forces in the rapid development of surface technologies. The intensification of working conditions (corrosive, abrasive, high temperature, mechanical loads, biological and chemical effects, etc.) brings with it the need to increase surface durability and properties. This situation reveals the necessity to produce and develop alternative methods and coating materials to traditional applications, create test reports, and increases inclination towards new technology methods, high-efficiency and high-performance applications. Various surface treatment technologies exist depending on the properties of the substrate (polymer, metal, glass, ceramic or composite surfaces), the application purpose, component geometry, quantity of components and expected performance from the coating, and continuous development and improvement activities are carried out on a sectoral basis. The process of development and implementation of new applications do not occur at the same pace. Both economic conditions, sectoral expectations, environmental factors, costs, as well as technical and physical constraints and specific sectoral and international standards play an important role in the entry of new technologies into the sector.

As a result of intense competition in the global market, every new technology requires numerous tests and approvals, reliability analyses, feasibility studies and standardization work in its journey into our lives.

Perhaps the most accurate term for a surface treatment is repeatable, sustainable quality standards. It is important for both manufacturer and user satisfaction that metallic parts passing through many processes from surface pre-preparation to the end of the post-coating process have the same quality characteristics. A good control, monitoring, tracking and testing system must be established for reproducible performance.   [caption id="attachment_103674" align="aligncenter"] Robotic, intelligent, digital manufacturing facilities[/caption]   Today's automation and digitalization processes enable transition to production that is more controlled and dependent on fewer personnel, with the aid of various sensors and measurement systems in monitoring stages, approval and rejection processes.

This process enables achieving highly precise, homogeneous surface treatments and production capability with efficient, faster processing, more economical and environmentally friendly surface treatments. Core objectives in automation and digitalization:

• Increase in the effectiveness and efficiency of manufacturing processes. • Improvement of ergonomics and occupational safety in production. • Product lifecycle optimization through quality and condition monitoring. • Optimization of product quality. • Environmental impact control, monitoring and process efficiency optimization. • Optimization of process costs. Digitalization and surface treatment have begun a new technological transformation starting with Industry 3 (robots and PLCs) and progressing with Industry 4 (Internet of Things, systems communicating with each other, artificial intelligence, big-data analysis). Both the development and rapid proliferation of additive manufacturing (3D metal printers) technology, as well as new and changing metal production technologies, changing surface qualities, point to the necessity of transformation and change in surface treatments and application methods. The most appropriate questions to ask at this point are: How prepared are we for this process? What will we encounter in this process? What is the cost of transition to this process? How will we adapt to this process, what investment planning should be made for this process, is our personnel competency suitable for this process? Despite containing such uncertainties, the process is advancing rapidly.

New surface textures:

The change in coating methods is trending towards thinner coating thicknesses, faster coating processes, faster and more effective pre-treatments and high-performance surface treatments. Attempts are being made to achieve higher coating performance with less coating thickness, and self-healing and self-cleaning coatings and surfaces are emerging. Additionally, it is anticipated that greater use will be made in the future of high-energy UV, ultrasonic sound, laser, plasma and electron beam sources together with controlled atmosphere and vacuum technologies. Besides this, standards will develop in surface texture, roughness and morphology. For example, there will be significant developments in isotropic surface finishing treatments, surface textures that reduce adhesion and sticking, and reduce friction on surfaces, and in surface architecture and surface textures. [caption id="attachment_103677" align="aligncenter"] Applications modifying surface chemical properties[/caption]

Developments in the surface treatment sector:

The chemical surface treatment market was valued at USD 10.62 billion in 2016 and is expected to reach USD 14.74 billion by 2022. The market's growth rate during the 2017-2022 period has been projected at 5.7% (MarketsandMarkets Report). The Covid-19 virus in the global market has affected the entire world, during which period a forced stagnation and decline have been observed in both the metal sector and the manufacturing sector. It is stated that 50-80% of world manufacturing sector producers will be negatively affected by the pandemic process (PWC Reports). This process will also cause increases in different demands regarding surfaces. In particular, the use of hydrophobic coatings, antiviral and antibacterial coatings (CoatingsWorld) along with precise and effective surface cleaning chemicals and efficient surface activation and cleaning methods (such as UV, plasma, laser beams) will rapidly accelerate. [caption id="attachment_103678" align="aligncenter"] Surface treatments for different material surface textures[/caption]

New surfaces in daily life

In the transfer of various intermediate materials and products between countries (particularly in logistics transport), stricter surface control systems, test and standardization work will be initiated. This process will inevitably lead to increased demand for new surface treatment and technologies, and the establishment of stricter control mechanisms. Moreover, all materials and surfaces used in public transport vehicles, buildings, household and hand tools, kitchen equipment and medical systems that we frequently use in our daily lives will require more effective cleaning, superior performance surface treatment and coating solutions. [caption id="attachment_103679" align="aligncenter"] Cleaning procedures and methods for public transport vehicles[/caption]

Antimicrobial surfaces: The antimicrobial coating market is estimated to have a growth rate of 12.1% from 2016 to 2021, and the market value is expected to reach USD 4.2 billion by 2021 (MarketsandMarkets). It is thought that this value will approach USD 6 billion by 2026.

It is anticipated that such coatings and surface solutions will be applied to doors, glass panels, walls, ventilation systems and workbenches in our work and daily life areas.

In addition, antimicrobial solutions, formulations, aerosols and coatings will be applied to masks, textile products and wood surfaces, gloves and floors. Increasing demand for high-quality coatings with rapid reaction times against a wide variety of pathogens will also increase antimicrobial coating market demand (gminsights). [caption id="attachment_103680" align="aligncenter"] Measures against viruses on metallic surfaces[/caption] Nanotechnology and surfaces: Literature research shows that nanoparticles of various metals and metal oxides such as zinc oxide nanoparticles (ZnONP), copper oxide nanoparticles (CuONPs), silver nanoparticles (AgNPs), nanoscale copper (I) iodide particles (CuINPs) are used for antibacterial purposes. In addition to this, gold nanoparticles on silica nanoparticles (Au-SiO2NPs) and also certain quaternary ammonium cations commonly called QUATs are described as promising in inactivating viruses (CoatingsWorld). As will be seen, nanotechnology coatings will rapidly enter our lives and applications, and intensive work will be launched on new nanotechnology coating compositions and coating systems in this scope. [caption id="attachment_103681" align="aligncenter"] Surface cleaning capability with nanotechnology[/caption]

Clean surfaces: Another important question is how long such viruses and bacteria will remain on surfaces and how frequently they need to be cleaned. Comprehensive work needs to be conducted on answering this question as well.

Research conducted on different viruses (such as SARS-Cov-2) has determined that on plastic product surfaces (3-7 days), on stainless steel (3-7 days), on copper (4 hours), on glass (4 days), on wood (2 days) (healthline). This example given for the purposes of presenting an approach tells us the following. In particular, the increase in demand, production and use of antibacterial metal materials such as zinc and copper will signal increased requirements for surface treatments to be applied to such metals in the future. Both surface cleaning treatments, surface chemicals and coatings will play a more important role in the future. [caption id="attachment_103682" align="aligncenter"] Effective surface cleaning chemicals[/caption]   Smartphones and tablets that we never part with in our daily lives have glass and body materials that are mostly polymeric in nature. At this point, new surface cleaning methods and special coating solutions for touchscreen glass will be needed.

The telecommunications sector will also create new demands in this regard. According to data, it is anticipated that such structures can remain on surfaces for up to 96 hours.

[caption id="attachment_103683" align="aligncenter"] Intelligent self-cleaning coatings on touchscreens[/caption]   Another important point that stands out during this pandemic period is that sterilization, surface cleaning and resistance of surgical instruments and equipment used in hospitals, care homes, operating rooms and medical operations against hospital microbes and reduction of harmful effects will increase interest in new coatings and surface treatments (Medicaldevicedirectory). Similar demands apply to surfaces in contact with food. New surface solutions will increase for all equipment used from shelves in stores to packaging systems, cold storage warehouses, cold chain transport, baby diapers, and packaging systems used in the cosmetics sector. [caption id="attachment_103684" align="aligncenter"] Surface solutions for surgical instruments and equipment[/caption]  

Surface sterilization

The term social distancing has rapidly entered and become established in our daily lives, and this process actually carries the risk of people in open and closed spaces moving very quickly transmitting viruses to each other if precautions are not taken. In this process, there will be increased need for cabins and tunnel systems when moving from one area to another. This process will increase the use of intensive cleaning and sterilization chemicals as seen below. [caption id="attachment_103685" align="aligncenter"] Surface sterilization tunnels, cabins[/caption]

Surface control

This raises the question of how surface sterilization, cleaning and antibacterial effect will be analysed, tested and controlled. Examinations under advanced microscopes will be conducted with statistical data analyses using advanced software. For all of us, the structure, morphology, size (~150nm), number, proportion and biological properties of this and all other possible viruses and bacteria will guide both vaccine development and the development of effective surface sterilization chemicals and surface treatments. Surface engineering will play an important role in this. [caption id="attachment_103686" align="aligncenter"] Covid-19 analysis in electron microscopy[/caption]

Intelligent surfaces and surface treatments:

As a result, it will be understood and seen that surface treatment technologies have the technological potential to adapt most rapidly in the face of changing manufacturing, daily life and new conditions. In the face of increasing demands, changing surfaces and surface treatments, the solution capability of both the sector and the academic world is quite high. Intelligent systems, intelligent factories and facilities, intelligent coatings, more effective surface treatments and surface treatment chemicals will await all of us in the near future. As TÜYİDER management board and scientific board, we will review our strategies during this period, and will conduct R&D, testing and training activities by increasing both the sector's technological capabilities and human resource competency and in the context of adaptation to new technologies. The cooperation protocol signed between Sakarya University of Applied Sciences Materials and Manufacturing Technologies Research and Application Centre (SUMAR) and TÜYİDER will conduct collaborations in testing, analysis and characterization activities for sectoral needs during this period, in engineering, surface and coating solutions, in increasing qualified researchers and human resources, in technology transfer, applied training and standardization work, and in joint R&D projects. [caption id="attachment_103687" align="aligncenter"] Intelligent manufacturing, surface treatment facilities[/caption]     Dr. Ekrem Altuncu European Thermal Spray Association - ETSA Sakarya University - Thermal Spray Technologies Research Application Laboratory - TESLAB Sakarya University of Applied Sciences - Materials and Manufacturing Technologies Research Application Centre - SUMAR Association of All Surface Treatments (TÜYİDER)