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Sulzer Metco Diamond-Like Coatings for Plastic

Molding

6000 North Bailey Avenue Suite 9 Amherst, NY 14226 Phone: 716-270-2228 Fax: 716-270-2230

Sulzer Metco

| slide 1

DLC vs Other Surface Treatments

Dylyn®/DLC Dylyn®

Cavidur® B4C Chrome Nickel Teflon WCC

DLN N * * * *

NAME

DIAMOND

LIKE

COATING

DIAMOND LIKE

NANOCOMPOSITE

COATING

TITANIUM

NITRIDE

Diamond

Black

Electroplated

CHROME

Electroless

Nickel

Teflon®

Composite

Tungsten

Carbide

Carbon

MICROHARDNESS

(GPa)25 18 30 23 35 8 - 12 4 - 8 10 - 12

ROCKWELL C 85 78 90 80 95 64 - 70 40 - 60 66 - 70

COEFFICIENT OF

FRICTION AGAINST

STEEL (DRY)

0.12 0.07 0.1 0.4 - 0.5 0.4 - 0.5 0.2 - 0.4 0.1 - 0.3 0.2 - 0.3

COATING

THICKNESS (µM)1 - 4 1 - 4 2 - 4 1 - 4 1 - 4 Up to 50 5 - 50 2 - 4

570 °F 750 °F 840 °F 1000 °F 1800 °F 600 °F 750 °F 570 °F

300 °C 400 °C 450 °C 600 °C 980 °C 325 °C 400 °C 300 °C

350 - 430 °F 350 - 430 °F 480 - 660 °F 500 - 950 °F 500 - 950 °F 120 - 175 °F 120 - 175 °F 440 - 480 °F

180 - 220 °C 180 - 220 °C 250 - 350 °C 260 - 500 °C 260 - 500 °C 50 - 80 °C 50 - 80 °C 225 - 250 °C

1 - 5 5 - 10 1 - 5 250 41

+++ +++ +++ ++ ++ + + ++

SURFACE ENERGY

(mN/m)40 - 50 20 - 40 40 - 50 40 - 42 20 - 30 46 - 53

COATING METHOD PACVD PACVDPVD /

PACVDPVD PVD

Galvanic

Plating

Electroless

PlatingPVD

Properties of Other Surface Properties of DLC CoatingsTiN

COATING

TEMPERATURE

MAX. WORKING

TEMPERATURE

COATING

MATERIAL

WEAR FACTOR

(x 10-8 mm3/Nm)

* Not a Sulzer Product listed for comparison purposes only.

Sulzer Metco

| slide 2

Traditional Methods of Surface Treatment

Dicronite® Dry Lube • deposition of 0.000020 inch (0.5 microns) “maximum”

• Not a line-of-sight process

• only corrosion hindering

• Composition - modified (WS2) Tungsten Disulfide in lamellar form.

• Hardness - 1.0 - 1.5 Moh’s scale.

• Co-efficient of Friction - 0.030 inclined plane method, against itself.

Electrolysis Nickel Teflon Composite • Excellent Lubricity (20 - 25% Teflon in deposit)

• Excellent release properties

• Lowest coefficient of friction

• Hardness: 62 Rc

• Weak adhesion to the surface

Chrome Plating • Finishing necessary on wear parts to eliminate chrome

nodules.

• For optimized frictional and lubricating properties surface

finish must be taken below 15 micro inches Rp

• Hardness: 68 Rc

• Edge build up a problem

400 X

Sulzer Metco

| slide 3

DLC Coatings

Hard amorphous carbon thin film

very hard

electrically insulating

wear resistant

Comprises C, H

Carbon in sp3 bonding => "Diamond-like" properties

There are a few variants of DLC coatings

Engineered interface layer for low film stress

a-C:H

DLC

a- C:H; a- Si:O

Hard amorphous carbon thin film

very hard

electrically insulating

wear resistant

lower friction

low film stress

Comprises C, H, Si, O

a-C:H ~ "Diamond-like" properties

a-Si:O ~ enhances high temperature stability

Dylyn® is a family of coatings

Low intrinsic stress

This is a Sulzer exclusive coating - Several US patents issued

Dylyn®

Sulzer Metco

| slide 4

ABRASION:

The high hardness of Diamond-Like Coatings reduce the likelihood of hard particle penetration into the tool or part.

Coatings Reduce Abrasive Wear

TOOL

PART

Hardness Comparison Hard Particle Soft

DLC Hard

8000

DLC Dylyn®

TiN CrN 52100

4000

5000

6000

7000

Vic

ke

rs (

HV

)

2000

0

Metal Carbon

1000

Hard Chrome

Nickel TeflonDiamond

Cavidur® N

3000

Sulzer Metco

| slide 5

Coatings Reduce Friction / Material Pickup

RESISTANCE TO ADHESION:

The chemically inert characteristics of diamond-like coatings dramatically reduce possibility of cold welding and material pickup on the surface of the tool

TOOL

PART

τ1

τ2

F=τ x A

τ1 > τ2

0.8

PTFE DLC TiN 52100

Dylyn®

CrN

0

Cavidur® N

Diamond Metal Carbon

Hard Chrome

0.1

Nickel Teflon

Co

eff

icie

nt

of

Fri

cti

on

0.7

0.6

0.5

0.4

0.3

0.2

Sulzer Metco

| slide 6

Surface Engery & Wetting Behavior of Different Coatings

lubricant fluid drop

with constant volume,

here water

wetting angle

of contact

fluid spreads

over the surface

TiAlN

TiN

Metal

Carbide DLC

Dylyn®

Better Wetting Behavior

Better Release Behavior

Close-up of a series of

liquid droplets on a

Dylyn® sample

•Surface energy is a

measure of the

affinity of a

substance to stick to

the material.

•The lower the value,

the less likely a

material will weld or

stick to a surface.

•PFTE has a surface

energy of 18 mN/m 20 - 40 40 - 42 42 - 46 46 - 53

Surface Energy (mN/m)

Sulzer Metco

| slide 7

DLC

TOOL PART

Corrosive Attack

Corrosion Test

Dylyn®

ASTM B 117-97 Salt Spray Test

The high density and

amorphous structure of

Diamond-Like Coatings

inhibit the corrosive by-

products from

penetrating into the

tool. TiN

Sulzer Metco

| slide 8

Plasma Assisted Chemical Vapor Deposition Process

Equipment designed & constructed by Sulzer Metco

Plasma Assisted Chemical Vapor Deposition (PACVD)

process

In-situ substrate cleaning via plasma etching

Substrate temperature does not exceed 220°C

Maximum part dimensions must fit within a 32” diagonal,

be less than 12” in height and weigh less than 100Kg

Sulzer Deposition System

Vacuum Pump

Reactive Plasma

Plasma Generator

Gas Supply such as CH4

Substrates

Sulzer Metco

| slide 9

Coating Penetration in Close Spaces

PACVD coating process is non-line of sight

Shadowing occurs in holes or thin slots

During the process there is a relative gas ion density.

As the gas ions travels into the restricted pathway; the charged part walls attracts the oppositely charged gas ions forming the coating.

As the gas ions go deeper into the restricted pathway, there are less available until no coating is formed.

This reduction of coating is called Shadowing and the coating forms only as deep as the width of the opening of the restricted pathway.

+

(-)

X

X

Taper

DLC Coating

+

+

+

+

+

+ + + +

+ +

+

+

+ +

+ +

+

+ + +

+ + + + + + + +

+

+ + +

+

+

+ + +

+

+ +

+ + + +

+ +

+ + + + + + +

+ +

+ +

+

+

Sulzer Metco

| slide 10

Sulzer uses an Reactive Ion Etching process to decoat diamond-like and other carbon based coating types

Stripped finish on 8620 steel typically changes about 1 to 2 Ra

This process can be used on titanium, beryllium copper and aluminum parts in addition to steels and ceramics

Stripped Masked Steel Sample

Sulzer Stripping Process

2 Ra As Coated

3 Ra

2.5 Ra

Stripped

Near Edge

Away from edge

Note: Chrome plated parts and small geometries may not be advisable to strip.

Sulzer Metco

| slide 11

Standard Coating

Multi-Layer Coating

Ti or Dylyn® Adhesion Layer

Dylyn®, Me-Dylyn® or DLC

Substrate

Substrate

Dylyn®, Me-Dylyn® or DLC

Dylyn®, Me-Dylyn® or DLC

Ti or Dylyn® Adhesion Layer

Ti or Dylyn® Adhesion Layer

Characteristics

All DLC coating have an adhesion layer

Adhesion layer influences important coating properties

Amount of hydrogen controls the hardness

Multi-layer structures

DLN interlayer acts as buffer layer, reducing stress.

Allows for thicker total coating

Thicker coating Longer wear life

Multilayer coatings resist Hertzian stresses due to their higher modulus of elasticity

Single Layer Mulit-layer

Stress Fracture

Diamond-Like Carbon Coatings (DLC)

Sulzer Metco

| slide 12

Matching the Coating & Applications / Cavidur®

Benefits of Multiple Layers

• Better Adhesion

• High Fracture Toughness

• Higher Modulus

2 to

5 µm

1 to 3 µm

1 to 2 µm

Adhesion Zone

DLC Zone

Base Material

Sorevi Coatings (Cavidur®)

Sulzer Metco

| slide 13

Comparison of sulzer vs Competitive DLC Coatings

Sulzer Dylyn®/DLC Competitive DLC

AFM – Topography (Z: 300nm/div)

Sulzer Metco

| slide 14

SEM-Comparison

Amorphous coating structure

without change in surface finish

2.5

µm

Dylyn®/DLC (PACVD) TiAlN (PVD)

5,000 X 1,000 X

Sulzer Metco

| slide 15

0.00E+00

2.00E-06

4.00E-06

6.00E-06

8.00E-06

1.00E-05

1.20E-05

1.40E-05

We

ar

(mm

3/N

m)

TiN Cr Dylyn®/DLC

Coating Wear Wear on Steel Ball (52100)

Comparison of Wear

Wear Factor

(x 10-8

mm3/Nm)

DLC 1 - 5

Dylyn®

5 - 10

WC/C 41

TiCN 60

TiN 250

TiAlN 790 - 1000

Coating

F

v Force (F): 20 N

Velocity (V): 200 RPM

Sliding Distance: 10,000

Revolutions

Sulzer Metco

| slide 16

Dry Running Properties of Materials

AISI 52100 (DIN 1.3505) uncoated

AISI 4140 (DIN 1.7225) nitrided

Cu Sn Pb - bronze AISI 52100 + BALINIT® C (WC/C)

Co

eff

icie

nt

of

fric

tio

n

Wear tracks of materials after dry running

Test time [min] 0 10 20 0

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

WC/C-PVD BALINIT C

Cold Welding

Scratches

Nearly No Wear

Dylyn®

DLC

AISI 52100 (DIN 1.3505) bearing steel, uncoated

AISI 4140 (DIN 1.7225) alloy steel, nitrided

Hard chrome plating

Electroless nickel

AISI 4135 (DIN 1.7707) alloy steel, oxynitrocarburised

Nickel-Teflon

CuSnPb-bronze

DLC Dylyn®

Sulzer Metco

| slide 17

Dylyn®/DLC is able to offer a wide variety of

properties with only ONE coating:

• lowest available coefficient of friction…

Summary

• …which is maintained by the high hardness

• no surface roughness changes … that could

influence galling and release properties • 100% corrosion protection

• Coating temperature below 200°C

• Removable!!

• Biocompatible

Sulzer Metco

| slide 18

General Application Guidelines for Diamond-Like Coating

For molding surfaces: Use the Dylyn® family of

coatings

For sliding surfaces: Use the DLC family of

coatings

Both coatings can work for molding or sliding

applications, but we typically look at the primary

need to determine which coating is the primary

choice

There are multiple recipes available and if the

first coating recipe did not fully satisfy; we can

determine by analyzing the results what the

optimum coating recipe should be