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Sulzer MetcoDiamond-Like Coatings for Plastic
Molding
6000 North Bailey Avenue Suite 9 Amherst, NY 14226 Phone: 716-270-2228 Fax: 716-270-2230
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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 - 70COEFFICIENT 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 (M)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 C1 - 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 SurfaceProperties 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.
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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 Mohs 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
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Sulzer Metco
| slide 3
DLC Coatings
Hard amorphous carbon thin film
very hard
electrically insulating wear resistant
Comprises C, H
Carbon in sp3bonding => "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
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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
1
2
F=x A
1> 2
0.8
PTFE DLC TiN 52100
Dylyn CrN
0
CavidurN
Diamond Metal Carbon
Hard Chrome
0.1
Nickel Teflon
CoefficientofFriction
0.7
0.6
0.5
0.4
0.3
0.2
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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
CarbideDLC
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 tothe 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/m20 - 40 40 - 42 42 - 46 46 - 53Surface Energy
(mN/m)
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Sulzer Metco
| slide 7
DLC
TOOLPART
Corrosive Attack
Corrosion Test
Dylyn
ASTM B 117-97 Salt Spray Test
The high density andamorphous structure of
Diamond-Like Coatings
inhibit the corrosive by-
products from
penetrating into the
tool.TiN
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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 220C
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 Supplysuch as CH4
Substrates
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Sulzer Metco
| slide 9
Coating Penetration in Close Spaces
PACVD coating process isnon-line of sight
Shadowingoccurs in holes orthin slots
During the process there is arelative gas ion density.
As the gas ions travels into therestricted pathway; thecharged part walls attracts theoppositely charged gas ionsforming the coating.
As the gas ions go deeper intothe restricted pathway, thereare less available until nocoating is formed.
This reduction of coating iscalled Shadowingand thecoating forms only as deep as
the width of the opening of therestricted pathway.
+
(-)
X
X
Taper
DLC Coating
+
+
+
+
+
+ +++
+ +
+
+
+ +++
+
+++
++ ++ ++ +
++
+ + +
+
+
+ + +
+
++
++ ++
+ +
++ ++++ ++ +
++
+
+
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Sulzer Metco
| slide 10
Sulzer uses an Reactive Ion Etchingprocess to decoat diamond-like andother carbon based coating types
Stripped finish on 8620 steel typicallychanges about 1 to 2 Ra
This process can be used on titanium,beryllium copper and aluminum parts inaddition to steels and ceramics
Stripped Masked Steel Sample
Sulzer Stripping Process
2 RaAs 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.
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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 totheir higher modulus of elasticity
Single Layer Mulit-layer
Stress Fracture
Diamond-Like Carbon Coatings (DLC)
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Sulzer Metco
| slide 12
Matching the Coating & Applications / Cavidur
Benefits of Multiple Layers
Better Adhesion
High Fracture Toughness
Higher Modulus
2 to
5 m
1 to 3 m
1 to 2 m
Adhesion Zone
DLC Zone
Base Material
Sorevi Coatings (Cavidur)
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Sulzer Metco
| slide 13
Comparison of sulzer vs Competitive DLC Coatings
Sulzer Dylyn/DLC Competitive DLC
AFM Topography (Z: 300nm/div)
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Sulzer Metco
| slide 14
SEM-Comparison
Amorphous coatingstructure
withoutchange insurface finish
2.5m
Dylyn/DLC (PACVD) TiAlN (PVD)
5,000 X 1,000 X
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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
Wear(m
m3/Nm)
TiN Cr Dylyn/DLCCoating 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
vForce (F):20 N
Velocity (V):200 RPMSliding Distance:10,000
Revolutions
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Sulzer Metco
| slide 17
Dylyn/DLC is able to offer a wide variety of
properties with only ONEcoating:
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 200C
Removable!!
Biocompatible
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Sulzer MetcoGeneral Application Guidelines for Diamond-Like Coating
For molding surfaces: Use the Dylynfamily of
coatings
For sliding surfaces: Use the DLC family of
coatings
Both coatings can work for molding or slidingapplications, 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