coating - gtma · 2017. 9. 5. · chemical vapour deposition cvd plasma assisted . chemical vapour...

Coating - Leading Edge PVD Technology

www.hardcoatingtech.eu

Introduction Coatings Technology Transfer

Coating Applications

HardCoating Technologies ______________________


Hardcoating provides High-tech coatings for Carbide Endmills & Drills.

(also indexable/hob service available)

UK Pick Up/Delivery Service

Fast Turnaround for your customer demands

Coatings for high-performance products Introduction


Introduction Hardcoating Coatings Technology Transfer


Hardcoating Technology for ______________________


Goals and benifits of coatings on cutting tools

Coatings

Wear resistance Tool life time Oxidation resistance Temperature resistance Thermal shock resistance Reduced friction Higher cutting data Dry machining


Coatings methods for cutting tools

Chemical Vapour Deposition CVD

Plasma assisted Chemical Vapour Deposition CVD

Physical Vapour Deposition PVD

Sputter-Process

ARC-Process

E-Beam-Process

Due to a high process temperature and a high residual stress of the CVD coating the carbide is weakend. The market share of the PVD coatings is rising constantly.

HIPIMS-Process


Coatings processes for cutting tools

ARC-Process

Sputter-Process

Advantages Disadvantages

- high layer rates - simple construction

- droplets -residual stress -Thick coatings not possible

Advantages Disadvatanges

-Droplet-free -flexibility - simple construction -no residual stress -Thick coatings possible

- lower layer rates

No droplets, no macroparticles


CemeCon Coatings Competitor Arc Coating Technology


Coatings – An Insight Into Production Coating methods

Arc method Arc discharge

Droplet

9


Hardcoating Technology HTL PVD Sputter Coating Technology


Coatings – An Insight Into Production Coating methods

Sputtering Cathodic sputtering

11


Arc Coating(competitor) Sputter Coating

Hardcoating Technology


Flexibility

PVD Sputtering Flexible target design future coating system


Hardcoating Flexibility

Monolayer Multilayer Gradient Nano structure


Residual stress

Substrate

Coating Compressive stress

Tension stress

stress Tension stress Compressive stress

CVD Sputter Arc


Residual stress, AIP- versus MSIP-PVD

Arc-PVD (Competitor)

Magnetron Sputtering-PVD (CC 800/9®)

Hardcoating Coatings


10N 20N 30N 40N 50N 60N

70N

80N 90N

Best adhesion! at 90N scratch test no coating malfunction

Spotlight: Adhesion

Hardcoating Technology


The sputter technology provides various possibilities regarding the selection and combination of coating materials.

Advantages of CemCon coatings extremely smooth high degree of hardness and temperature resistance extraordinary high level of adhesion oxidation-resistant low friction virtually no residual stress cost-effective production of large and small batches flexible choice of coating material auspicious as virtually all conductive and non-conductive materials

can be deposited on all substrates

Hardcoating Coatings PVD Sputter Coating Technology


n Primary Application o Also suited for

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ALOX SN² 0 n n n 0 0 0 0 n 0 0 0 0 0 o n n 0 n n n 0 nTINALOX SN² n n n 0 0 0 0 n 0 0 0 n n n o o 0 n n o n nHYPERLOX 0 o n o 0 0 0 0 n n n 0 n n o 0 0 0 n n o n nCC AluSpeed 0 0 0 0 n 0 0 o 0 o 0 0 n n o 0 0 0 n n n 0 0SUPERTIN 0 o n 0 0 0 0 0 o 0 0 0 o o n o o 0 o o n n 0CCplusC 0 n o o o 0 0 0 0 0 0 0 n n o 0 0 0 o o o n nCCplusD o o 0 n 0 n 0 0 0 0 0 n o 0 0 0 0 o o n n nCCDia 08 0 0 0 0 0 n 0 0 0 0 0 0 n o 0 0 0 0 0 n 0 0 nCCDia HiCo 0 0 0 0 0 n 0 0 0 0 0 0 n n o 0 0 0 o n o 0 nCCDia FiberSpeed 0 0 0 0 0 o n 0 0 0 0 0 o n n o 0 0 n n n o nCCDia Tiger 0 0 0 0 n o o n n 0 0 0 o o n n n 0 n n n o nCCDia TopSharp 0 0 0 0 n 0 n n n 0 0 0 n o 0 0 0 0 n n n n n

CarbonSpeed

MultiSpeed

TiALN TiALN (Thick layer)

ALTiN TiB2

www.hardcoatingtech.eu Ver-041117

TiALN Multi area - general purpose Supernitride for machining steel, cast iron, stainless or high temperature alloys • hardly any residual stress assures highest adhesion, especially when

there are dynamic forces in the machining process • extremely smooth surface for almost frictionless chip removal along

the flute • fine grained coating architecture: high toughness with high hardness • high oxidation resistance • suitable in dry and wet operations at “highest productivity” • most economical Supernitride coating (cost vs. performance) • Very well suited for machining steel, cast iron, stainless or high

temperature alloys • re-coating possible at a high quality level • successor of TINALOX® SN with improved features

01

40

TINALOX® SN²: Performance Characteristics

Material groups acc. to VDI 3323: 1,2,3,6,7,8,9,10,11,12,13, 14

15, 16, 17, 18, 19, 20 31, 32, 33, 34, 35, 36, 37

Application type acc. to VDI 3323:

Brilliant performance in fine machining.

Good performance in rough machining.


Increase of tool life Application

• material: GG35 • tool: mill, carbide • machining: milling, ø 8 mm (0,3152“), finish • parameter:

vc = 210 mm/min (689 sf/min) ft = 0,08 mm (0,003 ipr) ae = 0,1 mm (0,004”) ap = 9 mm (0,34”) t = 4

HARDCOATING solution • Performance criteria: wear • Results: HTL-TiALN® SN² 23% increase of

tool life

HTL - TiALN: Case Study

Milling of cast iron GG

0%

20%

40%

60%

80%

100%

120%

140%

TiAlN HTL-TiALN

100%

123%

mill

ing

way

[%]


Feed rate increased by 100% Application

• material: 100Cr6 • tool: drill Ø 1,5 mm (0,0591“) • machining: drilling • parameter:

TINALOX SN²: vc= 106 m/min; (348 sf/min) f = 0,14 mm/U; (0,006 ipr) TiAlN: vc = 74 m/min; (242 sf/min) f = 0,07 mm/U; (0,003 ipr)

HARDCOATING solution • Performance criteria: wear

Results: HTL-TiALN 1023 holes, significant increase of feed rate speed TiAlN 955 holes

HTL-TiALN: Case Study

Drilling of 100Cr6

0

0.04

0.08

0.12

0.16

TiAlN HTL-TiALN

0.07

0.14

feed

rate

[mm

/U]


ALTiN Supernitride for milling of hardened steel • fine grained coating architecture: very high toughness at

very high hardness • high oxidation resistance and red hardness • high thermal stability • extremely high adhesion, well suited for strong shear forces

e.g. for machining materials with “lubricating” and difficult cutting properties

• applicable for dry and wet machining at „highest productivity“

• extremely smooth surface for “frictionless” chip removal in the flute

• high performance coating (surface quality)

HTL-ALTiN: Performance Characteristics

Material groups acc. to VDI 3323: 1-13, 15-20, 31-37, 38,39,40, 41



Good performance in medium machining.

01

40


30% increase of tool life Application

• material: steel (62HRC) • tool: mill Ø 10 mm (0,394 “) ball nose • machining: milling • parameter: n = 5000 rev/min • cooling: dry

HARDCOATING solution • performance criteria: tool life • TiALN: 100% tool life • HTL-ALTiN: 125% tool life

HTL-ALTiN: Case Study

Milling of steel (61HRC)

0

20

40

60

80

100

120

140

TiALN HTL-ALTiN

100

125

tool

life

[%]


Milling of tempered steel 30 % increase of tool life • Application

• material: 1.2344, HRC 60 • tool: Carbide end mill, Ø 12 mm (0,47 “) • operation: milling • parameter: vc=180 m/min (590,5 sf/min)

fz=0,03 mm/t (0,0012 “/t) z=2

• cooling: dry

• HTL-ALTiN coating solution • performance criteria: wear • conv. TiAlN: 100%

HTL-ALTiN: 132%

HTL-ALTiN : Case Study

0

25

50

75

100

125

150

conv. TiAlN HTL-ALTiN

100

132

Tool

life

[%]


67% increase of tool life

• Application • material 56NiCrMoV7 • tool: carbide milling • operation: die sinking • parameter: vc=190m/min (623,352 sf/min)

vf= 1500mm/min (60 “/min) • cooling: oil

• HARDCOATING solution

• TiAlN: 120 min • HTL-ALTiN: 200 min • significant decrease of wear

HTL-ALTiN: Case Study

Milling of 56NiCrMoV7

0

30

60

90

120

150

180

210

TiALN HTL-ALTiN

120

200

Tool

life

[min

]


30% increase of tool life Application

• material: steel (61HRC) • tool: mill ø 6 mm (0,2364 “) ball nose • machining: milling • parameter: n = 25000 rev/min • cooling: oil mist

HARDCOATING solution • performance criteria: tool life • AlCrN: 100% tool life • HTL-ALTiN: 120% tool life

HTL-ALTiN Case Study

Milling of steel (61 HRC)

0

20

40

60

80

100

120

140

AlCrN HTL-ALTiN

100

120

tool

life

[%]


HTL – TiB2 Coating for machining aluminum-, copper and titanium (alloys) ideal application for sharp edges high toughness at high hardness self-lubricating properties: low affinity to cold welding / built up edges extremely smooth surface for almost frictionless chip emoval in the flute for both milling and drilling low friction at the leading edge resulting in excellent surface finish and hole concentricity

Material groups acc. to VDI 3323: 21, 22, 23, 24, 25, 26, 27, 28, 36, 37



Good performance in medium/rough machining.

01

40



Milling of Al 6061 80% increase of tool life • Application

• material: Al 6061 (0,5% Si) • tool: carbide end mill, Ø 10 mm (0,39 ”) • operation: milling • parameter: vc=320 m/min (1049,8 sf/min)

fz=0,13 mm/z (0,0051 ”/z) • cooling: dry

• Hardcoating coating solution

• performance criteria: wear • TiCN:100% • HTL – TiB2: 180%

HTL TiB2: Example

0

25

50

75

100

125

150

175

200

CompetitorTiCN

HTL-TiB2

100

180

Tool

life

[%]

Coating�- Leading Edge PVD�TechnologySlide Number 2Slide Number 3Slide Number 4Slide Number 5Slide Number 6Slide Number 7Slide Number 8Coatings – An Insight Into ProductionSlide Number 10Coatings – An Insight Into ProductionSlide Number 12Slide Number 13Slide Number 14Slide Number 15Slide Number 16Slide Number 17Slide Number 18Slide Number 19TINALOX® SN²: Performance CharacteristicsHTL - TiALN: Case StudyHTL-TiALN: Case StudyHTL-ALTiN: Performance CharacteristicsHTL-ALTiN: Case StudyHTL-ALTiN : Case StudyHTL-ALTiN: Case StudyHTL-ALTiN Case StudySlide Number 28HTL TiB2: Example

coating - gtma · 2017. 9. 5. · chemical vapour deposition cvd plasma assisted . chemical vapour...

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