Download - Session 11 Physical Vapour Deposition
1st Septmeber 2010
Nanotechnologies on a global scale
PVD thin film coating technology
Contents
Surface modification.
PVD coating technology.
PVD coatings.
Advantages
Applications
Case studies
Commercialization of PVD technology.
Conclusions
PVD thin film coating technology
Surface Modification
What is surface modification ?
PVD thin film coating technology
What is surface modification ?Surface modification is the act of modifying the surface of a material by
Bringing
Physical,
Chemical
Biological
Characteristics different from the ones originally found on the surface of a
material.
PVD thin film coating technology
PVD thin film coating Technology.
Surface Modification
Applications and Future of Surface Engineering
Surface engineering techniques are being used in the
Automotive Aerospace
Missile Power
Electronic Biomedical
Textile Petroleum Petrochemical Chemical
Steel, Power
Cement Machine Tools
Construction industries
Footnote 5 Date
PVD
E-Beam
Sputtering
Cathodic Arc
How Are Coatings Applied :
--
Reactive GasReactive Gas
----To PumpTo Pump
NN22NN22
ee--
ee--
MagnetsMagnets
TiTi++
TiTi++
Vacuum ChamberVacuum Chamber
E-Beam :E-Beam :
Magnetron Sputtering :Magnetron Sputtering :
To PumpTo Pump
Argon GasArgon Gas
ArAr
Reactive GasReactive Gas
NN22
ee--TiTi
++
Vacuum ChamberVacuum Chamber
TiTi++
TiTi++
TiTi++
TiTi++
TiTi++Reactive GasReactive Gas
NN22
Cathodic Arc : Cathodic Arc :
To PumpTo Pump
Vacuum ChamberVacuum Chamber
TiTi++
TiTi++
TiTi++
TiTi++
TiTi++
Physical Vapor Deposition (ARC - PVD ) :
Process Used to Deposit Thin Films from Plasma Produced
From A Solid Target Material
Steps Involved in ARC PVD
1) Emission from a Source
2) Metal Ion Transport in Vacuum
3) Deposition on Substrates
to be Coated
Structure of Coatings :
Not a “Paint” or “ Plating” but a
Complex Coating Structure
Diffused Metallic bondDiffused Metallic bond
CoatingCoating
SubstrateSubstrate
Ionbond Multipurpose PVD coatings :
Ty pe Ti N Al Ti N Ti CN Cr N M a x i mi z e r GCUl t r a
Col or gol d Li ght Gr e y B l ue bl a c k M e t a l i c B l a c k B- Br own
Ox i da t i on Te mpe r a t ur e ( C) 600 900 400 700 900 1100
Ha r dne ss i n Vi c k e r s 2600 3300 3000 2200 3500 3600
Fr i c t i on Coe f f i c e nt 0.4 0.4 0.4 0.4 0.4 0.4
S ur f a c e Roughne ss ( um) 0.2 0.15 0.18 0.2 0.2 0.2
Thi c k ne ss ( um) 2 -- 4 2 -- 4 2 -- 4 3--5 2--4 4--6
Uppe r Cr i t i c a l Loa d 70 70 65 70 70 70/ 75
P r oc e ss Te mpe r a t ur e i n C <500 <500 <500 <500 <500 <500
Applications of Coatings :
Connecting Rods and Piston Rings
Automotive and motorcycle decorative coatings.
Automotive decorative coatings are use for interior and exterior trim as well as name
badges / emblems, rims and accessories.
Main drivers• Improved durability of decorative items, quality “feel” and longevity
PVD Cutting Tool Applications.
Why Coatings : Properties
Elimination of Galling and Pickup
Better quality. Reduced downtime. Less frequent maintenance cycles. More pieces per tool.
Increased Hardness
By increasing surface hardness, the tool is protected from abrasive and erosive wear. Tool life is extended. More pieces per tool between maintenance.
Chemical Inertness
Chemical reaction between tool and substrate prevented. Micro welding eliminated.
Oxidation Resistance
Tool life extended.
Increased Lubricity
Metal will flow more freely compared to uncoated tools. Less energy, lower impact stresses and lessened metal fatigue.
Medthin Biocompatible PVD Medical Coatings
Decorative applications for design products.
The extra durable finish means coated items last longer, resisting wear, corrosion and scratching.
DUPLEX TREATMENT: NITRIDING + AlTiN PVD COATING
PVD Coating Portfolio - PVD Coatings for Forming.
Coating Material System Application Typical
Thickness (µ)
Microhardness
HV
Oxidation
Temp. (°C)
Friction
Coefficient Color
IonBond TiN MonolayerGeneral purpose cold forming,
punching, wire forming3 to 5 2300 600 0.4 Gold
IonBond TiCN Monolayer Blanking, stainless forming 1 to 3 3000 400 0.4 Blue-Gray
IonBond CrN MonolayerGeneral purpose stamping,
sheet metal forming3 to 8 1800 700 0.3 Silver
IonBond DeepDraw TiCrN Deep drawing 10 2200 700 0.5 Dark Gray
IonBond SheetForm TiCrN Sheet metal forming 5 to 10 2200 700 0.5 Dark Gray
IonBond UltraCast CrN based Die casting 6 to 8 3300 800 Silver-Gray
IonBond UltraCast II Nitriding + TiAlCrN High performance die casting 6 to 8 3300 1000 0.4 Anthracite
IonBond Forge Nitriding + TiAlCrN Hot forging 10 3300 1000 0.4 Anthracite
IonBond MoldProtect Sputtered CrN Anti corrosion coating for molds 2 1700 700 0.2 Silver
IonBond RubberMold Sputtered CrN Rubber molds 2 1700 700 0.2 Silver
IonBond WearProtect Sputtered TiNWear protection coating for
molds2 2000 600 0.2 Gold
IonBond ADLC DLC-based Medical / powder punches 2 4000 300 0.1 Black
IonBond AluForm DLC-based Aluminum forming 2 to 3 2200 350 0.1 Black
IonBond Slide DLC-based For sliding applications 2 to 3 2200 350 0.1 Black
IonBond MoldRelease DLC-basedCoating to improve mold release
properties2 2200 to 4000 300 0.1 Black
IONBOND COATING TO IMPROVE …
Abrasive wearAbrasive wearSolderingSoldering
Improve surface finishingImprove surface finishingReduce downtimeReduce downtime
Less cores consumptionLess cores consumptionReduce lubricant and demolding Reduce lubricant and demolding
agent agent
Ionbond: The Partner of Choice for Leading International The Partner of Choice for Leading International Aerospace Companies and their Supply ChainsAerospace Companies and their Supply Chains
Quality Accreditations
Ionbond UK Customer Approvals•Rolls Royce, Airbus, Saffran-Aircelle, SKF•Saint-Gobain Rencol, ASTM A967 clean and passivate•Many other blue chip company approvals•New for 2010 ISO13485 Medical Devices
AS 9100
(NATIONAL AEROSPACE & DEFENSE CONTRACTORS ACCREDITATION).
NADCAP has been operational in the USA since 1990. NADCAP is an industry managed approach to conformity assessment of “Special Processes” that brings together technical experts from prime contractors, suppliers and representatives from governmentto work together and establish requirements for approval of supplier’s using a standardised approach.Rolls Royce has now mandated that companies who provide a service in “Special Services” must obtain NADCAP approval.
Turbine Blade Application Coatings
Land based Gas Turbines
CVA Coatings
Air based Gas Turbines
CVA Coatings
Thick CVD and PVD coatings
Steam Turbines
Laser hardening process for impact protection of water droplets (condensed steam)
PVD thin film coating technology
Harsh Application Environment
In the past ten years, the inlet temperature for gas turbines has risen from
1100 to 1230 C (gas plus cooling air) and the gas itself can be as hot as 1550 C.
Due to the high operating temperatures and extreme operating conditions, surface treatments for turbine blades (as well as other hot section parts) have been developed to combat:
As turbine blades become more expensive, properly protecting
these critical components and optimizing yield becomes
increasingly important
Fatigue/Creep Corrosion/OxidationWear
.
Nanotechnologies on a global scale.
Contact : [email protected] BhutaniDr.Atul Kulkarni
September 2010