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


Surface Modification

What is surface modification ?


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.

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

++


TiTi++

TiTi++

TiTi++

TiTi++

TiTi++Reactive GasReactive Gas

NN22

Cathodic Arc : Cathodic Arc :

To PumpTo Pump


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)


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

session 11 physical vapour deposition

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