ICMCTF2006 Session G1: Innovations in Surface Coatings and Treatments
Friday, May 5, 2006 8:30 AM in Royal Palm 4-6
G1-1 Hybrid Coating Solutions for Industrial Applications
T. Hurkmans (Ionbond Netherlands BV, Netherlands)
Initially PVD coatings have been put on classical pre-treated surfaces. The last years pre-treatments and PVD coatings have been matched by serious surface engineering efforts. An overview will be given of recent changes in pre-treatments, to obtain a good performance of the total hybrid system. Examples are: - Combination of electroplated and PVD coatings on e.g. Aluminium substrates in automotive applications. One of the key issues is a proper corrosion resistance. It will be described how the desired corrosion performance is obtained. - Combination of hardening of stainless steel by Kolsterizing and DLC. This engineered surface offers corrosion and wear resistance and a low COF under dry running conditions. An ideal solution for the food and chemical industry. - Combinations of (carbo-) nitriding and PVD. Design rules will be given how to specify the pre-PVD surface.
G1-3 Breakthrough in PVD Coated Aluminium Oxide
D. Doerwald, T. Krug, R. Tietema (Hauzer Techno Coating BV, Netherlands)
For thin film applications alumina has many interesting material properties. Specifically the high temperature stability, chemical stability, low thermal and electrical conductivity are mentioned here. Today CVD coated alumina films are widely used on cemented carbide cutting inserts as a wear resistant coating material. Despite of its interesting properties alumina is not yet widely used in other applications. The major reason for this is the fact that on an industrial scale these coatings are mainly deposited by a thermal CVD process. Although there are many advantages of the CVD process the major disadvantage is the high temperature (1000°C) required for the process. Hauzer has developed a new process with which alumina can be deposited by PVD sputtering technology applied at typical temperature ranges of 350-600°C. This broadens the range of applications considerably. In this presentation, the coating properties will be discussed and some initial results of the performance of this new coating deposited by hybrid technology, a combination of arc and magnetron sputtering will be presented.
G1-5 Sputter Coatings for Collectors' Quality Coining Dies
D.G. Teer (Teer Coatings Ltd, United Kingdom); X. Li (Royal Canadian Mint, Canada)
The production of silver coins of collector quality are required to have a perfect highly polished die surface. This quality is traditionally associated with electro chrome plating on coining dies. It is not possibe for un-plated or un-coated dies to produce sufficient quality or reasonable die life without the dies being re-polished. Although applications of PVD coating on circulation coining dies have been achieved at the Royal Canadian Mint and other mints, these PVD coating techniques result in a less than perfect polished surface on the dies. Therefore a special ion cleaning and sputter coating technique has been developed and applied to coining dies. Significantly improved die life maintaining perfect surface finish can now be achieved without any re-polishing.
G1-9 New Process for Anodization of PVD Titanium Coatings
P.-A. Gay (University of Applied Sciences, SWITZERLAND); T. Heulin (Swiss Federal Institute of Technology EPFL, Switzerland); L. Coteaux, O. Banakh, P.-A. Steinmann (University of Applied Sciences, Switzerland)
This work develops a new process, which involves the deposition of thin titanium films by magnetron sputtering and their subsequent anodization in order to obtain interferential colors on the surface of the treated samples. The sputtering process of titanium coatings (grade 2 and 5) was studied in relation to the color of obtained anodic interferential layers. The anodization of the Ti coatings, carried out in a bath of sulfuric acid (2 vol.%), showed the repeatability of the process in the range of voltages from 5 to 90 V and from 5 to 97 V for the layers of Ti grade 2 and 5, respectively. The anodic oxide layers exhibit a large palette of interferential colors as determined with a spectrophotometer in the CIELAB color space. Both titanium coatings (grade 2 and 5) show similar behavior with respect to the color of the anodic layers. The titanium coating thickness, which was varied from 0.1 to 1µm, shows a weak influence to the color obtained after anodization. However, there is a dependence of the type of substrate material on the anodization quality. Indeed, the anodization of Ti layers deposited on stainless steel showed better results in terms of colors than layers formed on brass. In fact, the anodization of Ti coatings on brass substrates required a corrosion inhibiting interfacial layer to isolate the substrate from the coating. Several interfacial layers were studied: PVD (AlN, BN), galvanic (Ni, NiP, Rh), and CVD (parylene, SiO@sub2@) coatings. Also, the surface finishing of the substrate seems to be a parameter which notably influences the color obtained after anodization. In conclusion, this study shows the potential of this process for decorative applications in terms of its repeatability and the diversity of colors obtained.
G1-10 Industrial Deposition of Multi-layered Coatings Using Dual Cathode Arc Sources
R. Aharonov, H.O. Gekonde (IonBond, LLC)
Abstract Existing cathodic arc coating systems were retrofitted using Dual Cathode arc sources, in which two different target materials are mounted on each source. The multiplicity of the sources ensured uniform coating deposition throughout the chamber height. This arrangement enabled production of multi-layer coatings of various architectures under industrial processing environment. The coating systems retrofitted with dual sources featured higher product throughput as compared to the single cathode counterpart. The individual layer thickness distribution of the different layers throughout the height of the coating vessel was much more consistent than in systems using single cathode arrangement. Examples of TiN/AlTiN multi-layer coatings and their performance in machining with and without lubrication are shown in the current paper.