Next generation PVD coatings for tools and components

Next generation PVD coatings for tools and components
Dr. auf dem Brinke | June 2010

Our tools
Classification of Key Surface Treatments
1,200
Substrate temperature (°C)
1,000
800
600
400
200
IONIT OX
Plasma
Nitriding
Ion
Implant.
Chemical Vapor
Deposition (CVD)
Physical Vapor
Deposition (PVD)
Thermal Spray
Electroplating
Welding
(PTA)
0
-10 -1 0 0.1 1 10
100
1,000 10,000 100,000
Coating thickness (µm)
Graph for illustration purposes only, not scientifically exhaustive
Engine Expo 2010 auf dem Brinke June 2010| slide 2

Driving High Technology
The effect of PVD coatings – excellence of performance
Effective mass: MAXIT ® coatings
Without coating
We need for
100. 000 holes
1.000 drills -
equals 60 kg
With coating
We need for
100. 000 holes
250 drills -
equals 15 kg + 7,5 g
PVD-hard coating: 7,5 g TiN
Engine Expo 2010 auf dem Brinke June 2010| slide 3

Driving high technology
Introduction
Dry cutting
High speed cutting
Engine Expo 2010 auf dem Brinke June 2010| slide 4

Driving High Technology
Engine – Surface Treatments
Gear wheels
Rocker arms
Guide pins
Rail guides
Sprockets
Injection pump
covers
Injectors
Camshafts
Tappets
Valve springs
Valves
Valve seats
Piston rings
Pistons
Bearings
Crankshafts
- Nitriding
- Nitriding + Oxidation
- PVD
Engine Expo 2010 auf dem Brinke June 2010| slide 5

Driving High Technology
excellence in coating architecture and design
metallic
hard materials
covalent
bindings
C
SiC
+ hardness
+ HT-properties
- adhesion
covalent
hard materials
WC
TiB 2
TiC TiAlN
TiN
CrN
BN
AlN
Si 3 N 4
Al 2 O 3
ZrO 2
ionic
hard materials
metallic
bindings
+ toughness
+ adhesion
- hardness
all-round properties
heteropolar
bindings
+ chemical resistance
+ less chemical interaction
- brittleness
Engine Expo 2010 auf dem Brinke June 2010| slide 6

Driving High Technology
excellence in coating architecture and design
Schematic illustration of various possibilities to design advanced high
performance coatings
(Al,Ti)N
a-C, BN
(Al,Ti)N
CrN – CrCN – CrC - a-C:H
(Al,Ti)CN
(Al,Ti)N
CrN mod
micro-alloyed
M power
M tec
oder
AlTiN Saturn
substrate
substrate
substrate substrate substrate substrate
Engine Expo 2010 auf dem Brinke June 2010| slide 7

Driving High Technology
PVD ARC Technology
Vacuum measurement
and control system
Process gas
Vacuum
pump set
Power
supplies
Circular
Evaporators
Coating
chamber
Arc evaporators e.g. AlTi
Window
segmented targets
BIAS Power supply
(substrate)
Infraredtemperaturemeasurement
Substrate holder
Engine Expo 2010 auf dem Brinke June 2010| slide 8

How does it work?
low friction and anti sticking coatings MAXIT ® W-C:H
Deposition Working principle process
schematic view
Counterpart
Chromium
W-C
Chromium
S N
W-C
W-C
S
Multilayer Structure
Chromium
Low friction
+
Argon
Plasma
N
S
W-C
Substrate
W-C
W-C
+
Substrate
W-C
High Vacuum
Deposition Chamber
Substrate
S
Separation of substrate
and counterpart by a
chemical inert coating
W-C:H
+ C 2
H 2
bond layer Chromium
~ 1 - 10 µm
W-C
reduction of the roughness
Coating transformation
Chromium
Substrate
200 o C
Magnetron Sputtering
Substrate
Engine Expo 2010 auf dem Brinke June 2010| slide 9

Application W-C:H - Coating of gears
uncoated
1500 N/mm 2
1.35 x 10 6 cycles
20% grey spots
gear MAXIT ® W-C:H coated
counter-gear uncoated
1900 N/mm 2
5.4 x 10 7 cycles
W-C:H coated gears give an efficient protection
against grey spotting and also pitting. weight reduction
Engine Expo 2010 auf dem Brinke June 2010| slide 10

Application – clutch actuator pistons
low friction coating W-C:H for noise and vibration free clutch operation
extremely thin walled app. 0.5 mm
for components with high tribological
stress
gear, bearing and hydraulic
components
deposition temperature: 150 – 250 °C
color:
grey-black
coating morphology: multi-layer
thickness: 1 - 5 µm
hardness HK0.05: 1000 - 1300
friction against 100Cr6: 0.15 - 0.30 dry
running
Engine Expo 2010 auf dem Brinke June 2010| slide 11

Coating design
from bond layer to function
Tailored coatings
function layer a-C:H
W-C:H
bond system Cr - CrN
Engine Expo 2010 auf dem Brinke June 2010| slide 12

Application Tappet on Nitrided Camshaft
advantages:
improving fuel efficiency
improving engine power (+3-4%)
improving dry-running properties
minimum oil lubrication in field test
reduction of weight and size of
engine
W:C-H-mod
Thickness
3.0 ± 0.5 µm
Hardness
1750 ± 150 HV
Friction coeff. µ
Elastic modulus
0.15
200 GPa
Engine Expo 2010 auf dem Brinke June 2010| slide 13

Diesel injection pistons (heavy oil)
advantages:
improving fuel efficiency
less maintenance
improving dry-running properties
cavitation resistance by
trampoline effect (elasticity of
coating)
properties
hardness [HV]
TiN
ca. 2500
Hardchrom
e
800 - 1100
coatings
Me-C:H
ca. 1200
MAXIT ® W-C:H mod
ca. 1750
Dry friction coeff. µ
0,65 ± 0,05
0,6 - 0,65
0,20 ± 0,05
0,15 ± 0,05
Abrasion resistance
++
+
++
+ +
Cavitation resistance
++
– / +
+ +
+ ++
Running-in behavior
–
– / +
++
+++
Engine Expo 2010 auf dem Brinke June 2010| slide 14

Combination treatment of nitriding and PVD
Support for hard PVD layer – no eggshell effect
[N]
65
1.2344 CrN 1.2344 PN + CrN
[N]
65
70
70
Kraft
75
Kraft
75
80
indentation depth: 33 µm indentation depth: 6,5 µm
indication of coating failure
80
High scratch resistance at the surface also for “soft” materials
(smaller 40 HRC) caused by nitriding and coating
Engine Expo 2010 auf dem Brinke June 2010| slide 15

Influence of polishing on surface roughness
divided or integrated combination process
[R z ]
3,5
3,0
2,5
Roughness
2,0
1,5
1,0
0,5
polished PN polished CrN polished
Engine Expo 2010 auf dem Brinke June 2010| slide 16

metal forming – combi treatment
800
GGG 60
Härte (HV 0,5)
700
600
500
400
300
200
100
0
induktiv gehärtet und ionitriert
nur plasmanitriert
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7
Tiefe (mm)
3-4 times longer lifetime
rework possible
combi treatment PN + PVD
Engine Expo 2010 auf dem Brinke June 2010| slide 17

Driving High Technology
Elastomer processing
Calender roll Ø 180 x 850 mm
CrN-mod. coated
Threads
• deposits
• adhesion
Polish + CrN-mod coating
Prevention of deposits
Reduced adhesion
Die plate / CrN-mod. coated
Engine Expo 2010 auf dem Brinke June 2010| slide 18

Driving High Technology
Polymer Processing – Boosting Performance
Where can PVD coatings boost the performance?
Wear protection by high hardness
Reduction of penetration by f.e. glass fibers using combination
processes of nitriding plus PVD
Reduction of deposits by chemical unreactive coatings
Reduction of sticking tendency by non-reactive coatings
Reduction of friction by low friction coatings on f.e. ejector pins
Endurable surface quality
Engine Expo 2010 auf dem Brinke June 2010| slide 19

Driving high technology
The innovative APA evaporator technology
x 100
hard coating deposited by a
classic circular evaporator
comparable hard coating deposited
by an evaporator with extended
magnetic filed – APA –
Engine Expo 2010 auf dem Brinke June 2010| slide 20

Driving High Technology
Sophisticated coating designs
Demands on coatings for modern precision tools
• Hot hardness combined with sufficient toughness
• Thermal shock resistance
• Oxidation resistance
• Minimum chemical/physical interaction with work piece material to reduce
sticking and tribooxidation
Possible combination:
Nanocrystalline morphology
→ optimum hardness - toughness
nanocomposites
Nanostructured multilayers
→ increase of fracture toughness
amorphous
Matrix
nanograins
Engine Expo 2010 auf dem Brinke June 2010| slide 21

Driving high technology
Coating optimization by "micro alloying"
Nano-composite states: alloying - phases
doped coatings
CrN plus some
atoms e.g. Si
"micro alloyed"
grain boundary
segregation
e.g. AlTiNC/C
two or more phases
hcp AlN + fcc AlTiN
hcp (CrTi) 2 N + fcc TiCrN
starting at 17 at% Cr
Engine Expo 2010 auf dem Brinke June 2010| slide 22

Driving high technology
Micro alloyed coatings: How does it work?
a significant amount of 0.1 – 3 at% of an additional element
The element is incorporated into the crystal leading to higher stability,
higher oxidation resistance, etc.
The element is accumulated at the grain boundaries leading to an
amorphisation and thus forcing the formation of a nano-composite.
Influencing the nucleation towards smaller grain sizes and thus forming
nano-crystalline structures, e.g. nano-columns
Engine Expo 2010 auf dem Brinke June 2010| slide 23

Driving high technology
MAC: M power (TiSiXN)
M power from the METAPLAS machining Series
micro alloyed
MeSiXN based nano-composite
hardness 42 +/- 3 GPa, load 10mN
optimized structure of
AlTiN
hardness 29 +/- 2 GPa , load 10 mN
x30000
1µm
FIB prep
Engine Expo 2010 auf dem Brinke June 2010| slide 24

Driving high technology
Cutting test M power
Dry rough milling of X210Cr12, 200 HB annealed
v c = 150 m/min, f = 0.15 mm/tooth, a p x a e = 3 x 10mm
0.4
0.35
Flank wear Vbmax (mm)
0.3
0.25
0.2
0.15
0.1
TiSiN
M power
0.05
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Cutting length (m)
Engine Expo 2010 auf dem Brinke June 2010| slide 25

Driving high technology
Multilayer structure design: tailored M power
3000 nm
AlTiN
TiSiXN
100 nm
Engine Expo 2010 auf dem Brinke June 2010| slide 26

Driving high technology
Cutting test M powerNano
120
V c
(m/min):
finishing, material: 1.2767 (52-54 HRC)
≈250
100
V f
(mm/min): 2200
n (min -1 ): 13500
A1
B1
VB (!m)
80
60
40
f z
(mm/Zahn): 0,086
a p
(mm): 0,1
a e
(mm): 0,1
C1
20
Mpower
0
20 40 60 80 100 120 140 180 240 300 360 420
time (min)
Engine Expo 2010 auf dem Brinke June 2010| slide 27

Driving high technology
Hard machining
Hard milling, smoothing, Material 1.2379 60-62 HRC
250%
200%
150%
100%
50%
0%
AlTiN mod Mpower multi Mpower nano
dry, v c = 115m/min, f z = 0,05mm, a p = 0,1, a e = 0,2
Engine Expo 2010 auf dem Brinke June 2010| slide 28

Driving high technology
MAC: F fusion
TiC (U.T.T.E CVD) : 3,000 shots
CrN : 1,000 shots
M power
: 1,000 shots
No coating : never tried
The F fusion
coated tool is still working, 7,200 shots as for today
- cold pressing : working temperature is around 200°C (not 600°C!)
- sheet material: high tensile steel (SAPH400: JIS), thickness of 2-3mm
- pressing force : 3,000 ton.
- the tested die is for a part of the most critical area.
Engine Expo 2010 auf dem Brinke June 2010| slide 29

Driving high technology
HIPAC: a new evolution of HPPMS
HIPAC
HIPAC During results HIPAC in (High a highly Ionization ionized Plasma metal and for Advanced gas plasma
and allows Coatings), control the over gases
+
the are deposition preionized process
HIPAC coating blind hole L:D 2:1
HPPMS Standard L:D 1:2 AEGD (Arc Enhanced Glow Discharge)
power is applied to the magnetron in pulses of
a few tens of µs at a low frequency (< 2 kHz)
peak target current ~ 1000 A (at 800 V),
i.e. 1 MW
plasma density ~10 19 m -3
ionization of the sputtered material:
up to 90 % for Ti and Al
800 V
1000 A
magnetically designed arc evaporator
electrical circuit that functions as an ion source
for the sputtering gas
gas ionization up to 100 %
is used for clean-etching of the substrate
and/or high-flux-low-energy bombardment of
the substrate surface during growth
anode
HIPAC magnetron
+ +
- +- 0
+ - -
+
+ + - -
+ + 0 0
+
+ -
- + + + + + +
0 -
+ - -
0
+ -
+ +
+ - -
- + +
-
- -
- pulsed bias+
+ +
+ + +
- -
-
-
+ -
-
-
-
+
+ - - 0 +
+ + + +
0 0
- - -
+
+ +
- + + -
-
+ +
0 -
0
+
HIPAC magnetron
Engine Expo 2010 auf dem Brinke June 2010| slide 30

Driving High Technology
Hybrid processes (AIP & HIPAC)
Smooth and dense sputtered insulating top coat
HIPAC: insulating nano crystalline top layer
Arc: crystalline (Al,Ti)N
glass like
nano composite
2µm 1µm
fine columnar
Engine Expo 2010 auf dem Brinke June 2010| slide 31

Driving high technology
Conclusions
PVD coatings ensure high quality in component production
New developments open up economic machining of new materials
Lower coating temperatures allow even direct coating of plastics
Overcoming line-of-sight coating using HIPAC
New options for component design using PVD coatings
DLC coatings represent a group of their own and can be adapted to
existing components lowering friction losses and raising lifetime
Combination of ionitriding and PVD can help substituting expensive
materials and protect aftermarket
Combination treatment can make PVD coatings affordable for mass
production
Engine Expo 2010 auf dem Brinke June 2010| slide 32

Any Questions?
Thank you for your attention !
Engine Expo 2010 auf dem Brinke June 2010| slide 33