Basics On Sulzer Metco Dlc Coatings 070710
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Basics On Sulzer Metco Dlc Coatings 070710

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Thin Film basics for extended product life

Thin Film basics for extended product life

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  • 1. 6000 North Bailey Avenue Suite 9 Amherst, NY 14226 Phone: 716-270-2228 Fax: 716-270-2230 Sulzer MetcoDiamond-Like Coatings for PlasticMolding|
  • 2. DLC vs Other Surface Treatments Sulzer Metco Properties of DLC Coatings Properties of Other Surface ® ® COATING Dylyn®/DLC Dylyn Cavidur B4 C Chrome Nickel Teflon WCC TiN MATERIAL DLN N * * * Electroless * DIAMOND DIAMOND LIKE Tungsten TITANIUM Diamond Electroplated Nickel NAME LIKE NANOCOMPOSITE Carbide NITRIDE Black CHROME Teflon® COATING COATING Carbon CompositeMICROHARDNESS 25 18 30 23 35 8 - 12 4-8 10 - 12 (GPa) ROCKWELL C 85 78 90 80 95 64 - 70 40 - 60 66 - 70 COEFFICIENT OFFRICTION AGAINST 0.12 0.07 0.1 0.4 - 0.5 0.4 - 0.5 0.2 - 0.4 0.1 - 0.3 0.2 - 0.3 STEEL (DRY) COATING 1-4 1-4 2-4 1-4 1-4 Up to 50 5 - 50 2-4 THICKNESS (µM) MAX. WORKING 570 °F 750 °F 840 °F 1000 °F 1800 °F 600 °F 750 °F 570 °F TEMPERATURE 300 °C 400 °C 450 °C 600 °C 980 °C 325 °C 400 °C 300 °C COATING 350 - 430 °F 350 - 430 °F 480 - 660 °F 500 - 950 °F 500 - 950 °F 120 - 175 °F 120 - 175 °F 440 - 480 °F TEMPERATURE 180 - 220 °C 180 - 220 °C 250 - 350 °C 260 - 500 °C 260 - 500 °C 50 - 80 °C 50 - 80 °C 225 - 250 °C WEAR FACTOR 1-5 5 - 10 1-5 250 41 (x 10-8 mm3/Nm) +++ +++ +++ ++ ++ + + ++SURFACE ENERGY 40 - 50 20 - 40 40 - 50 40 - 42 20 - 30 46 - 53 (mN/m) PVD / Galvanic ElectrolessCOATING METHOD PACVD PACVD PVD PVD PVD PACVD Plating Plating * Not a Sulzer Product listed for comparison purposes only. | slide 1
  • 3. Traditional Methods of Surface Treatment Sulzer Metco Electrolysis Nickel Teflon Composite • Excellent Lubricity (20 - 25% Teflon in deposit) • Excellent release properties • Lowest coefficient of friction • Hardness: 62 Rc • Weak adhesion to the surface Chrome Plating • Finishing necessary on wear parts to eliminate chrome nodules. • For optimized frictional and lubricating properties surface finish must be taken below 15 micro inches Rp 400 X • Hardness: 68 Rc • Edge build up a problem Dicronite® Dry Lube • deposition of 0.000020 inch (0.5 microns) “maximum” • Not a line-of-sight process • only corrosion hindering • Composition - modified (WS2) Tungsten Disulfide in lamellar form. • Hardness - 1.0 - 1.5 Moh’s scale. • Co-efficient of Friction - 0.030 inclined plane method, against itself. | slide 2
  • 4. DLC Coatings Sulzer Metco  Hard amorphous carbon thin film  very hard DLC  electrically insulating  wear resistant  Comprises C, H  Carbon in sp3 bonding => "Diamond-like" properties  There are a few variants of DLC coatings  Engineered interface layer for low film stress a-C:H Hard amorphous carbon thin film  very hard   electrically insulating wear resistant Dylyn®  lower friction  low film stress Comprises C, H, Si, O  a-C:H ~ "Diamond-like" properties  a-Si:O ~ enhances high temperature stability Dylyn® is a family of coatings Low intrinsic stress a- C:H; a- Si:O This is a Sulzer exclusive coating - Several US patents issued | slide 3
  • 5. Coatings Reduce Abrasive Wear Sulzer Metco 8000 7000 Hardness Comparison 6000 Soft Hard Particle 5000 4000 DLC Hard 3000Vickers (HV) 2000 1000 0 Diamond DLC Dylyn® Metal Carbon Nickel Teflon Cavidur® N TiN CrN Hard Chrome 52100 PART TOOL ABRASION: The high hardness of Diamond-Like Coatings reduce the likelihood of hard particle penetration into the tool or part. | slide 4
  • 6. Coatings Reduce Friction / Material Pickup Sulzer Metco 0.8 0.7 0.6 0.5Coefficient of Friction 0.4 0.3 0.2 0.1 0 PTFE DLC Diamond Metal Carbon TiN 52100 Dylyn® Cavidur® N Nickel Teflon Hard Chrome CrN τ1 F=τ x A τ1 > τ2 τ2 PART TOOL RESISTANCE TO ADHESION: The chemically inert characteristics of diamond-like coatings dramatically reduce possibility of cold welding and material pickup on the surface of the tool | slide 5
  • 7. Surface Engery & Wetting Behavior of Different Coatings Sulzer Metco Close-up of a series of liquid droplets on a Dylyn® sample •Surface energy is a lubricant fluid drop measure of the wetting angle with constant volume, affinity of a here water of contact  substance to stick to fluid spreads over the surface the material.    •The lower the value, Metal the less likely a DLC TiN TiAlN material will weld or Carbide Dylyn® stick to a surface. •PFTE has a surface 20 - 40 40 - 42 42 - 46 46 - 53 energy of 18 mN/m Surface Energy Better Wetting Behavior (mN/m) Better Release Behavior | slide 6
  • 8. Corrosion Test Sulzer Metco Dylyn® Corrosive Attack DLC PART TOOL The high density and amorphous structure of Diamond-Like Coatings inhibit the corrosive by- products from penetrating into the TiN tool. ASTM B 117-97 Salt Spray Test | slide 7
  • 9. Plasma Assisted Chemical Vapor Deposition Process Sulzer Metco Sulzer Deposition System Vacuum PumpSubstrates Reactive PlasmaGas Supplysuch as CH4 Plasma Generator Equipment designed & constructed by Sulzer Metco Plasma Assisted Chemical Vapor Deposition (PACVD) process In-situ substrate cleaning via plasma etching Substrate temperature does not exceed 220°C Maximum part dimensions must fit within a 32” diagonal, be less than 12” in height and weigh less than 100Kg | slide 8
  • 10. Coating Penetration in Close Spaces Sulzer Metco PACVD coating process is DLC Coating non-line of sight Shadowing occurs in holes or + + + + + + + + + + + + thin slots + + + + + + + + + + + + + + + + + During the process there is a + + + + + + + + + + + + + + relative gas ion density. + + + As the gas ions travels into the + + X + + restricted pathway; the + + charged part walls attracts the + + + oppositely charged gas ions + forming the coating. + + (-) As the gas ions go deeper into + the restricted pathway, there Taper + are less available until no coating is formed. + This reduction of coating is called Shadowing and the X coating forms only as deep as the width of the opening of the restricted pathway. | slide 9
  • 11. Sulzer Stripping Process Sulzer MetcoStripped Masked Steel Sample Stripped 2 Ra Away from edge As Coated 2.5 Ra 3 Ra Near Edge Sulzer uses an Reactive Ion Etching process to decoat diamond-like and other carbon based coating types Stripped finish on 8620 steel typically changes about 1 to 2 Ra This process can be used on titanium, beryllium copper and aluminum parts in addition to steels and ceramics Note: Chrome plated parts and small geometries may not be advisable to strip. | slide 10
  • 12. Diamond-Like Carbon Coatings (DLC) Sulzer Metco Characteristics Multi-Layer Coating All DLC coating have an adhesion layer Adhesion layer influences important coating properties Dylyn®, Me-Dylyn® or DLC Amount of hydrogen controls the hardness Ti or Dylyn® Adhesion Layer Multi-layer structures  DLN interlayer acts as buffer layer, reducing stress. Dylyn®, Me-Dylyn® or DLC  Allows for thicker total coating Ti or Dylyn® Adhesion Layer  Thicker coating  Longer wear life Substrate  Multilayer coatings resist Hertzian stresses due to their higher modulus of elasticity Standard Coating Stress Fracture Dylyn®, Me-Dylyn® or DLC Ti or Dylyn® Adhesion Layer Substrate Single Layer Mulit-layer | slide 11
  • 13. Matching the Coating & Applications / Cavidur® Sulzer Metco Sorevi Coatings (Cavidur®) Benefits of Multiple Layers • Better Adhesion • High Fracture Toughness • Higher Modulus 1 to 2 µm DLC Zone 1 to 3 µm Adhesion Zone2 to5 µm Base Material | slide 12
  • 14. Comparison of sulzer vs Competitive DLC Coatings Sulzer Metco Sulzer Dylyn®/DLC Competitive DLC AFM – Topography (Z: 300nm/div) | slide 13
  • 15. SEM-Comparison Sulzer Metco 2.5 µm 5,000 X 1,000 X Amorphous coating structure without change in surface finish Dylyn®/DLC (PACVD) TiAlN (PVD) | slide 14
  • 16. Comparison of Wear Sulzer Metco Force (F): 20 N v Velocity (V): 200 RPM Sliding Distance: 10,000 Revolutions F Wear Factor Coating (x 10-8 mm3/Nm) 1.40E-05 1.20E-05 DLC 1-5 ® 1.00E-05 Dylyn 5 - 10Wear (mm3/Nm) 8.00E-06 WC/C 41 6.00E-06 TiCN 60 4.00E-06 TiN 250 2.00E-06 0.00E+00 TiAlN 790 - 1000 TiN Cr Dylyn®/DLC Coating Wear Wear on Steel Ball (52100) | slide 15
  • 17. Dry Running Properties of Materials Sulzer MetcoCoefficient of friction Wear tracks of materials after dry running 0. 8 AISI 52100 (DIN 1.3505) bearing steel, uncoated 0. AISI 4140 (DIN 1.7225) 7 alloy steel, nitrided Cold Hard chrome plating Welding 0. Electroless nickel 6 AISI 4135 (DIN 1.7707) alloy steel, oxynitrocarburised 0. AISI 52100 (DIN 1.3505) uncoated 5 CuSnPb-bronze Scratches Nickel-Teflon 0. WC/C-PVD 4 BALINIT C Nearly DLC No Wear 0. Dylyn® 30 0 10 20 Test time [min] AISI 4140 (DIN 1.7225) nitrided 0. 2 0. 1 Dylyn® DLC AISI 52100 + BALINIT® C (WC/C) Cu Sn Pb - bronze| slide 16
  • 18. Summary Sulzer MetcoDylyn®/DLC is able to offer a wide variety ofproperties with only ONE coating:• lowest available coefficient of friction…• …which is maintained by the high hardness• no surface roughness changes … that could influence galling and release properties• 100% corrosion protection• Coating temperature below 200°C• Removable!!• Biocompatible | slide 17
  • 19. General Application Guidelines for Diamond-Like Coating Sulzer MetcoFor molding surfaces: Use the Dylyn® family of coatingsFor sliding surfaces: Use the DLC family of coatingsBoth coatings can work for molding or sliding applications, but we typically look at the primary need to determine which coating is the primary choiceThere are multiple recipes available and if the first coating recipe did not fully satisfy; we can determine by analyzing the results what the optimum coating recipe should be | slide 18