Sulzer Thin Film Presentation July 28 2011


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Thin Film applications for the injection molding market. How to increase the productivity of your most valuable molding investment

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Sulzer Thin Film Presentation July 28 2011

  1. 1. SULZER Metco Thin Film TechnologyDan Schumacher | 27th July 2011
  2. 2. Who is Sulzer MyPresentation | slide 2
  3. 3. Where is Sulzer Metco Aufstrebende Märkte • Brasilien • Russland • Indien • China Productions Coating machines Customer service Sales MyPresentation | slide 3
  4. 4. Overview MyPresentation | slide 4
  5. 5. Portfolio Arc-PVD HVOF Materials for Plasma PTA*-welding DC, HF, HCPMS PACVD Arc IONIT IONIT OX Adding of materials for PTA Adding of materials by Adding of materials in thin Thermo chemical processes welding thermal spraying films IONIT IONIT OX (PVD, PACVD, Hybrid)Surface Substrate Substrate Substrate Substrate MyPresentation | slide 5
  6. 6. Overview General Processes CVD and PACVD PVD – APA Arc, Sputter Plasma Heat Treatment – Plasma-nitriding Special Processes Combi Treatment – Nitriding + PVD Hybrid – Combination of two high ionization coating technologies (Arc and Sputter; Arc and HPPMS) HIPAC MyPresentation | slide 6
  7. 7. Overview Two basic processes CVD (Chemical Vapour Deposition) – One or more chemical precursor gases are used CVD – Chemical reactions in the gas phase – PACVD / DLC PACVD PVD (Physical Vapour Deposition) – Arc PVD – Sputter PVD MyPresentation | slide 7
  8. 8. Overview MyPresentation | slide 8
  9. 9. CVD MyPresentation | slide 9
  10. 10. CVD CVD Thermal CVD - High-temperature PACVD (900–1050˚C) Plasma-Assisted CVD - Medium-temperature (720–900˚C) Classic Classic DLC layers hardcoating layers hardcoating layers (150–250°C) (400–600° C) MyPresentation | slide 10
  11. 11. PVD MyPresentation | slide 11
  12. 12. PVD Vacuum measurement Process gas and control system Vacuum pumpset Circular Evaporators Window Power supplies Infrared- temperature- measurement Substrate holder Coating chamber BIAS Power supply (substrate) MyPresentation | slide 12
  13. 13. PVD PVD coating Applied to most metal alloys and galvanised products (metals and plastics) Coating thickness: 0,5 -10 µm Hardness: 1.000 – 4.000 HV Temperature resistance: 300 – 900 °C Deposition temperature: 200 – 600 °C Structures: – Multilayer – Nanostructure Layers – Modified Layers MyPresentation | slide 13
  14. 14. PVD Arc Evaporation: Thermal electron beam__________________________________________________________________ Sputter: DC sputtering Magnetron sputtering HF sputtering MyPresentation | slide 14
  15. 15. PVD Coating deposited by a classic circular evaporator Arc________________________________________________________________ Coating deposited by an evaporator with extended magnetic filed APA Arc faster spot motion smaller spot size less droplet emission higher evaporation rate higher target utilization MyPresentation | slide 15
  16. 16. Thin Film Coatings Coating design and architecture substrate substrate substrate substrate substrate substrate MyPresentation | slide 16
  17. 17. PVD Benefits Low friction and low adhesion characters Strong wear resistance High hardness, high oxidation resistance and reduced chemical reactions New developments open up economic machining of new materials Coating of plastics Cost reduction Improved product quality Longer maintenance intervals Reduction of coolants and lubricants Increased life time MyPresentation | slide 17
  18. 18. Plasma Heat Treatment MyPresentation | slide 18
  19. 19. Plasma Heat Treatment – Plasma-Nitriding Conventional heat treatment Annealing, hardening and tempering For applications in tribological, corrosive, and mechanical-dynamic systems________________________________________________________________ IONIT®: Plasma-nitriding for alloyed steel, cast, sinter, and special materials IONIT OX®: Special process for improved corrosion and wear protection MyPresentation | slide 19
  20. 20. Plasma Heat Treatment – Plasma-Nitriding MyPresentation | slide 20
  21. 21. Plasma Heat Treatment – Plasma-Nitriding Plasma heat treatment High surface hardness Improved resistance against wear, corrosion, and fatigue Reproducible nitride structure Activation of high-alloyed steels High accuracy grade, low distortion Reduced adhesion and cold welding Environmentally friendly Our Service for Customers Tailored solutions Treatment of big parts (up to 13 metres length, 10 tons, 1.8 metres diameter) Long experience (over 40 years) Consultant service MyPresentation | slide 21
  22. 22. PACVD - DLC MyPresentation | slide 22
  23. 23. PACVD - DLC PACVD (Plasma-Assisted Chemical Vapour Deposition) Takes place at significantly lower temperatures than thermal CVD Differentiable in two application areas Deposition of classic hardcoating layers (TiN, TiCN, Al2O3) Deposition of hard amorphous carbon layers (DLC) MyPresentation | slide 23
  24. 24. PACVD - DLC System for DLC coatings advanced arc module graphite cathode planetary MyPresentation | slide 24
  25. 25. PACVD - DLC DLC coatings Amorphous Carbon based structure At temperatures below 200° on the basis of pulsed glow discharges or high-frequency C discharges All DLC coatings have an adhesion layer, multilayer possibly Coatings can be tailored with respect to: – Electrical conductivity – Hydrophobic/hydrophilic behaviour Applications Tribological applications Automotive, Racing, Engineering Plastic injection and molding Optical industries MyPresentation | slide 25
  26. 26. PACVD - DLC Hardness Coefficient of friction MyPresentation | slide 26
  27. 27. PACVD - DLC Corrosion test Salt spray exhalation test DIN SS 50021 (100% rel. humidity, 35° 5% NaCl) C, New After 192 hours MyPresentation | slide 27
  28. 28. Surface energy θ θ θ Metal DLC TiN TiAlN CarbideSurface energy is a measure of the affinity to stickingThe lower the value, the less a material will weld or stick to a surface MyPresentation | slide 28
  29. 29. PACVD - DLC Benefits: High wear resistance Low coefficient of friction Excellent adhesion Corrosion resistance Smooth surfaces Chemical inertness Possibility to run two coated surfaces against each other for optimal performance and reliability MyPresentation | slide 29
  30. 30. Combi Treatment MyPresentation | slide 30
  31. 31. Combi Treatment Two steps: Plasma-nitriding Subsequent PVD or DLC coatings Plasma-nitrided surfaces considerably improve the supporting effect for PVD or DLC coating Surface treatment may be applied either in one single or two separate processes 1.2344 CrN 1.2344 PN + CrN [N] [N] Load Load Penetration depth: 33 µm Penetration depth: 6,5 µm MyPresentation | slide 31
  32. 32. Combi Treatment Basic precondition for successful combi treatment ensures best adhesion of the PVD layer Nitriding process usually generates a compound layer that has to be removed prior to coating Plot of hardness for a combi treatment CL = Compound layer DL = Diffusion layer SM = Substrate material MyPresentation | slide 32
  33. 33. Combi Treatment Not to be forgotten is a slight roughening of the surfaces during nitriding Necessitates intermediate polishing prior to PVD coating therefore permits only the classic combi treatment in two separate operations MyPresentation | slide 33
  34. 34. Combi Treatment Benefits Optimisation of tool and component properties Significantly longer tool and component life Increased production reliability and delivery reliability All types of PVD coatings can be applied (TiN, CrN, CrN-multilayer, CrN-mod, and DLC) Improvement of fatigue properties by residual compressive stresses Can make PVD coatings affordable for mass production MyPresentation | slide 34
  35. 35. Hybrid MyPresentation | slide 35
  36. 36. Hybrid Combination of two high ionization coating technologies Arc and Sputter Arc and HPPMS APA Arc module Magnetron sputter MyPresentation | slide 36
  37. 37. Hybrid Coating structure Sputtered insulating amorphous coating 1 µm Arc deposited crystalline 2 µm AlTiN MyPresentation | slide 37
  38. 38. HIPAC MyPresentation | slide 38
  39. 39. HIPACIOT RWTH Aachen MyPresentation | slide 39
  40. 40. HIPAC HIPAC = High Ionisation Plasma for Advanced Coatings A slight modification of the HPPMS (or HIPIMS) technology Combination of two high ionization coating technologies Arc and Sputter Arc and HPPMS Characteristics Low duty time (< 5 %) low frequency (< 1000 Hz) High peak power (> 0.5 MW) Low plasma temperature (possibility to perform low temperature depositions) MyPresentation | slide 40
  41. 41. HIPAC Deposition in edges and holes By DC processes By HIPAC 20 mm 10 mm MyPresentation | slide 41
  42. 42. HIPAC Benefits Very high plasma density Dense and smooth coatings High target utilization Very low substrate temperature Homogeneous coating thickness in complex substrates Deposition inside tubes and trenches with high aspect ratios MyPresentation | slide 42
  43. 43. Pre-Treatment MyPresentation | slide 43
  44. 44. Pre-Treatment Cleaning of the surfaces Wet chemical cleaning of oil, grease and other contaminations Rinsing of the parts using de-ionized water in a three stage cascade Blown dry using nitrogen or hot dry air, or dried in a tunnel kiln Optimization of the roughness profile Removal of surface layers, or their systematic Adjustment by means of nitriding MyPresentation | slide 44
  45. 45. Pre-Treatment AEGD (Arc-Enhanced Glow Distance) Ion cleaning: cleaning of the surfaces in plasma Performed in vacuum coating machine Removal of reaction layers and activation of the surface Optimizing adhesion to ensure adequate coating functionality MyPresentation | slide 45
  46. 46. Post-Treatment MyPresentation | slide 46
  47. 47. Post-Treatment Procedures can be used for post-treatment, depending on the application: Blasting Brushing Polishing Functional layers on tools and components are smoothed Thanks to their amorphous structure DLC coatings are already very smooth after coating, no pre-treatment is needed MyPresentation | slide 47
  48. 48. Thin Film Equipment MyPresentation | slide 48
  49. 49. Thin Film Equipment Modular METAPLAS-DOMINO technology platform Magnetron sputter modules HIPAC technology DLC technology modules (PACVD, PACVD plus PVD) Combi Treatments (plasma-nitriding and PVD) Hybrid technology (sputtering plus Arc, HPPMS plus Arc) AEGD (Arc-Enhanced Glow Distance) Different system sizes: – 300x300 – 400x500 – 600x700 – 1200x1100 (usable volume) MyPresentation | slide 49
  50. 50. Thin Film Coatings MyPresentation | slide 50
  51. 51. Thin Film Coatings Coating design and architecture substrate substrate substrate substrate substrate substrate MyPresentation | slide 51
  52. 52. Thin Film Coatings Classic PVD coatings TiN, TiCN, TiCNgrad CrN, CrNmulti, CrNmod Special PVD coatings AlTiN, AlTiN Saturn W-C:H Micro alloyed coatings M A C for Plastics, Forming, Machining Amorphous coatings PACVD coatings – Cavidur® – DYLYN®, DYLYN® Plus MyPresentation | slide 52
  53. 53. TiN Monolayer structure Coating thickness 2 to 7 m; Hardness 2500 High oxidation resistance Very good adhesive properties of the coating______________________________________TiCN Multilayer structure Coating thickness 3 to 7 m; Hardness 2800 High degree of oxidation resistance Excellent adhesive properties of the coating MyPresentation | slide 53
  54. 54. Thin Film Coatings CrN Monolayer structure Coating thickness 2 to 7 m; Hardness 2300 High oxidation resistance Very good adhesive properties of the coating Resistant to solvents _______________________________________ CrNmulti Multilayer structure Coating thickness 3 to 7 m; Hardness 2500 High degree of oxidation resistance Very smooth surface Excellent adhesive properties of the coating ________________________________________ CrNmod Multilayer structure with a glass-like cover coating Coating thickness 3 to 7 m; Hardness 2500 Extremely low tendency of sticking Very low tendency of cold welding MyPresentation | slide 54
  55. 55. Thin Film Coatings Builds of the CrN layers CrN Chrom Applications - PE, PP, PET, POM - PVD extrusion - die casting - versatile usable - die casting - PUR MyPresentation | slide 55
  56. 56. Thin Film Coatings AlTiN Monolayer Coating thickness 1 to 7 m; Hardness 3400 High degree of oxidation resistance Very good adhesion Solvent resistant Insensitive to fingerprints ________________________________________ AlTiN Saturn Monolayer Coating thickness 1 to 7 m; Hardness 3400 High aluminium content Extremely high oxidation resistance Very smooth surface Nanocrystalline morphology Excellent adhesion Combination of high hardness and fracture toughness MyPresentation | slide 56
  57. 57. Thin Film Coatings Micro Alloyed Coatings (M A C) Based on APA evaporation technology Individually adjustable coating design by micro alloying Targeted optimisation of particle size, ductility, oxidation resistance, hot hardness, wear resistance, thermal conductivity Extended tool life, energy efficiency, and environmentally sensible savings MyPresentation | slide 57
  58. 58. Thin Film Coatings Plastics Longer lifetime Extended cleaning intervals Prevention of adhesion and sticking _______________________________________ Forming Higher forming speeds Improved quality of parts Prevention of cold welding and sticking _______________________________________ Machining Higher cutting rates Higher rates of feed Reduction of wear and friction MyPresentation | slide 58
  59. 59. Thin Film Coatings W-C:H Cutting of Al and non ferrous metals Coating temperature: 150 – 200 °C Hardness: 1000 – 1200 HV multilayer structure with a – Cr adhesion layer; – WC supporting layer – and a functional layer WC/C Multilayer the coating thickness can be adjusted MyPresentation | slide 59
  60. 60. Thin Film Coatings W-C:H tribological coatings wind power application uncoated W-C:H coated Load: 1500 N/mm2; 1.35 x 106 cycles Load: 2000N/mm2; 5.4 x 107 cycles W-C:H provides plus 30% power density MyPresentation | slide 60
  61. 61. Thin Film Coatings Cavidur® for Racing Amorphous PACVD coating Coating takes place in a clean room Coating temperature from 180 – 350 °C Very high adhesion and hardness Extremely low friction MyPresentation | slide 61
  62. 62. Thin Film Coatings Benefits Extending component life Performance boost Increased hardness Reduces wear on counter parts Coating mostly used on engine parts, gears MyPresentation | slide 62
  63. 63. Thin Film Coatings DYLYN®, DYLYN® Plus Amorphous PACVD coating Coating takes place in a clean room Coating temperature from 200 – 390 °C High hardness Low friction High wear resistance Little or no lubricants needed Less production stops No change of design needed Less maintenance MyPresentation | slide 63