In the last few years, advances in coating deposition technologies have led to the development of nano-structured coating materials with unique properties, such as superhardness (defined as hardness H>40 GPa) in combination with high toughness. Coatings prepared by plasma assisted deposition are often known to exhibit increased hardness compared to their corresponding bulk counterparts, due to factors such as grain size refinement, high growth-defect density and residual compressive stress, induced by the deposition process.

As the demand for PVD coating grows, it becomes increasingly apparent that the single element coatings are neither functional nor effective for the diverse applications of modern day machinery. A new generation of specifically engineered surface coating is taking over the PVD coating market.

The engineered coatings incorporate numerous thin films, comprised of a unique coating system, which yields superior tribological properties. The selection of the various phases of such coating processes and the "blueprint" in which they are presented provides an important control parameter. In addition, many applications require that the coating process operates at a multi-functional mode, such as coupling temperature and oxidation resistance, while providing a low coefficient of friction under adverse conditions. Often times, these mechanical, chemical and physical demands cannot be met with monolithic thin film.

PVD coating uses multi-component (layered) coatings arranged in specific designs to provide the properties needed. These coating systems typically comprise of the following layers:
-An adhesion layer that ensures the bonding between the substrate and the coating system
-An intermediate layer that supports the synergy between the adhesion layer and the outer functional layer
-A functional layer possesses favorable properties on contact with the working component and environment

Usually these three layers are applied by different PVD methods, depending upon specific needs and requirements. By filtering through the advantages and disadvantages of each coating method, choosing an appropriate coating selection, and incorporating different levels of ion bombardment energy through bias control we are able to come up with the optimal surface coating.

There are also methods to combat the complexity of the multilayer deposition, by offering multi-element, monolith layer coating. This method offer better coating process control than the multi-layer deposition. Instead of igniting many element targets in systematic way, several alloyed targets are able to achieve the same task.

Thin hard PVD coatings are today frequently used in order to improve the tribological performance of forming tools, cutting tools, and machine elements. In all these applications the surface roughness of the coated part is of utmost importance since it will affect the friction, wear and fatigue characteristic of the tribo-system. Since most PVD coatings are significantly harder than the counter surface material a high coating surface roughness will result in a high wear rate of the counter surface. In general, a high coefficient of friction is due to a significant contribution from the ploughing component of friction because protruding surface asperities (macroparticles, etc.) of the harder rough coating surface will also increase the material pick-up tendency which may cause problems such as galling in metal forming application. A pronounced surface roughness will also increase the tendency to crack initiation and surface fatigue of the coated part due to high contact stresses at the asperities. Finally, a rough substrate surface may also result in problems related to poor adhesion, i.e. coating spalling. In order to reduce these problems, PVD coatings of less hard materials such as diamond like carbon and carbon rich metal carbide based structures can be used. These coatings are gentler to the counter surface and show a beneficial friction coefficient towards many engineering materials also under dry sliding conditions. The mechanisms controlling the low friction properties of these coatings are not fully understood by the industry and they are strongly dependent of the tribo-system. However, most of the studies suggest that the lubricity of these coating(s) is/are determined by interfacial tribo-films generated during sliding (i.e. oxides that are formed during application) and not by the properties of the coatings themselves.


TiN (Titanium Nitride)

Titanium Nitride is the most traditional coating and one of the most frequently requested coatings by customers. TiN was the first general purpose PVD coating to be successfully applied and it remains the most recognized coating in the manufacturing industry. This coating is distinguished by its attractive gold finish.

TiN coating is ideal for a wide range of applications that require increasing the overall hardness, heat resistance, oxidation resistance, and lubricity of a substrate. TiN is also biocompatible and has been approved by the medical industry. For years, TiN has been used as the finishing touches for implants and surgical devices. Consult our application engineer for more information.

Applications
Gear cutting tools - hobs and shaper cutters
Cutting Tools - drills, mills, reamers and taps
Plastic molding tools - especially high finish tools
Press tools - stamping and cold forming
Medical - implants, surgical devices


TiCN

Carbide and Nitride coatings are well suited for increasing the performance of tools due to their high hardness, thermal stability, and chemical inertness. In fact, spurred by the improved functionality over titanium nitride, there has been large interest to improve the formulation of the commercial TiCN coating. Ti(CN) coatings exist in a rather broad composition range. Not only can coatings be produced with composition TiCxNx, where x ranges from 0 to 1 and nitrogen can substitute for carbon in the face-centered cubic structure, but a high fraction of vacancies can also exist on the carbon or nitrogen sites, which will also affect properties such as hardness

TiCN incorporates the hydrocarbon molecules into the TiN coating process. The resulting product is a coating that exhibits excellent increased hardness and wear resistance, exceeding that of TiN coating. TiCN is the ideal coating for machining, stamping, and forming high carbon steel or tool steel, as well as other abrasive materials. With its immaculate gray-blue color finish, TiCN is an ideal coating to satisfy decorative coating needs.

Applications
TiCN is a desirable coating for various cutting, milling and general machining of high strength steel and stainless steels. In addition, it is suitable for applications where high impact shock to tool cutting edges is to be expected. Furthermore, it is used to protect the punching, stamping and forming tools. Consult our application engineer for more information.


TiAlN / AlTiN (Titanium Aluminum Nitride / Aluminum Titanium Nitride)

In the last decade, Tix-Alx-N coatings have become the standard choice for many applications. Their high level of hardness, exceptional wear resistance, and oxidation prevention under high temperature make them ideal especially for high speed dry cutting operations. However, the disadvantage of this coating system is the higher coefficient of friction that it exhibits compared to other coatings. To combat this problem, dry lubricant top coating such as WC, MoS2 have been used. In addition, other low coefficient elements have been deposited in combination with the Tix-Alx-N coating. In other cases, low coefficient element(s) is/are alloyed with the TiAl target for more uniform deposition.

TiAlN and AlTiN coatings are Titanium and Aluminum based coatings. The name and color varies with the Titanium (Ti) and Aluminum (Al) content (if the Al content is greater than Ti content, the coating can be referred to as AlTiN). Ti-Al coatings offer superior performance for a range of metal machining and fabricating applications that surpasses Titanium based coatings at a high temperature and speed. These coatings are most popular with carbide tooling and CNC machining uses, as the coatings excel at high temperatures and at high speed.

At high temperatures, the aluminum forms an oxidation layer with air and acts as a second layer on top of the PVD coating for better wear resistance and lubricity. Even though the higher Aluminum content offers better overall hot hardness, the greater Titanium content will provide a better ductile property. The coating strength can be tailored to each customer’s need. The properties of the Ti-Al coating make it suitable for high temperature cutting operations with a minimal use of lubricant or dry machining. It is an ideal choice for cast iron, high nickel alloys, various grades of stainless steel and steel. Consult our application engineer for further information.

E-002

This coating a Ti-Al base coating that is designed to elongate the tool life of your electroplated grinding wheel up to between: 50% to 100% depending upon application. Consult our application engineer for more information.


CrN (Chromium Nitride)

This coating is designed to replace hard chromium (hard chrome) with its superior resistance to adhesive wear, chemical corrosion, and oxidation. Its low coefficient of friction makes it ideal for die cast, molding components applications that require reduction of, galling during process. CrN is also ideal for medical instruments due to its corrosion and oxidation resistance that exceed that of the TiN (Titanium Nitride). This coating is being replaced by the ZN54 product line in many applications because of its improved hardness over CrN. Consult our application engineer for more information


CrNiN (Chromium Nickel Nitride)

This coating is an improvement of CrN with added abrasion resistance. Consult our application engineer for more information


The New Generation of Efficiency Coating Series

ZN54

ZN54 is a Zirconium based series of coatings, designed to enhance lubricity of the parts during application. This extra lubricity will cut down the abrasion caused by the targeted material to protect the working part. Because of its bright finish it is also popular in the decorative coatings industry. ZN54 is also ideal for the medical industry because of its crystalline-like structure. ZN54 offers better chemical erosion/corrosion resistance and is biocompatible for implant and surgical use. Consult our application engineer for more information.

ZN54 X1 for general lubricity applications in molding, injection molding, also milling, cutting, drilling of thermal plastic, plastic material and most polymer material. In addition, it also excels in aluminum and 12L14 steel applications.
ZN54 X2 (Axelia) is designed to resolve cold welding abrasion issues during milling, cutting and drilling among applications with target materials of titanium, titanium alloys, 410 stainless steel and other similar materials. It has 50% more maximum working temperature than ZN54 X1.
ZN54 X3 is similar to X2 but with a higher maximum working temperature due to added element for thermo-barrier, and added wear resistance and hardness. It is extremely good for increasing the lubricity of the tool, in the case of working with anodized aluminum or other treated alloyed material. It can also be used with fiber filler thermoplastic.


TSN51

This is a Niobium based series of coating that is designed to enhance the hardness, oxidation resistance, and heat resistance of the tool. It's one of our more versatile coatings. Consult our application engineer for more information

TSN51 X1 for general applications, working with higher Rockwell hardness, such as anodized aluminum, cast iron, heat-treated steel and stainless steel.
TSN51 X2 designed for milling, cutting, drilling of inconel, and other engineered alloy steel
TSN51 X3 designed for the new generation of Ni-Cr alloys such as hastelloy, monel, etc.