PVD Coating for The Next Stage of Modern Manufacturing
SurfTech’s coating process uses Physical Vapor Deposition or PVD, but two patented cutting edge nanotechnologies: Ion Activation Devices (IAD) and Nanostructured Material Synthesis (NMS).
The SurfTech IAD processing involves proprietary and patented plasma–based devices.
The NMS technology is based on coatings developed over the past 20 years to make state–of–the–art x-ray mirrors and aerospace quality, space–qualified patented solid film lubricating films.
PVD Coating Below Annealing Temperatures
Other companies consider 850°F – 900°F to be low–temperature coating. We believe anything above the boiling point of water is a high temperature.
We can apply a PVD coating at temperatures BELOW 200º F.
All electrically conducting materials and surfaces including all traditional tool and wear component substrates can be coated.
Plus, for the first time, all electrically non-conducting materials including; composites, cermet, silicon nitride, black ceramic, silicon carbide, pure alumina, PCD and CBN.
Your Substrate Stays the Same
SurfTech treatments perfectly conform to the component’s surface because of the controlled use of plasma beams to precisely conform the nanostructures to the surface topography. Because SurfTech controls the plasma beam particle energies and number independently, we can put the necessary thermal and chemical energy into the surface treatment process, not into heating the chamber and the bulk mass of the components. SurfTech uses less energy to get this job done and can perform this work on large, small, flat, or round components—in the same batch—without exceeding 200°F.
This unprecedented degree of control results in:
- No annealing of the substrate
- No softening of the substrate
- No warping,
- No bending
- No twisting
We can also control our coating thicknesses to a tighter tolerance as well as assuring greater uniformity of the applied PVD coating, thereby maintaining the fine sharp cutting edges on tools and the component’s fine details. Your substrate material’s surface finish is also unaffected.
Nothing happens in our PVD coating process to affect the dimensions of your component.
Increase Feed and Speed with a SurfTech PVD Coating
Tooling or components that are coated usually have a much higher wear period well beyond that of an uncoated tool or component. The advantage of coating cutting tools is that it takes fewer tools, the speeds and feeds can usually be increased thereby increasing production, decreasing machine downtime by alleviating frequent tool changes, and the finished part quality is generally improved.
The ability to coat parts and tools with multiple layers can increase the speed and feed—how fast the cutting tool moves and cuts. One original equipment manufacturer put the hard, wear-resistant material and molly disulfide combination from SurfTech on its product and increased speeds and feeds by 30 percent. That 30 percent benefit was passed on to the end-user who was able to produce parts that much faster.
Reduce Abrasive And Adhesive Wear
Abrasive wear is the most familiar type of wear. It is caused when a tool or component comes in contact with hard particles. A PVD coating from SurfTech supplies a surface that has more lubricity and hardness to protect against this type of condition.
Adhesive wear is caused when small particles weld or gall themselves to the tool cutting edges or the face or contact point of a component. As these particles break away they leave a rough cratered-type condition which helps promote this condition but at an increased rate.
A build-up edge is formed (a) on the edge of a cutting tool which changes during the cutting operation allowing it to become torn and embedded in the workpiece, leading to poor finishes and tolerances. (Fig. 1) A galling condition is formed on a wear component (b) which causes excessive wear, higher torques to operate and eventually component seizure or catastrophic failure. (Fig. 2)
The added lubricity of the PVD coating provides protection from this condition. In a cutting tool, the coating improves chip formation and reduces chip welding and build-up on the edge.
Coating adds lubricity to the cutting edge allowing the chip to slide off the cutting edge more quickly, thereby reducing heat build-up and chips being welded to either the tool or the cutting edges, leading to better finishes. (Fig. 3) A galling condition or excessive wear condition are also prevented on wear components by reducing friction and adding lubricity. (Fig. 4)