PVD thin film coating technology

Nanotechnologies on a global scale

1st Septmeber 2010

PVD thin film coating technology

Contents
Surface modification.

PVD coating technology.

PVD coatings.
Advantages
Applications
Case studies

Commercialization of PVD technology.

Conclusions
PVD thin film coating technology

Surface Modification

What is surface modification ?

PVD thin film coating technology

What is surface modification ?

Surface modification is the act of modifying the surface of a material by
Bringing

Physical,

Chemical

Biological

Characteristics different from the ones originally found on the surface of a

material.
PVD thin film coating Technology.

Surface Modification
Applications and Future of Surface Engineering
Surface engineering techniques are being used in the
Automotive Aerospace
Missile Power
Electronic Biomedical
Textile Petroleum
Petrochemical Chemical
Steel, Power
Cement Machine Tools
Construction industries
Footnote 5 Date
How Are Coatings Applied :

PVD

E-Beam

Sputtering

Cathodic Arc
E-Beam :

Reactive Gas
Magnets
Vacuum Chamber -
- N2
- N2
-
+
Ti
e
e- Ti
+ To Pump
Magnetron Sputtering :

Vacuum Chamber

To Pump

Ti
+ e-
Ar N2
Argon Gas
Reactive Gas
Cathodic Arc :

Reactive Gas +
+
Ti
Ti To Pump

N2
++ Ti++
Ti
Ti Ti

++ Ti++
Ti
Ti Ti

Vacuum Chamber
Physical Vapor Deposition (ARC - PVD ) :

Process Used to Deposit Thin Films from Plasma Produced

From A Solid Target Material

Steps Involved in ARC PVD

1) Emission from a Source

2) Metal Ion Transport in Vacuum

3) Deposition on Substrates
to be Coated
Structure of Coatings :

Not a “Paint” or “ Plating” but a

Complex Coating Structure

Coating

Diffused Metallic bond

Substrate
Ionbond Multipurpose PVD coatings :

Type TiN AlTiN TiCN CrN Maximizer GCUlt ra

Color gold Light Grey Blue black Met alic Black B- Brown
Oxidat ion Temperat ure ( C) 600 900 400 700 900 1100
Hardness in Vickers 2600 3300 3000 2200 3500 3600
Frict ion Coef f icent 0.4 0.4 0.4 0.4 0.4 0.4
Surf ace Roughness ( um) 0.2 0.15 0.18 0.2 0.2 0.2
Thickness ( um) 2 -- 4 2 -- 4 2 -- 4 3--5 2--4 4--6
Upper Crit ical Load 70 70 65 70 70 70/75
Process Temperat ure in C <500 <500 <500 <500 <500 <500
Applications of Coatings :
Connecting Rods and Piston Rings
Automotive and motorcycle decorative
coatings.

Automotive decorative coatings are use for interior and exterior trim as well as name
badges / emblems, rims and accessories.
Main drivers
• Improved durability of decorative items, quality “feel” and longevity
PVD Cutting Tool Applications.
Why Coatings : Properties

Increased Hardness Elimination of Galling and

By increasing surface hardness, the tool is Pickup
protected from abrasive and erosive wear. Tool Better quality. Reduced
life is extended. More pieces per tool between downtime. Less frequent
maintenance. maintenance cycles. More
Chemical Inertness pieces per tool.
Chemical reaction between tool and substrate
prevented. Micro welding eliminated.
Oxidation Resistance
Tool life extended.
Increased Lubricity
Metal will flow more freely compared to
uncoated tools. Less energy, lower impact
stresses and lessened metal fatigue.
Medthin Biocompatible PVD Medical Coatings
Decorative applications for design products.

The extra durable finish means coated items last longer,

resisting wear, corrosion and scratching.
DUPLEX TREATMENT: NITRIDING + AlTiN PVD COATING
 PVD Coating Portfolio - PVD Coatings for Forming.

Coating Material System Application Typical Microhardness Oxidation Friction

Thickness (µ) HV Temp. (°C) Coefficient Color
General purpose cold forming,
IonBond TiN Monolayer 3 to 5 2300 600 0.4 Gold
punching, wire forming
IonBond TiCN Monolayer Blanking, stainless forming 1 to 3 3000 400 0.4 Blue-Gray
General purpose stamping,
IonBond CrN Monolayer 3 to 8 1800 700 0.3 Silver
sheet metal forming
IonBond DeepDraw TiCrN Deep drawing 10 2200 700 0.5 Dark Gray
IonBond SheetForm TiCrN Sheet metal forming 5 to 10 2200 700 0.5 Dark Gray
IonBond UltraCast CrN based Die casting 6 to 8 3300 800 Silver-Gray
IonBond UltraCast II Nitriding + TiAlCrN High performance die casting 6 to 8 3300 1000 0.4 Anthracite
IonBond Forge Nitriding + TiAlCrN Hot forging 10 3300 1000 0.4 Anthracite
IonBond MoldProtect Sputtered CrN Anti corrosion coating for molds 2 1700 700 0.2 Silver
IonBond RubberMold Sputtered CrN Rubber molds 2 1700 700 0.2 Silver
Wear protection coating for
IonBond WearProtect Sputtered TiN 2 2000 600 0.2 Gold
molds
IonBond ADLC DLC-based Medical / powder punches 2 4000 300 0.1 Black
IonBond AluForm DLC-based Aluminum forming 2 to 3 2200 350 0.1 Black
IonBond Slide DLC-based For sliding applications 2 to 3 2200 350 0.1 Black
Coating to improve mold release
IonBond MoldRelease DLC-based 2 2200 to 4000 300 0.1 Black
properties
IONBOND COATING TO IMPROVE …

Abrasive wear
Soldering
Improve surface finishing
Reduce downtime
Less cores consumption
Reduce lubricant and demolding
agent
Ionbond: The Partner of Choice for Leading International
Aerospace Companies and their Supply Chains
Quality Accreditations

AS 9100

(NATIONAL AEROSPACE & DEFENSE CONTRACTORS ACCREDITATION).

NADCAP has been operational in the USA since 1990. NADCAP is an industry managed approach to conformity assessment of
“Special Processes” that brings together technical experts from prime contractors, suppliers and representatives from government
to work together and establish requirements for approval of supplier’s using a standardised approach.
Rolls Royce has now mandated that companies who provide a service in “Special Services” must obtain NADCAP approval.

Ionbond UK Customer Approvals

•Rolls Royce, Airbus, Saffran-Aircelle, SKF
•Saint-Gobain Rencol, ASTM A967 clean and passivate
•Many other blue chip company approvals
•New for 2010 ISO13485 Medical Devices
PVD thin film coating technology

Turbine Blade Application Coatings

Land based Gas Turbines

CVA Coatings

Air based Gas Turbines

CVA Coatings
Thick CVD and PVD coatings

Steam Turbines
Laser hardening process for impact protection of water droplets
(condensed steam)
 Harsh Application Environment
In the past ten years, the inlet temperature for gas turbines has risen from
1100 to 1230 C (gas plus cooling air) and the gas itself can be as hot as 1550 C.

Due to the high operating temperatures and extreme operating conditions,

surface treatments for turbine blades (as well as other hot section parts) have been
developed to combat:

Wear Fatigue/Creep Corrosion/Oxidation

As turbine blades become more expensive, properly protecting

these critical components and optimizing yield becomes
increasingly important
.

Nanotechnologies on a global scale.

Contact : infoin@ionbond.com
Dharmesh Bhutani
Dr.Atul Kulkarni

September 2010