off to new shores of blue oceans

CYAN MAGENTA JAUNE NOIR

WerkzeugTechnik

Technology – System – Logistic

ISSN Nr. 0997 - 6981www.werkzeug-technik.com

15 July 2011Nr. 120b

Technical magazine for cutting tools and measurement in the manufacturing

Off to New Shores of Blue Oceans

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Off to New Shores of Blue Oceans

COATING

2 ● Werkzeug Technik 120b ● 15 July 2011

Abstract"Sooner or later, something funda-

mental in your business world willchange." [1.1]

In booming times the owners of theSMEs (small and medium size compa-nies, e.g. grinders and tool makers) tryto create enough production capacities,to be able to deliver their products intime.

In the recession the companies do notneed capacity increasing. Innovativetechnologies, however, can lead to ahigher product quality and/or to branchout into new markets. They may help toprevent or even end the crisis.

"When you take the catastrophe out ofa crisis it can be quite productive". [1.2]

The In-House-Coating (IHC) is surlyone of the most promising business models to realize this with the help ofcompact and flexible PVD units. – The change to the own coating away

from the job coating makes the pro-duction more stable, more qualitative,

more innovative and independent.– The change to new markets, to the

"Blue Ocean" from the over crowed"Red Ocean" increases the profit andaccelerates the payback of new in-vestments (image 1). On the way to the "Blue Ocean" the

grinders should leave the secured har-bour of the cutting tools, but "the shipsare not build for the harbour" [1.3].

The units of the In-House-Coatingshould be able to deposit any coatingsfrom simple TiN through Nanocompos-ites and oxides up to DLC. Since 2003

DLC and Oxynitrides Also as UpgradesT. Cselle1, O. Coddet1, V. Hayek2, P. Holubar2, M. Jilek2, A. Lümkemann1,

M Morstein1, J. Prochazka1, B. Torp3

Image 1: Off to New Shores for Tool Makers

and Regrinders to "Blue Ocean".

PLATIT's mainly SME customers haveworked worldwide with the p coatingsystems with their rotating cathodes.This article describes the newest devel-opments for this product family like:– Oxide and oxynitride coatings as well

as– DLC coatings, preferably produced as– TripleCoatings® in combination with

Nanocomposite coatings.

1. What is important for the coating users?

"All tool manufacturers can mastercutting materials and tool geometries.The competitiveness will be decided bythe used coatings." [1.4].

Standard coating offered by job coa-ters all over the world will not helpcompanies stay ahead of the competi-tion. In order to be successful they needexclusive dedicated (tailor made) coa-tings adapted to the specific applica-tion. This exclusivity is only possible ifyou make your own coatings in yourIn-House-Coating centre. All major re-quirements of coating users [3] bearwitness to the validity of this statement(image 2).

Image 2: What is Important for Coating Users?

1 PLATIT AG, Selzach, Switzerland - 2 PLATIT-PIVOT as, Sumperk, Czech Republic - 3 PLATIT Inc., Libertyville, USA

TAP-Platit anglais 120b_TAP-Platit anglais.qxd 15/07/2011 11:45

COATING


The wide variety of applications hasled to an increasing number of coatings.Today there are no less than 80 diffe-rent types in existence with all kinds ofchemical compositions. There are evenmore than 250 considering all the diffe-rent stochiometries [11].

2. What is flexible coating?

Flexible coating systems will only beintegrated into proprietary productionprocesses when:– Turnkey coating systems [5] are avai-

lable. They should provide:• pre- and after-treatment of cutting

edges and surfaces [6], [7]• stripping• cleaning and• quality control systems.

– the system can be operated even with-out high qualified personnel

– the system reaches cost-efficiency wit-hin two years

– the system enables the deposition of• conventional as well as high perfor-

mance coatings • dedicated coatings for specific ap-

plications.

2.1 Innovative coating units

Innovation distinguishes between aleader and a follower. Innovation iswhen the customer opens his valet" [1.5].

The cores of the p technology are therotating cathodes ([5], [8], [9]) withdouble shutters (image 3a):

– Before coating the targets are beingcleaned by means of the Virtual Shut-ter® preventing contamination of sub-strates (tools):

• The Tube Shutter® is closed to preventthe tools from being contaminated byprevious processes.

• the ARC ignites toward the back;the Virtual Shutter® is activated.

– Deposition (coating) begins with cleantargets• the Virtual Shutter® is deactivated,• the Tube Shutters® are open,• the ARC ignites toward the tools.

Image 3: LARC®-Cathodes and -Shutters.

This double shutter technique gives avery good adhesion (without prolongedetching) as well as smooth, droplet-armsurfaces.

2.2 Wide coating spectrum

The smooth change-over from oneproduction setup to the next enables themanufacturing of a wide variety of coatings as well as short processing times.

2.2.1 Conventional coatings

Thanks to its cathodes sitting rightnext to each other the LARC (LateralRotating Cathodes) technology enablesthe use of cost effective non alloyed tar-gets as well as the deposition of a greatnumber of coatings with the same cath-odes. Composition and stochiometry canbe further defined through the use ofsoftware. Thus the cathode configura-tion (Cr-Al-Ti) shown in image 3b e.g. al-lows for the production of practicallyall popular PVD coatings from themarket;– TiN, TiCN, TiCN-MP, Ti2N, Super-

TiN;– TiAlN (50/50%) , AlTiN (60/40 ,

67/33%);– TiAlCN (75/25, 80/20%)– C r N , C r Ti N , A l C r N ( 7 0 / 3 0 ,

80/20%)– TiAlCrN = All-in-One – all coatings also with DLC top coating.

Image 4: TripleCoatings® ; Combination of

Conventional and Nanocomposite Coatings.


COATING


2.2.2 Nanocomposite coatings For the deposition of Nanocomposite

coatings the Al cathode (image 3b) is re-placed with an AlSi cathode. The spin-odal segregation [10] needed for thisprocess is achieved thanks to the close-ness of the Ti-AlSi and/or Cr-AlSi cathodes.

The nanocrystalline TiAlN or AlCrNgrains are embedded in the amorphousSiN matrix thus enabling the build-up ofNanocomposite structure and coatings[8], [9]:– nACo®: TiAlN/SiN– nACRo®: CrAlN/SiN– nATCRo®: AlTiCrN/SiN

The SiN matrix encases the grains,impedes their growth and this structuremakes the increasing of the hardnesspossible [10].

2.2.3 TripleCoatings®

TripleCoatings [5], [9], [11] consist ofconventional and Nanocompositecoatings. . – nACo3® : TiN + AlTiN + nACo®

– nACRo3® : CrN + AlTiCrN + nACRo®

– n A T C R o 3 ® : C r T i N + A l T i N+ nATCRo®.They are deposited in three phases

(image 4):– The best adhesion is achieved by

using titanium and/or chrome with-out using of alloyed targets. Thanksto the similar Young's moduli the adhesive layer allows a smooth tran-sition between substrate and coating.

– Because of its low internal stress themiddle layer provides a robust corewith a good resistance to wear as well as superior hardness. The central

cathode (CERC®: Central Rotating Ca-thode [5]) ensures a high deposition rate it means high productivity.

– The Nanocomposite top layer showsan extremely high hardness and an ex-cellent thermal isolation (silicon!) aswell as a high resistance against ab-rasive wear.

Due to their different structures theTripleCoatings® lend themselves for allkinds of applications as shown under([4], [5], [14]) (image 5).

2.2.4 Oxide and oxynitride coatings

"Creativity is the combination ofideas"[1.5].

A successful PVD deposition and/orapplication of oxide and oxynitride isonly possible in conjunction with othercoatings. Otherwise, the end result lacksthe desired adhesion, cohesion, andhardness. When combined with con-ventional nitr ides and especial ly

Nanocomposite coatings the range ofapplications is pretty wide.

Oxide and oxynitride coatings serveto separate tool/component and work-piece and achieve a low affinity betweenthe two, especially in dry cuttingprocesses (image 5) where high tem-peratures are reached [12]. They offerthe following advantages: – High resistance against:

• adhesive wear• abrasive wear• oxidation, oxygen diffusion (the

layer already is as an oxide)– Chemical and thermal isolation and

chemical indifference – Reduced friction

• Even at temperatures of more than1000°C

– Fewer built-up edges and less mate-rial inter diffusion in the tribo contactzone.

Image 5: TripleCoatings® and Oxynitride-

Coatings at Dry Turning with High Cutting

Speeds.

Image 6: Structures of Oxide-

and Oxynitride-Coatings from PLATIT.


COATING


As a metal nitride basis is needed to prevent cracking and plastic defor-mation the coatings are (like with CVD)being built into a multi-layer structure(image 6).

Our current oxide coatings are basedon an evolution of the TripleCoatings®

principle:– AlCrNoX : CrN + AlCrN + AlCrON

(optional + AlCrN)– nACoX®: TiN + nACo + AlCrN +

AlCrON (optional + AlCrN)ARC processes with oxygenic gaseousmixtures are particularly stable thanks tothe rotating LARC® cathodes:

– No increase in ARC voltage dur-ing the process.

– Possibility of using high ionic currentsand therefore high deposition rates.

– Possibility of using DC BIAS ampli-fiers with low O2 contents where char-ges can be avoided by means of an MFpulsed BIAS (up to 350 kHz).

– The preferred nitrogen/oxygen rate is:N/O: 50/50% - 80/20%.

– Typical coating thickness at turntable:7 - 18 µm

– Typical overall hardness: 30 GPa

– Typical Young's modulus: ~400 GPa.

2.2.5 DLC coatings

(Diamond-Like-Carbon)

Diamond-Like Coating (DLC) is ametastable form of amorphous carbonwith a high percentage of cubic sp3 ele-ments (image 7).

The metal-doped first generation ofPLATIT DLC coatings (CBC; a-C:H:Me)is deposited in a pure PVD process. Inorder to achieve good adhesion it is be-ing manufactured in a batch in combi-nation with hard coatings. Hence theirnames:

– CROMVIc® = CrN+CBC

– cVIc®= TiCN+CBC

– nACVIc®: nACRo+CBC usw.

CBC coatings improve the running-incharacteristics of chip removal and form-ing tools and play an important role inthe treatment of soft and adhesive ma-terials which cause built-up edges.

The metal-free second generation ofPLATIT DLC coatings (CBC2: a-C:H:Si)is deposited in a combined PVC/PECVDprocess [5]. Here specific siliceous gases help improve the following char-acteristics:

– chemical stability

– optical transparency

– extremely good adhesion (DLC coa-tings) (Lc1> 55 N, Lc2 > 75 N,

Lc3> 100 N)

– high mechanical hardness (> 25 GPa)

– smooth surfaces ( Sa < 0.03 µm)

– low friction coefficient (µ<0.1 for gooddurability without break-through;image 8).

Image 7: Structures of DLC-Coatings

from PLATIT.

Image 8: Comparison of Friction Behavior

of PLATIT-DLC-Coatings.


COATING


Today, DLC coatings are mainly usedin component mass production to pro-tect against wear and tear through lessfriction. This is, however, not a field ofbusiness PLATIT will participate in. Asopposed to standard equipments thenew machines (p111+DLC, p300+DLC,PL1001+DLC, image 10) feature the fol-lowing additional characteristics [5]:

– Virtual Shutter® in combination with Tube Shutters®

– 350 kHz BIAS amplifier

– Pulsed ARC amplifier (optional)– Additional gas tanks and pipes with

mass flow controller– Specific heaters with dust filter– Optional upgrades at operator plant

The CBC2 coatings deposited withthese equipments are ideal for high-quality tools and components as well asthe requirements of high tech installa-tions (image 9): – die, stamp and forming tools, – thread moulding– medical instruments and implants– heavy-duty components in motor

sports like valve rods, lever grips, etc.

– general engineering components liketurbine blades, sewing-machine spind-les, etc.The CBC2 coatings are manufactured

with at least one thin adhesive PVDlayer, but also in combination with com-plete PVD coatings in one batch. Themost important types of structures andfields of applications are:– cViC2®: TiCN + CBC2; die and forming

tools, medical instruments and im-plants

Image 9: Different Applications for

PLATIT-DLC-Coatings.

Image 10: PLATIT's Coating Units

for Deposition of Oxynitride-

and DLC-Coatings.


COATING


[1] Credits:

[1.1] Andrew Groove, Intel Corp. - [1.2]; Max Frisch.

[1.3] Grace Hopper, US Navy - [1.4]; Michael Müller, Walter AG.

[1.5] Steve Jobs, Apple Inc - [1.6]; Renée Mauborgne, W. Chan Kim, INSEAD.

[2] Groove, A.: Only the paranoid survive – Doubleday, New York, 1996.

[3] Thin-Film Coating Market – Study – LEK ConsultingGmbH, München, 2007.

[4] Jilek, M., a.o.: New Machine Concept for TripleCoatings®

ICTCMF,G7-2-905, San Diego, April/2008.

[5] Compendium 2009 – PLATIT AG, Grenchen, 2009 – Download: www.platit.com

[6] Cselle, T.: Influence of Edge Preparation on the Perfor-mance of Coated Cutting Tools Invited talk on the International Conference on Metallurgical Coatings andThin Films - San Diego, April/2007 - Download: www.platit.com.

[7] Holubar, P.: Large-Scale Industrial Applications of Superhard Nanocomposites and Development of Ad-vanced Coating Technology, Nanocoatings, Budapest, April/2008.

[8] Lümkemann, A., u.a.: Nanocomposite Coatings and Triple Coatings on High Performance Tools with Dedicated Edge Preparation - ICTCMF, GP-1, San Diego, April/2009.

– CROMVIc2®: CrN +CBC2; componentswith low coating temperatures

– CROMTIVIc2®: CrTiN + CBC2; compo-nents with corrosion protection, toolsfor aluminium chip removal

– nACVIc2®: nACRo® + CBC2; chip re-moval and forming tools for specificmaterials (Inconel, titanium alloys, etc.

– Fi-VIc2®: nACo® + CBC2; heavy-dutycomponents (e.g. valve rods)

3. SummaryFrom a high-quality coating plant

manufacturer SMEs expect not only reg-ular technical support, but also a con-tinuous product development e.g. forspecific applications [13]. This is theonly way companies can stay ahead ofthe competition.

This article describes the current de-velopments of the p family of coatingmachines from PLATIT. The existingequipment can be upgraded on-site by

means of hardware and software in or-der to produce oxide, oxynitride and/ora new generation of DLC coatings.

These upgrades enable: – The production of coatings for cutting

tools in new fields of applications and

– the break into new markets fields [14]."Sustainable success can only be

achieved by developing new and inno-vative markets and offering the cus-tomer a differentiated and relevant value system." [1.6], [15], [16]

[9] Morstein, M. a.o.: Rotating ARC PVD Cathodes – Five

Years of Dependable High Performance - ICTCMF,

G7-6, San Diego, April/2007 .

[10] Veprek, S., a.o.: Different Approaches to Superhard Coat-

ings and Nanocomposites - Thin Solid Films, Elsevier,

Amsterdam, 476 (2005) p. 1-29.

[11] Cselle, T., u.a.: TripleCoatings – New Generation of PVD-

Coatings for Cutting Tools - Machine Manufacturing,

Budapest, 1/2009, p.19-25.

[12] Morstein, M. u.a.: Influence of the Chemical Composition

on the Tribological Properties of Nitride-Based Nanocom-

posite Coatings - ICTCMF, B6-3-3, San Diego, May/2009.

[13] FETTE-IFT-PLATIT: LMT-NANOSPHERE: Massge-

schneiderte Werkzeugbeschichtungen senken die

Lebensdauerkosten - LMT-Symposium, Oberkochen,

März/2009.

[14] Cselle, T. u.a.: Flexible Beschichtung von TiN über

Nanocomposite und Oxide zu DLC – Industrie-Work-

shop, Schmalkalden, 16.06.2009.

[15] Mauborgne, R., Kim C.W.: Blue Ocean Strategy: How

to Create Uncontested Market Space and Make Compe-

tition Irrelevant, Harvard, Boston, 2005.

[16] Förster, A., Kreuz, P.: Different Thinking! - Redline

Wirtschaftsverlag, München, 2005.

References


PLATIT AGAdvanced Coating SystemsEichholz St. 9CH-2545 Selzach / SOSwitzerland

Phone: +41 (32) 544 62 00Fax: +41 (32) 544 62 20E-Mail: [email protected]: www.platit.com

HeadquartersMoosstrasse 68CH-2540 GrenchenSwitzerland

Phone: +41 (32) 654 26 00

Advanced Coating SystemsS W I S S Q U A L I T Y

BRAZILPdB: Premium customerwith PLATIT technologyRua José e Maria, 264CEP 83.050-634, São José dos Pinhais - PR

Phone: +55 (41) 3588 0100Fax: +55 (41) 3382 8992E-Mail: [email protected]

CZECH REPUBLICPLATIT PIVOT a.s.Advanced Coating SystemsPrumyslova 3

CZ-78701 Sumperk


CZECH REPUBLICLISS Coating CenterLISS a.s.Dopravni 2603

CZ-75661 Roznov p. R.


HONG KONG, CHINATechmart PLATIT Ltd.PLATIT RepresentativeUnit B, 6/F, Howard Factory Building,66 Tsun Yip Street, Kwun Tong, Kowloon

Phone: +852 2341 9898Fax: +852 2713 2597E-Mail: [email protected]

GERMANYPLATIT RepresentativeAR Industrievertretungen CDHLautlinger Weg 5 / Postfach 810 169D-70567 Stuttgart / D-70518 Stuttgart

Phone: +49 (711) 718 7634-0Fax: +49 (711) 718 7634-4E-Mail: [email protected]

SCANDINAVIAPLATIT ScandinaviaUniversitetsparken 7 / PO Box 30DK-4000 Roskilde

Phone: +45 46 74 02 38Fax: +45 46 74 02 50E-Mail: [email protected]

RUSSIATechnopolice Group: Premium customer with PLATIT technologyButlerova Str. 17, Office 1707RU-117342, Moscow

Phone: +7 (495) 330 98 41, 330 97 06Fax: +7 (499) 724 81 77E-Mail: [email protected]

SINGAPOREPLATIT Service51 Ubi Ave #05-08, Paya Ubi Industrial ParkSingapore 408933

Phone: +65 9672 9528Fax: +65 6234 2773E-Mail: [email protected]

SHANGHAI, CHINAPLATIT Advanced Coating Systems

Phone: Fax: +E-Mail: [email protected]

Rijing Road 161, ShangDu building,Waigaoqiao, FTZ Pudong, 200131

+86-21-5867397686-21-58673953

RUSSIATechnolada: Sales AgentZastavskaya Street, 33, Letter G, Office 416RU-196084 Sankt Petersburg

Phone: +7 812 334 35 30Fax: +7 812 388 92 08E-mail: [email protected]

HUNGARYPannon: Premium customerwith PLATIT technologyTarko u. 11H-1182 Budapest


ITALYPLATIT RepresentativeCorso Siccardi 11bIT-10122 Torino (Italy)


INDIAARCI: Premium customerwith PLATIT technologyBalapur P.O.Hyderabad – 500 005


JAPANPLATIT RepresentativeYKT CORPORATION5-7-5, Yoyogi Shibuya-KuTokyo 151-8567, Japan

Phone: +81 3 3467 1252Fax: +81 3 6368 4617E-Mail: [email protected]

SOUTH KOREAPLATIT Support Center


Gyunggy-Do Suwon-Sy Youngtong-Gu Wonchuen-Dong 554INOPLEX 3-403

SPAINMetal Estalki: Premium customer with PLATIT technologyCtra Sto. Domingo 4 bis – Nave 1Poligono Ugaldeguren 1ES-48160 Derio (Vizcaya)


U.S.A.PLATIT, Inc.Advanced Coating Systems1840 Industrial Drive, Suite 220Libertyville, IL 60048-9466

Phone: +1 (847) 680-5270Fax: +1 (847) 680-5271E-Mail: [email protected]

FRANCEDMX: Premium customerwith PLATIT technology165 rue de Prés, ZI des Grands Prés IIIF-74300 Cluses

Phone: +33 (04) 50 18 29 13Fax: +33 (04) 50 18 47 23E-Mail: [email protected]

SWITZERLANDPLANAR Technologie SARue de l'industrie 11CH-1632 Riaz

Phone: +41 (26) 919 50 11Fax: +41 (26) 919 50 12E-Mail: [email protected]

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TURKEYErde: Sales Agent

Phone:Fax:E-Mail: [email protected]

ERDE Dis Ticaret Ltd. StiEgitim Mah.Kasap Ismail Sk. Nr.:6 D:4 TR- 34722 Hasanpasa – Kadikoy / Istanbul

+90 216 3302400+90 216 3302401

off to new shores of blue oceans

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