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28 Technology Hydrogen-Free DLC Coatings Make Tools Hard and Smooth A PVD coating technology with high potential in toolmaking is transferred from the automotive field. In the development of physicalvapour-deposition (PVD) coatings, market cross-fertilization has been important. For example, the forming- and cutting-tool market can take advantage of coatings developed for use on automotive engine components. The Dutch PVD coating expert Hauzer Techno Coating B.V. has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool market with excellent results. Coating hardness and adhesion are key in many tool applications, but other features of coatings also can be hugely advantageous. Nonsticking performance, for instance, is essential in the machining of soft materials such as aluminium and plastics, enhancing both tool life and productivity. Smoothness, on another hand, is very desirable in forming tools. This property can eliminate the need for a posttreatment processing step. All of these coating characteristics have been studied in automotive coating applications, and coatings have been optimized. Figure 2 Figure 1 DLC coatings are common in automotive applications because of their excellent tribological properties. Their coefficient of friction is low and they display nonsticking behaviour. Depending on how the coating is deposited (sputtering, plasma-assisted chemical vapour deposition or arc evaporation), properties can be adapted to the purpose. DLC is suitable for coating drills, inserts, end mills, saw blades, taps, punches, plastics moulds, and dies. Applications for DLC-coated tools include the machining of aluminium, other nonferrous metals, and plastics. Another example of technology transferred from one market to another is hydrogen-free DLC, or ta-C. During the European Nanocoat project in which Hauzer took part, tests were performed on several DLC coatings used on automotive engine components at the Fiat Research Centre in Turin. The researchers concluded that ta-C coatings were unsurpassed in their combination of high hardness and low friction coefficient. Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C. The result is a range of ta-C coatings that have good adhesion and hardness values (40–70 GPa and DB 1–2) and can be used industrially. Hauzer has coated end mills with ta-C (Figure 1). Measurements of impact effect taken by an engine manufacturer showed that the ta-C coating was still intact following an impact load of 2 kN; only small cracks were visible. Such an impact load had previously removed a benchmark coating. A Rockwell indent reveals the ta-C coating’s good adhesion (Figure 2). Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure. They can achieve a typical hardness between 3,000 and 7,000 HV. Their typical coefficient of friction falls between 0.02 and 0.1. The advantageous features of ta-C, taken together with Hauzer’s solution of the adhesion issues, make this coating promising for the future of precision tooling. » Hauzer Techno Coating B.V. Venlo, Netherlands www.hauzertechnocoating.com European Tool & Mould Making | May 2011 | www.etmm-online.com
Ejection solutions DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS? Use the NEW double ejection with integrated ejection plate guiding! Key features: - Also works as the ejector guide pins and bushes, having the possibilty of eliminating the need to install extra items. - Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for installation is drastically reduced leaving more space for other mechanisms. - The rear plates stops and the upper plates continues for the full ejection stroke. More information at Internet under Products / News. www.cumsa.com Mold closed. DX Superior Double Ejection 1st Stroke: Both ejector plates advance. Check www.cumsa.com for your official dealer! 2nd Stroke: Only upper ejector plates advance. INNOVATIVE SOLUTIONS FOR MOLDS
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