BALINIT ALCRONA

Advanced tool service treatments
ISTMA world tooling conference
Dr. Andreas Reiter
23rd June 2010
Company Overview – Six core competencies
Oerlikon
Textile
Page 2
Oerlikon
Coating
ISTMA world tooling conference
Oerlikon
Solar
Oerlikon
Vacuum
Oerlikon
Drive Systems
Oerlikon
Advanced
Technologies
Dr. Andreas Reiter
Close to you – anywhere in the world
22 Centres
39 Centres
24 Centres
America
Argentina
Brazil
Canada
Mexico
USA
Europe
Liechtenstein
Austria
Benelux
Czech Rep.
Finland
France
Germany
Great Britain
Hungary
Asia
China
India
Indonesia
Japan
Korea
Singapore
Thailand
Page 3
ISTMA world tooling conference
Italy
Poland
Portugal
Romania
Russia
Spain
Sweden
Switzerland
Turkey
As of April 2010
Dr. Andreas Reiter
Oerlikon Balzers Market Segments
Tools
Business Lines
Market Segments
Page 4
ISTMA world tooling conference
Cutting
Tools
Components
Forming
Tools
Precision
Components
Automotive
Dr. Andreas Reiter
Wear protection coatings for Forming tools
Punching
Forming
Page 5
ISTMA world tooling conference
Plastics
processing
Die casting
Dr. Andreas Reiter
Consideration points for a good working tool
Coating System
Heat Treatment
Sheet Material
Surface Finish
Tool Steel
Page 6
ISTMA world tooling conference
Dr. Andreas Reiter
Consideration points for a good working tool
Coating System
Heat Treatment
Sheet Material
Surface Finish
Tool Steel
Page 7
ISTMA world tooling conference
Dr. Andreas Reiter
BALINIT® - one brand for many applications
BALINIT® A
BALINIT® B
BALINIT® C
BALINIT® C STAR
BALINIT® CNI
BALINIT® D
BALINIT® DLC
BALINIT® DLC STAR
BALINIT® ALCRONA
BALINIT® ALDURA
BALINIT® CROVEGA
Page 8
ISTMA world tooling conference
BALINIT® DIAMOND CLASSIC
BALINIT® DIAMOND PLUS
BALINIT® FUTURA TOP
BALINIT® FUTURA NANO
BALINIT® HARDLUBE
BALINIT® HELICA
BALINIT® LUMENA
BALINIT® MICRAN
BALINIT® TRITON
BALINIT® X.CEED
BALINIT® X.CELL
Dr. Andreas Reiter
BALINIT® coatings in punching/forming
BALINIT® A
BALINIT ® B
BALINIT® C
BALINIT® D
BALINIT®
LUMENA
BALINIT®
ALCRONA
TiN
TiCN
WC/C
CrN
TiAlN
AlCrN
2’300
3’000
1’000
1’750
3’400
3’200
0,4
0,4
0,15 - 0,2
0,5
0,4
0,4
thickness (µm)
3-4
3-4
3-4
4 - 10
8 -15
6-7
stress (GPa)
- 2,5
- 4,0
- 1,0
- 1,5 /
- 2,0
- 1,5
- 3,0
thermal stability (°C)
600
400
300
700
800
1100
colour
gold-yellow
blue-grey
black-grey
silver-grey
violet-grey
blue-grey
structure
monolayer
graded
lamellar
monolayer
monolayer
monolayer
coating
microhardness
(HV 0,05)
friction coefficient
against steel (dry)
Page 9
ISTMA world tooling conference
Dr. Andreas Reiter
Comparison of PVD treatments available
ƒ Punching/piercing/trimming/
3200HV
Balinit Alcrona
Balinit Lumena
3300HV
Balinit D (CrN)
1750HV
Balinit B (TiCN)
3000HV
Microhardness HV 0.05
Page 10
ISTMA world tooling conference
ƒ metal sheet forming
3300HV
Balinit Futra Nano (TiAlN)
Balinit A (TiN)
ƒ Extrusion
2300HV
Coating Strength
Dr. Andreas Reiter
BALINIT® ALCRONA
Punching of metal sheet
flank wear width after 800.000 parts
wear in µm
150
100
tool:
punch
die
50
piece:
material
0
®
BALINITA A
BALINIT
(TiN)
BALINIT
ALCRONA
BALINIT®ALCRONA
(AlCrN)
Page 11
ISTMA/Andreas Reiter
: SPM 60 HRC 64+2
: S290
HRC 68+2
:1.1191 ( CK 45E )
annealed
Sheat
thickness :1.8 mm
Consideration points for a good working tool
Coating System
Heat Treatment
Sheet Material
Surface Finish
Tool Steel
Page 12
ISTMA world tooling conference
Dr. Andreas Reiter
ADVANCED technology
Compressive Strength of Tool Materials
Ceramic [2400 MPa]
Hardmetal
[3500-4500 MPa]
PM-Steel 2
[3500 MPa]
PM-Steel
[3200 MPa]
High Speed Steel
[3000 MPa]
Cold Work Steel
[2400 MPa]
Cast Steel
[2000 MPa]
Nodular Cast
m
o
C
p
S
e
iv
s
s
re
th
g
n
e
r
t
[540 MPa]
Laminar
[325 MPa]
Dr. Andreas Reiter
ADVANCED technology
Tool Steel – Compressive Strength
FA
microcracks
FA = FR
FR
FA
FA > FR
FR
delamination
With the increased loads from AHSS, the tool steel must work harder to
support the coating
Page 14
ISTMA world tooling conference
Dr. Andreas Reiter
ADVANCED technology
Tool Wear and Failure Through Compressive Failure
Overview of area
compressive cracking
1mm
Small compressive
cracking
Significant compressive
cracking
100 µm
100 µm
Causes of compressive load failures
ƒ Incorrect selection of tool steel
ƒ Incorrect Heat Treatment process applied
Page 15
ISTMA world tooling conference
ƒ High surface load due to material bunching
Dr. Andreas Reiter
ADVANCED technology
Advantages
ADVANCED technology advantages
ƒ Higher substrate surface hardness
ƒ Homogeneous hardness profile
ƒ Compressive stress on substrate
Improved
ƒ Adhesion
ƒ Critical load
ƒ Abrasive wear resistance
ƒ Impact resistance
Page 16
ISTMA world tooling conference
Dr. Andreas Reiter
ADVANCED technology
Advantages
F
HV
Plastic
deformation
of substrate
material
PVD
Surfaced overload
F
HV
ADVANCED
technology
Page 17
ISTMA world tooling conference
Improved
resistance
Dr. Andreas Reiter
ADVANCED technology
Available coatings with potential forming tools applications
BALINIT® ALCRONA
BALINIT® LUMENA
BALINIT® FUTURA NANO
ƒ Punching
ƒ „Heavy“ metal sheet forming
ƒ „Soft“ metal sheet forming
ƒ Piercing
ƒ Bulk forming
ƒ Punching
ƒ Fine blanking
ƒ Al-die casting (molds & cores)
ƒ Stamping
ƒ Al-die casting (cores)
Page 18
ISTMA world tooling conference
Dr. Andreas Reiter
ADVANCED technology
Application example: Wear comparison after 1.5 Mio strokes
Application:
Punching
BALINIT® ALCRONA
Tool:
Punch
DIN 1.2379 (~AISI D2), 60-62HRC
Size: 40x60x80 mm
Workpiece:
Furniture fittings
Workpiece material DC1 sheet material
Customer problem:
Low tool lifetime
BALINIT® ALCRONA
ADVANCED
Coating:
BALINIT® ALCRONA ADVANCED
Page 19
ISTMA world tooling conference
Dr. Andreas Reiter
Consideration points for a good working tool
Coating System
Heat Treatment
Sheet Material
Surface Finish
Tool Steel
Page 20
ISTMA world tooling conference
Dr. Andreas Reiter
Surface Finish
Roughness Comparisons
Ra 2 to 3
Page 21
ISTMA world tooling conference
Ra 0.3
Ra 0.15
Dr. Andreas Reiter
Surface Finish
Dependency surface roughness to coating adhesion
100
Slidi
ng
Rectengular to grinding direction
Parallel to grinding direction
direc
tion
Critical load [N]
80
60
Critical load
40
load
20
0
diamant dip
0
0.2
0.4
0.6
0.8
1.0
Surface roughess Ra [µm]
Page 22
ISTMA world tooling conference
Dr. Andreas Reiter
Surface Finish
Polish - Preparation of the dies for treatment
Coefficient of friction
Friction coefficient on the forming surface
Coil lubrication = 2
g/m2
Rz
optimal
Rz (µm )
Topography of the surface
after coating
20
µm
Surface topography is matched to the forming
requirements
Page 23
ISTMA world tooling conference
Dr. Andreas Reiter
Page 24
ISTMA world tooling conference
Dr. Andreas Reiter
PPDTM - Pulse Plasma Diffusion Technolgy
Page 25
ISTMA world tooling conference
Dr. Andreas Reiter
Large Automotive Cast Iron Tools in the PPD Process
Page 26
ISTMA world tooling conference
Dr. Andreas Reiter
HV
1200
1000
800
600
400
200
0
Cross section through a nodular
cast iron + PPDTM
0
Compound layer
10/30 µm
ƒ Gradual reduction in hardness through the
cast iron
ƒ Compound layer 30µm with hardness of
900 - 1200Hv
0,1
0,2
ƒ Re-workable and can be welded
ƒ High hardness 750Hv (60HRC = 800Hv)
0,3
ƒ Deepness 0.3 – 0.4 mm
0,4
Diffusion Depth = 0,5
mm
Cross Section FCD700
Dr. Andreas Reiter
Comparison - Cross Section through
FCD700 + Chrome Plating
HV
1200
1000
800
600
400
200
0
35 µm
0
ƒ Sharp reduction in hardness from chrome
to the base material
ƒ Chrome thickness of 30µm with hardness
of 1200Hv
0,1
ƒ Not re-workable (chrome needs to be
stripped first)
ƒ High hardness 1200 HV
0,2
ƒ Good Zinc Build up reduction
0,3
Dr. Andreas Reiter
PPDTM - Pulse Plasma Diffusion Technolgy
Surface Finish Ion Nitriding versus PPD
After Ion-Nitriding
After PPD
After Ion-Nitriding + polish
Page 29
ISTMA world tooling conference
After PPD and polish
Dr. Andreas Reiter
PPDTM - Pulse Plasma Diffusion Technolgy
Benefits of applying PPDTM Technology
Clean
technology
Page 30
ISTMA world tooling conference
Dr. Andreas Reiter
Benefits of applying PPDTM compared to Hard Chrome
Costs PPDTM versus hard chrome plating (one project; skin parts inner and outer)
[€ x 1000]
Benefits
Much lower treatment costs
over the whole service life of
the tool (five years)
Less machine downtime
1st
2nd
3rd
4th
5th
Hard chrome costs: first treatment
Hard chrome costs: second treatment
1st Year
PPDTM: only once for the whole service life
Source: Customer information
Page 31
ISTMA world tooling conference
Dr. Andreas Reiter
Close to you – anywhere in the world
22 Centres
39 Centres
24 Centres
Thanks for your attention
America
Argentina
Brazil
Canada
Mexico
USA
Page 32
ISTMA world tooling conference
Europe
Liechtenstein
Austria
Benelux
Czech Rep.
Finland
France
Germany
Great Britain
Hungary
Italy
Poland
Portugal
Romania
Russia
Spain
Sweden
Switzerland
Turkey
Asia
China
India
Indonesia
Japan
Korea
Singapore
Thailand
As of April 2010
Dr. Andreas Reiter