PVD coating technology for press hardening 8th October 2008

Transcription

PVD coating technology for press hardening
8th October 2008
Balzers coating Korea
Tae-Gil. Lee
Professional Engineer
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Oerlikon: Six Areas of High Tech Competencies
Group »
Segments »
Oerlikon
Textile
Oerlikon
Coating
Oerlikon
Solar
Oerlikon
Vacuum
Oerlikon
Drive Systems
Oerlikon
Components
Business »
Units
07 Sales CHF 5.6 billion – 19,350 employees – 1,500 scientists – 35 countries – 170 locations
Page 2
Presentation
Unique global network: 88 coating centres in 31 countries
America(5)
Argentina
Brazil
Canada
Mexico
USA
Europe(19)
Liechtenstein
Austria
Belgium
Czech Rep.
Finland
France
Germany
Great Britain
Hungary
Italy
Asia(7)
China
India
Indonesia
Japan
Korea
Singapore
Thailand
Luxemburg
Netherlands
Poland
Portugal
Romania
Spain
Sweden
Switzerland
Turkey
Development number of coating centres
88
82
72
CAGR 96-08: 10%
Coating service
77
61
56
20,000 customers
1.2 million orders
4 million order items
100 million tools
100 million components
Page 3
Presentation
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44
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01
02
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28
31
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97
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00
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Oerlikon Balzers Coating Korea
Pyongtaek center (HQ)
Eyon-Hansan Industrial Park (5B-3,4,5)
833-2 Hansan-Ri Chongbuk-Myeon
Pyongtaek, Kyonggi-Do, Korea 451-833
T +82 31 680 9900
F +82 31 683 9905
Gyeongsan Center
1194-3 Sinsang-Ri Jillyang-Eup
Gyeongsan-Si,
Korea 712-830
T +82 53 854 9900
F +82 53 854 9903
Busan Center
Busan Science Local Industrial
Complex (28B)
1204 Jisa-Dong, Kangseo-Gu, Busan,
Korea 618-230
T +82 51 974 9900
F +82 51 974 9905
Gunsan center
Standard factory #3, The Gunsan Free
Trade Zone , 551-1, Osikdo-dong,
Gunsan-si , Jeollabuk-do, Korea 573540
T +82 63 460 9900
F +82 63 460 9905
Page 4
Presentation
Oerlikon Balzers enables Clean Technology…
by reducing wear in
cutting and forming
metals
§ reduced material
consumption
§ reduced use of
lubricants
by reducing friction
in engine parts
§ higher fuel
efficiency
§ reduced CO2
emission
Page 5
Presentation
Contents
What is presshardening
Why is PVD coating requested
Wear analysis for direct presshardening
Experience with BENTELER worldwide
Production experience
Page 6
Presentation
Page 7
Presentation
Process descripition
up to
Preforming
descaling Piercing/
hot forming and Scaled
quenching down to sheet of the sheet blanking
100°C
´+ corrosion
protection
Heating furnace
hot forming and unscaled
up to
quenching down to sheet
800 – 900 °C
100°C
hot forming
Indirect
Sheet coated
Page 8
Heating furnace
800 – 900 °C
hot forming
Direct
Sheet
uncoated
Presentation
Piercing/
blanking
Process descripition
Hot blank just
before stamping
Destacking before oven
entrance
SOFEDIT Pictures
Temperature ~ 900°C,
Austenitization of blanks
Rapid transfer from oven
to the die set
Simultaneous forming
and quenching
Dies are water cooled
Part temperature after
forming: ~ 80°C
Page 9
Presentation
Advantages of presshardening
§ production feasibility of
complex geometries
§ improved mechanical
properties (particularly yield
strength)
§ weight reduction
Change of material
properties due to
process
§ …….
Source: Salzgitter AG
Page 10
Presentation
Application examples
Hood reinforcement
A-pillar reinforcement
Door beams
B-pillar reinforcement
Bumper beam
Side rail member
Page 11
Presentation
Why PVD is requested
Process characteristics
USIBOR
AlSi-coated
BTR 165
uncoated
Ultraform
zinced
22MnB5
Nano X (painted)
Why ?
Protect sheet surface
against scaling
Application problem
Thermal load
Surface treatment
Application
problems
Type of metal sheet
Adhesive wear
Extreme abrasive wear
Not wildly used
wear
Formation of scale on
the sheet surface acts
like a grinding powder
coating
BALINIT® ALCRONA mod
Sticking of AlSi-coating
on tool surface
coating
Page 12
Presentation
BALINIT® ALCRONA mod
BALINIT® LUMENA
BALINIT® ALCRONA
makes your tools fit for the ultimate in performance
Page 13
Presentation
BALINIT® ALCRONA –
the first coating of G6 Generation
AlCrN BALINIT
®
ALCRONA
Abrasive wear resistance
Hot hardness
Oxidation properties
AlTiN BALINIT
WC/C
DLC
BALINIT®
BALINIT®
®
X.CEED
Oxidation behaviour
Toughness
C
TRITON
TiAlN
BALINIT® FUTURA
BALINIT® FUTURA NANO
BALINIT® X.TREME
Hot hardness
Oxidation properties
TiCN
BALINIT® B
Hardness
Abrasive wear resistance
TiN
Page 14
Presentation
BALINIT® A
Optimised properties of AlCrN-coatings
TiAlN
Hardness
Wear resistance
Hot hardness
Oxidation resistance
TiN
+
+
-
TiAlN
++
+
++
++
AlN
++
++
+++
CrN
+
+
+
AlCrN
++
+++
+++
+++
AlN
++
++
+++
AlCrN
Hardness
Wear resistance
Hot hardness
Oxidation resistance
Page 15
Presentation
Benefit: hardness and hot hardness
Even high thermal stresses
hardly affect the superior
hardness of the coating.
1 µm
Structure
Hardness HV 0.05
3,200
Residual compressive
stress [GPa]
- 3.0
Max. service
temperature [°C]
1,100
Coefficient of friction
Page 16
AlCrN Monolayer
0.35
Presentation
Its high hot hardness results in
excellent abrasion resistance
even at high cutting speeds.
BALINIT® ALCRONA: hot hardness
Comparison with titanium-based coatings
3000
3000
Hardness
2800
HV(0.05)
2600
2800
2400
2400
2200
2200
2600
BALINIT®
ALCRONA
TiAlN
TiCN
AlTiN
2000
1800
1600
2000
1800
1600
1400
1400
25
Page 17
500
600
Presentation
700
800
900
1000 Temperature [°C]
Benefit: chemical stability and oxidation resistance
The high level of chemical
stability reduces the incidence
of reactions between the
workpiece and the tool.
200 nm
Structure
Hardness HV 0.05
3,200
Residual compressive
stress [GPa]
- 3,0
Max. service
temperature [°C]
1,100
Coefficient of friction
Page 18
AlCrN Monolayer
0.35
Presentation
At temperatures of up to
1100°C, BALINIT® ALCRONA
remains chemically stable and
does not oxidise. This means
higher performance at higher
service temperatures.
BALINIT® ALCRONA: oxidation resistance
Comparison with titanium-based coatings
Completely oxidised
900
800
Oxidised layer [nm]
700
600
500
TiCN
TiAlN
AlTiN
400
300
BALINIT® ALCRONA
200
100
0
550
600
650
700
750
800
850
900
950
1000 1050 1100 1150 1200
Oxidation temperature [°C]
Holding time ½ hour in ambient atmoshpere
Page 19
Presentation
Worn bumper tool segment coated with BALINIT® ALCRONA mod
Sample preperation
Severe abrasive wear
Substrate + coating
Areas with unaffected coating, oxidized
coating and abrasive wear
Oxidized
coating
Abrasive wear
+
Sticked material
Possible wear mechanism
§ oxidative onset of the coating
Unaffected coating
§ thus abrasive coating wear
§ uncovering of substrate material
§ abrasive wear of the substrate +
material built up
Wear progress: most extreme wear on the die.
Wear starts on the radius but is stabilized after
20,000 to 40,000 strokes
Experience with BENTELER worldwide
Paderborn
production
Goshen
First contact
Burgos
production
Page 23
Presentation
Changchun
production
Experience with Benteler worldwide
Germany
additional information
§ coated tools:
- bumper
- door beam
- B-pillar
§ increase of lifetime BALINIT®
ALCRONA between
50% and 100 %
§ Material: punch and die are
mostly made of Cr7V (warm
work steel of German steel
maker Kind&Co)
Page 24
Presentation
Germany
Production batche examples
e.g. a door beam tool is coated together with bumper tool
Page 25
Presentation
Germany
Coating thickness distribution
Coating
thickness [μm]
7,92
8,24
6,66
Germany
Coating thickness distribution
Coating
thickness [μm]
10,27
6,53
8,44
Example door beam and bumper in one batch
Production issues
Order handling
Page 28
condition
Adjust surface as good as possible in order
to reduce pre-treatment efforts
pretreament
Polishing quality: technical gloss
nitriding
Plasma nitriding
coating
Balinit® Alcrona mod
post treatment
Technical finishing
ordering
Balinit® Alcrona mod is a special coating
and can only ordered batchwise. If possible
send orders where we have a full batch.
pricing
batchwise
Presentation
Hot-forming of chassis parts:
AlSi-coated Boron-alloyed sheet metal
AlSi coated steel protect against oxidation
From high temperature of forming process.
Lumena reduce the building of AlSi-residues
on the die-surface.
Hot-forming unit in VW
New VW – Passat chassie
Hot-forming of channel
Tool:
Pictures
GP7V , 54+-2 HRC
Plasma-nitrided Nht 0,1mm
HV1100HV
Schicht:
BALINIT® Lumena
Thickness: 8-10 µm
result:
Maintance (welding) is reduced
Parts
are confidational!
Workpiece:
Channel: B -alloyed
T = 1-2 mm
Temp.: 900°C
„Nano X“- precoating
100,000
50,000
Source: VW
0
uncoated
plasmanitrided +
Lumena
Mumme_Springer/mdgKSatag/Nov.2005
Piercing of presshardned B-pillar
Application:
Piercing of press hardned B-pillar
Tool:
punch
Material: ASP 2023 (1.3394)
Workpiece:
Material: AlSi pre-coated 22MnB5
(Uhle), 1400-1500N/mm2
Process parameter:
Schuler press
6,000
number of parts
5,000
4,000
Lubrication: yes
3,000
Operation: hole punching in a
B-pillar
Benefit:
Wear reduction – burr reduction
Enabling series production
2,000
1,000
0
Page 31
®
BALINIT
TiN A
® ALCRONA
BALINIT
ALCRONA
(AlCrN)
Presentation
Close to you – anywhere in the world
Thanks for your attention
America
Argentina
Brazil
Canada
Mexico
USA
Page 32
Europe
Liechtenstein
Austria
Benelux
Czech Rep.
France
Germany
Great Britain
Hungary
Presentation
Italy
Poland
Portugal
Spain
Sweden
Switzerland
Turkey
Asia
China
India
Japan
Korea
Singapore
Thailand

PVD coating technology for press hardening 8th October 2008

Transcription

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