finally a solution to the pvd coating dilemma for high ... · dilemma for high performance cutting...
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Finally a Solution to the PVD Coating Dilemma for High Performance Cutting Tools
PerformCoat – a New Approach to PVD and PeCVD Coatings In 2010 industry veterans founded PerformCoat in order to provide the cutting tool industry with innovative thin film technologies. Quickly thereafter, experienced engineers and process experts joined the group.
PerformCoat offers a wide range of technologies from PVD by Cathodic Arc and Sputtering to PeCVD by DC and RF as well as innovative solutions for Plasma Nitriding. Thanks to their vast expertise and experience the group offers innovative, and application-specific solutions for
cleaning, de-coating, and edge preparation.
After thirty years of use and refinement, PVD is a mature technology. Today it is possible to produce flexible, robust, easy to operate, and affordable equipment.
The PerformCoat Advantage
• Innovative and application-specific PVD coatings • PVD: Arc and sputter technology for hard coatings • PeCVD: DC and HF technology for DLC coatings • PeCVD/PVD for hybrid coatings
• Flexible and easy to use PVD equipment at competitive up-front investment and low running cost
• Turnkey PVD solutions including cleaning, de-coating, edge preparation, and quality control
• Local support for spare parts, maintenance, and process development
Cutting Edge Technology
Coat and Control by Yourself:
Delivery time
Precise thickness
Performance
Your margin
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Cutting Edge Technology
Coat and Control by Yourself:
Delivery time
Precise thickness
Performance
Your margin
During the past ten years, requirements for cutting tools have changed dramatically due to the development of tougher materials and improved capabilities of modern machining centers. The performance of modern cutting tools depends mainly on geometry, carbide grades, edge preparation and coating. Tool makers control geometry and material. Coating-wise, they depend on standard broad-band coatings, which do not provide them with the opportunity to differentiate themselves from their competitors. This is where PerformCoat can make a difference. Improved application-specific solutions can be achieved by the optimized combination of coating composition (structure, morphology, and thickness) and surface finish together with proper edge preparation.
Today many innovative tool makers realize the opportunity to differentiate themselves from their competitors by integrating coatings and edge preparation into their production process.
At the same time, more and more standard tooling gets replaced by expensive special tooling. Short lead times for re-grinding and re-coating become essential. Tool makers and larger re-grinding houses find it to be
advantageous to bring the coating process in house. To justify such a step, the equipment must be easy to operate and maintain, cost effective, and have technology support readily available.
At PerformCoat Everything Starts with the Application
At PerformCoat everything starts with an in-depth understanding of the application. Once the requirements for an application are completely understood, PerformCoat starts finding the best solution for the specific application.
The core competences of PerformCoat are application know-how, engineering, and process development. For other disciplines such as electrical wiring, software,
machining, and vacuum chambers, PerformCoat has developed strong partnerships with expert suppliers for these specific disciplines.
The machines are assembled in Europe using only proven components which are available worldwide. They are based on standard platforms which can be equipped with different technologies. This concept keeps the complexity low while allowing high flexibility in chamber size, design, and technology.
Another advantage of the modular system is that it enables PerformCoat to manage spare parts locally with high availability at reasonable costs. Service and spare parts centers are operational in North America, Asia, and Europe.
Trends in the Cutting Tool Industry
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Short but Impressive Track Record
Since its beginnings PerformCoat has installed more than 45 PVD and PeCVD machines and seven turnkey PVD operations. PerformCoat machines work around the clock in the USA, Mexico, Brazil, Japan, China, South Korea, Taiwan, Malaysia, Philippines, Germany, Italy, and France.
Process Development in the USAIn its coating center in Battle Creek, Michigan, PerformCoat develops new coatings, trains new equipment customers, manages spare parts for the Americas, and provides local coating services.
One example of the success of PerformCoat’s innovative approach is shown below. HPfC Titan is a new tool coating for the machining of tough materials.
Milling of TiAI6V4Carbide endmill D 10 mm
Drilling in Stainless SteelCarbide drill D 6 mm; hole 4.5 x D;Stop criteria 0.1 mm corner wear
1000
800
600
400
200
0
# o
f h
ole
s
Vc 60m/min; fz 0.08mm/rev
CompetitorAlCrN
HPfC Titan 125
100
75
50
25
0Co
rner
wea
r in
µm
30 45 60 75 90 105Vc 60m/min; fz 0.04mm/rev; ae 5 mm; ap 10 mm
Competitor A & BAlCrN
HPfC Titan
Increase your productivity by 75% with more aggressive cutting conditions
Vc 90 m/minfz 0.14 mm
Only HPfC Titan is able to work at this condition
PerformCoat equipment assembly
Performance of PerformCoat’s recently developed HPfC Titan coating for materials difficult to machine
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Cutting Edge Technology
Coat and Control by Yourself:
Delivery time
Precise thickness
Performance
Your margin
Salvador RiveraGeneral ManagerPrimus Coating, Toluca/Mexico(www.primuscoating.com)
“We bought a complete turnkey solution from PerformCoat early 2013. Overall it was an amazingly smooth process. Our guys received excellent training, not only in running the equipment but also in the use of PerformCoat’s efficient operating system. Instead of developing our own operating system, we decided to completely duplicate what we saw and learned at PerformCoat’s coating center in Battle Creek, Michigan. This included everything from the product portfolio, quality system, work instructions, and maintenance to the logistics system and fixturing. It was the right decision. Within one month we were able to provide competitive products and outstanding service to the automotive and aerospace industries in Mexico. Whenever we have questions or problems of any sort, Christian and his team provide immediate support.”
Markus Knecht, Owner
Dettingen/Germany (www.plasma-plus-pvd.de)
“After thorough analysis of well-known and established PVD equipment suppliers, I decided to go with PerformCoat for the following reasons:
• Best control of coating thickness (+/- 0,2 µm)
• High flexibility• Easy to operate and maintain• Robust design• Very low running costs• Short cycle times of less than four hours
In the meantime, we operate three coaters from PerformCoat six days per week, 24 hours per day.
Our customers are excited about our products and the short turnaround time. The development of new coatings with PerformCoat is unbelievable. It is efficient, professional, and produces outstanding innovative products.”
PerformCoat Equipment LLC12816 Stahl DriveKnoxville, TN 37934, USA+1 865 321 [email protected]
PerformCoat Michigan LLC319 McIntyre LnSpringfield, MI 49037, USA+1 269 680 [email protected]
JapanUnited Machine Tool Co.,Ltd.324-4, Nozomigaoka, Meito-ku465-0046, Nagoya, Japan+81 52 771 5077 [email protected]
South Korea59-12 Dongo 4-gil, HyangnamHwaseong, Gyeonggi 18624 South Korea+82 10 3818 [email protected]
TaiwanPan-Folk International Corp.6F., No.348, Sec 7Chengteh Rd. Taipei, Taiwan+886 228 282 [email protected]
ChinaDongGuan HS Vacuum Coating Co., LtdC Building NengTian AiLingKan DaLingShan Town, China+86 1771 730 1316 [email protected]
PVD & PeCVD Equipment
Cutting Edge Technology
Hardware Features• robust design• octagonal, double-wall cooled, stainless chamber• proprietary cathode design using planar targets• two-cathode configuration• ultra-fast heating and etching (plasma and metal ion)• Plug ‘n Play• Plasma volume: dia 300mm, height 400mm• compact size: LxWxH = 2.2 x 1.4 x 2.0m• minimal floor space requirement = 3 x 3m• controlled by PLC and industrial PC
Throughput• 5 to 6 batches per day in 3-shift operations• cycle times for 2.5 μm: TiN 2.5h, AlTiN 3h• full process monitoring and data logging• remote access through secure connection via internet
Coatings and Tolerance• High Performance coatings: TiN, TiCN, CrN, TiAlN, AlTiN, AlTiCrN, AlCrN, AlTiSiN, HPfCAlu• multilayer, nanolayer and graded coatings• thanks to the cathode and chamber design, the tolerance on coating thickness is the best in the industry.
Complete Turnkey Solutions Tailored to Customers’ Need PerformCoat offers complete packages for a new coating operation to be integrated in production. It comes with training, all required hardware, and operating procedures.
We guarantee a smooth production ramp-up with experienced technicians.
for Europe: PerformCoat Germany Ferdinand-Porsche-Str. 10 88451 Dettingen-Iller Germany [email protected] Tel. +33 676 332598
for Americas: PerformCoat of North America 319 McIntyre Lane Springfield, Mi 49037 US [email protected] Tel. +1 865 321 3932
for Rest of Asia: PerformCoat of Asia 6F.,No.348, Sec.7, Chengteh Rd. Taipei, Taiwan [email protected] Tel. +886 (02) 28 28 27 50
for Japan: Nobu Fujita324-4 Nozomigaoka Meitu-ku 465-0046 Nagoya Japan [email protected] Tel. +81 90 9043 5385
Support, Services and Spare Parts Sites in Asia, Europe and North America · Contact us at: www.performcoat.com
Order Grind Coat
Produce in 24 hrs
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+/- 0.1 µm