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1 Kunststof Oppervlaktetechniek 12 April 2012 Balinit Coatings; The non-metallic finishing touch

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Page 1: Wim Geurts - Oerlikon

1

Kunststof Oppervlaktetechniek12 April 2012

Balinit Coatings;The non-metallic finishing touch

Page 2: Wim Geurts - Oerlikon

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BALINIT® coatings for tools (exception = Oerlikon Balinit Hartec)

Cutting

Tool lifeProductivity

Punching/forming

Tool lifeDry running

Plastics processing

Mould protectionShorter cycle timesMoving elements withoutOil / grease

Die casting

Wear resistance

Wat zijn PVD coatings ?

Are attached at temperatures between 200 and 500 °C

Thickness of the coating typical: 1-16 µmStandard : 31 µm

Strong adhesion of the coatings High hardness and low coëfficiënt of friction.

Physical Vapour Deposition

Uiterst dunne keramische coatings.Anders dan bij galvanische technieken zijn de eigenschappen van de afzonderlijke bestanddelen niet meer aanwezig!!!Niet alleen de vereiste gladheid of structuur van gereedschappen wordt geseald met deze deklaag.Eigenschappen als corrosiebescherming, slijtageweerstand, lossing en matrijsvulling worden stuk voor stuk positief beïnvloed.Last but not least is “dry running” in veel gevallen (medisch / food) een keiharde eis.

Page 3: Wim Geurts - Oerlikon

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0 2000 4000 6000 8000 10000

Warmarbeidsstaal

Snelstaal (64 HRC)

Hardchroom

Nitreerlagen

Hardmetaal

CrN

TiN

TiCN

FUT NANO

X.TREME

BNc

Diamant

Hardness (HV)

Comparison on scale of hardness

Page 4: Wim Geurts - Oerlikon

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Thinness of the coating in comparison

Human hair0.05 mm

BALINIT® hard coating0.003 mm

7

Page 8

Dry running properties of sliding materials

Sliding distance [m]

Coefficient of friction

0

0.1

0.2

0.3

0.4

0.5

0.6

0 500100 200 300 400 600 700

Coatingwith PTFE

Coatingwith MoS2

MoS2

PVD

BALINIT® Cnearly no wear

x x x

xx

CuSnPbbronze

Ni-PTFE

x End of test due to adhesive wear

Page 5: Wim Geurts - Oerlikon

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Hydrophilic surface Hydrophobic surface

CA 42° CA 102.5°

High surface energy (63 mN/m) Low surface energy (22 mN/m)

uncoated steel surface

a-C:H:Si coating

Characterization of carbon coatings

Contact angle, wettability, sticking behaviour

Carbon based coatings

Har

dnes

s

Sp2 versus Sp3 bonding

BALINIT®

DiamondCVD

NaturalDiamond

ta-CAIP

BALINIT®

DLCa-C:HDC/RF

BALINIT®

Me-C:HRF

BALINIT®

Me-C:HDC

coat

ing

thic

knes

s

1

6

8

1

2

Page 6: Wim Geurts - Oerlikon

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Types of carbon based coatings

Page 11

BALINIT® CMe-C:H• very good adhesion• high elasticity• moderate hardness (2,000 HV)

BALINIT® DLCa-C:H • high wear resistance• high hardness (to >2,500 HV)• low friction

BALINIT® DIAMOND • max. wear resistance• max. hardness (10,000 HV)• T resistance up to 800⁰C

Hard Carbon (ta-C) • hydrogen-free • high hardness (5,000 HV)• greater temperature resistance

Page 12

DLC

CrC

Cr

Substrate (Fe)

Balinit DLC - SEM Cross Section

Page 7: Wim Geurts - Oerlikon

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Coating: Hydrogen-free carbon (ta-C) SEM Fracture Cross Section and Hardness

Typical hardness: Hv = 4000 – 5000

Balinit Hardcarbon

Coating material Tetrahedral amorphous carbon (t-aC)

Microhardness (Hv 0.01) 4000 - 5000

Coefficient of friction against steel (pin-on-disc, dry)

< 0.15 (w/o post-treatment)

Max.application temperature 500°C

Coating colourdepending on thickness: rainbow,

black, grey

Coating type monolayer

Coating thickness(depends on tool geometry)

0.3 to 3 µm

Coating temperature (C°) < 150°C

Page 8: Wim Geurts - Oerlikon

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BALINIT ARCTIC coating series

What does ARCTIC mean ?

ARCTIC coating series

- BALINIT® A ARCTIC

- BALINIT® D ARCTIC

- BALINIT® FUTURA NANO ARCTIC

Deposited at 200°C

Page 9: Wim Geurts - Oerlikon

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BALINIT® ARCTIC coating series

Coating temperature at 200°C has the benefits of

no loss of hardness for low tempered steel grades

no effect on corrosion resistance

prevention of distortion

BALINIT® properties and performance are unaltered

Excellent coating adhesion

No loss of hardness for low tempered steel grades

40

44

48

52

56

60

64

68

0 100 200 300 400 500 600 700

Tempering diagram for steel:K107(1.2436)

Hardness [HRC]

Tempering temperature [°C]

Standard coatingtemperature

ARCTIC coatingtemperature

Page 10: Wim Geurts - Oerlikon

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No effect on corrosion resistance

40

60

80

100

120

0 100 200 300 400 500 600 700

Tempering diagram for steel:M310(1.2083)

Corrosion resistance [%]

Tempering temperature [°C]

Standard coatingtemperature

ARCTIC coatingtemperature

Prevention of distortion

-0.15

-0.1

-0.05

0

0.05

0.1

0.15

0 100 200 300 400 500 600 700

Tempering diagram for steel:M310(1.2083)

Dimensional change [%]

Tempering temperature [°C]

Standard coatingtemperature

ARCTIC coatingtemperature

Page 11: Wim Geurts - Oerlikon

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Some examples….

Zyk

lus

-Z

eit

Hahnleiste Discofix® C aus Polyamid 12

Page 12: Wim Geurts - Oerlikon

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Hahnleiste Discofix® C aus Polyamid

0

5

10

15

20

25

30

unbeschichte

t

Balinit

A

Balinit

ALCRONAZ

yklu

s -

Zei

t

Kern:

- Werkstoff: HSS- Dimension:

2,5 mm (keine Kühlung möglich)KS - umspritzte Länge: ca.52 mm

Schicht: BALINIT® ALCRONA Top

Zyklus – Zeiteinsparung: 37%

10 s

ec

Automotive: PA + Weich-Komponente von Sika

Anwendung:Automotive: PA + Weich-Komponente von SikaTeile werden zB zwischen Aussen- undInnenteil in Autos montiert.Die weiche Sika-Komponente wird beimEinbrennlackieren aufgeschäumt.

Problem:Starkes Verkleben (schlechte Entformbarkeit)Bis anhin nur mit PTFE-Beschichtung entformbar.

Lösung Bei Versuchen auf einer 4-fach-Form konnten verschiedene PVD-Schichten getestet werden.ALCRONA war die einzige Schicht die annähernd die gute Entformbarkeit der PTFE-Beschichtung erreichte.

Page 13: Wim Geurts - Oerlikon

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Vergaser-Krümmer

Verarbeitet wird eine spez. VITON-Mischung (FKM oder FPM) Kg-Preis: > Fr.300.-Formtemperatur: 190°C +/-5°C

Balinit ALCRONA PRO - Bessere Entformbarkeit (ca. 20%)- Weniger Trennmittel (ca. 80 Teile ohne Trennmittel)- Weniger Reinigungsaufwand

15

17

Balinit A

-12%

Balinit ALCRONA

Zyk

lusz

eit

• Medizinalteil: Scheidenspülung

• Kunstoff: keine Angaben

• Tiefe Shor Härte

Page 14: Wim Geurts - Oerlikon

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Spühlkasten

Entformungsprobleme:• Werkzeug noch in Bemusterung• Anzugvergrösserung nicht erlaubt

Verarbeitet wird:• PP-C Borealis + Masterbatch• PP-C Moplen EP340M + Masterbatch

Kern: • Werkstoff: 1.2738 / nitriert• Oberfläche: gestrahlt

Lösung:• ALCRONA AC3 TOP

Formeinsatz mit ALCRONA PRO

Umstellung der Beschichtung Balinit A auf Balinit ALCRONA PRO

Vorteil: Weniger Verschleiss im Formbereich /

Kavitäten Bessere Entformung des KS Teil Weniger Verzug des KS Teil

Versuch noch nicht abgeschlossen

Ba

linit®

AP

art

ielle

Ab

nu

tzu

ng

de

r S

chic

ht n

ach

ca

. 20

0‘0

00

Sch

uss

erk

en

nb

ar

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www.coating-guide.balzers.com

• Coating Guide

• Material library

• Coatings information

• Sample applications

• Balzers world-wide

Thank you for your attention !