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IM-079 (2012-2013)
Industrial & Manufacturing Engineering Department, NED University of Engineering and Technology
University Road, Karachi -75270, Sindh, Pakistan
1
im079um@gmail.com
umair.an@ymail.com
I. INTRODUCTION
In recent years, in the machining field, the requirements of
the cutting tools are becoming increasingly diverse, including
higher speed, higher efficiency and also increased
performance stability, extended tool life, and reduced cost to
use under harsher condition ever in normal environment.
Materials such as carbide, Sintered carbide, cemented and
CBN are used but using these tools independently, the diverse
needs are not perfectly obtained. It is therefore, coated tools
were invented. Initially in 1969 the TiC and WC cotted tools
became normal in metal machining industries because these
coating consequently improve the ability and life of tool up to
200 to 300% or more.
In cutting tools it is necessary requirement that a tool must
have high hardness, high strength, abrasion resistant, and as
well as it must be chemically inert to prevent the chemical
reaction between the newly generated surface of work piece
and that of tool. To be effective the coating must be fine
grained free of binders and porosity. Naturally the coating
must be metallurgic to the substrate.
Coated tools are finding wide acceptance in many
manufacturing applications. Coated tools have two or three
times the wear resistance than the best uncoated tools. It is
therefore, these tools have a broader range of applications.
The advancement of the coated carbide tool technology has
greatly attributed the advancement in manufacturing
technology. There are basically two types of coating methods
named as Chemical Vapour Deposition (CVD) and Physical
Vapour Deposition (PVD).
II. CHEMICAL VAPOUR DEPOSITION
Chemical Vapour Deposition (CVD) is an atmosphere
controlled process conducted at elevated temperatures
(~1925 F) in a CVD reactor. During this process, thin-film
coatings are formed as the result of reactions between various
gaseous phases and the heated surface of substrates within the
CVD reactor. As different gases are transported through the
reactor, distinct coating layers are formed on the tooling
200C (400F)
Ni+ 4CO
TiC + 4HCl
900C 1650F
TiN + 4HCl
B. Types of PVD
Physical vapor deposition coating is gaining in popularity for
many reasons, including that it enhances a products
durability. In fact, studies have shown that it can enhance the
lifespan of an unprotected product tenfold.
Variants of PVD include,
Cathodic Arc Deposition: In which a high-power
electric arc discharged at the target (source) material
blasts away some into highly ionized vapor to be
deposited onto the work piece.
Electron beam physical vapor deposition: In which
the material to be deposited is heated to a high vapor
pressure by electron bombardment in "high" vacuum
and is transported by diffusion to be deposited by
condensation on the (cooler) work piece.
Evaporative deposition: In which the material to be
deposited is heated to a high vapor pressure by
electrically resistive heating in "low" vacuum.
Pulsed laser deposition: In which a high-power laser
ablates material from the target into a vapor.
Sputter deposition: In which a glow plasma discharge
(usually localized around the "target" by a magnet)
bombards the material sputtering some away as a
vapor for subsequent deposition.
C. Applications of PVD Coated Tools
A PVD coating (Physical Vapor Deposition) or PACVD
coating (Plasma Assisted Chemical Vapor Deposition) is a
hard, thin layer of metallic coating or ceramic coating by use
of plasma under vacuum on metal, ceramic or plastic
substrates. The best known applications of PVD coating
technology are decorative coatings, tri-bological
coatings (mostly automotive engine components and machine
components) and tool coating. Additionally PVD hard coating
technology is applied in innovative coating concepts in new
markets. PVD coatings are engineered for a specific set of
properties:
High wear resistance
High hardness at high operating temperatures
High oxidation resistance
Low friction
Anti-sticking
Scratch resistant
Brilliant finish in specified colour
The Typical applications of the PVD tools in the
manufacturing industries are:
Plastic Processing industry
Extrusion
Injection die molding
Machining Industries
Cutting tools
Toothing
Broaching
Forming Industries
Forming
Primary shaping
Semiconductor Industries
Wafer contact applications
Components used in positioning systems
Automotive Industry
Engine components
Pump applications
Engineering
Wind energy technology
Aviation technology
Medical technology
A. Processing Temperature
The process temperatures for our PVD coatings can range
from 385F-750F depending upon the particular coating
being deposited. Please note that we recommend draw
temperatures of 750F+ in order to avoid distortion or
hardness changes. If these draw temperatures are not possible
for your parts, then we recommend you contact us for special
instructions in order to provide for the safe processing of your
parts.
The process temperature for CVD coating will reach
1925F; therefore, any tool steels or HSS being CVD coated
will be annealed during coating. After coating, we will
vacuum heat-treat all steels in order to achieve the customers
required hardness.
B. Coating Thickness
The average thickness of our various PVD coatings is 2-5
microns (.00008-.0002).
The average thickness of our various CVD coatings is 5-10
microns (.0002-.0004).
C. Others
Some other characteristics of the PVD & CVD processes are
defined in the table shown below.
VI. CONCLUSIONS
In the recent days it is a top priority of an industry to reduce
the cost of manufacturing rather than increasing the price of
product, to get huge profit margins. Tools play a vital role in
reducing the cost of product. Here we found that vapour
deposition on the tools increases the life, strength as well as
we can obtain our desired properties, which are needed in the
tool for a particular operation. We found that these coated
tools are little expensive than the conventional tools, but at the
back these tools have high strength, high productivity rate,
and have the long life, well wear resistance than the
conventional tools. In these days researchers are paying their
attentions towards the improvement of coating methods and
hence not only the new methods have been discovered. These
coating methods are not only limited for the tool
manufacturing but now these coating methods are also being
used for different things to satisfy the market needs.
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