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Abstract
The advantages of the application of hard coatings, which are well knownfor cutting tools, are to a much lesser extent explored for casting, extrusion, molding and forming tools. Increasing the lifetime of these tools is an important task in surface engineering because of complex loading conditionsand often complicated tool geometry. The plasma-enhanced chemical vapor deposition (PECVD) technique is well suited to deposit hard coatings onto large dies and moulds. The aim of this study was to discuss deposition processes suitable for coating of the often large three-dimensional molds and dies used in metal forming. Furthermore, results obtained using different hard coatings in industrial applications for several case studies like aluminum pressure die-casting; plastics injection molding and sheet metal forming are presented and discussed. For best coating performance, a careful optimization of both substrate pretreatment and coating deposition is necessary. The plasma-enhanced chemical vapor deposition (PECVD) technique shows advantages for these applications because of the high flexibility in pre-treatment using chemical etching and plasma-nitriding, because of its ability to coat large complexly shaped tools and because of the possibility of deposition of low-chlorine containing low-friction coatings.
Highlights
The advantages of the application of hard coatings, which are well known for cutting tools, are to a much lesser extent explored for forming tools [1,2]
Sheet metal forming In sheet metal forming, the main wear mechanisms have been identified as adhesive wear due to the high loads applied, abrasive wear by highly strain-hardened wear debris, and mechanical fatigue due to cyclic loading [18]
By applying a plasma-enhanced chemical vapor deposition (PECVD) Ti(C,N) coating, brush lubrication could be reduced to every 50 strokes, and 26000 parts could be produced without cleaning until the test was stopped due to the limited production quantity
Summary
The advantages of the application of hard coatings, which are well known for cutting tools, are to a much lesser extent explored for forming tools [1,2]. Being an important task in surface engineering, increasing thelifetime of these tools is often difficult because of complex loading conditions and often complicated tool geometry These peculiarities impose very specific requirements on the deposition process itself.In the first part of this work, techniques suitable for the deposition of hard coatings on molds and dies and their specific limitations are described. For pre-treatment of the tools, the surface can be cleaned using combined sputtering and chemical etching Another advantage of PECVD is that the load support of relatively soft hot work tool steels could be relatively enhanced using plasma nitriding prior to coating deposition. One can conclude that these characteristics of the PECVD process should make this technique ideally suited for coating of the large and complexly shaped tools used in casting, molding or sheet metal forming
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