PVD High Energy Deposition Coating Technology
IBC Coatings’ High Energy Deposition coating process produces consistently high-performance parts using a variety of materials and material combinations that meet the wear and corrosion resistance needs of the most demanding applications. This PVD technology has been optimized through years of development to produce a more durable coating for a variety of applications. The process is:
- Arc plasma technology vaporizes a refractory metal or alloy (Vanadium, Titanium, Chromium, Titanium/Aluminum, Zirconium, etc.) from a cathode plate. The metal particles are ionized 90-100% (vs. 10-50% in competitive systems), doubling the coating process productivity and the performance of the coating.
- Charged particles (plasma) are magnetically accelerated toward the parts to coat, with energies 100 to 1,000 times higher than in electron beam machines traditionally available. This very high energy bombardment results in high density coatings with excellent adhesion to the part.
- Highly ionized nitrogen and/or carbon delivered in the gas phase, combine with the metal ions to form the desired coating.
- Coatings can be single layer, multi-layer, or gradient with multiple cathodes and combinations of gases being utilized.
- The advantage of using multilayer coatings is the reduction in stresses which provides better adhesion to the substrate, especially in applications where a great degree of ductility or high impact resistance is needed. Having a coating that is made up of multiple layers containing different elements allows an initial “adhesion” layer to be deposited that is characterized as having good adhesion to both the substrate and the film that is to be deposited on top. Additionally, it allows the layers to flex at the interface regions, improving ductility when external forces are applied, as opposed to cracking or delaminating.
- IBC can coat parts up to 40” (101.6 cm) in diameter and 40” (101.6 cm) in height and 3,000 lbs. (1,360 kg).
- For very extreme applications, IBC combines High Energy Ionization with a Deep Diffusion Deposition process, resulting in parts life increases of 50-500% vs. traditional PVD (Physical Vapor Deposition). Coating process temperatures are maintained below 750°F (400°C) so as not to affect dimensions or heat-treat properties of the base material. The coated part can be stripped and recoated an unlimited number of times, with no effect on the substrate.
- IBC combines PVD coating technology with polishing, vibratory finishing, and grit-blasting to achieve the desired properties for each individual application.
IBC Coatings teams with you to find and optimize a solution to your problem – coating, part material, part design, and manufacturing process. We have experienced specialists in all these fields that can recommend and create two independent sets of requirements during the development process:
1 For the part (toughness, mass, cost, etc.).
2 For the coating surface (hardness, friction coefficient, thermal properties, chemical inertness).
IBC Coatings assures the performance of these coatings via our ISO-9001 Quality Management System and our state-of-the-art Laboratory using inspection and sampling with each order.
The High Ionization Deposition (HID™) coating process produces consistently high performance parts, with 3-5 day turnaround
- Arc plasma technology vaporizes a refractory metal or alloy (Titanium, Chromium, Titanium/Aluminum, Zirconium, etc) from a cathode plate. The metal particles are ionized 90-100% vs. 10-50% in competitive systems, doubling coating process productivity and performance of coating.
- Charged particles (plasma) are magnetically accelerated toward the parts to coat, with energies 100 to 1,000 times higher than in electron beam machines available. The very high energy bombardment results in high density coatings with excellent adhesion to the part.
- IBC can coat parts up to 30 x 30 x 20 in (750 x 750 x 500 mm) and 1000 lbs (450 kg). If necessary, IBC can construct chambers for parts up to 60 x 60 x 120 in (1500 x 1500 x 1500 mm).
- For very heavy duty applications, IBC uses HI3D™ (High Ionization Deep Diffusion Deposition) process, resulting in parts life increases of 50-500% vs. traditional PVD (Physical Vapour Deposition) . All coating components are externally supplied, and the process does not rely on the carbon from steel composition for the reactions producing the deposition. As a result, the coating doesn't weaken the top layer of the tool. The tool may be re-coated an unlimited amount of times.
- For extra corrosion protection, specify HIDC process.
- We team with your specialists to find and optimize a solution to your problem – coating, part material and design, manufacturing process changes. We have experienced specialists in all these fields.
- We offer to your designers the capability to create two independent sets of requirements during tool development – for the part (toughness, mass, cost, etc) and for the coating surface (hardness, friction coefficient, thermal properties, chemical inertness).
Coatings Presently Available:
Very high performance Titanium Nitride-based coating, providing 40 to 200% longer life than available brands. With a hardness of 2400 HV (Vickers) - compared to 900 for hard chromium - reduced friction and release force, good corrosion resistance and chemical inertness, has numerous applications and the best documented track record. The temperature limit is 600°C for continuous exposure. A rich gold color serves well in decorative applications.
Implementation of Titanium Carbo-Nitride-based coating. Our process consistently produces a high performance coating with a hardness of 3200 HV, with excellent results in the most difficult working conditions. Recommended in the processing of tool, alloy and carbon steel, as well as series PH stainless.
Titanium Carbide-based coatings, with a hardness of 3500 HV for applications requiring extra wear resistance.
Chromium Nitride-based coatings, with enhanced adhesion, toughness, and wear performance. At 2000 HV, these coatings have more than twice the hardness of hard chromium, without the hydrogen embrittlement and environmental problems resulting from the electroplating process. The reduced friction, high corrosion resistance, and the 750°C temperature limit find numerous applications.
Chromium Carbide-based coatings, for 2500 HV hardness in a tough, abrasion resistant Chromium coating with high temperature and corrosion resistance.
A state-of-the-art Titanium Aluminum Nitride-based coating for very high temperature (900°C), corrosion resistance, and hardness (4000 HV). Recommended for the processing of Aluminum, 300 Stainless Steel, Titanium, and high temperature alloys based on Nickel and Cobalt, dry or semi-dry machining.
Newest addition to our capabilities, for superior finish of processed parts and a further enhancement of tool life in paper, wood and plastic cutting.
All these multilayer coatings are engineered for a gradual build-up of properties between the base material and the coating surface, to avoid or limit development and propagation of cracks under mechanical or thermal loads.
Coating of test samples is free. We continue testing until expected results are reached.