PVD Coatings for Forming

Applying the correct PVD Coating to Press Tools, Stamping Dies and Forming Tools will greatly improve die tool life- use heat treated alloys, together with a very strong coating for best performance. Metal pick-up (galling) during metal forming is a growing issue during the fabrication of sheet metal parts, due to an increase in the use of high strength and stainless steels. Higher press forces are required to fabricate these steels which result in an increase in galling and tool damage. To further improve the performance of PVD coating, a hard nitride layer (~70Rc)is produced on the press tool beneath the PVD coating to support the coating under the high forces applied to the surface of tools during operation. This Duplex surface treatment (IONTEC-H) works extremely well. The wide range of IONTEC-H Duplex Surface Treatments Aalberts Surface Technologies provide, will always significantly enhance the tool life.

Although a lot of the steels which are IONTEC-H treated by Aalberts Surface Technologies are Stamping Dies (where outstanding results have been achieved), the Duplex Surface Treatment process can be, and is, applied very successfully to components, where the steel substrate is normally not hard enough to work in the application. 
 
 
 
PVD Data - Forming

 Duplex Iontec

 
 
 
Make contact with our sales co-ordinator

For Technical or Sales enquiries:


peter.jones@aalberts-st-heat.co.uk
 
 
 
Although a lot of the steels which are IONTEC-H treated by Aalberts Surface Technologies are Press Tool Forming dies (where outstanding results have been achieved), the Duplex Surface Treatment process can, and is, applied very successfully to components, where the steel substrate is normally not hard enough to work in the application.

Nitriding the steel before application of the wear resistant PVD coating improves fatigue and indentation resistance. This allows the coating to function correctly in a more heavily loaded situation.

Correct Surface Finish (i.e. high mirror polish) of the press tool die is also extremely important if optimum performance is to be achieved.
 
 
 

case study #1 –Press Tool

Uncoated BD2 press tool hardened to 58-60Rcrepeatedly in tool maintenance for press repair for scoring. 13 tool maintenance notes were raised and associated excessive downtime in press. Maintenance cost estimated at £7K. 

Since the press tool was IONTEC-HV Duplex treated at a cost of £900, zero maintenance has been required and the tool has made >600K components. 

Since treatment (4 years) there has been no downtime in press for scoring.

case study #2 – Chain Cropping Punch

BD2 cropping punch hardened to 58-60Rc produces slide links for industrial chain. The chain material is 6mm thick En19T. 

AIM: To increase the life of the tool, by reducing flank wear. 

Chain links produced untreated 2K operations. 
Chain links produced after TiCN coating 12K operations.
Chain links produced after IONTEC-HT Duplex surface treatment >60K operations!

case study #3 – Large Stamping Die

Fuel Cradle stamped from 1.6mm DC06 material required the tool to be polished after every 500 parts produced.

Iontec - HV duplex surface treatment was applied to the BD2 steel inserts, resulting in no evidence of wear or pick up after over 80K parts.

The tool continues to be used and is occasionally wiped down to remove oil residues.
 
 
 
specialised PVD coatings
 
 
 

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Aalberts Surface Technologies Heat Ltd | Disclaimer

Registered Address.: Aalberts Surface Technologies Heat Ltd, Blackhorse Road, Letchworth. SG6 1HD 

Tel: 01462 472147