Supplier Spotlight

Video Exclusives

Ferrari 812 Superfast powertrain

gtr

Ferrari details its IEOTYA 'Above 4-liter' category winning engine, as fitted to its latest model, the 812 Superfast


Jaguar E-Pace extreme testing

gtr

As Jaguar continues to ready the E-Pace ahead of its global market debut, the development team gives some insight in to the comprehensive program


Click here/on image to watch video

In light of Volvo's ambiguous announcement that all of its car will 'go electric' by 2019; do you consider 48V systems to be a necessary segue between current-generation ICE and a full EVs?

Web Exclusives

« back to listing

Coating technology trends

The right coatings can enhance performance and prolong the life of tools and component according to international specialist IHI Hauzer Techno Coating

Michiel Eerden and Gabriela Negrea

 

Tool life improvement is the result of several upgraded functionalities, depending on the use of the tool. Hardness, temperature resistance and the contact between the tool and the material that needs to be cut or formed can be positively influenced. In some cases coated tools can realize a tool life that is ten times longer than uncoated tools.

One important trend that is influencing tool coatings is the cutting of lightweight materials. In the automotive industry, lightweight materials are being chosen because of less fuel consumption and less CO2 emissions. As a result, materials such as aluminium, magnesium and carbon reinforced plastics are gaining importance. Apart from the reduced weight, these materials have one thing in common, they have the tendency to stick to the cutting tool resulting in shorter tool life. This trend has stimulated the development of tetrahydral amorphous carbon (ta-C) coating, which is a hydrogen-free diamond like carbon (DLC) coating with a low coefficient of friction.

It is a practical example of a crossover development originated from tribology and applied in the tool coating market. In tribological applications this hydrogen-free diamond like carbon (DLC) coating is used to reduce wear and friction. Applied to the tool industry, ta-C coatings have proven to be extremely suitable for cutting lightweight metals and fibre reinforced plastics that tend to stick to the tool. A ta-C coating for tools is much thinner with a typical layer thickness of 0.5 µm. With ta-C coating the tool life can be significantly increased. The coatings are deposited with a circular arc technology, guaranteeing a strong adhesion of the coating itself.

In every industry cost efficiency is a driving factor that needs constant attention. The tool industry is no exception. The cost of the tool coatings is only a small part of the total cost of a tool, but because the coating is positioned at the end of the production line, it is very important that the coating is of high quality. Therefore in tool coating, reliability is as important a factor as costs. When Hauzer developed their new circular arc technology CARC+ for depositing nitride coatings in the Hauzer Flexicoat 850, they succeeded in making many cost of ownership factors more efficient than ever before. CARC+ is characterized by short batch times, high target efficiency and smooth coatings that need minimal post-treatment. CARC+ technology is nowadays proven technology for nitride coatings, including a highly functional AlCrN coating for hobs used in gear cutting.

The awareness of sustainable production methods becomes more and more mainstream, also in the tool industry and related fields up and down the supply chain. Important factors here are the future scarcity of raw materials, energy consumption, renewable energy, toxicity of materials and recycling in biological or industrial circles. In the tool industry some answers to these challenges are found in larger speed and feed. Some coated tools can achieve not only longer cutting lengths, also a larger depth of cut per contact will be possible, saving time and energy along the way. The meters per minute are deciding and speed meets performance in the Hauzer Flexicoat 850 with CARC technology, so that can be a contributing factor. Another trend that is driven by sustainability as well as cost efficiency is less use of cooling liquids. Dry cutting or minimum quantity lubrication (MQL) are trending, which leads to increased temperatures of the tool cutting edges and hence a need for improved oxidation resistance.

The trends in the tool industry are all related. The trends for cost efficiency and environmental awareness lead to lower use of cooling fluids, which in turn leads to higher temperatures during cutting. The industry answers with a different choice of component materials and coatings that can withstand the high temperatures. Component materials such as titanium (Ti) and nickel (Ni) alloys are difficult to cut because of their sticking tendency and toughness, but ta-C coating will not bring any solutions here because of its operating temperature maximum of around 500°C. CARC coatings are therefore a better solution. These nitride coatings can function at operating temperature levels of up to 1100°C or even 1500°C.

Application directed development has been done to adapt the coatings made with CARC technology to specific applications, such as high speed milling and roughing finishing. Hauzer has developed silicon containing nanocomposite coatings and is fine-tuning AlTiN for specific applications.

Trends such as the use of lightweight and high strength materials, the need for high temperature resistance materials and the drive towards sustainability and cost efficiency strongly influence tool coating developments. Hauzer is convinced that by joining tool production and application knowledge such as geometry, substrates and cutting materials with knowledge about deposition technology, coatings and building machines with a low cost of ownership, a lot of progress can be made. Innovative, highly functional and affordable coatings will be the result.

January 7, 2016
Michiel Eerden and Gabriela Negrea

 

7 January 2016

Read Latest Issue

International Engine of the Year Awards
Read Latest Issue
Read Latest Issue

Web Exclusive Articles

Engines on test: Honda 3.5-liter bi-turbo V6
The long-awaited replacement for Honda's NSX supercar has finally arrived. Engine Technology International samples the 2017 supercar's electrically-assisted 3.5-liter bi-turbo V6 in an unusual setting
Read Now

Jaguar E-Pace: The Knowledge
Perhaps the most important new model to be added to Jaguar's line-up, the all-new E-Pace is the first Jaguar to exclusively feature Ingenium petrol and diesel engines  
Read Now

Engines on test: Jaguar Land-Rover AJ126 3.0-liter V6
A sports car engine in an SUV? Does JLR's AJ126 supercharged 3.0-liter V6 help the Range Rover Sport live up to its nameplate? 
Read Now


Supplier Spotlight

Supplier SpotlightClick here for listings and information on leading suppliers covering all aspects of the engine technology industry. Want to see your company included? Contact aboobaker.tayub@ukimediaevents.com for more details.

فروشگاه اینترنتی فروشگاه اینترنتی سیستم همکاری در فروش کانال تلگرام چت روم ماهواره آنلاین اندروید دانلود فیلم فروشگظ;ه اینترنتی

Submit your industry opinion

Industry BlogDo you have an opinion you'd like to share with the engine technology community? We'd like to hear your views and opinions on the leading issues shaping the industry. Share your comments by sending up to 500 words to d.slavnich@ukimediaevents.com

Submit Your Recruitment Ad

Recruitment AdTo send us your recruitment advertising or to receive information on placing a banner please email aboobaker.tayub@ukimediaevents.com