Forming and Molding

High Performance Coatings for Forming and Molding

PD2i has engineered an optimum solution for every application. Deep drawing, trimming, punching, blanking, cold forming, hot stamping, hot forging, powder pressing, nonferrous metal forming and Aluminum die casting all require different surface properties to perform properly.

 

Designing a successful coating is achieved by balancing the following six properties within the thin film:

  • High Hardness – for wear resistance
  • Hot Hardness – for hot applications
  • High Toughness – for high strength metal forming
  • Low Friction Coefficient – to reduce adhesive wear and micro welding
  • Heat Resistance – for thermal stability and thermal fatigue
  • Oxidation Resistance – for hot forging, hot stamping and Aluminum die casting.

For Plastic Injection molding theses additional properties are required for mold cavities, cores, and injector runner systems:

  • Corrosion Resistance
  • Scratch Resistance
  • Improve Mold Filling and Mold Release

Additional considerations for coating can be dependent on the substrate and application conditions:

  • Substrate Material – Tool Steel, Carbide, Non Ferous, Surface Cleanliness, etc.
  • Heat Treatment – Critical Quench and Temper conditions.
  • Workpiece Temperature – Cold forming, hot forming, die casting, forging, etc.
  • Tool Failure – Abrasive wear, chemical wear, chipping, heat checking, edge wear, oxidation, welding, etc

The PD2i coating portfolio offers the optimum balance of properties for each application.

PD2i Duplex Coating:

Plasma Nitriding + Hard PVD Coating

Improving the mechanical properties in the supporting structure underneath the coatings has proven to dramatically improve the coatings ability to perform longer. The Nitriding layer provides a graded interface, which is harder and less likely to micro crack under the stresses of forming, than a surface without the Nitride layer. When nitride and coating processes are performed in a single step (in-situ) within the chamber, this combination provides superior surface properties.

The PD2I coating equipment for forming and molding applications is engineered with our unique device and process to make the Nitriding process in the PVD coater.

Heavy forming, hot forging and aluminum die casting require an improvement of the mechanical properties of the under layer to get a hardness gradient from the core hardness to the hard coating. The Nitriding layer increases the compressive strength, the hot hardness and the mechanical and thermal fatigue properties.

PD2i offers experienced technical assistance to guide you in matching your application parameters to the best coating choice.

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