CemeCon the Coating technology CC800 /9

Transcription

1 CemeCon the Coating technology CC800 /9

2 CemeCon coating systems Proven quality from 25 years experience Diamond coating machines in the coating center Würselen 2

3 The coating system for premium coatings Ultra-smooth, 100% droplet-free PVD-coatings Up to 20 µm thick Multilayer-Diamond coatings Adhesive coatings thanks to CemeCon Booster-technology Economical, fast and reliable Highest capacity for cutting tools For high-precision tools in small and large quantities Fully automatic operation around the clock PVD layers up to 15 µm thickness Fast, simple change from one coating system to another in less than 30 min. Flexible all PVD coatings can be produced on one machine Coating include metals, transition metals, oxides, ceramic materials such as TiB 2 and B 4 C and DLC coatings Flexible use in research and development Very compact design Easy to operate Upgradeable and future-proof 3

4 Partner in Premium Coating More than 25 years of pioneering coating technology Smooth, droplet-free sputter coatings for tools and components in a unique selection of materials Multilayer Diamond coatings with highest hardness The experience of 300 coating systems worldwide World leader for cutting tools with Diamond coating, Sputter- and HiPiMS technology World s largest coatings center for cutting tools, with more than 40 coating systems (in Würselen, germany) Complete delivery program, from coating service to coating units, peripherals, measurement technology and turnkey coating centers. innovative turnkey technology solutions for customer-specific in-house manufacturing Service presence in Europe, America and Asia THE EASY WAY TO PREMIUM COATING CUSTOMERS Tool manufacturers, Tool grinders, Tool coaters, Component producers, research and Development Collaboration with more than 30 universities and research partners around the world 4

5 INHOuse-sOlutION CemeCon PVD Sputter coatings smoothest surfaces without droplets high-adhesion, low-friction, low internal stress up to 15 mm thick PVD coatings innovative coating materials: * CemeCon Supernitrides * CemeCon Powernitrides micro-tools CemeCon PVD Sputter systems CC800 /9 ml 6(10) CC800 /9 xl CC800 /9 HiPiMS CC800 /9 mlt 6(10) Support Turnkey solutions Workflow support Service programs Training sessions Technical hotline 24-hour delivery TOOLS / COMPONENTS COATINGS COATING SYSTEMS INHOuse-sOlutION CemeCon CVD Diamond coating patented Multilayer with smooth surface high adhesion and high precision up to 20 µm high level of hardness similar to natural diamonds innovative coating materials: * CCDia CemeCon CVD Diamond system CC800 /9 DIA Support turnkey solutions workflow support service programs training sessions technical hotline 24-hour delivery 5

6 PVD Sputter coatings from CemeCon Smooth, droplet-free coatings for cutting tools and components Since 1986, CemeCon has been a pioneer in developing hard-material coatings using PVD Sputter technology. During Sputtering, the material is vaporized for producing the coating and turns from a solid state directly into the gas. In traditional processes, the coating material must be melted. This inevitably creates droplets that form defects in the coating structure and lead to a very rough surface. During Sputtering, these droplets do not appear. A valuable advantage of Sputter technology, which ensures a perfect coating and extremely smooth, defect-free surfaces. Integrated plasma booster and pulsed substrate BIAS technology in all PVD systems make for very high plasma ionization. The results are thorough but gentle cleaning, activation of surfaces and outstanding coating adhesion. While scratch test adhesion values of 100 Newtons are already standard for CemeCon DC Sputter systems, CemeCon HiPIMS technology reaches scratch loads of more than 130 Newtons. These values are still unequalled on the market. Another advantage of Sputter technology is a significant reduction in the coating s internal stress. This allows AITiN coatings to be deposited to a thickness of 15 µm. An unbeatable advantage in all applications with a great demand for wear volume. Extremely smooth: In contrast to processes that leave droplets on the surface (left), surfaces from the PVD Sputter process (right) are extremely smooth. i Sputtering is enormously flexible. It can be used to produce all known coatings. Whether it is metals, oxides, nitrides, borides or carbides with Sputtering, almost any coating material can be deposited. The coating knows no limits from the smallest micro-tool with less than a 0.1 millimeter diameter to hob cutters or very heavy components. Both electrically conductive and non-conductive coatings can be produced on both electrically conductive and nonconductive substrates. Most coatings are produced at temperatures of 250 C to 500 C. The pulsed Sputtering process allows temperatures below 150 C. 6 PVD Sputter coatings

7 CVD diamond coatings from CemeCon Patented Multilayers for machining graphite, glass- or carbon-reinforced plastics and composites The world s hardest material used as a coating for maximum wear protection when machining graphites, fiber-reinforced plastics (composites) and abrasive non-ferrous metals. For many years, CemeCon has used CVD technology to produce diamond coatings for cutting tools and components true crystalline sp 3 diamonds with a hardness of nearly 10,000 Vickers. More than 20 years ago, CemeCon developed the hot filament process to market maturity and is now the world leader in diamond coatings and technologies. In the hot filament process, diamond is produced from gas. In an H 2 -C x H y gas atmosphere, carbon is turned into pure, crystalline diamond in vacuum. This can produce up to four carat diamond per hour. Depending on the application, it can be deposited as a micro-crystalline, nano-crystalline or Multilayer coating. The fully automatic coating technology, paired with optimal pretreatment of the substrate, allows the deposition of coatings with thicknesses of more than 20 µm and outstanding adhesion. spread beyond the layer boundaries. Thanks to their extreme hardness with up to 10,000 HV 0.05, close to natural diamonds all coatings in the CCDia product group are extremely wear resistant. Performance of shaft tools and indexable inserts made of solid carbide is significantly increased with a CCDia coating. The diamond coating s high heat conductivity makes for fast heat dissipation. This is enormously important when processing temperature-sensitive materials such as carbon- and glass-fiberreinforced plastics, and allows higher processing speed during machining. All of these properties make the CCDia line of coating materials the first choice for machining graphites, composites, nonferrous metals, green parts and ceramics according to VDI standard More and more components are enhanced with a diamond coating. Diamond is extremely hard and barely deformable. It is chemically inert to nearly all media, has very low friction and high heat conductivity. These unique properties constantly open new fields of application for diamond coatings in many industries. substrate Micro-Crystalline Diamond Coating substrate Nano-Crystalline Diamond Coating CemeCon s patented Multilayer technology ensures maximum stability by interlocking the individual layers within the coatings. If cracks arise, they cannot substrate Multilayer Diamond Coating source: Airbus CVD diamond coatings 7

8 HiPims sputter Coating system The CC800 /9 HiPIMs coats tools with extremely hard, especially tough, oxidation-resistant coatings for machining materials like stainless steel, titanium or nickel-based alloys. For these hardto-machine materials, it is equipped with CemeCon s latest patented HiPiMS technology. The high metal ionization of nearly 100 percent offers the best coating adhesion. Tests, such as the scratch test, verify loads of more than 130 newton. Additionally, HiPiMS gives a closed, homogeneous coating distribution on complex 3D geometries and thanks to high deposition rates up to 2,5 µm an hour allows very short process times. Six individually controllable Sputter cathodes ensure the greatest flexibility. The CC800 /9 HiPiMS is best suited to coating industrial-scale tools. All available Sputter coatings can be deposited. Sure, all the coatings done with a CC800 /9 HiPiMS are very smooth and free of droplets. 8 HiPiMS Sputter coating system

9 CC800 /9 HiPIMS Coating area Ø x h [mm] Ø400 x 400 Substrate table Ø x number of satellites [mm], number Ø400 x Ø130 x 6 Quick replacement table Optional Sputter cathodes items [mm] 6 x 500 HiPIMS High Power Impulse Magnetron Sputtering Cathode Maximum substrate dimensions Ø x h [mm] Ø400 x 800 Drill capacity Ø6 mm x 60 mm item 1,800 Insert capacity 12.7 mm x 3.5 mm item 4,920 Maximum substrate weight [kg] 250 Cycle time for 3 µm HPN1* [h] 4.5 (HPN1) HiPIMS BIAS DC Processes Substrate pre-treatment (plasma etching) HiPIMS and sputtering with booster technology. All established CemeCon coatings may be used. Booster, MF and HiPIMS etching HiPIMS DC Puls Electrically conductive coatings Yes Electrically non-conductive coatings Yes Electrically non-conductive substrates Yes Rated power [kw] 80 Power consumption per batch for 3µm HPN1* [kwh] 120 Outer dimensions (w x l x h) [mm 3 ] 1,450 x 3,350 x 2,200 Weight (empty) ~ 3,200 * On a 10 mm milling cutter Homogeneous coating thickness distribution on the cutting edge Coating Volume 400 mm 400 mm 130 mm 700 mm 130 mm 130 mm 400 mm 650 mm 650 mm ML 6 ML 10 XL HiPIMS Sputter coating system 9

10 DC SPUTTEr Coating system CemeCon coating systems with DC Sputter technology are especially flexible and applicable universally. For many years they have been the backbone of many tool coatings around the world. Depending on the quantities required, the ML and XL versions are available. Both of them coat quickly and easily with all nitride-, boride- and carbonbased materials. Add-on modules allow further individual adjustments. The CC800 /9 Ml is the economical system for medium unit quantities and frequent changes in batch and coating material. With the optional flex module, your capacity can be further enlarged and quickly adapted to current order volume. Due to its high flexibility, the CC800 /9 ML line has proved its worth in research and development. The system s open, modular design allows it to be equipped with many extensions and options, such as measuring devices. if necessary, it can be equipped with HiPiMS or pulse modules, among others. CemeCon has developed the CC800 /9 Xl for large unit quantities or large components. With the same external dimensions as the ML model, it has considerably larger coating volume. it coats drills or cutting inserts and tools up to 800 millimeters long and 650 millimeters in diameter in just one operation. The electro-hydraulically driven quickchange table allows fast loading and unloading of tool batches. 10 DC Sputter coating system

11 Coating area Ø x h [mm] CC800 /9 Ml 6 (10) Ø400 x 400 (Ø650 x 400) CC800 /9 Xl Ø650 x 700 DC-MagNetrON-sPutterN substrate table Ø x number of satellites Quick replacement table [mm] number Ø400 x Ø130 x 6 (Ø650 xø130 x 10) Mechanical or electro-hydraulic Ø650 x Ø130 x 10 Electro-hydraulic Cathode sputter cathodes items [mm] 4 x x 800 Maximum substrate dimensions Ø x h [mm] Ø400 x 800 (Ø650 x 800) Ø650 x 800 DC Drill capacity Ø6 mm x 60 mm item 1,800 (3,000) 4,500 Insert capacity 12.7 mm x 3.5 mm item 4,920 (8,200) 16,400 bias Maximum substrate weight [kg] 250 (500) 500 Cycle time for 3 µm Hyperlox * [h] 5 6 Processes Sputtering with booster technology Sputtering with booster technology DC Puls substrate pre-treatment (plasma etching) Booster and MF etching Booster and MF etching electrically conductive coatings Yes Yes electrically non-conductive coatings no no electrically non-conductive substrates no no rated power [kw] Power consumption per batch for 3µm Hyperlox * Outer dimensions (w x l x h) [mm 3 ] [kwh] ,050 x 3,350 x 2,200 1,050 x 3,350 x 2,200 Weight (empty) 3,000 3,300 ~ 3,300 * on a 10 mm milling cutter ALOX SN 2 coating with 12.5 µm coating thickness COatINg VOluMe 700 mm 400 mm 130 mm 400 mm 130 mm 130 mm 400 mm 650 mm 650 mm Ml 6 Ml 10 CCC800 /9 Ml Xl CC800 /9 Xl DC Sputter coating system 11

12 Pulse sputter Coating system The CC800 /9 Mlt is recommended for coating components, molds, dies and tools with tribological coatings like DLC at low temperatures up to max. 150 C. it is excellently suited to coating electrically non-conductive substrates. Additionally, it can deposit many conventional hard coatings, such as TiAln, AlTin, etc. BiAS lead to high plasma ionization and thus very good adhesion even at low substrate temperatures. They can be set within a range of 150 C to 450 C. Like all CemeCon Sputter systems, the CC800 /9 MLT delivers smooth, dropletfree coatings for immaculate surfaces. Using pulsed plasma, it is possible to achieve high coating speeds even at low temperatures. This makes the CC800 /9 MLT outstandingly suited for economical coating of medium-sized and large series. The built-in plasma booster and pulsed 12 Puls Sputter coating system

13 CC800 /9 Mlt 6 (10) Coating area Ø x h [mm] Ø400 x 400 (Ø650 x 400) substrate table Ø x number of satellites Quick replacement table [mm] number Ø400 x Ø130 x 6 (Ø650 x Ø130 x 10) Mechanical or electro-hydraulic Puls MagNetrON sputtern Cathode sputter cathodes items [mm] 4 x 500 Maximum substrate dimensions Ø x h [mm] Ø400 x 800 (Ø650 x 800) Drill capacity Ø6 mm x 60 mm item 1,800 (3,000) Insert capacity 12.7 mm x 3.5 mm item 4,920 (8,200) Maximum substrate weight [kg] 250 (500) Cycle time [h] Depending on process bias Puls Processes Sputtering with bipolar pulsing substrate pre-treatment (plasma etching) Booster and MF etching DC Puls electrically conductive coatings Yes electrically non-conductive coatings Yes electrically non-conductive substrates Yes rated power [kw] 60 Power consumption per batch [kwh] Depending on process Outer dimensions (w x l x h) [mm 3 ] 1,050 x 3,350 x 2,200 Weight (empty) ~ 3,000 3,300 Vehicle component with DLC coating COatINg VOluMe 700 mm 400 mm 130 mm 400 mm 130 mm 130 mm 400 mm 650 mm 650 mm Ml 6 Ml 10 Xl Puls Sputter coating system 13

14 DiAMonD Coating system Smooth, high-adhesive and resistant thanks to Multilayer coating The CC800 /9 DIa coats tools for processing fiber-reinforced plastics, graphites and abrasive nonferrous metals with the world s hardest coating material real diamond crystals. With the CC800 /9 DiA, extremely smooth, especially adhesive nanocrystalline, crystalline or Multilayer diamond coatings can be deposited on more than 80 different tungsten carbide grades. Thanks to the hot filament process, even complex three-dimensional tools and components receive very homogeneous coating thickness distribution within tight tolerances. Despite its compact external dimensions, the CC800 /9 DiA is the largest-capacity automatic diamond coating system on the market. Three independently operating coating chambers make it especially flexible and economical. 14 Diamond coating system

15 Coating area, number x (b x t x h) [mm 3 ] CC800 /9 DIA 1 x (740 x 360 x 30) or 3 x (50 x 560 x 70) Maximum substrate dimensions Ø x h [mm] Tools 30 x 500 Maximum substrate weight [kg] 250 Hot-Filament Diamond Coating System Filaments Processes Hot filament Electrically conductive coatings Yes Electrically non-conductive coatings Electrically non-conductive substrates Yes Yes Horizontal Vertical Rated power [kw] 90 External dimensions (w x l x h) [mm 3 ] 1,260 x 3,600 x 2,070 Weight (empty) [kg] 4,000 Diamond-coated seal ø330mm Composite airplane wings, drilling and reaming the rivet holes with diamond-coated tools Diamond-coated electrode up to 550mm x 250mm Diamond coating system 15

16 Turnkey In-house coating systems In-house coating competence is a competitive advantage CemeCon is doing coating - every single day. And it does it in one of the world s largest coating centers for machining tools. A turnkey solution brings this wealth of experience and proven CemeCon coatings into your production. With cutting tools, the coating is often the crucial competitive advantage. The skill gained through integrating your own coating system ensures you full control over your product and allows flexibility and fast reaction. The complete package, including the coating system, substrate pretreatment and peripherals, covers the entire workflow. This entirety is the result of technology and a proven process, easing your entry into in-house coating technology. With experience from 300 completed systems, and as your project partner, CemeCon takes responsibility for creating an individual turnkey solution. The service team draws up the time, space and connection plan, handles country-specific details, assists in cooperation with public authorities and delivers a coating production ready to use. You gain from CemeCon s continuous development of coatings. Our development team will help you at any time with future applications. Comprehensive support and service ensures the system s continuous operation. 16 In-house coating systems

17 The Wolf coating center for components and cutting tools in Bruchmühlbach three good reasons for choosing a CemeCon turnkey coating line Proven coating recipes from CemeCon contract coating on proven coating systems. An individually adapted production process that ensures fast and efficient production runs. Service right from the start: CemeCon handles complete advance planning and sets up the system and peripherals. Coating, substrate and geometry adjusted by one supplier makes for the perfect tool. Take advantage of having your own coating technology! CC800 /9: premium coating, simply and efficiently CemeCon s CC800 /9 system series includes modularly designed models for smooth, droplet-free PVD Sputter and HiPiMS coating, as well as for superhard CVD diamond coatings. All of them combine premium quality with maximum performance in a compact design. fully automatic process control graphical user interface full internet connection flexible design for all available coatings open to future materials CemeCon advises the individual customer and offers solutions adapted to nearly any component size or unit quantity. Whether a tool manufacturer, contract coater or in research and development, every customer gets a complete turnkey solution designed to their needs, including complete peripherals: Pre- and posttreatment technology, cleaning, cooling and compressed air systems, as well as quality inspection equipment. All components are integrated into their production processes and infrastructure and existing machines are used effectively. CemeCon s contract coating is the ideal place to give your employees intensive training on the selected system model and on coating processes specifically adapted to suit your applications. Technicians will instruct you in the simple operation of your new coating system on site. So you can be sure that you can deliver the first coated tools immediately after your in-house system is installed. 24/7 support for machine customers around the world i in-house coating systems 17

18 PEriPHErALS AnD ACCESSoriES integrated in THE MoST optimal WAY Coating quality depends on all of the necessary steps in the process fitting together perfectly. CemeCon offers all of the components for a complete in-house coating center from one source perfectly matched with one another. The CemeCon advantage: Accessories and all components, machines and processes for pre- and post-treatment and quality control are always adapted to customer requirements and existing infrastructure. blasting and cleaning systems CemeCon blasting and cleaning systems provide the best possible substrate preparation. Blasting systems free tools of burrs and grinding burn and remove loose carbide grains and cobalt smearing. if necessary, preparation of cutting edges can be optimized. Cleaning systems remove impurities gently and completely. The product line extends from manual systems for small or medium production quantities to fully automatic systems for large coating centers. All of the solutions are environmentally friendly and economical, thanks to the regeneration of blasting and cleaning media. Cooling systems During coating, cooling systems dissipate heat and provide necessary process safety. CemeCon offers compact, reliable, energy-saving cooling systems for every system size and every coating technology. targets Blasting system Quality control Thanks to a special bonding process, CemeCon Targets ensure the highest quality and process reliability. They are optimally adapted to the coating process and, thanks to plug technology, are available in a wide choice of materials. When it comes to quality control when goods are received or dispatched, CemeCon offers the right testing device for every need. Tailor-made quality assurance packages can be assembled from ball cratering test devices, rockwell testers, microscopes and impact testers. 18 Peripherals and accessories

19 COATING EQUIPMENT AT A GLANCE CC800 /9 ML 6 (10) CC800 /9 XL CC800 /9 HiPIMS CC800 /9 MLT 6 (10) CC800 /9 DIA Coating area Ø x h* [mm] Ø400 x 400 (Ø650 x 400) Ø650 x 700 Ø400 x 400 Ø400 x 400 (Ø650 x 400) 1 x (740 x 360 x 30) or 3 x (50 x 560 x 70) Substrate table Ø x number of satellites [mm] number Ø400 x Ø130 x 6 (Ø650 x Ø130 x 10) Ø650 x Ø130 x 10 Ø400 x Ø130 x 6 Ø400 x Ø130 x 6 (Ø650 x Ø130 x 10) Depending on use Quick replacement table Mechanical or electro-hydraulic Electro-hydraulic Optional Mechanical or electro-hydraulic Sputter cathodes items [mm] 4 x x x x 500 Filaments Maximum substrate dimensions Ø x h [mm] Ø400 x 800 (Ø650 x 800) Ø650 x 800 Ø400 x 800 Ø400 x 800 (Ø650 x 800) Tools Ø30 x 500 Drill capacity Ø6 mm x 60 mm Insert capacity 12.7 mm x 3.5 mm item 1,800 (3,000) 4,500 1,800 1,800 (3,000) item 4,920 (8,200) 16,400 4,920 4,920 (8,200) Depending on process Depending on process Maximum substrate weight [kg] 250 (500) (500) 250 Cycle time for 3 µm Hyperlox SN 2 ** [h] (HPN1) Depending on process Depending on process Processes Sputtering with booster technology Sputtering with booster technology HiPIMS and sputtering with booster technology. All established CemeCon coatings may be used. Sputtering with bipolar pulsing Hot filament Substrate pre-treatment (plasma etching) Booster and MF etching Booster and MF etching Booster, MF and HiPIMS etching Booster and MF etching Electrically conductive coatings Electrically non-conductive coatings Electrically non-conductive substrates Yes Yes Yes Yes Yes No No Yes Yes Yes No No Yes Yes Yes Rated power [kw] Power consumption per batch for 3µm Hyperlox ** [kwh] Depending on process Depending on process Outer dimensions (w x l x h) [mm 3 ] 1,050 x 3,350 x 2,200 1,050 x 3,350 x 2,200 1,450 x 3,350 x 2,200 1,050 x 3,350 x 2,200 1,260 x 3,600 x 2,070 Weight (empty) 3,000 3,300 ~ 3,300 ~ 3,200 ~ 3,000 3,300 4,000 * CC800 /9 DIA: Coating area, number x (b x t x h) ** On a 10 mm milling cutter Coating equipment at a glance 19

20 GERMANY USA CHINA CZECHIA DENMARK INDIA JAPAN KOREA TAIWAN RUSSIA CemeCon ag Phone: CemeCon Inc. Phone: baoding tianwei CemeCon Coating technology Co. ltd. suzhou Phone: Peking Phone: CemeCon s.r.o. Phone: CemeCon scandinavia a/s Phone: M+V Marketing & sales Pvt. ltd. Contact: Manish Adwani Phone: Correns Corporation Contact: Shigeru Kuroda Phone: japan@cemecon.com JetztKorea ltd. Contact: Hong-Silk Cho Phone: korea@cemecon.com DKsH taiwan ltd. Contact: Vincent Chu Phone: taiwan@cemecon.com ZaO rosmark-steel Contact: ilya Mozgov Phone: +7 (812) mozgov@rosmark.ru editor CemeCon ag Adenauerstr. 20 a Würselen germay